SW884/994 SHOP MANUAL
3498-6568B-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.
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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. SW884 2-001 1-2. SW994 2-003 1-3. SW884ND 2-005 1-4. SW994ND 2-007 1-5. Common Specifications 2-009 2. TABLE OF STANDARD VALUES 2-1. Engine 2-010 2-2. Propulsion 2-010 2-3. Hydraulic System 2-010 2-4. Steering 2-011 2-5. Brakes 2-011 2-6. Capacities 2-011 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating 2-012 3-2. Recommended Lubricants 2-012 4. TIGHTENING TORQUE CHART 2-013
0-001
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3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 3-001 2. FUEL SYSTEM 3-002 3. EXHAUST SYSTEM 3-1. Exhaust System 3-004 3-1-1. DRT ASSY 3-005 3-1-2. SCR ASSY 3-006 3-2. Urea Piping 3-007 4. CONTROL SYSTEM 4-1. Forward-reverse Control 3-008 5. PUMP MOUNT 5-1. Pump Mount 3-009 5-1-1. 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 (SW884/994) 4-003 1-2-2. Hydraulic circuit diagram (SW884ND/994ND) 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 ASSY (propulsion + vibrator) 4-007 2-2-2. Propulsion hydraulic motor (F) 4-009 2-2-3. Propulsion hydraulic motor (R) 4-011 2-2-4. Neutral solenoid valve 4-013 2-2-5. Parking brake solenoid valve 4-014 2-3. Description and Operation of Propulsion System 4-016 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping 4-019 3-1-1. Vibrator hydraulic piping (SW884/994) 4-019 3-1-2. Vibrator hydraulic piping (SW884ND/994ND) 4-020
0-002
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3-2. Hydraulic Component Specifications 4-021 3-2-1. Vibrator hydraulic motor (SW884/994) 4-021 3-2-2. Vibrator hydraulic motor (SW884ND/994ND) 4-022 3-2-3. Flush and boost pressure valve 4-023 3-3. Description and Operation of Vibrator System 4-025 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping 4-026 4-2. Steering Wheel 4-027 4-3. Hydraulic Component Specifications 4-028 4-3-1. Steering • charge pump 4-028 4-3-2. Orbitrol 4-029 4-4. Description and Operation of Steering System 4-031 4-4-1. Description and operation of steering system 4-031 4-4-2. Structure and operation of Orbitrol 4-032
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 1-2. Electrical Equipment Installation 5-002 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram (SW884/994) 5-003 2-2. Electrical Circuit Diagram (SW884ND/994ND) 5-004 3. ELECTRICAL COMPONENTS 3-1. Wiring Harness Layout (1) 5-005 3-2. Wiring Harness Layout (2) 5-006 3-3. Wiring Harness Layout (3) 5-007 3-4. Wiring Harness Layout (4) 5-008 4. WIRING HARNESSES 4-1. Main Harness 5-009 4-1-1. Main harness (1) 5-009 4-1-2. Main harness (2) 5-011 4-1-3. Main harness (3) 5-013 4-2. Fuse • Relay Harness 5-015 4-3. Engine Harness 5-017 4-4. Hydraulic Pump Harness 5-018 4-5. ECM Harness 5-019 4-5-1. ECM harness (1) 5-019 4-5-2. ECM harness (2) 5-021 0-003
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4-6. Battery Harness 5-023 4-7. F-R Lever Harness 5-025 4-8. Panel (L) Harness 5-027 4-9. Panel (R) Harness 5-029 4-10. Water Spray Pump (R) Harness 5-031 4-11. Frame (F) Harness 5-032 4-12. Floor Board Harness 5-033 4-13. Solenoid Harness 5-034 4-14. SCR Harness 5-035 4-15. DRT Harness 5-036 4-16. Backup Buzzer Harness 5-037 4-17. Horn Harness 5-038 5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Potentiometer 5-039 5-2. Exact Meter 5-040 5-3. Resistor Unit 5-041 5-4. Lever Switch 5-042 5-5. Fuse Box (1) 5-043 5-6. Fuse Box (2) 5-044 5-7. Combination Meter 5-045
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 6-008 3. VIBRATORY DRUM ASSY (SW884/994) 3-1. Vibratory Drum ASSY 6-009 3-2. Disassembly and Reassembly of Vibratory Drum 6-010 3-2-1. Disassembly of vibratory drum 6-010 3-2-2. Reassembly of vibratory drum 6-023 4. VIBRATORY DRUM ASSY (SW884ND/994ND) 4-1. Vibratory Drum ASSY 6-046 4-2. Disassembly and Reassembly of Vibratory Drum 6-047 4-2-1. Disassembly of vibratory drum 6-047 4-2-2. Reassembly of vibratory drum 6-059
0-004
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7. BRAKE 1. BRAKE PEDAL 7-001 2. BRAKE SYSTEM 7-003 2-1. Description and Operation of Brake Circuit 7-003
8. OPERATOR STATION 1. FLOORBOARD 1-1. Structure of Operator Station 8-001 1-2. Adjustment of Swivel Lock Release Pedal 8-002
9. WATER SPRAY SYSTEM 1. WATER SPRAY PIPING 9-001
10. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment 10-001 1-2. Preparation for Inspection and Adjustment 10-001 1-3. Precautions for Inspection and Adjustment 10-001 1-4. Warm-up 10-001 1-5. Inspection and Adjustment of Engine Related Items 10-001 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement 10-002 2-2. Adjustment 10-003 2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value 10-003 2-2-2. If pressure on either forward or reverse side deviates from maximum circuit pressure range 10-004 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 10-005 3-1. Measurement 10-005 3-2. Adjustment 10-006 4. M EASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4-1. Measurement 10-007 5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 10-008 5-1. Measurement 10-008 6. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement 10-009 6-2. Adjustment 10-010 0-005
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7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT PRESSURE 10-011 7-1. Measurement 10-011 7-2. Adjustment 10-012 8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-1. Measurement 10-013 8-2. Inspection 10-014 9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9-1. Measurement of Propulsion Pump Case Pressure 10-015 9-2. Measurement of Vibrator Pump (F) Case Pressure 10-016 9-3. Measurement of Vibrator Pump (R) Case Pressure 10-017 10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10-1. Measurement 10-018 11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11-1. Measurement (SW884/994) 10-019 11-2. Measurement (SW884ND/994ND) 10-020 12. ADJUSTMENT OF F-R LEVER POTENTIOMETER 12-1. Adjustment of F-R Lever Operating Force 10-021 12-1-1. Adjustment of disc spring tension 10-021 12-1-2. Adjustment of steel ball thrust 10-022 12-2. Adjustment of Potentiometer 10-023 12-2-1. Adjustment of potentiometer 1 voltage when F-R lever is in “N” 10-023 12-2-2. Adjustment of potentiometer 1 voltage when F-R lever switch operates 10-024 12-2-3. Adjustment of potentiometer 1 voltage when backup buzzer switch operates 10-025
11. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting 11-001 1-2. Important Information for Troubleshooting 11-001 1-3. Before Starting 11-002 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis 11-003 2-1-1. Precautions to take during electrical circuit fault diagnosis 11-003 2-1-2. Inspection procedures using a tester 11-004 2-1-3. Inspection of electrical system 11-009
0-006
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2-2. Engine Diagnosis Trouble Code 11-011 2-2-1. Description of fault code (SPN,FMI) 11-011 2-2-2. Fault code list 11-012 2-3. Error Codes 11-033 2-3-1. Description of error codes 11-033 2-3-2. Error code list 11-033 2-4. Engine 11-036 2-4-1. Engine will not start (Starter motor does not run) 1/15 11-036 2-4-1. Engine will not start (Starter motor does not run) 2/15 11-038 2-4-1. Engine will not start (Starter motor does not run) 3/15 11-040 2-4-1. Engine will not start (Starter motor does not run) 4/15 11-042 2-4-1. Engine will not start (Starter motor does not run) 5/15 11-044 2-4-1. Engine will not start (Starter motor does not run) 6/15 11-046 2-4-1. Engine will not start (Starter motor does not run) 7/15 11-048 2-4-1. Engine will not start (Starter motor does not run) 8/15 11-050 2-4-1. Engine will not start (Starter motor does not run) 9/15 11-052 2-4-1. Engine will not start (Starter motor does not run) 10/15 11-054 2-4-1. Engine will not start (Starter motor does not run) 11/15 11-056 2-4-1. Engine will not start (Starter motor does not run) 12/15 11-058 2-4-1. Engine will not start (Starter motor does not run) 13/15 11-060 2-4-1. Engine will not start (Starter motor does not run) 14/15 11-062 2-4-1. Engine will not start (Starter motor does not run) 15/15 11-064 2-4-2. No charging 11-066 2-4-3. Grid heater does not work (Engine starting performance is bad in cold weather) 11-066 2-4-4. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied 11-068 2-4-5. Engine speed cannot be switched 11-070 2-5. Propulsion 11-072 2-5-1. Machine and engine suddenly stops 1/9 11-072 2-5-1. Machine and engine suddenly stops 2/9 11-074 2-5-1. Machine and engine suddenly stops 3/9 11-076 2-5-1. Machine and engine suddenly stops 4/9 11-078 2-5-1. Machine and engine suddenly stops 5/9 11-080 2-5-1. Machine and engine suddenly stops 6/9 11-082 2-5-1. Machine and engine suddenly stops 7/9 11-084 2-5-1. Machine and engine suddenly stops 8/9 11-086 2-5-1. Machine and engine suddenly stops 9/9 11-088
0-007
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2-5-2. Machine and engine suddenly stops in automatic speed mode 1/2 11-090 2-5-2. Machine and engine suddenly stops in automatic speed mode 2/2 11-092 2-5-3. Machine moves neither forward nor backward 1/6 11-094 2-5-3. Machine moves neither forward nor backward 2/6 11-096 2-5-3. Machine moves neither forward nor backward 3/6 11-098 2-5-3. Machine moves neither forward nor backward 4/6 11-100 2-5-3. Machine moves neither forward nor backward 5/6 11-102 2-5-3. Machine moves neither forward nor backward 6/6 11-104 2-5-4. Machine speed cannot be changed 11-106 2-5-5. Auto speed function does not work 1/10 11-108 2-5-5. Auto speed function does not work 2/10 11-110 2-5-5. Auto speed function does not work 3/10 11-112 2-5-5. Auto speed function does not work 4/10 11-114 2-5-5. Auto speed function does not work 5/10 11-116 2-5-5. Auto speed function does not work 6/10 11-118 2-5-5. Auto speed function does not work 7/10 11-120 2-5-5. Auto speed function does not work 8/10 11-122 2-5-5. Auto speed function does not work 9/10 11-124 2-5-5. Auto speed function does not work 10/10 11-126 2-5-6. Brake cannot be released 11-128 2-5-7. Brake does not work 11-130 2-5-8. Emergency exit propulsion switch does not work 11-132 2-6. Vibration 11-134 2-6-1. No vibration occurs 1/5 11-134 2-6-1. No vibration occurs 2/5 11-136 2-6-1. No vibration occurs 3/5 11-138 2-6-1. No vibration occurs 4/5 11-140 2-6-1. No vibration occurs 5/5 11-142 2-6-2. Vibration frequency cannot be switched (SW884/994) 1/3 11-144 2-6-2. Vibration frequency cannot be switched (SW884/994) 2/3 11-146 2-6-2. Vibration frequency cannot be switched (SW884/994) 3/3 11-148 2-6-3. Vibration type cannot be switched (SW884ND/994ND) 1/2 11-150 2-6-3. Vibration type cannot be switched (SW884ND/994ND) 2/2 11-152 2-6-4. Continuous/automatic vibration mode cannot be switched 1/2 11-154 2-6-4. Continuous/automatic vibration mode cannot be switched 2/2 11-156 2-6-5. Front and rear vibratory drums cannot perform one-drum vibration 11-158
0-008
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2-7. Exact Meter 11-160 2-7-1. Exact meter indicator lamp does not illuminate while driving 1/10 11-160 2-7-1. Exact meter indicator lamp does not illuminate while driving 2/10 11-162 2-7-1. Exact meter indicator lamp does not illuminate while driving 3/10 11-164 2-7-1. Exact meter indicator lamp does not illuminate while driving 4/10 11-166 2-7-1. Exact meter indicator lamp does not illuminate while driving 5/10 11-168 2-7-1. Exact meter indicator lamp does not illuminate while driving 6/10 11-170 2-7-1. Exact meter indicator lamp does not illuminate while driving 7/10 11-172 2-7-1. Exact meter indicator lamp does not illuminate while driving 8/10 11-174 2-7-1. Exact meter indicator lamp does not illuminate while driving 9/10 11-176 2-7-1. Exact meter indicator lamp does not illuminate while driving 10/10 11-178 2-7-2. No vehicle speed indication on display 1/3 11-180 2-7-2. No vehicle speed indication on display 2/3 11-182 2-7-2. No vehicle speed indication on display 3/3 11-184 2-8. Water Spray 11-186 2-8-1. Continuous water spray does not operate 1/4 11-186 2-8-1. Continuous water spray does not operate 2/4 11-188 2-8-1. Continuous water spray does not operate 3/4 11-190 2-8-1. Continuous water spray does not operate 4/4 11-192 2-8-2. Continuous water spray works, but intermittent water spray does not operate 1/2 11-194 2-8-2. Continuous water spray works, but intermittent water spray does not operate 2/2 11-196 2-8-3. C ontinuous water spray works, but automatic water spray does not operate 11-198 2-9. Lighting 11-200 2-9-1. Head lamp and flood lamp do not light 11-200 2-9-2. Illumination of combination meter does not light 11-202 2-9-3. Hour meter is abnormal 11-204 2-9-4. Fuel meter is abnormal 11-204 2-9-5. Hydraulic oil filter warning lamp remains ON 11-206 2-9-6. Vibration indicator lamp does not light 11-208 2-9-7. Water spray indicator lamp does not light 11-210 2-9-8. ECO mode indicator lamp does not light 11-212 2-9-9. Parking brake indicator lamp does not light 11-212 2-9-10. Horn does not sound 11-214 2-9-11. Backup buzzer does not sound 11-214
0-009
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3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting 11-215 3-2. Propulsion System 11-216 3-2-1. Machine moves neither forward nor backward 1/2 11-216 3-2-1. Machine moves neither forward nor backward 2/2 11-217 3-2-2. Machine moves in one direction only (forward or backward) 11-217 3-2-3. Slow machine speed or small drive force 1/2 11-217 3-2-3. Slow machine speed or small drive force 2/2 11-218 3-2-4. Machine speed cannot be switched 11-218 3-2-5. Machine does not stop completely with F-R lever in “N” 11-218 3-2-6. Propulsion system is overheating 11-219 3-2-7. Abnormal noise from propulsion system 11-219 3-3. Vibrator System 11-220 3-3-1. No vibration 11-220 3-3-2. Vibration wheel does not switch 11-221 3-3-3. Vibrator frequency is too low 1/2 11-221 3-3-3. Vibrator frequency is too low 2/2 11-222 3-3-4. Vibration mode does not switch 11-222 3-3-5. Vibratory drum does not changeover vibrating 11-222 3-3-6. Vibrator does not stop 11-222 3-3-7. Vibrator system is overheating 11-223 3-3-8. Abnormal noise from vibrator system 11-223 3-4. Steering System 11-224 3-4-1. Steering wheel is hard to turn 11-224 3-4-2. Steering response is slow 11-224 3-4-3. Steering wheel backlash or play is large 11-225 3-4-4. Steering system is overheating 11-225 3-4-5. Abnormal noise from steering system 11-225
0-010
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
SW884
1. SPECIFICATION DATA
2205 2245
2245 2205
1-1. SW884
3540 5940
750
750
1505 1200
0
121
140
2000
0
140
121
335
750
750
2375
3250
2195
2000 0568-99025-0-11997-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Shipping weight
with ROPS without ROPS
Load on front axle Load on rear axle Overall length Overall width Overall height
Dimensions
Wheelbase Compaction width Front drum Rear drum Ground clearance Kerb clearance Side clearance Leveling blade width
2-001
with ROPS without ROPS
width × dia. × thickness width × dia. × thickness Left Right Left Right
SAKAI SW884 with ROPS VIBRATORY TANDEM ROLLER 12,890 kg ( 28,415 lbs. ) N/A kg ( N/A lbs. ) 13,610 kg ( 30,005 lbs. ) 12,110 kg ( 26,695 lbs. ) 11,560 kg ( 25,485 lbs. ) 6,350 kg ( 14,000 lbs. ) 6,540 kg ( 14,420 lbs. ) 5,940 mm ( 234 in. ) 2,245 mm ( 88 in. ) 3,250 mm ( 128 in. ) 2,375 mm ( 94 in. ) 3,540 mm ( 139 in. ) 2,000 mm ( 79 in. ) 2,000 mm × 1,400 mm × 22 mm (79 in. × 55 in. × 0.9 in.) 2,000 mm × 1,400 mm × 22 mm (79 in. × 55 in. × 0.9 in.) 335 mm ( 13.1 in. ) 750 mm ( 29.6 in. ) 750 mm ( 29.6 in. ) 121 mm ( 4.8 in. ) 121 mm ( 4.8 in. ) N/A mm ( N/A in. )
SW884
SPECIFICATIONS Low Centrifugal amplitude force High amplitude Front
4,000 vpm 3,000 vpm 2,500 vpm 3,000 vpm 2,500 vpm
Low amplitude Frequency High amplitude Low amplitude High amplitude 4,000 vpm Low 3,000 vpm Centrifugal amplitude 2,500 vpm force 3,000 vpm High amplitude 2,500 vpm Amplitude
Vibrator system
Rear
Low amplitude Frequency High amplitude
Performance
Amplitude
Low amplitude High amplitude
Static linear Front drum pressure Rear drum 4,000 vpm Low 3,000 vpm amplitude Front drum 2,500 vpm 3,000 vpm Linear High Dynamic pressure amplitude 2,500 vpm linear 4,000 vpm pressure Low 3,000 vpm amplitude Rear drum 2,500 vpm 3,000 vpm High amplitude 2,500 vpm Number of speed shift 4,000 vpm Speed 1st 3,000 vpm Speed range 2,500 vpm 2nd 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
0 0 0 0
160 kN ( 35,970 lbf. 90 kN ( 20,230 lbf. 63 kN ( 14,160 lbf. 177 kN ( 39,790 lbf. 123 kN ( 27,650 lbf. 66.7 Hz ( 4,000 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 0.33 mm ( 0.013 in. 0.64 mm ( 0.025 in. 160 kN ( 35,970 lbf. 90 kN ( 20,230 lbf. 63 kN ( 14,160 lbf. 177 kN ( 39,790 lbf. 123 kN ( 27,650 lbf. 66.7 Hz ( 4,000 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 0.33 mm ( 0.013 in. 0.64 mm ( 0.025 in. 311 N/cm ( 178 lbf./in. 321 N/cm ( 183 lbf./in. 1,111 N/cm ( 635 lbf./in. 761 N/cm ( 435 lbf./in. 626 N/cm ( 358 lbf./in. 1,196 N/cm ( 683 lbf./in. 926 N/cm ( 529 lbf./in. 1,121 N/cm ( 640 lbf./in. 771 N/cm ( 440 lbf./in. 636 N/cm ( 363 lbf./in. 1,206 N/cm ( 688 lbf./in. 936 N/cm ( 534 lbf./in. 2 speed to 7.2 km/h ( 0 to 4.5 mph to 5.5 km/h ( 0 to 3.4 mph to 4.5 km/h ( 0 to 2.8 mph to 11.0 km/h ( 0 to 6.8 mph 29 % ( 16 ° 4.2 m ( 166 in. 6.4 m ( 252 in. 4.3 m ( 170 in. 6.3 m ( 249 in. ± 36.7 ° / ± 6.5 °
) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )
2-002
SPECIFICATIONS
SW994
2285 2325
2325 2285
1-2. SW994
96
3540 5940
750
750
1505 1200
0
2130
140
0
140
96
335
750
750
2375
3250
2195
2130 0569-99009-0-10916-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Shippng weight
with ROPS without ROPS
Load on front axle Load on rear axle Overall length Overall width Overall height
Dimensions
Wheelbase Compaction width Front drum Rear drum Ground clearance Kerb clearance Side clearance Leveling blade width
2-003
with ROPS without ROPS
width × dia. × thickness width × dia. × thickness Left Right Left Right
SAKAI SW994 with ROPS VIBRATORY TANDEM ROLLER 13,270 kg ( 29,255 lbs. ) N/A kg ( N/A lbs. ) 14,000 kg ( 30,865 lbs. ) 12,500 kg ( 27,555 lbs. ) 11,950 kg ( 26,345 lbs. ) 6,530 kg ( 14,395 lbs. ) 6,740 kg ( 14,860 lbs. ) 5,940 mm ( 234 in. ) 2,325 mm ( 92 in. ) 3,250 mm ( 128 in. ) 2,375 mm ( 94 in. ) 3,540 mm ( 139 in. ) 2,130 mm ( 84 in. ) 2,130 mm × 1,400 mm × 22 mm (84 in. × 55 in. × 0.9 in.) 2,130 mm × 1,400 mm × 22 mm (84 in. × 55 in. × 0.9 in.) 335 mm ( 13.1 in. ) 750 mm ( 29.6 in. ) 750 mm ( 29.6 in. ) 96 mm ( 3.8 in. ) 96 mm ( 3.8 in. ) N/A mm ( N/A in. )
SW994
SPECIFICATIONS Low Centrifugal amplitude force High amplitude Front
4,000 vpm 3,000 vpm 2,500 vpm 3,000 vpm 2,500 vpm
Low amplitude Frequency High amplitude Low amplitude High amplitude 4,000 vpm Low 3,000 vpm Centrifugal amplitude 2,500 vpm force 3,000 vpm High amplitude 2,500 vpm Amplitude
Vibrator system
Rear
Low amplitude Frequency High amplitude
Performance
Amplitude
Low amplitude High amplitude
Static linear Front drum pressure Rear drum 4,000 vpm Low 3,000 vpm amplitude Front drum 2,500 vpm 3,000 vpm Linear High Dynamic pressure amplitude 2,500 vpm linear 4,000 vpm pressure Low 3,000 vpm amplitude Rear drum 2,500 vpm 3,000 vpm High amplitude 2,500 vpm Number of speed shift 4,000 vpm Speed 1st 3,000 vpm Speed range 2,500 vpm 2nd 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
0 0 0 0
173 kN ( 38,890 lbf. 98 kN ( 22,030 lbf. 68 kN ( 15,285 lbf. 185 kN ( 41,590 lbf. 128 kN ( 28,775 lbf. 66.7 Hz ( 4,000 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 0.34 mm ( 0.013 in. 0.65 mm ( 0.026 in. 173 kN ( 38,890 lbf. 98 kN ( 22,030 lbf. 68 kN ( 15,285 lbf. 185 kN ( 41,590 lbf. 128 kN ( 28,775 lbf. 66.7 Hz ( 4,000 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 50.0 Hz ( 3,000 vpm 41.7 Hz ( 2,500 vpm 0.34 mm ( 0.013 in. 0.65 mm ( 0.026 in. 301 N/cm ( 172 lbf./in. 310 N/cm ( 177 lbf./in. 1,113 N/cm ( 635 lbf./in. 761 N/cm ( 434 lbf./in. 620 N/cm ( 354 lbf./in. 1,169 N/cm ( 668 lbf./in. 902 N/cm ( 515 lbf./in. 1,123 N/cm ( 641 lbf./in. 770 N/cm ( 440 lbf./in. 630 N/cm ( 359 lbf./in. 1,179 N/cm ( 673 lbf./in. 911 N/cm ( 520 lbf./in. 2 speed to 7.2 km/h ( 0 to 4.5 mph to 5.5 km/h ( 0 to 3.4 mph to 4.5 km/h ( 0 to 2.8 mph to 11.0 km/h ( 0 to 6.8 mph 28 % ( 15 ° 4.2 m ( 166 in. 6.5 m ( 256 in. 4.3 m ( 170 in. 6.4 m ( 252 in. ± 36.7 ° / ± 6.5 °
) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )
2-004
SW884ND
SPECIFICATIONS
2205 2245
2245 2205
1-3. SW884ND
3540 5940
735
735
1490 1200
0
121
137
2000
0
137
121
320
735
735
2360
3235
2195
2000 0568-99031-0-12142-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Shippng weight
with ROPS without ROPS
Load on front axle Load on rear axle Overall length Overall width Overall height
Dimensions
Wheelbase Compaction width Front drum Rear drum Ground clearance Kerb clearance Side clearance Leveling blade width
2-005
with ROPS without ROPS
width × dia. × thickness width × dia. × thickness Left Right Left Right
SAKAI SW884ND with ROPS VIBRATORY TANDEM ROLLER 13,230 kg ( 29,165 lbs. ) N/A kg ( N/A lbs. ) 13,950 kg ( 30,755 lbs. ) 12,450 kg ( 27,445 lbs. ) 11,900 kg ( 26,235 lbs. ) 6,520 kg ( 14,375 lbs. ) 6,710 kg ( 14,795 lbs. ) 5,940 mm ( 234 in. ) 2,245 mm ( 88 in. ) 3,235 mm ( 127 in. ) 2,360 mm ( 93 in. ) 3,540 mm ( 139 in. ) 2,000 mm ( 79 in. ) 2,000 mm × 1,370 mm × 21 mm (79 in. × 54 in. × 0.8 in.) 2,000 mm × 1,370 mm × 21 mm (79 in. × 54 in. × 0.8 in.) 320 mm ( 12.5 in. ) 735 mm ( 29.0 in. ) 735 mm ( 29.0 in. ) 121 mm ( 4.8 in. ) 121 mm ( 4.8 in. ) N/A mm ( N/A in. )
SW884ND Centrifugal Vibration force Oscillation Vibration Frequency Front Oscillation Vibration Amplitude Oscillation Vibrator system Centrifugal Vibration force Oscillation Vibration Rear Frequency Oscillation Vibration Amplitude Oscillation Static linear Front drum Operating weight pressure Rear drum Operating weight Performance Linear Operating Front drum Vibration Dynamic pressure weight linear Operating pressure Rear drum Vibration weight Number of speed shift Vibration Speed 1st Speed range Oscillation 2nd 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
SPECIFICATIONS 158 kN 172 kN 50.0 Hz 46.7 Hz 0.55 mm 0.60 mm 158 kN 172 kN 50.0 Hz 46.7 Hz 0.55 mm 0.60 mm 320 N/cm 329 N/cm
( ( ( ( ( ( ( ( ( ( ( ( ( (
35,585 lbf. 38,600 lbf. 3,000 vpm 2,800 vpm 0.022 in. 0.024 in. 35,585 lbf. 38,600 lbf. 3,000 vpm 2,800 vpm 0.022 in. 0.024 in. 183 lbf./in. 188 lbf./in.
1,111 N/cm
(
635 lbf./in. )
1,121 N/cm
(
640 lbf./in. )
2 speed 0 to 5.5 km/h ( 0 to 0 to 6.4 km/h ( 0 to 0 to 11.0 km/h ( 0 to 28 % ( 4.2 m ( 6.4 m ( 4.3 m ( 6.3 m ( ± 36.7 ° / ± 6.5 °
3.4 mph 4.0 mph 6.8 mph 15 ° 166 in. 252 in. 170 in. 249 in.
) ) ) ) ) ) ) ) ) ) ) ) ) )
) ) ) ) ) ) ) )
2-006
SW994ND
SPECIFICATIONS
2285 2325
2325 2285
1-4. SW994ND
2195
U T L E O W E
T
R
320 3540 5940
735
735
735
1490
2360
3235
P
735
O
1200
0
96
137
2130
0
137
96
2130 0569-99010-0-10943-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Shippng weight
with ROPS without ROPS
Load on front axle Load on rear axle Overall length Overall width Overall height
Dimensions
Wheelbase Compaction width Front drum Rear drum Ground clearance Kerb clearance Side clearance Leveling blade width
2-007
with ROPS without ROPS
width × dia. × thickness width × dia. × thickness Left Right Left Right
SAKAI SW994ND with ROPS VIBRATORY TANDEM ROLLER 13,590 kg ( 29,960 lbs. ) N/A kg ( N/A lbs. ) 14,320 kg ( 31,570 lbs. ) 12,820 kg ( 28,265 lbs. ) 12,270 kg ( 27,050 lbs. ) 6,690 kg ( 14,750 lbs. ) 6,900 kg ( 15,210 lbs. ) 5,940 mm ( 234 in. ) 2,325 mm ( 92 in. ) 3,235 mm ( 127 in. ) 2,360 mm ( 93 in. ) 3,540 mm ( 139 in. ) 2,130 mm ( 84 in. ) 2,130 mm × 1,370 mm × 21 mm (84 in. × 54 in. × 0.8 in.) 2,130 mm × 1,370 mm × 21 mm (84 in. × 54 in. × 0.8 in.) 320 mm ( 12.5 in. ) 735 mm ( 29.0 in. ) 735 mm ( 29.0 in. ) 96 mm ( 3.8 in. ) 96 mm ( 3.8 in. ) N/A mm ( N/A in. )
SW994ND Centrifugal Vibration force Oscillation Vibration Frequency Front Oscillation Vibration Amplitude Oscillation Vibrator system Centrifugal Vibration force Oscillation Vibration Rear Frequency Oscillation Vibration Amplitude Oscillation Static linear Front drum Operating weight pressure Rear drum Operating weight Performance Linear Operating Front drum Vibration Dynamic pressure weight linear Operating pressure Rear drum Vibration weight Number of speed shift Vibration Speed 1st Speed range Oscillation 2nd 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
SPECIFICATIONS 158 kN 172 kN 50.0 Hz 46.7 Hz 0.54 mm 0.56 mm 158 kN 172 kN 50.0 Hz 46.7 Hz 0.54 mm 0.56 mm 308 N/cm 318 N/cm
( ( ( ( ( ( ( ( ( ( ( ( ( (
35,585 lbf. 38,600 lbf. 3,000 vpm 2,800 vpm 0.021 in. 0.022 in. 35,585 lbf. 38,600 lbf. 3,000 vpm 2,800 vpm 0.021 in. 0.022 in. 176 lbf./in. 181 lbf./in.
1,051 N/cm
(
600 lbf./in. )
1,061 N/cm
(
606 lbf./in. )
2 speed 0 to 5.5 km/h ( 0 to 0 to 6.4 km/h ( 0 to 0 to 11.0 km/h ( 0 to 28 % ( 4.2 m ( 6.5 m ( 4.3 m ( 6.4 m ( ± 36.7 ° / ± 6.5 °
3.4 mph 4.0 mph 6.8 mph 15 ° 166 in. 256 in. 170 in. 252 in.
) ) ) ) ) ) ) ) ) ) ) ) ) )
) ) ) ) ) ) ) )
2-008
SPECIFICATIONS
1-5. Common Specifications Name Model 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
Brake system
Steering system
Drum and tyres
Sprinkler system
2-009
Reverser Differential type
All speed governor Full forced pressure feed Full flow Integrated water cooled
Air cleaner type
Dry
Cooling type Cooling fan type Alternator Starter Battery
Pressurized water forced circulation Inhale 12 V 135 A 12 V 4.8 kW 12 V (CCA1000) × 1 pcs. (12 V) 348 kg (767 lbs.) Hydrostatic 2 speed shifts Switching the direction of flow delivered from the variable pump N/A N/A Planetary gear Planetary gear Hydraulic Double eccentric shafts Dynamic brake through hydrostatic drive system (F-N-R lever) 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
Dry weight Transmission
CUMMINS QSF3.8 (Diesel, EPA-Tier 4) 4-cycle, Water-cooled, 4-cylinder in-line, overhead valve, direct injection type, with turbo charger 102 mm × 115 mm (4.02 in. × 4.53 in.) 3.800 L ( 229.0 cu.in ) 2,200 min-1 97.0 kW ( 130 HP ) 488 N·m ( 360 lbf·ft ) at 1,600 min-1 234 g/kW·h ( 0.385 lb/HP·h ) at 2,200 min-1 27 L/h with full load ( 7.1 gal with full load ) Diesel (ASTM D975-2D) Inline injection pump
Type Speed
Front Rear Front Final drive Rear Power transmission type Vibrator type Service brake Secondary brake (Emergency brake) Parking brake Power transmission type Steering type Front Use Rear Front Suspension type Rear Water spray type Liquid spray type
SPECIFICATIONS
2. TABLE OF STANDARD VALUES 2-1. Engine Item
Standard value CUMMINS QSF 3.8 97/2,200 kW/ min-1 ( 130/2,200 HP/ min-1 ) 2,200 rpm 900 rpm 90 N·m 66 lbf·ft ( ) 90 N·m 66 lbf·ft ( ) Tighten additional 90° 24 N·m 18 lbf·ft ( ) 43 N·m 32 lbf·ft ( ) 0.254 mm 0.01 in. ( ) 0.508 mm 0.02 in. ( ) 101.6 mm of H2O ( 4.0 in. of H2O )
Engine model Rated output Max. rpm under no load Min. rpm under no load 1st 2nd 3rd Intake manifold tightening torque Exhaust manifold tightening torque Valve clearance (intake) Valve clearance (exhaust) Crankcase blowby Cylinder head tightening torque
Remarks
Use mano meter
2-2. Propulsion Item 1st SW884/ Travel 994 speed 2nd (Forward/ reverse) SW884ND/ 1st 994ND 2nd
4,000 vpm 3,000 vpm 2,500 vpm Vibration Oscillation
0 0 0 0 0 0 0
Standard value ( 0 to 4.5 mph to 7.2 km/h ( 0 to 3.4 mph to 5.5 km/h ( 0 to 2.8 mph to 4.5 km/h ( 0 to 6.8 mph to 11.0 km/h ( 0 to 3.4 mph to 5.5 km/h ( 0 to 4.0 mph to 6.4 km/h ( 0 to 6.8 mph to 11.0 km/h
) ) ) ) ) ) )
Remarks
Standard value 40.2 ± 1.0 MPa ( 5,829 ± 145 psi 37.3 ± 1.0 MPa ( 5,409 ± 29 psi 2.5 ± 0.2 MPa ( 362 ± 29 psi 2.5 ± 0.2 MPa ( 362 ± 29 psi 0.4 MPa ( 58.0 psi 0.3 MPa ( 43.5 psi 1.5 MPa ( 218 psi 10.7 L/min ( 2.8 gal./min 10.9 L/min ( 2.9 gal./min 31.5 ± 1.0 MPa ( 4,567 ± 145 psi
) ) ) ) ) ) ) ) ) )
2.5 ± 0.2 MPa
(
)
0.4 MPa 0.15 MPa 0.17 MPa 6.4 L/min 10.5 L/min
( ( ( ( (
2-3. Hydraulic System Item High pressure relief valve setting Cut off valve setting Charge relief Pump valve setting Motor (F) Propulsion Pump Case pressure Motor Brake release pressure SW884/994 Motor drainage SW884ND/994ND High pressure relief valve setting Charge relief valve setting Vibration
Pump (R)
Pump (F),(R) SW884/994 Motor SW884ND/994ND SW884/994 Motor drainage SW884ND/994ND Case pressure
Steering oil pressure
17.5 ± 1.0 MPa
362 ± 29 psi 58.0 psi 21.8 psi 24.7 psi 1.7 gal./min 2.8 gal./min
( 2,538 ± 145 psi
Remarks
) ) ) ) ) )
or less or less
or less or less
(orbitroll relief pressure + charge relief pressure)
2-010
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 Item Clearance between brake pedal and floorboard (as released)
Standard value
Remarks
132 mm (5.2 in.) Note 1: See dimensions Note 1
Clearance between brake pedal and floorboard (when pressed down)
75 mm (3.0 in.) Note 2: See dimensions
Propulsion motor inner brake wear limit Thickness of disc assembly (7 discs)
18.5 to 19.1 mm (0.73 to 0.75 in.) Note 3: See dimensions Allowable when thickness is within this range. Replace all 7 discs when thickness becomes 18.5 or less.
Note 2 SW880-02001
Note 3
SW880-02002
2-6. Capacities Item Engine oil pan Fuel tank Coolant Gear box Hydraulic oil tank Vibrator case Water spray tank DEF tank
2-011
SW884/994 SW884ND/994ND
Standard value 11 L ( 2.9 gal. ) 292 L ( 77.1 gal. ) 22 L ( 5.8 gal. ) 3.6 L × 2 ( 0.95 gal. × 2 ) 65 L ( 17.2 gal. ) 22 L × 2 ( 5.8 gal. × 2 ) 75 L × 2 ( 19.8 gal. × 2 ) 600 L × 2 ( 158.5 gal. × 2 ) 19 L ( 5.0 gal. )
Remarks
SPECIFICATIONS
3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating 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 grade CJ-4
SAE5W-40
SAE5W-40
SAE5W-40
MIL-L-2104B
Gear oil
API grade GL5
SAE80W-90
SAE90
SAE140
MIL-L-2105
Anti wear
ISO-VG32 Over VI 140
ISO-VG46 Over VI 140
ISO-VG68 Over VI 110
ISO-3448
Lubricant
Hydraulic oil Grease
Lithium type extreme pressure
Fuel
Diesel oil
DEF
ISO22241-1 or AUS32
NLGI-2 ASTM D975-2D
3-2. Recommended Lubricants Lubricant Engine oil API-CJ4
Gear oil API GL 5
Hydraulic oil ISO-VG 46
Grease (NLGI-2)
CHEVRON
DELO 400 LE
RPM Universal Gear Lubricants
Rando HDZ 46
Multifak EP 2
BP
—
BP Energear HYPO-U
Bartran HV 46
BP Energrease LS-EP 2
CASTROL
Tection Extra
EXP Gear OILS
Castrol Hyspin AWH 46
Castrol Spheerol ELP 2
EXXON MOBIL
Mobil Delvac 1 ESP
Mobilube HD
Mobil DTE 10 Excel 46
Mobilux EP 2
SHELL
Shell Rimula R4 L
Shell Spirax S2 A 90
Shell Tellus S2V 46
Shell Alvania Greases EP 2
Oil company
2-012
SPECIFICATIONS
4. TIGHTENING TORQUE CHART
Metric fine screw
Metric coarse screw
N·m
2-013
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
A
4
C
B 3
2
13 14 15
12
7 8 9
6
5
10
16
11
DETAIL B
DETAIL C
VIEW A 0568-01805-0-11972-C
(1) (2) (3) (4) (5) (6)
Engine Bolt : M12×35 Shim Bracket Bracket Bracket
(7) Bolt : M12×80 (8) Damper (9) Bolt : M 8×20 (10) Nut : M12 (11) Bolt : M10×30
(12) Bracket (13) Bolt : M12×35 (14) Bolt : M16×50 (15) Bolt : M12×25 (16) Damper
N•m
(2) Bolt M12×35 : 108 N·m ( 80 lbf·ft ) (9) Bolt M 8×20 : 31 N·m ( 23 lbf·ft ) (10) Nut M12 : 108 N·m ( 80 lbf·ft )
(13) Bolt M12×35 : 108 N·m ( 80 lbf·ft ) (14) Bolt M16×50 : 265 N·m ( 195 lbf·ft ) (15) Bolt M12×25 : 108 N·m ( 80 lbf·ft )
3-001
ENGINE AND CONTROLS
2. FUEL SYSTEM
1
B
9
C 8
C
7
2 3
4
A
A B 6 (1) Fuel tank (2) Hose ( 3 → 12) (3) Suction (fuel tank) (4) Fuel gauge unit (5) Return (fuel tank) (6) Hose (11 → 5) (7) OUT (main filter) (8) IN (main filter) (9) Main filter (10) Drain plug (fuel tank) (11) Return (engine) (12) IN (pre-filter) (13) OUT (pre-filter)
(14) Pre-filter (15) Hose (13 → 24) (16) WIF sensor (17) Hose ( 7 → 23) (18) Hose (25 → 8) (19) Filler cap (20) Fuel supply port (21) Filter (22) Fuel pump (23) Suction (engine) (24) IN (fuel pump) (25) OUT (fuel pump)
5
10
SECTION A-A
0568-02806-0-11973-D
3-002
ENGINE AND CONTROLS
11
2
13
12
14
18 17
D 16 15
VIEW B-B
19 20
21 Engine
SECTION C-C
Suction
22
Return
(17)
Main filter (18)
Fuel pump
(6) (15)
Pre-filter
25
Suction 24
23
DETAIL D Arrow “
(2)
Return
Fuel tank Fuel system diagram
” symbols show the hose connection and the direction of the flow of the fuel. 0568-02806-0-11973-D
3-003
ENGINE AND CONTROLS
3. EXHAUST SYSTEM 3-1. Exhaust System DRT harness
NOx sensor
(P.5-036)
Mark D_NOx (P.5-023)
DRT ASSY
SCR ASSY
(P.3-005)
(P.3-006)
A
SCR harness
(P.5-035)
Mark E5
(P.5-019),(P.5-035)
NOx sensor
Mark S_NOx (P.5-035)
SCR in out temp
Mark S_TEMP (P.5-035)
DETAIL A
Diffuser 0568-05805-0-11976-E
3-004
ENGINE AND CONTROLS
3-1-1. DRT ASSY
A
1
2
VIEW A SW884-03003
(1) DEF dosing injector valve (2) NOx sensor
3-005
ENGINE AND CONTROLS
3-1-2. SCR ASSY
1
2
3
SW884-03004
(1) NOx sensor (2) SCR in temperature sensor (3) SCR out temperature sensor
3-006
ENGINE AND CONTROLS
3-2. Urea Piping DEF pump
Discharge
Suction (3)
B
Engine 5
(9)
(13) (2)
Coolant inlet
DEF system diagram 2
(8)
Coolant outlet
DEF tank 25
4
Tee 2 (6)
(12)
Return Return
Outlet
(7)
Engine
DRT
3
Coolant outlet
Tee 1 Intlet
2
DEF tank
DEF tank heating valve
(1)
(7)
1
Coolant inlet
DRT
Coolant inlet
Coolant outlet
DEF tank heating diagram
A 6 7
13
26 1 28
2
6
8
29
12 8
11
15
16
F 13 9 27
DETAIL D
DETAIL F
DETAIL E
13
D
19
9 10 12
18 14
17
DETAIL A
E
(1) Hose (22 ⇒ 26) (2) Hose (25 → 29) (3) Hose (21 ⇒ 15) (4) DEF tank (5) Hose (16 ⇒ 20) (6) Hose (17 → 29) (7) Hose (14 → 19) (8) Hose (28 → 14) (9) Hose (29 → 10) (10) Coolant inlet (engine) (11) Coolant outlet (engine) (12) Hose (11 → 28) (13) Hose (28 → 27) (14) DEF tank heating valve (15) Return (DEF tank) (16) Outlet (DEF tank) (17) Coolant outlet (DEF tank) (18) Breather (19) Coolant inlet (DEF tank) (20) Suction (DEF pump) (21) Return (DEF pump) (22) Discharge (DEF pump) (23) DEF pump (24) DEF connector (25) Coolant outlet (DRT) (26) Inlet (DRT) (27) Coolant inlet (DRT) (28) Tee 1 (29) Tee 2
20 21 22
24
Arrow “ Arrow “
” symbols show the hose connection and the direction of the flow of the DEF. ” symbols show the hose connection and the direction of the flow of the coolant.
DETAIL C
23
C
VIEW B
0568-05805-0-11976-E
3-007
ENGINE AND CONTROLS
4. CONTROL SYSTEM 4-1. Forward-reverse Control Apply grease *1
4 5 6
Black face Apply grease *1
7 8 9 10
Apply grease *1
11
SECTION A-A 2
1 R
N F
Apply grease *1 Apply grease *2
A
A B
B 13
12
SECTION B-B
3
0568-12805-0-11265-C
(1) (2) (3) (4) (5)
F-R lever switch F-R lever Backup buzzer switch F-R lever potentiometer 2 Bush
(6) (7) (8) (9)
Washer Nut : M16 Washer Disc spring
(10) Collar (Do not apply grease) (11) F-R lever potentiometer 1 (12) Nut : M16 (13) Screw : M16
*1 : Lithium-based grease *2 : Molybdenum-based grease 3-008
ENGINE AND CONTROLS
5. PUMP MOUNT 5-1. Pump Mount 1
2
A
7
B
A 6
5
4
3
M8 1.25
8
SECTION A-A
M10 1.5
VIEW B 0568-36812-0-11986-B
(1) Bolt (2) Bolt (3) Pump (4) Bolt
: M10×50 : 3/8-16UNC×22 : M20×50
(5) Housing (6) Flange (7) Hub (8) Bolt : M12×35
N•m
(1) Bolt M10×50 : 60 N·m ( 44 lbf·ft ) (2) Bolt 3/8-16UNC×22 : 69 N·m ( 51 lbf·ft ) 3-009
(4) Bolt M20×50 : 539 N·m ( 398 lbf·ft ) (8) Bolt M12×35 : 86 N·m ( 63 lbf·ft )
ENGINE AND CONTROLS
5-1-1. Installation of pump • When the pump 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 Attach hub (7) to pump (3) aligning it with end surface of shaft. ③ Secure hub (7) with bolts (8). N•m
(8) Bolt M12×35 : 86 N·m (63 lbf·ft)
④ Position flange (6) as shown in the figure, and secure to flywheel with eight bolts (2). N•m
(2) Bolt 3/8-16UNC×22 : 69 N·m (51 lbf·ft)
(NOTICE) • Bolt (2) is treated with thread-locking fluid. Use new thread-locking fluid treated bolt for installation. ⑤ Position housing (5) as shown in the figure, and secure to flywheel housing with twelve bolts (1) and washers. N•m
(1) Bolt M10×50 : 60 N·m (44 lbf·ft)
⑥ Engage hub (7) with flange (6). ⑦ Secure pump (3) to housing (5) with six bolts (4) and washers. N•m
(4) Bolt M20×50 : 539 N·m (398 lbf·ft)
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 1-2-1. Hydraulic circuit diagram (SW884/994)
LOV
G2 (1/4") (1/4")
SBA
Neutral solenoid valve
LOB
(1/4")
BST
BSP
LO1
Hydraulic oil filter 1 LS1
SBP
(1/4")
Parking brake solenoid valve BSA
Bypass valve
T
(1/2")
BV1
R
15.0Mpa
(1/2")
G4
(1/2")
(1/4")
400 cc/rev
BVA
Hydraulic oil filter 2 G1
LOP
(1/2")
LO2
L
P
Orbitrol
LS2
PT2
PSF
POF PMB
a
PPB
b
a
VT2
2.5MPa
70X
(1/2")
46.0cc/rev
ARS
Steering cylinder (R)
31.5MPa
28.3cc/rev 46.0cc/rev
SRD
35-380ST
SRF SRL
37.3MPa
2.5MPa
31.5MPa
40.2MPa
PX2
FPA
31.5MPa
125cc/rev
PX1
VT1
RPB
40.2MPa
SW884/994 ENGINE 4033-54000-0 CUMMINS QSF3.8 97kW /2200rpm 488N・m/1600rpm HIGH IDLE 2200rpm ECO MODE 1850rpm
b
(3/8")
(3/4")
PT1
b
ALS
VTP
(3/4")
a
(1/2")
BV2
(1/2")
BVB
(3/8")
G3
PPS PMA
Propulsion pump
PPA
RPA
Vibrator pump (R)
Vibrator pump (F)
SLG SLR
SLD
31.5MPa
FPG
70X
FPB
35-380ST
Steering cylinder (L)
PDO CSP CSM PDC SCD
FMB FMA
Forward
PPB
FMB
BAF
FMA 2.5MPa
PBF (3/4") FMB (1/4")
1.5MPa
65.7 cc/rev
FMP
i=39.000
Drum (F)
16.0 cc/rev
2000(SW884) 2130(SW994)
FMD
FVA
FD1 FVB FD2
(1/2")
PPB
RMA
RMA
Forward
(1 1/4")
(1/2")
(3/4")
(3/4")
(3/4")
CVO
T2
PPA
RMB
PPB
RMA
Reverse
PPA
T5
Ω 65.7 cc/rev
i=39.000
Drum (R)
(1/4")
RMP
RMD
Vibrator motor (R)
RVA
16.0 cc/rev
(3/4")
RMB RMB
n 1.5MPa
T1 150mesh
T7
Propulsion motor (R)
(3/4")
1400
VTT
T6
Vibration:HI (3000VPM) (2500VPM)
FVA
VPA
FVB FVA
VPB VPA
FVB
VPB
SCS
2000(SW884) 2130(SW994)
RD1 RVB RD2
Vibration:LO (4000VPM) (3000VPM) (2500VPM)
Vibration:HI (3000VPM) (2500VPM)
(1/2") (1/2")
VPT
1.6MPa
i=1:1
P.T.O
Steering charge pump
VPB
Flush and boost pressure valve
(3/4")
CVS
T4
Vibration:LO (4000VPM) (3000VPM) (2500VPM)
(3/4")
VTM
24.9 cc/rev
VPA
(1/2")
PPB PPA
BAR
Reverse
(3/4")
Vibrator motor (F)
(3/4")
(1/2")
PAR
CO
PAF
FMA
PBR
PPA
Propulsion motor (F)
1400
Oil CS cooler
RVA
RPA
RVB
RPB
RVA
RPA
RVB
RPB
(3/4")
(1"1/4")
0568-99023-0-11994-A
4-003
HYDRAULIC SYSTEMS
1-2-2. Hydraulic circuit diagram (SW884ND/994ND) LOV
G2 (1/4") (1/4")
SBA
Neutral solenoid valve
LOB
(1/4")
BST
BSP
LO1
Hydraulic oil filter 1 LS1
SBP
(1/4")
Parking brake solenoid valve BSA
Bypass valve
T
(1/2")
BV1
R
15.0Mpa
(1/2")
G4
(1/2")
(1/4")
400 cc/rev
BVA
Hydraulic oil filter 2 G1
LOP
(1/2")
LO2
L
P
Orbitrol
LS2
PT2
PSF
POF PMB
a
PPB
b
a
VT2
2.5MPa
70X
(1/2")
46.0cc/rev
ARS
Steering cylinder (R)
31.5MPa
28.3cc/rev 46.0cc/rev
SRD
35-380ST
SRF SRL
37.3MPa
2.5MPa
31.5MPa
40.2MPa
PX2
FPA
31.5MPa
125cc/rev
PX1
VT1
RPB
40.2MPa
SW884/994 ENGINE 4033-54000-0 CUMMINS QSF3.8 97kW /2200rpm 488N・m/1600rpm HIGH IDLE 2200rpm ECO MODE 1850rpm
b
(3/8")
(3/4")
PT1
b
ALS
VTP
(3/4")
a
(1/2")
BV2
(1/2")
BVB
(3/8")
G3
PPS PMA
Propulsion pump
PPA
RPA
Vibrator pump (R)
Vibrator pump (F)
SLG SLR
SLD
31.5MPa
FPG
70X
FPB
35-380ST
Steering cylinder (L)
PDO CSP CSM PDC SCD
FMB FMA
Forward
PPB
FMB
BAF
FMA 2.5MPa
PBF (3/4") FMB (1/4")
1.5MPa
65.7 cc/rev
FMP
i=39.000
Drum (F)
FD1 FVB FD2
(1/2")
PPB
RMA
RMA
Forward
(1 1/4")
(1/2")
(3/4")
(3/4")
(3/4")
CVO
T2
PPA
RMB
PPB
RMA
Reverse
PPA
Ω 65.7 cc/rev
i=39.000
Drum (R)
VPB VPA
FVB
VPB
(1/4")
RMP
RMD
Vibrator motor (R)
RVA
2000(SW884) 2130(SW994)
RD1 RVB RD2
1.6MPa
P.T.O
Steering charge pump
VPB
RVA
RPA
RVB
RPB
RVA
RPA
RVB
RPB
Vibration :Oscillation (2800VPM)
Vibration :Normal (3000VPM)
(1/2") (1/2")
VPT
i=1:1
Flush and boost pressure valve
35.0 cc/rev
(3/4")
RMB RMB
n 1.5MPa
T1 150mesh
T5
Propulsion motor (R)
(3/4")
1370
VTT
T7
FVB FVA
SCS
(3/4")
CVS
T6
VPA
Vibration :Normal (3000VPM)
(3/4")
VTM
T4
FVA Vibration :Oscillation (2800VPM)
35.0 cc/rev
2000(SW884) 2130(SW994)
FMD
FVA
24.9 cc/rev
VPA
(1/2")
PPB PPA
BAR
Reverse
(3/4")
Vibrator motor (F)
(3/4")
(1/2")
PAR
CO
PAF
FMA
PBR
PPA
Propulsion motor (F)
1370
Oil CS cooler
(3/4")
(1"1/4")
0568-99029-0-12140-A
4-004
HYDRAULIC SYSTEMS
2. PROPULSION HYDRAULIC SYSTEM CVO
2-1-1. Propulsion hydraulic piping (1) Hose (PDO
CSP)
Propulsion pump
PX2
2-1. Propulsion Hydraulic Piping
Check valve CVS
Hydraulic oil tank
Hose (PDC
PT1
PT1
PSF
PDO
T4
CVS) PMB
CSP
PMA PT2
T6
POF
PDC
PPS
VIEW A BV1
BV2
BVA
SECTION C-C
VIEW B Coupling : G3 High pressure gauge port
BVB
Bypass valve
BST
Coupling : G4 High pressure gauge port
BSP
SBA
SBP
BSA BAF
(P.4-006)
BAR PX1 CS
CSM
(P.4-006)
PX2
Hose (PX1
SBA)
Hose (PX2
(P.4-006)
Neutral solenoid valve SBP)
Parking brake solenoid valve
DETAIL D
T2
LO1
LO2
LS2
C
Oil cooler
T4
Coupling : G1 Charge pressure gauge port
LOB
T6
D
LOP Hydraulic oil filter 2
C Hose (LOB
T3 Hose (BST Hose (PMA
Hose (T2 PPS)
BSP) LOV
PT2)
(P.4-019) (P.4-020)
A
Hose (CO T6)
Hose (T3 Tank drain)
Hose (PMB
Hydraulic oil filter 1 BVB)
PSF) LS2)
BVA)
Tank drain CO
B
Hose (LOP Hose (POF
Coupling : G2 Charge pressure gauge port
The letters and numbers in the figure such as “PMA” and “BVA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0568-36813-0-11987-B
4-005
HYDRAULIC SYSTEMS
2-1-2. Propulsion hydraulic piping (2)
Hose : FP
Parking brake solenoid valve
Propulsion motor (R)
BAR
BAF
(P.4-005)
(P.4-005)
Front : FMA Rear : RMA
Hose : FB
C
Front : FMD Rear : RMD (P.4-019) (P.4-020)
C
Hose : RA
Hose : FA
C
Front : FMP Rear : RMP
Hose : RP
Hose : FD
Hose : RB
SECTION B-B
C
SECTION C-C Hose : RP
AFP
C
Front : FMB Rear : RMB
VIEW A
Hose : RA
AFD
C AFB
(Front / Rear)
Hose : RB
AFA
DETAIL D ARP
VIEW E PPB
PBR
PBF
PAR
PAF
ARA
B
ARB
CSM
Propulsion motor (F) Hose : FA (AFA FMA) Hose : FB (AFB FMB)
PPA
VIEW F
B (P.4-005)
Hose : FD (FMD AFD) Hose : FP (AFP FMP)
Hose : RA (ARA RMA)
D G
Hose : RP (ARP RMP)
Hose (AFD
SECTION H-H CSM)
Hose : RB (ARB RMB)
Hose (PBF
AFB)
Hose (PBR
E F
ARP)
H
A
A
FMD
ARA) Hose (BAR
FMP
G The letters and numbers in the figure such as “ARB” and “RMB” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
Hose (PAF
AFA)
Hose (PAR
H ARB)
Hose (BAF
AFP)
SECTION G-G 0568-36814-0-11988-D
4-006
HYDRAULIC SYSTEM
2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump ASSY (propulsion + vibrator) 3-3
3-14 3-15 2-3
2-5, 3-5
2-1, 3-1
2-14 2-15
1
2-15, 3-15
3-13
2-11
2-9, 3-9 2-12, 3-12
2-11, 3-11
2-13
VIEW C
SECTION B-B 1-6
1-5 1-1 1-19
3-13, 3-1 3-2 3-14 3-3
2-8, 3-8
2-13, 3-13
3-11
2-13,
2 2-1 2-2 2-14 2-3 3
1-3 1-4 1-5
2-6, 3-6
2-14, 3-14
C
1-1 1-2
1-11 1-10 1-8, 1-6, 2-5 2-4 1-9 (Back side) 1-7 (Back side) 1-9
1-12
1-8
1-13 2-6
2-7
3-5
3-4
2-8 3-6
3-7
3-8
1-8
B 1-19
A
1-16 1-17
1-9
1-18
1-18
B
1-7
1-17 1-16 1-9 1-15 1-14 2-12
2-11 2-10 2-9 3-12 3-11 3-10 3-9
VIEW A 1-3 1-17
1-12
1-1
1-11
1-16
1-5
1-19 1-131-6
1-18 1-14 1-7
2-15 2-12
2-6
2-1
Pump circuit diagram 4-007
2-5
2-3
2-8
2-13
2-11 2-14
3-15 3-12
3-3 3-13
3-6
3-1
3-5
3-8
3-11 3-14
SW884-04001
HYDRAULIC SYSTEM (1) Propulsion pump (1-1) Servo pressure gauge port (1-2) Solenoid valve a (Reverse) (1-3) Drain port (1-4) Cut off valve (1-5) Filter port (From filter) (1-6) Port B (Forward) (1-7) Port A (Reverse) (1-8) High pressure relief valve (For Port B) (1-9) High pressure relief valve (For Port A) (1-10) Solenoid valve b (Forward) (1-11) Servo pressure gauge port (1-12) Control pressure port (1-13) High pressure gauge port (For Port B) (1-14) High pressure gauge port (For Port A) (1-15) Charge relief valve (1-16) Charge pressure gauge port (1-17) Drain port (1-18) Charge pump suction port (1-19) Filter port (To filter) Specifications • Displacement Propulsion pump Charge pump • High pressure relief valve pressure setting • Charge relief valve pressure setting • Cut off valve pressure setting
: : : : :
[PX1] :
(2) Vibrator pump (R) (2-1) Servo pressure gauge port (2-2) Solenoid valve a (High amplitude/Normal)* (2-3) High pressure gauge port (For Port B) (2-4) Solenoid valve b (Low amplitude/Oscillation)* (2-5) Servo pressure gauge port (2-6) Control pressure gauge port (2-7) High pressure relief valve (For Port B) (2-8) Charge pressure gauge port (2-9) Charge relief valve (2-10) High pressure relief valve (For Port A) (2-11) High pressure gauge port (For Port A) (2-12) Drain port [VT2] (2-13) Port A (Low amplitude/Oscillation)* [RPA] (2-14) Port B (High amplitude/Normal)* [RPB] (2-15) Drain port
9/16-18UNF
[PT1] : 1 5/16-12UN [PSF] : 1 5/16-12UN [PPB] : SAE 1 1/4” [PPA] : SAE 1 1/4”
[PX2] : : [PMB] : [PMA] :
9/16-18UNF 9/16-18UNF 7/16-20UNF 7/16-20UNF
: 7/ 8-14UNF [PT2] : 1 5/16-12UN [PPS] : 1 7/8-12UN [POF] : 1 5/16-12UN
3
125 cm /rev ( 7.63 cu.in./rev 28.3 cm3/rev ( 1.73 cu.in./rev 40.2 MPa ( 5,829 psi 2.5 MPa ( 363 psi 37.3 MPa ( 5,409 psi
Specifications • Displacement : • High pressure relief valve pressure setting : • Charge relief pressure setting :
) ) (at 2,000 min-1) ) ) )
: 7/16-20UNF : 7/16-20UNF : 9/16-18UNF : 3/ 4-16UNF
: 7/16-20UNF : 7/ 8-14UNF : SAE 3/4” : SAE 3/4” : 7/ 8-14UNF
46 cm3/rev ( 2.81 cu.in./rev ) 31.5 MPa ( 4,568 psi ) 2.5 MPa ( 363 psi )
(3) Vibrator pump (F) (3-1) Servo pressure gauge port (3-2) Solenoid valve a (High amplitude/Normal)* (3-3) High pressure gauge port (For Port B) (3-4) Solenoid valve b (Low amplitude/Oscillation)* (3-5) Servo pressure gauge port (3-6) Control pressure gauge port (3-7) High pressure relief valve (For Port B) (3-8) Charge pressure gauge port [FPG] (3-9) Locking set (3-10) High pressure relief valve (For Port A) (3-11) High pressure gauge port (For Port A) (3-12) Drain port [VT1] (3-13) Port A (Low amplitude/Oscillation)* [FPA] (3-14) Port B (High amplitude/Normal)* [FPB] (3-15) Drain port Specifications • Displacement : • High pressure relief valve pressure setting :
: 7/16-20UNF
: 7/16-20UNF : 7/16-20UNF : 7/16-20UNF : 9/16-18UNF : 3/ 4-16UNF
: 7/16-20UNF : 7/ 8-14UNF : SAE 3/4” : SAE 3/4” : 7/ 8-14UNF
46 cm3/rev ( 2.81 cu.in./rev ) 31.5 MPa ( 4,568 psi )
ASSY Specifications • Allowable pump case pressure : 0.4 MPa ( 58 psi ) or less • Weight : 145 kg ( 320 lbs. )
* : High amplitude, Low amplitude (STD type), Normal, Oscillation (ND type)
4-008
HYDRAULIC SYSTEM
2-2-2. Propulsion hydraulic motor (F) 1
2
5
6
7
8
X
9
4 3
10
X
11
SW800- -04005
(1) Port B (Forward) (2) Port A (Reverse) (3) Parking brake pilot port (4) Drain port (5) High pressure gauge port (For Port B) (6) High pressure gauge port (For Port A) 6
[FMB] : SAE 1” [FMA] : SAE 1” [FMP] : 9/16-18UNF [FMD] : 7/8-14UNF : 9/16-18UNF : 9/16-18UNF
(7) Motor (8) Reduction gear (9) Filler cap : 7/8-14UNF (10) Shuttle valve (11) Charge pressure gauge port : 7/16-20UNF
3 Flow of oil (Rotation direction is when viewed in direction of X-X.)
2 10
1 2
2 Clockwise rotation 1 Counterclockwise rotation
1 11
5
4
Motor circuit diagram Motor specifications • Displacement • Maximum working pressure • Brake release pressure • Allowable motor case pressure Reduction gear specifications • Reduction ratio • Propulsion hydraulic motor weight 4-009
SW880-1-04002
: 65.7 cm3/rev ( 4.0 cu.in./rev ) : 41.8 MPa ( 6,063 psi ) : 1.5 MPa ( 218 psi ) : 0.3 MPa ( 43.5 psi ) : 1/39.000 :
191 kg
(
421 lbs.
)
HYDRAULIC SYSTEM 1) Internal structure of propulsion hydraulic motor (F)
7
7-1
8-1
8
8-2
7-2
8-3
8-4
8-5
8-6
SECTION A-A 8-7
7-11
A
A
7-10
7-9
7-8
7-7
7-6
7-5
7-4
7-3
8-9
8-8
SW800-
(7) Motor (7-1) Cylinder block kit (7-2) Bearing (7-3) Oil seal (7-4) Shaft (7-5) Swash plate assembly (7-6) Brake stopper (7-7) Friction plate (7-8) Separate plate (7-9) Piston brake (7-10) Journal bearing (7-11) Shuttle valve
-04006
(8) Reduction gear (8-1) Floating seal kit (8-2) Angular bearing (8-3) Planetary gear 2nd (8-4) Needle roller (8-5) Carrier (8-6) Planetary gear 1st (8-7) Needle roller (8-8) Sun gear 2nd (8-9) Sun gear 1st
4-010
HYDRAULIC SYSTEM
2-2-3. Propulsion hydraulic motor (R) Speed sensor specifications
1
2
Sensor pin I/O ±0.25V
1 Output signal 2
・Supply power voltage
5V
・Maximum required current
25 mA
2 Revolving direction output
・Output signal
21 pulses/rev.
3 Output signal 1
・Connector
4 Supply power voltage
DEUTSCH DTM-Series 6-Pin
5 0 V (GND) 6 -
DTM 04-6P Phase shift
Counter Clockwise clockwise High : *91.5
Output signal 1
Lo :
Output signal 2
3.5%
High : *91.5
3.5%
*8.5
3.5%
High : *91.5
3.5%
Lo :
6
10
7
8
3.5%
*8.5
Lo :
**Rotation direction output
5
1 2 3
6 5 4
*8.5
*Output voltage proportional to supply voltage **Rotation direction is as seen 3.5% from X-X.
9
X
4 3
X
SW880-1-04001
(1) Port B (Forward) [RMB] : SAE 1” (2) Port A (Reverse) [RMA] : SAE 1” (3) Parking brake pilot port [RMP] : 9/16-18UNF (4) Drain port [RMD] : 7/8-14UNF (5) High pressure gauge port (For Port B) : 9/16-18UNF (6) High pressure gauge port (For Port A) : 9/16-18UNF 6
3
(7) Motor (8) Reduction gear (9) Filler cap (10) Speed sensor
: 7/8-14UNF
10
2
Flow of oil (Rotation direction is when viewed in direction of X-X.) 1 2
2 Clockwise rotation 1 Counterclockwise rotation
1 5
4 Motor circuit diagram Motor specifications • Displacement • Maximum working pressure • Brake release pressure • Allowable motor case pressure Reduction gear specifications • Reduction ratio • Propulsion hydraulic motor weight 4-011
SW880-1-04003
: 65.7 cm3/rev ( 4.0 cu.in./rev ) : 41.8 MPa ( 6,063 psi ) : 1.5 MPa ( 218 psi ) : 0.3 MPa ( 43.5 psi ) : 1/39.000 : 192 kg
(
423 lbs.
)
HYDRAULIC SYSTEM 1) Internal structure of propulsion hydraulic motor (R)
7-11
7-1
7
8-1
8
8-2
7-2
8-3
8-4
8-5
8-6
8-7
7-10
7-9
7-8
7-7
7-6
7-5
7-4
7-3
8-9
8-8
SW880-04004
(7) Motor (7-1) Cylinder block kit (7-2) Bearing (7-3) Oil seal (7-4) Shaft (7-5) Swash plate assembly (7-6) Brake stopper (7-7) Friction plate (7-8) Separate plate (7-9) Piston brake (7-10) Journal bearing (7-11) Speed sensor
(8) Reduction gear (8-1) Floating seal kit (8-2) Angular bearing (8-3) Planetary gear 2nd (8-4) Needle roller (8-5) Carrier (8-6) Planetary gear 1st (8-7) Needle roller (8-8) Sun gear 2nd (8-9) Sun gear 1st
4-012
HYDRAULIC SYSTEM
2-2-4. Neutral solenoid valve
1
2 8
3 4 6
7
5
7
8 6 Hydraulic circuit diagram
(＋)
(−)
Connection diagram K-40146
(1) Solenoid (2) O-ring (1B P14) (3) Spool (K) (4) Body (5) Spring (6) Port T : 9/16-18UNF-2B (7) Port A [SBA] : 9/16-18UNF-2B (8) Port P [SBP] : 9/16-18UNF-2B Specifications • Rated flow • Rated pressure • Weight
4-013
: 30 L/min ( 7.9 gal./min ) : 4.9 MPa ( 710 psi ) (7, 8) : 0.5 MPa ( 72.5 psi ) (6) : 1.5 kg ( 3.3 lbs. )
HYDRAULIC SYSTEM
2-2-5. Parking brake solenoid valve
1
2 8
3 4 6 5
7 7
6 8 Hydraulic circuit diagram
(＋)
(−)
Connection diagram J-40146
(1) Solenoid (2) O-ring (1B P14) (3) Spool (J) (4) Body (5) Spring (6) Port P [BSP] : 9/16-18UNF-2B (7) Port A [BSA] : 9/16-18UNF-2B (8) Port T [BST] : 9/16-18UNF-2B Specifications • Rated flow • Rated pressure • Weight
: 30 L/min ( 7.9 gal./min ) : 4.9 MPa ( 710 psi ) (6, 7) : 0.5 MPa ( 72.5 psi ) (8) : 1.5 kg ( 3.3 lbs. )
4-014
HYDRAULIC SYSTEM Fig.: Propulsion circuit
10 n 7
11 1
4
9
8
12 a 2
c
B d b
d
e
1 3
f
A
A g
h
1. Engine 2. Coupling 3. Propulsion pump a. Control valve (forward-reverse) b. Charge relief valve c. Servo piston d. High pressure relief valves e. Cut off valve f. Charge pump 4. Steering・charge pump 5. Propulsion motor (F) g. Shuttle valve h. Brake j. Reduction gear 6. Propulsion motor (R) k. Brake m. Reduction gear 7. Neutral solenoid valve 8. Bypass valve 9. Parking brake solenoid valve 10. Orbitrol n. Relief valve 11. Hydraulic oil filter 1 12. Hydraulic oil filter 2 13. Oil cooler 14. Suction filter 15. Drum (F) 16. Drum (R) 17. Check valve
j
13 B 5
15
A k
m
B
17
6
16
14 SW884-04002
4-015
HYDRAULIC SYSTEM
2-3. Description and Operation of Propulsion System Description • Made up of propulsion pump (3), propulsion motor (F) (5), (R) (6), drum (F) (15), (R) (16), and parking brake solenoid valve (9).
Basic function of propulsion pump and motor Propulsion pump: • A piston pump is used. By varying swashplate angle which varies the piston stroke, forward travel, bringing to neutral and backing are achieved. Propulsion motor: • A fixed displacement piston motor is used.The displacement per rotation of the motor shaft is not variable.
Operation (It is assumed that the machine travels forward.) • Assemblies such as pump ASSY and motor ASSY are indicated by numbers such as “1” and “2”, while component parts of assemblies are shown by small letters such as “a” and “b”. • The parking brake is supposed to have been released. • Operation of the F-R lever forward puts pump control valve (a) into function. Servo piston (c) tilts the pump swashplate in the forward travel direction. • Propulsion pump (3) discharges oil from its port B. Then the oil flow branches into two lines; one line connecting to port B in propulsion motor (5) and one line to port A in propulsion motor (6). • The oil fed into the ports of the motors drives the motors, flowing out from the opposite side ports (port A in propulsion motor (5) and port B in propulsion motor (6)) and joins again to flow into port A in propulsion pump (3). At the same time, part of oil is drained to hydraulic oil tank via shuttle valve (g) and the motor casing. (NOTE) • Because the propulsion circuit is a closed circuit, the relationship between the suction port and discharge port is reversed when the travel direction is reversed. (The direction of oil flow reversed.) • The power from propulsion motor (5), (6) is delivered to drums (15), (16) through reduction mechanism in reduction gear (j), (m).
4-016
HYDRAULIC SYSTEM Fig.: Propulsion circuit
10 n 7
11 1
4
9
8
12 a 2
c
B d b
d
e
1 3
f
A
A g
h
1. Engine 2. Coupling 3. Propulsion pump a. Control valve (forward-reverse) b. Charge relief valve c. Servo piston d. High pressure relief valves e. Cut off valve f. Charge pump 4. Steering・charge pump 5. Propulsion motor (F) g. Shuttle valve h. Brake j. Reduction gear 6. Propulsion motor (R) k. Brake m. Reduction gear 7. Neutral solenoid valve 8. Bypass valve 9. Parking brake solenoid valve 10. Orbitrol n. Relief valve 11. Hydraulic oil filter 1 12. Hydraulic oil filter 2 13. Oil cooler 14. Suction filter 15. Drum (F) 16. Drum (R) 17. Check valve
j
13 B 5
15
A k
m
B
17
6
16
14 SW884-04002
4-017
HYDRAULIC SYSTEM
Two-step Speed selection (High-Low) From Low to High: • The pump discharge increases or decreases in proportion to the lever displacement. • Tilt the F-R lever, the pump discharge increases and vehicle speed increases.
To release parking brake • Propulsion motor (5), (6) contains brake (h), (k). • Actuation of the brake switch on the instrument panel in the driver’s station energizes parking brake solenoid valve (9). The oil under pressure is fed, via parking brake solenoid valve (9), into the brake cylinders. • This moves the brake pistons against the compression spring load, releasing the brake.
Circuit protection against high pressure • Cut off valve (e) is fitted in the propulsion pump. If the circuit pressure exceeds the setting of the valve, the valve functions and exerts oil pressure on the pump servo piston to reduce pump delivery. • Decrease in delivery (travel speed reduction) lowers the circuit pressure. • In addition to this cut off valve, the circuit includes high pressure relief valve (d) which opens to protect the circuit if the circuit pressure exceeds the permissible maximum of the cut off valve.
Charge circuit • The propulsion circuit is of a closed circuit, which needs feeding of oil into it for making up deficiency. • In the charge circuit, oil from charge pump (f) goes to propulsion pump (3) via hydraulic oil filter 2 (12). • Charge relief valve (b) built in propulsion pump (3) maintains the pressure to operate the pump swashplate when the F-R lever is in the neutral position. When travelling, shuttle valve (g) built in propulsion motor (5) performs oil renewal, cooling or removal of foreign material as well as keeping the necessary pressure to control the pump swashplate angle. • For the “To disengage the brake when towing”, refer to page 7-003.
4-018
HYDRAULIC SYSTEMS
3. VIBRATOR HYDRAULIC SYSTEM
Hose (VT1
3-1. Vibrator Hydraulic Piping 3-1-1. Vibrator hydraulic piping (SW884/994)
VTP) Hose (LOV
VTP
RPB VPA FPG) VPB
FPG Vibrator motor (F)
Hose (VTT
T7)
Hose (FVD
Vibrator pump (F),(R)
T5)
Hose (RMD
RD2)
Propulsion motor (R)
VTT
RMD
VT2
(P.4-006)
RPA
Flash and boost pressure valve
VTM VT1
VPT
VIEW A
VIEW B Hose (VRA
Hose (VRB T5 T7
SECTION G-G
Hose (VMP Hose (VFA
VFB
DETAIL F
VIEW D
Hydraulic oil tank
Vibrator motor (R)
E
FD1
C
Hose (RD1 Hose (VRA
D
FVA
RVA
FVB)
E
Hose (RVD
VTM)
F RVD)
G
RVA)
RD1
A
B
Hose (VFB
VRB
G
FD2)
FVB
VIEW C
VRA
VFB)
LOV
FVA)
FD2
RVB)
RVD
VFA
VFA)
FVD) (P.4-005)
RVD)
VMP)
Hose (VPB Hose (FD1
Hose (RD1
FVD VMP
Hose (VPT Hose (VPA
RVA)
Hose (VRB
RVB)
RVB
RD2
Hose (RPA
VRA)
Hose (RPB
VRB)
VIEW E
The letters and numbers in the figure such as “VRA” and “RVA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0568-49810-0-11989-C
4-019
HYDRAULIC SYSTEMS
3-1-2. Vibrator hydraulic piping (SW884ND/994ND)
Hose (VT1
VTP) Hose (LOV
VTP Vibrator motor (F)
Hose (VTT
Hose (FVD
T7)
T5)
Vibrator pump (F),(R)
Hose (RMD
RD2)
VPA FPG) VPB
FPG
RMD
Propulsion motor (R)
RPB
(P.4-006)
VTT
VT2
RPA
Flash and boost pressure valve
VTM VT1
VPT
VIEW A
VIEW B Hose (VRA
Hose (VRB T5 T7
SECTION G-G
FVA
FVA)
Hose (VFB
Hose (VRB
(P.4-005)
FVB
E
RVB)
Hose (VRA
G C
VIEW C
RVD
VFA
VFA)
VRA
VFB
VRB
VFB)
DETAIL F
Vibrator motor (R)
LOV
FVB)
RVB)
VMP)
Hose (VPB
Hose (VFA
RVD)
FVD VMP
Hose (VPT Hose (VPA
Hose (RD1
RVA)
VIEW D
Hydraulic oil tank
G
RVA)
Hose (RVD
VTM)
F
RVB RVA
G
D A
B
FD1
FD2
Hose (FD1
Hose FVD) (VMP
FD2)
E
Hose (RD1
RVD)
RD2
RD1
Hose (RPA
VRA)
Hose (RPB
VRB)
VIEW E
The letters and numbers in the figure such as “VRA” and “RVA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0568-49813-0-12078-C
4-020
HYDRAULIC SYSTEMS
3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor (SW884/994)
1
X
X 2
3
2
A
3
1
4
4
Motor circuit diagram Flow of oil (Rotation direction is when viewed in direction of X-X.) 4 3
(1) Drain port (T1) (2) Drain port (T2) (3) Port B (4) Port A
VIEW A
3 Clockwise rotation 4 Counterclockwise rotation
[FD1][RD1] [FD2][RD2] [FVB][RVB] [FVA][RVA]
SW800-04015
: G1/2 : M12×1.5 : 1 1/16-12UN-2B : 1 1/16-12UN-2B
Specifications • Displacement : 16 cm3/rev ( 0.98 cu.in./rev ) • Working pressure : 22.5 MPa ( 3,263 psi ) • Allowable motor case pressure : 0.15 MPa ( 21.6 psi ) • Weight : 5.4 kg ( 11.9 lbs. )
4-021
HYDRAULIC SYSTEMS
3-2-2. Vibrator hydraulic motor (SW884ND/994ND)
2
1
A
5
4
3 2
CW
1 3,4,5
CCW
Motor circuit diagram Flow of oil (Rotation direction is when viewed in direction of arrow A.)
VIEW A
2 1
1 Clockwise rotation 2 Counterclockwise rotation SV400-2-04012
(1) Port B [FVB][RVB] (2) Port A [FVA][RVA] (3) Drain port (4) Drain port [FD1][RD1] (5) Drain port [FD2][RD2]
: 1 1/16-12UN : 1 1/16-12UN : 7/ 8-14UNF : 7/ 8-14UNF : 7/ 8-14UNF
Specifications • Displacement : 35.0 cm3/rev • Working pressure : 34.5 MPa • Allowable motor case pressure : 0.17 MPa • Weight : 11 kg
4-022
( 2.1 cu.in. ) ( 5,003 psi ) ( 24.7 psi ) ( 24.3 lbs. )
HYDRAULIC SYSTEMS
3-2-3. Flush and boost pressure valve 1
2
5
3
4
4
5
1
3
2
Hydraulic circuit diagram
SW884-04005
(1) Port A (2) Port A1 (3) Port B1 (4) Port B (5) Port T
[VPA] : 1 1/16-12UN : 1 1/16-12UN : 1 1/16-12UN [VPB] : 1 1/16-12UN [VPT] : 9/16-18UNF
Specifications • Rated pressure : 40.0 MPa • Flushing relief valve pressure setting : 1.6 MPa • Weight : 3.0 kg
( 5,800 psi ( 232 psi ( 6.6 lbs.
) ) )
4-023
HYDRAULIC SYSTEMS Fig.: Vibrator circuit
1. Engine 2. Coupling 3. Propulsion pump 4. Vibrator pump (R) a. Proportional solenoid valve b. Charge relief valve c. High pressure relief valves 5. Vibrator pump (F) d. Proportional solenoid valve e. High pressure relief valves 6. Flush and boost pressure valve f. Flushing valve g. Flushing relief valve 7. Steering・charge pump 8. Vibrator motor (F) 9. Vibrator (F) 10. Vibrator motor (R) 11. Vibrator (R) 12. Orbitrol 13. Hydraulic oil filter 1 14. Suction filter
12
13
B1
1
7
A1
f e
e
6
d
g
5 A B2
A2
8
b c
B
9
c
a
4
A
B
10
3 11 2 1
14 SW884-04003
4-024
HYDRAULIC SYSTEMS
3-3. Description and Operation of Vibrator System Description • Made up of vibrator pump (F) (5), (R) (4), vibrator motor (F) (8), (R) (10), vibrator (F) (9) and (R) (11).
Basic function of vibrator pump and motor Vibrator pump: • A piston pump is in use. Varying the pump swashplate angle varies the piston stroke to select low amplitude/ oscillation, neutral and high amplitude/normal. Vibrator motor: • A fixed displacement piston motor is used.The displacement per rotation of the motor shaft is not variable.
Operation (It is assumed that HIGH amplitude/NORMAL is selected.) • The operation of the vibration switch actuated proportional solenoid valve (a), (d) built in vibrator pump (4), (5) to discharge oil from the port B1, B2. • Oil fed into the port B of the vibrator motor (8), (10) powers the motor and displaced from the opposite side port A, getting back to the port A1, A2 of vibrator pump. (NOTE) • Because the vibrator system also uses a closed circuit (HST) like the propulsion circuit, every time the amplitude selection is changed from low amplitude to high or vice versa, the function of the pump inlet and outlet is reversed with each other. • ND type switches oscillation and normal. • When the front drum is selected by the vibratory drum select switch, proportional solenoid valve (d) operates, only the vibrator pump (F) (5) discharges oil, the vibrator motor (F) (8) operates, and the vibrator (F) (9) rotates. • When the rear drum is selected by the vibratory drum select switch, proportional solenoid valve (a) operates, only the vibrator pump (R) (4) discharges oil, the vibrator motor (R) (10) operates, and the vibrator (R) (11) rotates. • When both drums are selected by the vibratory drum select switch, proportional solenoid valves (a), (d) operates, both vibrator pumps discharges oil, both vibrator motors operates, and both vibrators rotates.
Circuit protection against high pressure • High pressure relief valves (c), (e) built in the vibrator pump (4), (5) relieve pressure to protect the circuit when the pressure exceeds the setting of the valves.
Charge circuit • The vibrator circuit is also of a closed circuit, which needs feeding of oil into it for making up for deficiency and for other purposes. • In the charge circuit, oil from steering • charge pump (7) flows into Orbitrol (12), then the whole amount of oil goes to vibrator pump (4), (5) via hydraulic oil filter 1 (13) irrespective of the steering wheel operation. • Charge relief valve (b) maintains the charge pressure when the machine is not in motion. When travelling, the charge pressure is kept by the flushing relief valve (g).
4-025
HYDRAULIC SYSTEMS
4. STEERING SYSTEM 4-1. Steering Hydraulic Piping
T SRD
Steering cylinder (R)
SRF
SCS
P Orbitrol
Steering charge pump
L R
Hose (AAF
DETAIL A
SRL
LS1)
Hose (SRF
VIEW B
Hose (SCD
ASA)
SLD) AAF
Hose (SLG
SCD
ASA
Hose (T ATA)
Hose (AAP
ATA
AAP
SRD)
P)
SLR
B VIEW C SLD
Steering cylinder (L)
SLG
Hose (ATA
AAF)
VIEW D
Hose (ASA
AAP)
A Hydraulic oil tank
T1
Hose (T1 SCS)
LS1 Hose (R
D
Suction filter
E C
Hose (ARS
SLR)
Hose (ALS
ARS)
Hose (L
ARS
ALS
ALS)
SRL)
VIEW E
The letters and numbers in the figure such as “ALS” and “SRL” show each port. Arrow “ ; ” symbols show the hose connection and the direction of the flow of the oil.
0568-32809-0-11985-A
4-026
HYDRAULIC SYSTEMS
4-2. Steering Wheel
2
3
5
4
9
6
8
7
1
0431-32801-0-10036-C
(1) Tilt lock handle (2) Tilt ASSY (3) Column shaft (4) Nut (5) Steering wheel
(6) Bolt (7) Orbitrol (8) Bolt (9) Bolt
: M12 P=1.25
(4) Nut M12 P=1.25 (6) Bolt M10×35 (8) Bolt M10×25 (9) Bolt M10×25
: : : :
64 N·m ( 49 N·m ( 49 N·m ( 49 N·m (
• Steering wheel ASSY weight
:
18 kg
: M10×35 : M10×25 : M10×25
47 lbf·ft 36 lbf·ft 36 lbf·ft 36 lbf·ft
) ) ) )
( 40 lbs.
) 4-027
HYDRAULIC SYSTEMS
4-3. Hydraulic Component Specifications 4-3-1. Steering • charge pump 1
A
2
3
2
3
Hydraulic circuit diagram
VIEW A
SV540-04004
(1) Pump (2) Outlet port [SCD] : 7/ 8-14UNF (3) Inlet port [SCS] : 1 5/16-12UN Specifications • Displacement : 24.9 cm3/rev ( 1.5 cu.in./rev ) • Rated pressure : 20.6 MPa ( 2,987 psi ) • Weight : 3.8 kg ( 8.4 lbs. ) 4-028
HYDRAULIC SYSTEMS
4-3-2. Orbitrol
5
1
3
1
2
4
3
2
4
Hydraulic circuit diagram ORB-SD-04150
(1) Port L (2) Port R (3) Port P (4) Port T (5) Relief valve
[L] [R] [P] [T]
: : : :
3/4-16UNF 3/4-16UNF 3/4-16UNF 3/4-16UNF
Specifications • Displacement • Relief valve pressure setting • Weight
: : :
400 cm3/rev ( 24.4 cu.in./rev ) 15.0 MPa ( 2,175 psi ) 7 kg ( 15 lbs. )
4-029
HYDRAULIC SYSTEMS Fig.: Steering circuit c
8
8
b a
7
9
1
6 10
5
1. Engine 2. Coupling 3. Propulsion pump 4. Vibrator pump (F) 5. Vibrator pump (R) 6. Steering・charge pump 7. Orbitrol a. Relief valve b. Check valve 8. Steering cylinders c. Piston rods 9. Hydraulic oil filter 1 10. Suction filter
4
3 2 1
4-030
SW884-04004
HYDRAULIC SYSTEMS
4-4. Description and Operation of Steering System 4-4-1. Description and operation of steering system Description • Made up of steering • charge pump (6), Orbitrol (7) steering cylinders (8) and hydraulic oil filter 1 (9).The steering mechanism is of an articulated type in which the machine frame is articulated at its center.
Operation • The oil discharged from steering • charge pump (6) enters Orbitrol (7), and a certain quantity of oil that matches the handle turning direction and speed is supplied to steering cylinders (8). • The oil that enters the steering cylinder shifts piston rod (c) to operate it, while the oil pushed out of the port on the opposite side returns to Orbitrol (7), flowing into the charge circuit of vibrator pump (4), (5) through hydraulic oil filter 1 (9). • For the “Charge circuit”, refer to page 4-026. • Relief valve (a) built in Orbitrol (7) opens to relieve the pressure if the system pressure exceeds the setting of the valve, thus protecting the circuit.
4-031
HYDRAULIC SYSTEMS
4-4-2. Structure and operation of Orbitrol • Orbitrol used here is a load-sensing type, in which oil is supplied from the steering hydraulic pump according to the steering wheel rotating speed.
Structure Valve section: • The valve is a rotary-type direction changeover valve composed of spool (1) and sleeve (2), and the spline connects the steering wheel to spool (1). • When the steering wheel is not operated, spool (1) and sleeve (2) are held at the neutral position by centering spring (6), and the oil groove of spool (1) is not aligned with the oil hole of sleeve (2), completely stopping the oil flow into the steering cylinder. • When the steering wheel is operated, the oil groove of spool (1) is aligned with the oil hole of sleeve (2) to open the circuit, allowing the oil to flow into the steering cylinder. Rotor section: • The rotor is a kind of internal gear, functioning as a hydraulic motor when the valve section (spool and sleeve) opens. • The rotation of rotor (4) is transmitted to the valve section by drive shaft (5), controlling the valve opening according to the steering wheel rotating speed.
1. Spool 2. Sleeve 3. Stator 4. Rotor
5. Drive shaft 6. Centering spring 7. Cross pin 8. Check valve SV414-04006
SV414-04007
4-032
HYDRAULIC SYSTEMS
Operation Neutral (when the steering wheel is not operated): • Spool (1) and sleeve (2) in the valve section have a slit respectively, and centering spring (6) is set in the slit in combination with a flat spring. • When steering wheel is not operated, spool (1) and sleeve (2) are held in the neutral position by centering spring (6). • This Orbitrol is a load-sensing, non-load reaction normallyclosed type valve. All the oil holes of the spool are out of place when Orbitrol is in the neutral position, and the flow of oil from the hydraulic pump into the steering cylinder is closed completely. Swing (when the steering wheel is operated): • All the ports of the valve section are closed when Orbitrol is in the neutral position. The oil in the rotor has been sealed up, and rotor (4) is fixed. Sleeve (2) is coupled with rotor (4) via cross pin (7) and drive shaft (5), and it is fixed also. • When the steering wheel is operated, the turning force is applied to spool (1), contracting centering spring (6) that has been set in the slit. As a result, the oil groove of spool (1) is aligned with the oil hole of sleeve (2), opening the hydraulic circuit. • Consequently, all the four ports (hydraulic pump, tank, and steering cylinder circuits on the right and left sides) open to permit oil to flow, and rotor (4) rotates.
1. Spool 2. Sleeve 3. Stator 4. Rotor
5. Drive shaft 6. Centering spring 7. Cross pin 8. Check valve
SV414-04009
SV414-04008
SV414-04010
4-033
HYDRAULIC SYSTEMS Operation of feedback mechanism: • When the steering wheel is operated and the centering spring generates the displacement angle (misalignment in the circumferential direction) between the spool and sleeve, the oil from the hydraulic pump enters Orbitrol to rotate the rotor, and the oil flows into the steering cylinder. • As a result, the sleeve rotates slightly later than the spool, following the rotation of the spool. This phenomenon permits the spool to rotate continuously, permitting the steering wheel to turn and the vehicle to swing continuously. • When the steering wheel operation is stopped, the spool stops rotation immediately, but the oil flows into Orbitrol if the displacement angle exists between the spool and sleeve, permitting the rotor to rotate continuously. This rotation allows the sleeve to catch up with the spool, closing the hydraulic circuit. Finally, the centering spring returns the spool and sleeve back to the neutral position, completely stopping the oil flow.
4-034
SV414-04011
HYDRAULIC SYSTEMS Steering speed and flow control: • In the steering mechanism, the flow to the steering cylinder must be increased or decreased according to the rotational speed of the steering wheel. • Orbitrol controls the flow by changing the displacement angle between spool (1) and sleeve (2). In other words, sleeve (2) follows the rotation of spool (1) during the steering wheel operation, closing the hydraulic circuit. • When rotational speed of the steering wheel increases, the delay of sleeve (2) (displacement angle) increases, increasing the flow. Hydraulic pump flow and operating force: • When the hydraulic pump discharge is sufficient, the steering operating force is used simply to overcome the sliding resistance of sleeve (2) and the rotor, permitting the steering wheel to rotate easily. • When the hydraulic pump discharge is insufficient, the displacement angle between spool (1) and sleeve (2) reaches the maximum, reducing the quantity of oil flowing from the hydraulic pump into the rotor even if the hydraulic circuit opens widely, causing the rotor to rotate slowly. • As a result, the spool rotation becomes faster than the rotor rotation to increase the displacement angel to a maximum extent, and the spool rotates the rotor via the cross pin and drive shaft. At that time, the rotor functions as a hydraulic pump, preventing the steering wheel from rotating smoothly.
Slow steering speed
1
Small displacement angle
6 2
Fast steering speed
Large displacement angle
1 6 2
1. Spool 2. Sleeve 6. Centering spring SV414-04012
4-035
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
BW
Black/ White stripe
BY
Black/ Yellow stripe
BR
Black/ Red stripe
BG
Black/ Green stripe
W White
WR
White/ Red stripe
WB
White/ Black stripe
WL
White/ Blue stripe
WY
R Red
RW
Red/ White stripe
RB
Red/ Black stripe
RY
Red/ Yellow stripe
G Green
GW
Green/ White stripe
GR
Green/ Red stripe
GY
Y Yellow
YR
Yellow/ Red stripe
YB
Yellow/ Black stripe
Br Brown
BrW
Brown/ White stripe
BrR
L
LW
Blue/ White stripe
Lg Light green LgR
Light green/ Red stripe
Blue
YO
Yellow/ Orange stripe
White/ White/ WG Yellow stripe Green stripe
LO
Blue/ Orange stripe
RG
Red/ Green stripe
RL
Red/ Blue stripe
GO
Green/ Orange stripe
Green/ Yellow stripe
GB
Green/ Black stripe
GL
Green/ Blue stripe
GyR
Gray/ Red stripe
YG
Yellow/ Green stripe
YL
Yellow/ Blue stripe
YW
Yellow/ White stripe
GyL
Gray/ Blue stripe
Brown/ Red stripe
BrY
Brown/ Brown/ BrB Yellow stripe Black stripe
BrG
Brown/ Green stripe
LR
Blue/ Red stripe
LY
Blue/ Yellow stripe
LB
Blue/ Black stripe
LG
Blue/ Green stripe
P
PB
Pink/ Black stripe
LgY
Light green/ Light green/ LgB Yellow stripe Black stripe
LgW
Light green/ White stripe
LgL
Light green/ Blue stripe
Pu Purple
BL
Black/ Blue stripe
O
Orange
Gy Gray (Gr)
BrL
Brown/ Blue stripe
Sb Sky blue Pink
1-2. Electrical Equipment Installation When wiring electrical components to this machine (for example, additional lighting or electrical devices), connect all grounds to a common ground location and then return to the negative side of the battery. Do not wire to the engine block, starter or alternator terminals. Reference picture is below.
Attention! Do NOT wire to engine, alternator or starter motor.
Alternator nator tor
Engine Eng Sta Starter tarte motor moto mo Lighting
Lighting
Electrical device
5-002
Common ground
+ Battery
ELECTRICAL SYSTEM
2. SYSTEM CIRCUIT DIAGRAM
R
206 WR
139 0.5W
140 B
145 0.5W
F-R LEVER POTENTIOMETER2
121 0.5B
X
6 RY
78 O
210 0.5G
OUT W
CL
91 2YR 90 2R
241 2GR
89 WR
CABIN (OPTION)
REAR
AIR・CONDITIONER UNIT
25 0.5WB 25 0.5WB 25 0.5WB 25 0.5WB
X B
40
5
1
6
2
7
3
12
4
24
11
25
31
41 0.5LW 42 0.5BrW
32
38
13
39
44
47
45
48
14
49
15
X 0.5B
3
128 0.5GW
26 BrB 2 6 27 LB 5
X2 2B
8
16 17 18
21 22
25 26 27
30
174 1.25W
68 2G
69 2W
75 2L
FUSE BOX
172 3BY
30A
172 1.25BY
93 5WL
10 5WR
FUSE BOX
FUSE
171 BW 171 BW 171 BW 171 BW
15 LgR 52 1.25BR
3 1
4 166 GB 5
X B
2
176 BR
WIF SENSOR 1 2
STARTER SWITCH RELAY 120Ω TERMINATING RESISTOR
12V/120W
18 L
187 LgY
185 RB
47 LgB
186 RY
23 GB 161 P 4
120Ω
TERMINATING RESISTOR
YB
X B 5 2
12 BW 3
196 BrY
X B 1
64 LgW
2
162 Gr
1
DIAGNOSTIC SWITCH
74 BrY
1
12
28 GB
3
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
5 2RL
23 134 2WR
1
133 2B 4
148 YL
56 1.25LB
HYDRAULIC OIL FILTER SWITCH 1
2 RW
23 GB
X B
X B
53 G
22
HYDRAULIC OIL FILTER SWITCH 2
23 GB
FUEL GAUGE UNIT
161 P
3 1
13
4
153 1.25Y
5
X B
2
STARTER MOTOR RELAY
243 L
2
NOX SENSOR
68 2G
3 1
11
205 L
205 L
204 G
204 G 3
5
134 2WR 133 2B
AFTERTREATMENT RELAY 4
NOX SENSOR
133 2B
134 2WR
UP STREAM NOx (DRT SIDE:SCR INLET) 4 1 134 2WR DEF LEVEL/ 205 L 133 2B
204 G
QUALITY TEMPERATURE/ 204 G 2 SENSOR DEF TANK
120Ω
TERMINATING RESISTOR
3
REGEN. DISABLE SWITCH
3
1
SCR IN TEMP OUT TEMP
134 2WR
3
2 1
94 Br
95 LY 96 LgB 97 BR 193 LgB
COOLANT C A
B
194 YB 195 WB
51
27
52
28
73
5
66 94
13
39 BrR 3
1
34 Br
31 YW 2
147 LY
Y
COM
NC
170 GR
38 GY B
2 34 Br
O COM
44 Br
4
53 G
5
181 GW
30 1.25Y
3 MID SPEED CONTROL RELAY
183 LR
175 B
22
76
46
75 54 6 16
87
B
175 B
CYL.BLOCK
175 B
2
178 G 3
1 181 GW
2
175 B 189 BrR 3
5
B X
1
4
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
1
7 38
53
39
77
40
32
3
35
84
8
85
183 LR
10 5WR
177 Y
3
1
2
108 B
12
109 G
10
110 R
11
111 W
3
DEF SUPPLY PUMP 8
4
5 132 Br
132 Br 4
6 133 B
112 L
5 2
133 2B
75 2L 3 1
113 P 4 117 O 5 2
2 19
114 Y
114 Y 4
117 O
117 O 5
118 GB
2
20
131 GR
1
4
DEF TANK HEATING VALVE
1
1
2
2
1
SUCTION PRESSURE BACKFLOW LINE LINE LINE HEATER HEATER HEATER
X 1.25B
63 Br 3
117 O
5 2
X1 5B X1 5B
49 5L F.L.65A 50
COM E
45 5Y 57 5Y 85 5Y 202 5Y 156 RG
46 5R F.L.65A 58 5R F.L.65A 86 5R F.L.65A 203 5R F.L.65A 155 R
30
+
ALTERNATOR (150A) W D
5A
B
E
AV60,R
STARTER MOTOR AV30,B
215 5B
BATTERY 12V +
FUSE
63 Br
1
47 LgB
63 Br 3
63 Br
1
: OPTION
BACKFLOW LINE HEATER RELAY
116 Lg 4 2
51 5WG
PRESSURE LINE HEATER RELAY
116 Lg
118 GB
BATTERY RELAY
BR
GRID HEATER RELAY
MODULE RELAY
6 DEF SUPPLY
VIBRATION MODE SELECT SWITCH
35 YB
172 3BY
181 GW
75 L
113 P
119 LB
AV30,B
177 Y 9
112 L
5
4 31 YW
37 YL 5
L
STARTER RELAY
F.L.65A 59 5WR F.L.65A 92 5WB F.L.65A 11 5W F.L.65A AV30,B 52 1.25BR
AV30,B
181 GW
1 31 YW
2 NC
31 YW
160 2WL
FUSE (250A) NO
GRID HEATER
G
6
15A 61 5WL
AV30,B
RELAY
107 L
FUSE
62 5WB
93 5WL
THROTTLE SWITCH
192 RW
25 2WR
4 31 YW
192 RW 5
178 G
4
190 L
3
60 5W
44 Br 6
2
83
91
1
175 3B
5 THROTTLE
82 193 LgB
175 B
3
COM
36 GB 3
VIBRATION SWITCH 31 YW
SPEED CHANGE SWITCH F-R LEVER AUTO SPEED SET SWITCH
NO
3 170 GR
31 YW 1
31 YW
1 31 YW
2
27 0.5LB 26 0.5BrB
5 31 YW
IPF SELECT SWITCH
X B
127 0.5LgB
62
57
4
SCR THERMISTOR CONTROLLERS
50
26
81
DEF DOSING INJECTOR VALVE LEVEL SENSOR
25
2
2 187 LgY
2
1 DOWN STREAM NOx (SCR OUTLET) 2 1 205 L 133 2B
3
3
2
4
49
79
187 LgY
174 1.25Ｗ
204 G 205 L
REGEN. MANUAL SWITCH
197 B
DATA LINK INTERFACE 69 2W
J4(24PIN) 7
153 1.25Y
D E C F A B J G H
ENGINE ECM. (CM2350)
14 INTERLOCK RELAY
33
103 W
1
3 31 YW
42 BrW 6
148 YL
243 L 171 3BW
1 31 YW
40 GW 2
CIS (OPTION)
6 RY
53 0.5G 125 0.5BrW
1 3B
3030151510 5 10 A A A A A A A
2
5
7 WB
3
19 18 17 16 15 14 13
62 5WB
5 2020151515152020152020 A A A A A A A A A A A A
63 2Br
1
60 5W
76 2LB
2
89 WR
29 2WB
3
90 2R
3 2WR
242 1.25Br
7 WG
13 WL
70 2W
14 WY
31 YW
19 2W
30 1.25BY
4
SUB POWER
2 RW
32
35
5
1
186 RY
31
34
6
171 BW
185 RB
28 29
7
X 1.25B
23 24
8
9
4
2 6 33 L
12 BW
126 0.5Lg
ENGINE ECM. (CM2250)/J2(96PIN)
242 1.25Br
19 20
B R1 R2 ACC BR C
47 LgB
21
31 YW 4
124 0.5Br
50
195 WB
15
12 11 10
166 GB
STARTER SWITCH R1 OFF ACC ST
7
14
52 1.25BR
64 LgW
6
13
49 5L
B
6
1 2 3 4 5 6 (NOTCH POSITION)
F-R LEVER NO VIBRATION SWITCH
4 1.25GY
R1 BR ACC
176 BR
64 LgW
5
12
4 31 YW
SPRAY SWITCH
C
5
RESISTOR3 UNIT 1
3 32 G
31 YW 1
NO F-R LEVER WATER
R2
2
41 LW 4
43 GR R
56 1.25LB
1
4
WATER SPRAY PUMP (R, 2)
1
WATER SPRAY PUMP RELAY (R, 2)
X1 2B
B
P
WATER SPRAY TIMER
1 31 YW
DISPLAY CHANGE SWITCH (OPTION)
155 R
3
VIBRATION FREQUENCY SELECT SWITCH
POWER SUPPLY (OPTION)
4
11
4
77 0.5GW
19 2W
3
10
3
2
152 G
18
148 0.5YL
NC
161 P
9
28 GB
25 0.5WB
5 2RL
COMBINATION METER 2
1
VIBRATORY DRUM SELECT SWITCH
122 0.5L
ROLL LIGHT (OPTION)
1
152 G
53 0.5G
12 0.5BW
WORKING CONTROLLER 42
2
28 GB
120 0.5WL
129 0.5B
37 MC050-110 43
165 0.5LgB
CONTROL PANEL
48
30
123 0.5B
X B
27
29
206 0.5WR
COMPRESSOR MAGNET CLATCH
47
a(Hi)
84 2LW O 3
5
X B
AV60,B
+V
138 R
39
40 0.5GW
157 2LR 169 2LY 4
36 0.5GB
X1 2B
B
P
WATER SPRAY PUMP (R, 1)
6
2
WATER SPRAY TIMER SWITCH
37 0.5YL
O
AV60,R
73 0.5Lg
38
46
151 GL
X B
17 0.5Y 162 0.5Gr
30
50
130 0.5B
6 RY
37
83 2L
208 5W
7 WG
140 B
X2 3B
240 2GW
X2 2B
206 0.5WR
F-R LEVER POTENTIOMETER1
BACKUP BUZZER
5 2RL
FLOOD LAMP(L) 55W
145 W
26
b(Lo)
5
X1 2B
B
P
4 157 2LR
X 2B
70 2W
145 0.5W
36
35 0.5YB
O
209 5BW
OUT W
138 R
24
34 0.5Br
X B
X1 2B
B
P
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
199 2BR
4
6 RY
162 Gr 3 2WR
FLOOD LAMP(R) 55W
X2 2B
165 LgB
25 WB
141 YW
129 B
X
R
GND B
X2 2B
71 LY
137 0.5GB
35
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
5
3 83 2L
152 G
42 BrW
2 2RW
210 0.5G
23
32 0.5G
3 1
6
80 2Y
39 BrR
1
FRONT
HEAD LAMP(L) 55W
+V
32
39 0.5BrR
167 GR
4
5
4
38 GY
2 2RW
73 0.5Lg
139 0.5W
GND B
LIGHTING SWITCH HEAD LAMP(R) 55W
17 0.5Y
BACKUP BUZZER SWITCH
17
3
43 0.5GR 38 0.5GY
76 2LB
2 17
37 YL
6 5 2RL 5
B
31
19
162 0.5Gr
137 GB
25
14
TRAVELING CONTROLLER 33 20 MC050-155 34
12 0.5BW
AUTO SPEED INDICATOR
13
2
3
5
X B
1 169 2LY
2
82 2GW
168 2LW 4
36 GB
W
PROPULSION PUMP NEUTRAL HOLDING RELAY
2
143 0.5WB
13 WL
X B R
2
2 2RW 3
140 B
21
147 0.5LY
1
35 YB
X B
142 0.5GL
22
9
a(Hi)
34 Br
5
6
X 0.5B
138 R
8
b(Lo)
6
33 L
1
5
139 W
18
186 0.5RY
WATER SPRAY PUMP RELAY (PUMP 2)
32 G
73 Lg
13 WL
0V(GND) NO USE
12 BW
R
4
4
NC
3
3
140 0.5B
78 O
NEUTRAL SOLENOID 71 LY
R
X B
SOL
OUT(SIGNAL2) +5V
138 0.5R 210 G
5
185 0.5RB
159 2RG
AV60,B
73 Lg
B
2
7
4 159 2RG
5
WATER SPRAY PUMP SWITCH (R) 16
O
WATER SPRAY PUMP (F, 1)
3 81 2G
X B
5
81 2G
1 168 2LW
2
2
X B
PROPULSION PUMP NEUTRAL RELAY (2)
W
1
OUT(DIRECTION SIG.)
6
4
214 B
EMERGENCY VIBRATOR PUMP (F) CONNECTOR PROPORTIONAL SOLENOID
4
79 2W
5
1
6
152 G
F
OUT(SIGNAL1)
3
123 B
120Ω
X 0.5B
3
28 GB
2
4
WATER SPRAY PUMP SWITCH (F)
41 LW
9
74 BrY
1
130 0.5B
1
WATER SPRAY PUMP RELAY (PUMP 1)
29 2WB
40 GW
2
F-R LEVER SWITCH
M
5
X B
F-R LEVER
CO
3
129 0.5B
2
213 L
X B
72 Br
4
128 0.5GW
129 128 B GW
* *
SPEED SENSOR
NO
73 Lg
25 0.5WB
78 O
212 B
122 L
15
3
77 GW 1
X B
TERMINATING RESISTOR
PROGRAMING CONNECTOR
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
PROPULSION PUMP NEUTRAL RELAY (1)
8
4
211 G
66 WR
2 EXACT METER RELAY
SOL
120 WL
121 B
126 Lg
18 L
2
3
143 WB
2
WATER SPRAY MODE SELECT SWITCH
X B
X B
17 Y
2 74 BrY
X B
a(R)
127 LgB
5
3 17 Y
15 LgR 1
NC
1
72 Br
b(F)
X B
3
15 LgR
4
CO M
71 LY
165 LgB
PROPULSION PUMP PROPORTIONAL SOLENOID
124 Br
FOOT BRAKE SWITCH
2 1 4 HORN RELAY
164 BW
5
142 GL
2
65 WY
X B
7 WG
1
25 WB
EMERGENCY EMERGENCY SWITCH CONNECTOR 1 67 WL
125 BrW
B COM
141 YW
RESISTOR UNIT
NO
HORN SWITCH
14 WY
3
9 GR 5
X B
B X
3
NO 8 Lg
X1 2B
4
130 B
R NC
HORN
10
15 LgR
THERMOMETER CONNECTOR (OPTION)
EXACT METER
EMERGENCY CONNECTOR
163 LgY
128 GW
2-1. Electrical Circuit Diagram (SW884/994)
63 Br 3
20
: Relay number of relay box.
63 Br
1
21 SUCTION LINE
HEATER RELAY
X B
0568-99024-0-11995-B
5-003
ELECTRICAL SYSTEM
2-2. Electrical Circuit Diagram (SW884ND/994ND)
+V
R
206 WR
139 0.5W 145 0.5W
F-R LEVER POTENTIOMETER2
121 0.5B
OUT W
CL
91 2YR 90 2R
241 2GR
89 WR
CABIN (OPTION)
REAR
AIR・CONDITIONER UNIT
25 0.5WB 25 0.5WB 25 0.5WB 25 0.5WB
X B
5
1
6
2
7
3
12
4
24
11
25
31
42 0.5BrW
32
38
13
39
44
47
45
48
14
49
15
X 0.5B
3
128 0.5GW
26 BrB 2
148 0.5YL 7 WB
124 0.5Br
148 YL
X2 2B
X2 2B 6 7 8
26 0.5BrB
1
11 12 13 14 15 16 17 18
21 22
25 26 27
30
147 LY 3
62 5WB
174 1.25W
68 2G
69 2W
75 2L
63 2Br 60 5W
76 2LB
89 WR
29 2WB
90 2R
3 2WR
242 1.25Br
7 WG
70 2W
13 WL
31 YW
19 2W
30 1.25BY
14 WY
3030151510 5 10 A A A A A A A FUSE BOX
172 3BY
FUSE
30A
243 L 171 3BW
171 BW 171 BW 171 BW 171 BW
52 1.25BR
3 1
4 166 GB 5
X B
2
176 BR
WIF SENSOR 1 2
STARTER SWITCH RELAY 120Ω TERMINATING RESISTOR 1
12V/120W
185 RB 186 RY
161 P 4
120Ω 21
TERMINATING RESISTOR
YB
X B 5 2
D
12 BW 3
196 BrY
X B 1
64 LgW
2
DIAGNOSTIC SWITCH
162 Gr
1
74 BrY
3 1
12
28 GB
4
4 1.25GY
22
5
X B
23
2
PARKING INTERLOCK RELAY
5 2RL 56 1.25LB
HYDRAULIC OIL FILTER SWITCH 1
2 RW
23 GB
X B
X B
53 G
134 2WR
1
133 2B 4
148 YL
HYDRAULIC OIL FILTER SWITCH 2
23 GB
FUEL GAUGE UNIT
161 P
3 1
13
243 L
4
153 1.25Y
5
X B
2
STARTER MOTOR RELAY
68 2G
2
NOX SENSOR
1
11
205 L
205 L
204 G
204 G
3 UP STREAM NOx (DRT SIDE:SCR INLET)
4 134 2WR DEF LEVEL/ 133 2B 3
1
2
3
134 2WR
5
133 2B
2
AFTERTREATMENT RELAY 4
NOX SENSOR
133 2B
134 2WR
1 DOWN STREAM NOx (SCR OUTLET) 2 1 205 L 133 2B
205 L
QUALITY TEMPERATURE/ 204 G 2 SENSOR DEF TANK
3
4
204 G
120Ω
TERMINATING RESISTOR
3
SCR IN TEMP OUT TEMP
134 2WR
REGEN. DISABLE SWITCH
3
1
94 Br
50
26
51
27
52
28
73
5
66 94
13
DEF DOSING INJECTOR VALVE
3
95 LY
2
96 LgB
1
97 BR 193 LgB
COOLANT C LEVEL SENSOR
B
194 YB 195 WB
175 B
22
76
46
75 54 6 16
87
B
1 181 GW
2
Y
COM
189 BrR 3
5
183 LR
3 1
4
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
1
7 38
53
39
77
40
32
3
35
84
8
85 82
183 LR
NC
170 GR
2 34 Br
O COM
10 5WR
177 Y
3
1
2
108 B
12
109 G
10
110 R
11
111 W
3
DEF SUPPLY PUMP 8
4
5 132 Br
132 Br 4
6 133 B
112 L
5 2
133 2B
75 2L 3 1
113 P 4 117 O 5 2
2 19
114 Y
L
114 Y 4
117 O
117 O 5 2
118 GB 20
131 GR
1
4
DEF TANK HEATING VALVE
2
1
1
2
2
1
63 Br
50 COM E
45 5Y 57 5Y
202 5Y 156 RG
117 O
5 2
46 5R F.L.65A 58 5R F.L.65A 86 5R F.L.65A 203 5R F.L.65A 155 R
30
+
ALTERNATOR (150A) W D
5A
B
E
AV60,R
STARTER MOTOR AV30,B
215 5B
X1 5B X1 5B
BATTERY 12V +
FUSE
63 Br
1
47 LgB
63 Br 3
63 Br
1
: OPTION
BACKFLOW LINE HEATER RELAY
116 Lg 4
SUCTION PRESSURE BACKFLOW LINE LINE LINE HEATER HEATER HEATER
X 1.25B
49 5L F.L.65A
85 5Y
3
VIBRATION MODE SELECT SWITCH
35 YB
51 5WG
PRESSURE LINE HEATER RELAY
116 Lg
118 GB
BATTERY RELAY
BR
GRID HEATER RELAY
MODULE RELAY
6 DEF SUPPLY
4 31 YW
37 YL 5
NC
31 YW
1 31 YW
2 6
172 3BY
181 GW
75 L
113 P
119 LB
AV30,B
177 Y 9
112 L
5
G
STARTER RELAY
F.L.65A 59 5WR F.L.65A 92 5WB F.L.65A 11 5W F.L.65A AV30,B 52 1.25BR
AV30,B
181 GW
COM
160 2WL
FUSE (250A) NO
GRID HEATER
SPEED CHANGE SWITCH
36 GB 3
VIBRATION SWITCH 31 YW
1 31 YW
F-R LEVER AUTO SPEED SET SWITCH
NO
3 170 GR
31 YW 1
31 YW
38 GY B
15A 61 5WL
AV30,B
RELAY
107 L
FUSE
62 5WB
93 5WL
THROTTLE SWITCH
192 RW
25 2WR
4 31 YW
192 RW 5
178 G
4
30 1.25Y
60 5W
44 Br 6
B X
181 GW
2
178 G 3
175 B 190 L
53 G
5
CONTROL RELAY
CYL.BLOCK
175 B
4
3 MID SPEED
2
83
91
175 3B
175 B
3 1
5 THROTTLE
57
193 LgB
175 B
62
81
4
SCR THERMISTOR CONTROLLERS
49
25
2
2 187 LgY
A
1
79
187 LgY
174 1.25Ｗ
204 G 205 L
REGEN. MANUAL SWITCH
197 B
DATA LINK INTERFACE 69 2W
J4(24PIN) 7
153 1.25Y
E C F A B J G H
ENGINE ECM. (CM2350)
14 INTERLOCK RELAY
33
103 W 187 LgY
47 LgB 23 GB
44 Br
1 3B
18 L
32
35
FUSE BOX
ENGINE ECM. (CM2250)/J2(96PIN)
19 18 17 16 15 14 13
SUB POWER
2 RW
31
34
1
15 LgR
185 RB
28 29
2
X 1.25B
23 24
3
171 BW
47 LgB
19 20
4
242 1.25Br
186 RY
34 Br
31 YW 2
5 31 YW
2
27 0.5LB
50
195 WB
10
B R1 R2 ACC BR C
5
172 1.25BY
R1 OFF ACC ST
6
93 5WL
5
7
5 2020151515152020152020 A A A A A A A A A A A A
166 GB
STARTER SWITCH
4
8
9
10 5WR
64 LgW
3
12 11 10
3 31 YW
39 BrR 3
F-R LEVER NO VIBRATION SWITCH
4 1.25GY
R1 BR ACC
176 BR
64 LgW
49 5L
1 31 YW
IPF SELECT SWITCH
X B
127 0.5LgB
POWER SUPPLY (OPTION)
52 1.25BR
CIS (OPTION)
6 RY
53 0.5G 125 0.5BrW
SPRAY SWITCH
B
2
42 BrW 6
12 BW
126 0.5Lg
NO F-R LEVER WATER
C
4
41 LW 4
77 0.5GW
43 GR R
R2
6
40 GW 2
DISPLAY CHANGE SWITCH (OPTION)
155 R
5
RESISTOR3 UNIT 1
1 2 3 4 5 6 (NOTCH POSITION)
4 31 YW
27 LB 5
NC
56 1.25LB
2
WATER SPRAY TIMER
1 31 YW
6
19 2W
COMBINATION METER
9
28 GB
25 0.5WB
5 2RL
161 P
2
4
1
4
WATER SPRAY PUMP RELAY (R, 2)
VIBRATORY DRUM SELECT SWITCH
ROLL LIGHT (OPTION)
1
2
3
53 0.5G 122 0.5L
12 0.5BW
WORKING CONTROLLER 42
3
120 0.5WL
129 0.5B
37 MC050-110 43
165 0.5LgB
CONTROL PANEL
40
30
123 0.5B
X B
48
29
206 0.5WR
COMPRESSOR MAGNET CLATCH 240 2GW
X2 2B
210 0.5G
140 B
X
78 O
138 R
27
1
WATER SPRAY PUMP (R, 2)
1
18
X1 2B
B
P
AV60,B
73 0.5Lg 162 0.5Gr
47
41 0.5LW
2
28 GB
152 G
AV60,R
7 WG
6 RY
6 RY
5 2RL
FLOOD LAMP(L) 55W
17 0.5Y
X2 3B
39
50
130 0.5B
F-R LEVER POTENTIOMETER1
BACKUP BUZZER
FLOOD LAMP(R) 55W
140 B
38
46
84 2LW O 3
5
X B
208 5W
70 2W
206 0.5WR
37
30
157 2LR
152 G
X1 2B
B
P
WATER SPRAY PUMP (R, 1)
6
2
169 2LY 4
36 0.5GB
O
199 2BR
4
6 RY
162 Gr 3 2WR
145 0.5W
145 W
26
b(OSCILLATION) a(NORMAL)
40 0.5GW
83 2L
WATER SPRAY TIMER SWITCH
37 0.5YL
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
X 2B
OUT W
138 R
36
35 0.5YB
X1 2B
B
P
4 157 2LR
5
X1 2B
B
P
O
209 5BW
X
R
24
151 GL
X B
165 LgB
25 WB
141 YW
129 B
130 B
NC
+V
GND B
X2 2B
2 2RW
137 0.5GB
35
34 0.5Br
X B
152 G
42 BrW
1
FRONT
HEAD LAMP(L) 55W
210 0.5G
23
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
6
80 2Y
5
3 83 2L
39 BrR
2 2RW
73 0.5Lg
139 0.5W
GND B
LIGHTING SWITCH HEAD LAMP(R) 55W
17 0.5Y
BACKUP BUZZER SWITCH
32
32 0.5G
3 1
2
38 GY
6 5 2RL 5
B
17
39 0.5BrR
167 GR
4
5
4
3
5
X B
17
37 YL
W
31
19
162 0.5Gr
137 GB
25
14
TRAVELING CONTROLLER 33 20 MC050-155 34
12 0.5BW
AUTO SPEED INDICATOR
13
3
43 0.5GR 38 0.5GY
76 2LB
36 GB
R
PROPULSION PUMP 10 NEUTRAL HOLDING RELAY
2
143 0.5WB
13 WL
X B
2
2 2RW 3
140 B
21
2
82 2GW
168 2LW 4
1 169 2LY
2
35 YB
X B
142 0.5GL
22
9
147 0.5LY
1
34 Br
5
6
X 0.5B
138 R
18
8
b(OSCILLATION) a(NORMAL)
6
33 L
1
13 WL
5
139 W
5
186 0.5RY
WATER SPRAY PUMP RELAY (PUMP 2)
32 G
73 Lg
4
0V(GND) NO USE
12 BW
R
NEUTRAL SOLENOID 3
4
78 O
X B
SOL
71 LY
W
R
3
140 0.5B
185 0.5RB
159 2RG
AV60,B
73 Lg
OUT(SIGNAL2) +5V
138 0.5R 210 G
7
4 159 2RG
5
WATER SPRAY PUMP SWITCH (R) 16
O
WATER SPRAY PUMP (F, 1)
3 81 2G
X B
5
81 2G
1 168 2LW
2
2
X B
PROPULSION PUMP NEUTRAL RELAY (2)
B
2
6
4
214 B
EMERGENCY VIBRATOR PUMP (F) CONNECTOR PROPORTIONAL SOLENOID
4
79 2W
5
1
6
152 G
F
1
OUT(DIRECTION SIG.)
3
123 B
120Ω
X 0.5B
3
28 GB
2
4
WATER SPRAY PUMP SWITCH (F)
41 LW
9
74 BrY
1
OUT(SIGNAL1)
1
WATER SPRAY PUMP RELAY (PUMP 1)
29 2WB
40 GW
2
F-R LEVER SWITCH
M
5
X B
F-R LEVER
CO
3
130 0.5B
2
213 L
X B
72 Br
4
129 0.5B
SPEED SENSOR
NO
73 Lg
128 0.5GW
129 128 B GW
* *
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
PROPULSION PUMP NEUTRAL RELAY (1)
8
4
25 0.5WB
78 O
212 B
122 L
126 Lg
18 L
2
PROGRAMING CONNECTOR
X B
X B
TERMINATING RESISTOR
15
3
77 GW 1
66 WR
2 EXACT METER RELAY
SOL
211 G
WATER SPRAY MODE SELECT SWITCH
X B
X B
17 Y
2 74 BrY
120 WL
121 B
a(R)
127 LgB
5
3 17 Y
15 LgR 1
NC
1
72 Br
3
143 WB
2
X B
3
15 LgR
4
CO M
71 LY
165 LgB
b(F)
X B
124 Br
FOOT BRAKE SWITCH
2 1 4 HORN RELAY
5
PROPULSION PUMP PROPORTIONAL SOLENOID
X B
7 WG
1
142 GL
EMERGENCY EMERGENCY SWITCH CONNECTOR 1 67 WL
2
65 WY
125 BrW
B COM
164 BW
141 YW
RESISTOR UNIT 25 WB
NO
HORN SWITCH
14 WY
3
9 GR 5
X B
71 LY
3
NO 8 Lg
X1 2B
4
128 GW
R NC
HORN
B X
15 LgR
THERMOMETER CONNECTOR (OPTION)
EXACT METER
EMERGENCY CONNECTOR
163 LgY
63 Br 3
20
: Relay number of relay box.
63 Br
1
21 SUCTION LINE
HEATER RELAY
X B
0568-99030-0-12141-B
5-004
ELECTRICAL SYSTEM
3. ELECTRICAL COMPONENTS
Mark D_NOx
Mark INJ
(BrR),(LR) (P.5-023)
(P.5-023),(P.5-036)
Battery harness
3-1. Wiring Harness Layout (1)
Mark E8 (upper) E7 (lower)
Water spray pump (R) harness
(P.5-031)
(P.5-019),(P.5-023)
Floor board harness (P.5-033)
(P.5-023)
Battery Mark BUZ
H (P.5-007)
Mark E1 (upper) E2 (lower) (P.5-019),(P.5-023)
(P.5-031),(P.5-037)
Mark FL1
(P.5-009),(P.5-033)
Main harness (1)
Mark E3 (upper) E4 (lower)
(P.5-009)
(P.5-017)
Vibrator pump (F) proportional solenoid a * (Hi/Normal) Mark FVa (P.5-018)
Frame (F) harness
Vibrator pump (R) proportional solenoid a * (Hi/Normal) Mark RVa (P.5-018)
(P.5-019),(P.5-023)
Engine harness
(P.5-032)
Mark HORN
Vibrator pump (F) proportional solenoid b * (Lo/Oscillation) Mark FVb (P.5-018)
To WIF sensor
Propulsion pump proportional solenoid a (R) Mark a (P.5-018)
(P.5-032),(P.5-038)
Mark FP
(P.5-019),(P.5-032)
Coolant level sensor
Flood lamp
ECM harness (1)
(B),(RL)
(P.5-019)
G
Hydraulic pump harness
(P.5-018)
Head lamp
Propulsion pump proportional solenoid b (F) Mark b (P.5-018)
(B),(RW)
Mark PRO
Mark ECM (P.5-017)
(P.5-018),(P.5-023)
J
B
G
(P.5-007)
F-R lever harness (P.5-025)
(P.5-007)
(P.5-006)
VIEW A
Mark EMR
* · Hi, Lo : STD type Normal,Oscillation : ND type
(P.5-023)
K
A
Vibrator pump (R) proportional solenoid b * (Lo/Oscillation) Mark RVb (P.5-018)
(P.5-008)
K
(P.5-008)
D
B
(P.5-006)
(P.5-006)
C
(P.5-006)
F
E
(P.5-006)
(P.5-006)
Speed sensor
(P.4-011)
0568-09833-0-11981-C
5-005
ELECTRICAL SYSTEM
3-2. Wiring Harness Layout (2)
Mark NO
Mark CO
B2
Mark E10
(P.5-023)
(P.5-023)
B3
Battery relay
Battery harness
(P.5-017),(P.5-019)
Mark BR
(P.5-023)
Mark E9
(P.5-023)
Fuse 30A
Ground
(P.5-017),(P.5-019)
(B)
Mark THR Mark FP
(P.5-023)
Fuse 5A
Mark B3
(P.5-019),(P.5-032)
(P.5-017),(P.5-023)
B2
Mark E
Diode
Mark E
B1
(P.5-019)
Fuse 15A
Mark B1
B3
Mark B4
(P.5-017),(P.5-023)
Starter relay
(P.5-032)
(P.5-032)
(P.5-017),(P.5-023)
Grid heater relay
(B),(BR),(BW),(W)
Frame (F) harness
Mark B2
VIEW B1
(P.5-017),(P.5-023)
Y
(GW),(Y)
Engine harness (P.5-017)
W B BR
ECM harness (1)
Mark CL
(P.5-019)
VIEW B
(P.5-017)
Mark 30 (W) (P.5-017)
Mark HYD
Neutral solenoid
(P.5-018),(P.5-023)
Mark NEU
Mark EMR
(P.5-034)
(P.5-023)
Mark B+
D1
Mark BRA
(4 pieces) (P.5-017)
Hydraulic oil filter switch 1
(P.5-023),(P.5-034)
Mark PRO
C1
Alternator
VIEW B3 Hydraulic oil filter switch 2
(P.5-023)
(P.5-017)
Starter motor
GW
VIEW B2
Battery harness
Engine harness
(P.5-017)
Mark L
BW
(P.5-034)
Hydraulic pump harness
(P.5-018)
Mark 50 (BW) R
Engine harness
(P.5-034)
Mark STD
(5 pieces) (P.5-017)
(P.5-017)
E1
Horn harness
(P.5-038)
Water spray pump (F,1)
Parking brake solenoid
VIEW C
VIEW C1 (B)
To Water spray pump (F,2)
To Water spray pump (F,1) Backup buzzer harness
Horn harness
(P.5-038)
E2
(P.5-037)
Mark 2B2
Mark 2B1
(P.5-032)
Water spray pump (R,2)
F1
VIEW D
F2
(P.5-032)
VIEW E
Backup buzzer harness (P.5-037)
(P.5-037)
Mark FP2
Mark FP1
Mark 2B2
To Water spray pump (R,1)
Mark 2B1
(P.5-031)
(P.5-031)
(P.5-032)
DETAIL E2
Mark RP2
(P.5-031)
Mark RP1
(P.5-031)
Water spray pump (R) harness
(P.5-032)
Frame (F) harness
VIEW E1
To Water spray pump (R,2)
Mark HI (RY)
(P.5-032)
Water spray pump (F,2)
(P.5-018)
(P.5-037)
(Lg)
Horn
VIEW D1
WIF sensor WIF
Mark NEG (B)
Horn
E1
Solenoid harness
(P.5-017)
LgB
Horn
Pre-filter
(P.5-031)
Water spray pump (R,1) F1 VIEW F1 VIEW F
DETAIL F2 0568-09829-0-11977-0 0568-09833-0-11981-C 0568-09833-0-11982-C
5-006
ELECTRICAL SYSTEM
3-3. Wiring Harness Layout (3)
Parking brake switch
EME
Speed change switch
PAR
Lighting switch 1(WR),3(RW),4(W),5(RL)
Diagnostic switch
LIT
Water spray pump switch (R)
MAN
Regen. manual switch
INH
Mark FP (P.5-025)
2(LgY),3(LY)
AUT
DIS
Display change switch (option) Exact meter (P.5-040)
(Gr)
Main harness (2) (P.5-011)
SECTION G-G
Mark RH1 (P.5-011),(P.5-029)
Combination meter
(P.5-042)
Mark LVR
(P.5-025)(P.5-042)
Mark TIM
H2
(P.5-025)
Sub power
Mark RH2 (P.5-011),(P.5-029)
(P.5-039)
Mark D/C
Panel (R) harness
(P.5-011)
(P.5-029)
(P.5-025),(P.5-039)
L B
Mark P/O
R
Mark POT2
(P.5-025),(P.5-039) (P.5-011),(P.5-025)
(P.5-027)
Potentiometer 2
COM (B)- RCOM (WG) NC (R)- RNC (Gr) NO (W)- RNO (RY)
Mark POT1
Mark L2
Panel (L) harness
(P.5-045)
Backup buzzer switch
(P.5-025)
Auto speed indicator
(GB),(B)
Lever switch
H1
Mark L1
Mark DIS
O G Y
(P.5-011),(P.5-027)
DETAIL H1
(P.5-011),(P.5-025)
(P.5-011),(P.5-040)
Mark LH
Mark RH4
Horn switch
(P.5-011),(P.5-029)
(GR)
Mark RH3
Potentiometer 1
(P.5-011),(P.5-029)
(P.5-039)
Main harness (2)
VIEW H2
(P.5-011)
Foot brake switch (P.5-025)
Mark L3
Main harness (2)
(P.5-011),(P.5-025)
(P.5-011)
Mark L4 (P.5-011),(P.5-025)
VIEW H
To F-R lever harness
COM (B)-COM (WY) NC (R)-NC (LgY) NO (W)-not in use insulation protection
(
(P.5-025)
(
F-R lever harness
(
1(YW),2(GW),3(YW),4(LW),5(YW),6(BrW)
D/C
Horn switch
Water spray timer Mark TIM (RB4B)
Vibration frequency select switch (STD type only) ND type : insulation protection IPF select switch
1(YW),3(G),4(YW),5(L)
IPF
(P.5-045)
Water spray timer switch Mark TIM (LE204)(P.5-025)
1(YW),2(BrB),4(YW),5(LB)
F/R
Combination meter
(P.5-025)
Vibratory drum select switch
L/H
Regen. disable switch
COM (B)- FCOM (WL) NC (R)- FNC (BW) NO (W)- FNO (O)
Water spray pump switch (F)
1(YW),2(Br),3(GR)
FRQ
(L),(BR),(LgW),(LB)
F-R lever switch
(P.5-025)
Vibration switch
C/A
KEY
1(Br),2(LgY)
Mark RP (P.5-025)
Vibration mode select switch
1(YW),3(GB),4(YW),5(YL)
DIA
Starter switch Water spray mode select switch Mark 1 , 2 , 4 , 5
Throttle switch 1(GW),3(G),4(YW),5(RW),6(Br)
S/M SPE
1(BrY),2(B)
(P.5-027)
(P.5-029)
1(LgR),2(BrY),3(Y),4(L),5(B) 1(YW),3(BrR)
Panel (L) harness
Panel (R) harness
1(WL),2(WY),3(WR)
(
Emergency switch
VIEW J
0568-09833-0-11982-C 0568-09839-0-12143-C 0568-12805-0-11265-C
5-007
ELECTRICAL SYSTEM
3-4. Wiring Harness Layout (4)
Main harness (1) (P.5-009)
Mark SUC
Mark BAC
(P.5-011)
(P.5-011)
Mark PRE
DEF tank sensor
(P.5-011)
Data link interface connector (P.5-009)
K4
DEF tank heating valve
Fuse relay box
Vibrator controller Mark 110 (P.5-009)
(GR),(LB)
Mark M7
ECM harness (2)
(P.5-013),(P.5-021)
Main harness (2)
K5
(P.5-011)
Propulsion controller Mark 155 (P.5-009)
(P.5-021)
Mark RES1
Fuse relay harness
VIEW K1
(P.5-013),(P.5-041)
(P.5-015)
Mark M6 (P.5-013),(P.5-021)
Main harness (3)
Resistor unit
Mark M5
(P.5-013)
(P.5-041)
(P.5-013),(P.5-021)
K2
ECM harness (2) (P.5-021)
Mark M3
K3 Mark ROLL
(P.5-013),(P.5-021)
Mark ROPS
(P.5-013)
(P.5-013)
Mark CAB1
Ground
Mark M4 (P.5-013),(P.5-021)
Fuel gauge unit
(P.5-021)
(P.5-013),(P.5-021)
Mark FU1
Mark M2
(P.5-009),(P.5-015)
(P.5-013),(P.5-021)
Mark P/C
Main harness (1)
(P.5-009)
(P.5-009)
Mark FU7
(P.5-021)
Mark CAB3
Mark M1
(B),(YB)
Mark CAB5
(P.5-013)
Mark RES1
K3
Mark CAB2 (P.5-021)
Mark CAB4
(P.5-013),(P.5-041)
(P.5-021)
ECM harness (2) (P.5-021)
VIEW K3
VIEW K2
(P.5-009),(P.5-015)
Mark FU6
(P.5-015),(P.5-021)
Mark FU11
K1
(P.5-015),(P.5-021)
Mark FU9
(P.5-009),(P.5-015)
Mark FU5 (P.5-009),(P.5-015)
Mark FU4
Mark FU10
Mark SPD
(P.5-013),(P.5-031)
(P.5-013),(P.5-031)
Mark X1 (P.5-013),(P.5-031)
Main harness (2) (P.5-011)
(P.5-009),(P.5-015)
(P.5-015),(P.5-021)
Mark FU12
Mark FU2
(P.5-015),(P.5-021)
(P.5-009),(P.5-015)
SECTION K-K
Mark SPR
Mark FU8
(P.5-015),(P.5-021)
Mark FU3
DEF pump
(P.5-009),(P.5-015)
VIEW K4
VIEW K5 0568-09833-0-11982-C
5-008
ELECTRICAL SYSTEM
4. WIRING HARNESSES
Twist pair cable with shield AVSSCS 0.75
4-1. Main Harness 4-1-1. Main harness (1) 10 9 8 7 6 73 17
0.5Lg 0.5Y
Vibrator controller
20 DRC26-50S01
A 185 186 B
150 Corrugate
145 30 206 0.5W 0.5WR
40
165 123 121 0.5LgB 0.5B 0.5B
25 25 25 25
0.5BW 0.5BW 0.5BW 0.5BW
X B C
*1 50 Tape
150 Corrugate
210 Corrugate
Twist pair cable with shield AVSSCS 0.5
58X-4F
58X-4M
39 73 17 43 38 21
0.5BrR 0.5Lg 0.5Y 0.5GR 0.5GY
37 35 34 33 32 31
155
58X-3F
159 157 2RG 2LR 169 168 FU4 2LY 2LW
70 3
140 Corrugate
30 Tape
170 Corrugate
84 82 2LW 2GW 199 FU7 2BR
30 Tape
130 Corrugate
19
174 B
W
J
HD10-9-1939P with HDC 16-9 (CAP)
Data link interface connector
H
30 Tape
SWP-12F
SWP-14M
53 243 113 G L P 114 116 117 178 Y G O G 181 183 189 FU1 L LR BrG 190 192 X L RW 1.25B
30 Tape
14 13 9 8 WY WL GR Lg 73 44 31 15 Lg Br YW LgR 165 164 163 78 FU3 LgB BW LgY O 176 174 172 167 BY W BY GR
30 Tape
· The earth wire "X" between "*1" (main harness (1)) and "*2" (main harness (3)) use "AVS3". · Where the numbers differ, wires of same color must not be united.
30 Tape
P/C
129 128 B GW
SWP-3F
Programing connector
SWP-3M (CAP) Marking tape (color:white)
100 Corrugate
Main harness (2) (P.5-011)
600 Corrugate
2 5
2RW 2RL
22
FU9
112 12 7 6 L BW WG RY 56 52 28 132 1.25LB 1.25BY GB Br FU2 162 152 74 242 Gr G BrY 1.25Br
SWP-16M
5-009
30 Tape
80 79 FU5
2W 2WR
133 134 2B 2WR
320 Corrugate
200 Corrugate
45 44 43 42 41
3W
Fuse・relay harness (P.5-015)
50 Tape
0.5YL 0.5YB 0.5Br 0.5L 0.5G
2Y 2W
58X-3M
G
100 Tape
0.5G 0.5G
40 120 42 41 40 36 0.5WL 0.5BrW 0.5LW 0.5GW 0.5GB 122 206 145 139 0.5L 0.5WR 0.5W 0.5W 50 49 48 47 46
B
C
185
FL1
0.5GB
0.5B 0.5B 0.5GW 0.5BW 0.5B 142 X 11 0.5GL 0.5B
240
30
L
197
28
DRC26-50S01
Twist pair cable with shield AVSSCS 0.75
5 4 3 2 1 130 129 128 25 X
290 Corrugate
Propulsion controller
140 138 186 185 0.5B 0.5R 0.5L 0.5G 20 162 12 147 143 0.5Gr 0.5BW 0.5LY 0.5WB 137 53 210
30 Tape
A
G
X2 3B
160 Corrugate
10 9 8 7 6
186
E
Fuel gauge unit
CA104
X
D
F
Terminating resistor
21 CB104
B,30
45 44 43 42 41
250 Corrugate
DT06-3S-E008 with DT04-3P-P006
YB,30
100 Corrugate
22
50 49 48 47 46
5 4 3 2 1
130 129 128 25 X 0.5B 0.5B 0.5GW 0.5BW 0.5B 26 27 53 162 12 11 0.5BrB 0.5LB 0.5G 0.5Gr 0.5BW 139 210 21 110 0.5W 0.5G 77 148 31 0.5GW 0.5YL 127 125 126 124 0.5LgB 0.5BrW 0.5Lg 0.5Br
G L
58X-3F Floor board harness (P.5-033)
120 Tape
6
650 Corrugate
130 Corrugate
*1
7
30 Tape
GPS
5
4
3
2
1
197 174 185 186 G L
7
8
B W
19 W
DTM06-12SA
Not in use (Insulation protection)
9 10 11 12
Twist pair cable with shield AVSSCS 0.75
150 Corrugate
1568-09310-0-12322-0
ELECTRICAL SYSTEM
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
X
B, 0.5B, 1.25B, 3B
15
X2
3B
3
110 -1, 155 -1, 13, FU1 , Fuel gauge unit, Terminating resistor-C FL1
2
RW, 2RW
5
FL1
1
3
3
2WR
2
FU5
1
1
5
RL, 2RL
4
FL1
1
2
1
6
RY
4
FU2
1
2
1
7
WG
3
FU2
1
2
8
Lg
2
FU3
1
9
GR
2
FU3
1
1
12
BW, 0.5BW
5
110 -11, 155 -19, FU2
3
2
13
WL
2
FU3
1
1
14
WY
2
FU3
1
1
15
LgR
3
FU3
1
1
1
17
Y, 0.5Y
4
110 -6, 155 -23
2
1
1
19
W, 2W, 3W
4
FU9 , GPS -12 (not in use)
2
2
21
2
Fuel gauge unit
1
1
9
110 -2, 47, 48, 49, 50, 155 -2
6
1
26
YB BW, 0.5BW, 2BW BrB, 0.5BrB
2
110 -15
1
27
LB, 0.5LB
2
110 -14
28
GB
3
31
YW
32
No.
CONTACT POINTS TOTAL
6
CONTACT POINTS TOTAL
52
1.25BY
3
FU2
1
1
143
WB, 0.5WB
2
155 -17
1
53
G, 0.5G
4
110 -13, 155 -27, FU1
3
1
145
W, 0.5W
3
110 -29, 155 -47
2
1
56
1.25LB
2
FU2
1
1
147
LY, 0.5LY
2
155 -18
1
1
70
2W
2
FU5
1
1
148
YL, 0.5YL
3
110 -31
1
2
73
Lg, 0.5Lg
4
110 -7, 155 -24, FU3
3
152
G
2
FU2
1
1
74
BrY
2
FU2
1
1
157
2LR
2
FU4
1
1
77
GW, 0.5GW
2
110 -32
1
1
159
2RG
2
FU4
1
1
78
O
2
FU3
1
1
162
Gr, 0.5Gr
4
110 -12, 155 -20, FU2
3
1
79
2W
2
FU5
1
1
163
LgY
2
FU3
1
1
80
2Y
2
FU5
1
1
164
BW
2
FU3
1
82
2GW
2
FU7
1
1
165
LgB, 0.5LgB
3
110 -39, FU3
2
1
84
2LW
2
FU7
1
1
167
GR
2
FU3
1
1
112
L
2
FU2
1
1
168
2LW
2
FU4
1
1
113
P
3
FU1
1
1
1
169
2LY
2
FU4
1
1
114
Y
3
FU1
1
1
1
172
BY, 1.25BY
2
FU3
1
116
G
3
FU1
1
1
1 174
W
3
FU3 , Data link interface connector-B,
3
No.
7
1
2 2 1
1
No. (2) (3)
Main Harness (1)
1
1
117
O
2
FU1
1
1
120
WL, 0.5WL
2
155 -40
1
1
121
B, 0.5B
2
110 -37
1
1
1
122
L, 0.5L
2
155 -50
1
1
1
1
123
B, 0.5B
2
110 -38
1
1
FU2
1
2
124
2
110 -42
1
1
5
FU3
1
4
G, 0.5G
3
155 -31
1
1
1
2
110 -44
1
1
33
L, 0.5L
3
155 -32
1
1
1
126
Br, 0.5Br BrW, 0.5BrW Lg, 0.5Lg
2
110 -43
1
1
34
Br, 0.5Br
4
155 -33
1
2
1
127
LgB, 0.5LgB
2
110 -45
1
1
35
YB, 0.5YB
3
155 -34
1
1
1
128
GW, 0.5GW
4
110 -3, 155 -3, P/C
3
1
36
GB, 0.5GB
3
155 -36
1
1
1
129
B, 0.5B
4
110 -4, 155 -4, P/C
3
1
37
YL, 0.5YL
3
155 -35
1
1
1
130
B, 0.5B
3
110 -5, 155 -5
2
1
38
GY, 0.5GY
3
155 -21
1
1
1
132
Br
2
FU2
1
1
39
BrR, 0.5BrR
3
155 -25
1
1
1
133
B, 2B
4
FU9
1
2
40
GW, 0.5GW
3
155 -37
1
1
1
134
2WR
3
FU9
1
1
41
3
155 -38
1
1
1
137
GB, 0.5GB
2
155 -30
1
1
3
155 -39
1
1
1
138
R, 0.5R
3
155 -8
1
1
139
W, 0.5W
3
110 -25, 155 -46
2
43
LW, 0.5LW BrW, 0.5BrW GR, 0.5GR
2
155 -22
1
1
140
B, 0.5B
3
155 -9
1
44
Br
2
FU3
1
1
142
GL, 0.5GL
2
155 -14
1
25
42
2
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
(2) (3)
Main Harness (1)
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
125
1
1
1
GPS -3 (not in use) 176
BY
2
FU3
1
178
G
2
RH2
1
1
181
L
3
FU1
1
1
183
LR
2
FU1
1
185
G, 0.5G
6
155 -6, Data link interface connector-C, Terminating resistor-A,
1 1 1
4
1
1
4
1
1
GPS -7 (not in use) 186
L, 0.5L
6
155 -7, Data link interface connector-D, Terminating resistor-B, GPS -8 (not in use)
189
BrG
2
FU1
1
1
1
190
L
2
FU1
1
1
1
192
RW
2
1
197
B
3
FU1 Data link interface connector-A,
199
2BR
2
206
WR, 0.5WR
210
1 1
1
(2) (3)
Main Harness (1)
1 1
1
2
1
FU7
1
1
3
110 -30, 155 -48
2
G, 0.5G
3
110 -24, 155 -26
2
242
1.25Br
2
FU2
1
243
L
2
FU1
1
GPS -4 (not in use)
1 1 1 1 5-010
ELECTRICAL SYSTEM
4-1-2. Main harness (2) SWP-8M
58X-4F
58X-4M
162 167 206 242 Gr GR WR 1.25Br
28 31 35 38 GB YW YB GY 43 77 152 X GR GW G 1.25B
81 159 2G 2RG 83 157 2L 2LR
79 80 2W 2Y 168 169 2LW 2LY
L4
L3
L2
L1
100 Tape
50 Tape
100 Tape
50 Tape
F-R Lever harness (P.5-025)
Panel (L) harness (P.5-027) SWP-16F 26 27 31 32 BrB LB YW G 33 34 36 37 L Br GB YL 40 41 42 137 GW LW BrW GB 170 X GR B
18
350 Corrugate
32
776164-1
12 186 185 47 20
L
COM 23 35 53
G LgB 64 196 LgW BrY
G
100 Tape
250 Corrugate 660 Corrugate
Combination meter (P.5-045)
Twist pair cable with shield
LH
RY WG BW WL
78 138 140 145 O R B W
430 Corrugate
SWP-12F 6 7 12 13
120 Tape
250 Corrugate
28
RH1
21 YB 2 RW
X 64 155 1 B LgW R 23 47 18 2 13 GB LgB L RW 148 5 28 24 YL RL GB
15 17 18 31 L YW 39 52 56 X BrR 1.25BY 1.25LB B
LgR Y
SWP-12F
64 65 66
2
7 X WG B SWP-2M (CAP)
100 2 204 133 3 Tape G 2B
14
9
100 Tape
CA104
CB104
CB104
Foot brake switch
19 ROPS 256 3R 3W
58X-2F
163
Horn switch
58X-2M (CAP)
Twist pair cable with shield
SWP-14F
G LgR Br
Panel (R) harness (P.5-029)
L RW BrY
3 70
2W RH3 2WR 2 5
58X-4F
RH4 49 5L
58Y-1F
30 Tape
B B YW DIS GW 25 X 165
SWP-8F
30 Tape
31 147 D/C YW LY
SWP-2F
Display change switch (option)
SWP-2M
(CAP)
280 Corrugate
350 ate rug
DT06-4S
100 Tape
120 Tape
67 74 94 95
RH2 WL178BrY187BrG44LY 181 192 196
Cor
DEF tank sensor
1 205 134 4 L 2WR
SWP-2F
100
DC12V Tape
150 Corrugate
3
CIS (option)
50 Tape
GR,50
131 GR 4
58X-3M (CAP)
WY,50
119 LB
58X-3F
SWP-6F
COM
DEF tank heating valve
1
SWP-6M (CAP)
LgY,50
1-967325-1
100 Tape
240 241 ROLL 2GW192GR 2W
100 Tape
NC
148 6 12 YL RY BW FRONT 100 170 34 Tape GR Br ROLL
200 Corrugate
LgW WY WR
2RW 2RL
128 129 130 141 BW B LgB
Exact meter (P.5-040)
Marking tape
300 Corrugate
°
° 180 Corrugate
1
1-1703639-1
DEF pump
7
A 205 204 B 100 L G X Tape B C
· Where the numbers differ, wires of same color must not be united.
5-011
Main harness (3) (P.5-013)
Tape
100
DT06-3S-E008 with DT04-3P-P006
100 Tape
AVSSCS 0.75
100 Tape Twist pair cable with shield
170 Corrugate
°
90
Main harness (1) (P.5-009)
5 4 3 2 133 132 193 111 195 6 B Br GB W W 108 110 109 107 119 12 B R G L LB 11 10 9 8
350 Corrugate
90
90
50
(color:white)
PRE
BAC
SUC
2 113 118 1 P GB
2 114 118 1 Y GB
2 116 118 1 G GB
DT06-2S
DT06-2S
DT06-2S
Pressure line heater
Backflow line heater
Suction line heater
1568-09310-0-12322-0
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONNECTION and NUMBER OF CONTACT POINTS
CONTACT POINTS TOTAL (1)
No.
Main Harness (2)
(3)
SIZE, COLOR
CONNECTION and NUMBER OF CONTACT POINTS
CONTACT POINTS TOTAL (1)
No.
Main Harness (2)
(3)
X
B, 1.25B
15
COM -3, DIS , L3 , LH , RH1 , 6 Terminating resistor-C, 7 DC12V (option)
2
RW, 2RW
5
1
COM -13, 20, RH3
3
3
2WR
2
1
RH3
1
5
RL, 2RL
4
1
COM -27, RH3
2
1
6
RY
4
1
L4 , FRONT ROLL (option)
2
1
7
WG
3
1
L4 , DC12V (option)
2
9
GR
2
1 Horn switch
12
BW
5
3
L4 , FRONT ROLL (option)
2
13
WL
2
1
L4
1
14
WY
2
1
COM
1
15
LgR
3
1
RH1
1
1
17
Y
4
2
RH1
1
1
18
L
2
COM -14, RH1
2
19
2W, 3W
4
2
ROPS (option), ROLL (option)
2
21
YB
2
1
COM -18
1
23
GB
2
COM -16
1
1
25
BW
9
6
DIS
1
2
26
BrB
2
1
LH
1
27
LB
2
1
LH
1
28
GB
3
1
COM -25, L3
2
31
YW
5
1
L3 , LH , RH1 , D/C (option)
4
32
G
3
1
LH
1
1
33
L
3
1
LH
1
1
34
Br
4
1
LH , FRONT ROLL (option)
2
1
35
YB
3
1
L3
1
1
36
GB
3
1
LH
1
1
37
YL
3
1
LH
1
1
38
GY
3
1
L3
1
1
128
GW
4
BAC , PRE , SUC DEF supply pump-8, DEF tank heating valve-1 3 DIS
39
BrR
3
1
RH1
1
1
129
B
4
3
DIS
1
40
GW
3
1
LH
1
1
130
B
3
2
DIS
1
41
LW
3
1
LH
1
1
131
GR
2
DEF tank heating valve-4
2
42
BrW
3
1
LH
1
1
132
Br
2
43
GR
2
1
L3
1
44
Br
2
1
RH2
1
133
B, 2B
4
47
LgB
3
COM -10, 15
2
134
2WR
3
2 1
1
1
SIZE, COLOR
CONNECTION and NUMBER OF CONTACT POINTS
CONTACT POINTS TOTAL (1)
Main Harness (2)
(3)
RH4
1
1
137
GB
2
1
LH
1
1
RH1
1
1
138
R
3
1
L4
1
1
4
3
COM -35
1
140
B
3
1
L4
1
1
1.25LB
2
1
RH1
1
141
YW
2
DIS
1
1
64
LgW
3
COM -2, 22, RH2
3
145
W
3
2
L4
1
65
WY
2
RH2
1
1
147
LY
2
1
D/C (option)
1
66
WR
2
RH2
1
1
148
YL
3
1
COM -27, FRONT ROLL (option) 2
67
WL
2
RH2
1
1
152
G
2
1
L3
1
70
2W
2
1
RH3
1
155
R
2
COM -1
1
74
BrY
2
1
RH2
1
157
2LR
2
1
L2
1
77
GW
2
1
L3
1
159
2RG
2
1
L2
1
78
O
2
1
L4
1
162
Gr
4
3
L4
1
79
2W
2
1
L1
1
163
LgY
2
1
NC
1
80
2Y
2
1
L1
1
165
LgB
3
2
DIS
1
81
2G
2
L2
1
1
167
GR
2
1
L4
1
83
2L
2
L2
1
1
168
2LW
2
1
L1
1
94
BrG
2
RH2
1
1
169
2LY
2
1
L1
1
95
LY
2
RH2
1
1
170
GR
2
LH , FRONT ROLL (option)
2
107
L
2
DEF supply pump-9
1
1
178
G
2
1
RH2
1
108
B
2
DEF supply pump-12
1
1
181
L
3
1
RH2
1
1
109
G
2
DEF supply pump-10
1
1
185
G
6
4
COM -11
1
1
110
R
2
DEF supply pump-11
1
1
186
L
6
4
COM -12
1
1
111
W
2
DEF supply pump-3
1
1
187
LgR
2
RH2
1
1
113
P
3
1
PRE
1
1
192
RW
2
RH2
1
114
Y
3
1
BAC
1
1
193
GB
2
DEF supply pump-4
1
1
116
G
3
1
SUC
1
1
195
W
2
DEF supply pump-2
1
1
118
GB
4
3
1
196
BrY
2
2
119
LB
3
2
1
204
G
3
205
L
3
206
WR
3
COM -21, RH2 DEF tank sensor-2, Terminating resistor-B DEF tank sensor-1, Terminating resistor-A 2 L4
240
2GW
2
ROLL (option)
1
1
241
2GR
2
ROLL (option)
1
1
242
1.25Br
2
L4
1
256
3R
2
ROPS (option)
1
49
5L
2
52
1.25BY
3
53
G
56
1 DEF supply pump-5 DEF supply pump-6, 1 DEF tank sensor-3 1 DEF tank sensor-4
1
1 2
1
1
1
1
1
1
2
1
2
1
1
1
5-012
ELECTRICAL SYSTEM
4-1-3. Main harness (3)
138 139 R W 140210 B G
SWP-4F
Water spray pump (R) harness (P.5-031)
83 84 2L 2LW 6 RY
58X-3F
100 SPD Tape
100 SPR Tape
150 Corrugate
M1
180 Tape
M2
49 X1 5L 5B
58Y-2F
M3
199 25 2BR 2BW 133 134 2B 2WR
58X-4M
170 Tape Main harness (2) (P.5-011)
X1 5B
58Y-1M
58X-2M (CAP) (option) 58X-2F (CAP) (option)
58X-4M (CAP) (option)
58X-2F
58X-2M
X1
140 Tape
X7 256 3B 3R
100
ROPS Tape
400 Corrugate
2 5 100 2RW 2RL 91 X2 CAB1 Tape 1.25YR 3B
180 Corrugate
32
120 Tape
82 81
2G M4 2GW X X2
58X-4F
3B 3B
25
BW
65
WY
RES2
30 Tape
M5
Twist pair cable with shield
400 Corrugate
M7
8 15 94 95 Lg LgR BrG LY 107 108 109 110 L B G R 111 112 113 114 W L P Y 116 117 118 119 G O GB LB 131 164 172 GR BW 1.25BY
040DL-20PM
91 176 181 183 1.25YR BY L LR 185 186 187 189 G L LgR BrG 190 193 195 197 L GB W B 204 205 243
SWP-16F
17 23 47 52 Y GB LgB 1.25BY 66 67 73 155 WR WL Lg R 120 121 122 123 WL B L B 124 125 126 127 Br BrW Lg LgB 141 142 143 YW GL WB
040DL-20PF
Twist pair cable with shield
M6
32 33 34 35 G L Br YB 130 36 37 38 39 RES1 GB YL GY BrR Tape 40 41 42 X GW LW BrW B
· The earth wire "X" between "*1" (main harness (1)) and "*2" (main harness (3)) use "AVS3". · Where the numbers differ, wires of same color must not be united.
ECM harness (2) (P.5-021)
G L L
140 Tape
5-013
58X-3M
100 X7 241 2B 2GR ROLL Tape
58X-4F
SWP-3M
X7 3B
*2
5B,100
100 Tape Resistor unit (P.5-041)
240 2GW
210 Tape
SWP-12M
Resistor unit (P.5-041)
1568-09310-0-12322-0
ELECTRICAL SYSTEM
CONNECTION and NUMBER CONTACT OF CONTACT POINTS POINTS TOTAL (1) (2) Main Harness (3)
No.
SIZE, COLOR
X
B, 3B
15
X1
5B
2
X2
3B
3
X7
2B, 3B
3
2
2RW
5
1
5
2RL
4
6
RY
8
No.
SIZE, COLOR
CONNECTION and NUMBER CONTACT OF CONTACT POINTS POINTS TOTAL (1) (2) Main Harness (3)
134
2WR
3
1
1
M3
1
M4
1
138
R
3
1
1
SPD
1
SPR
1
139
W
3
2
SPD
1
SPR
1
140
B
3
1
1
SPD
1
M7 , CAB1 (option)
2
141
YW
2
1
M6
1
1
M5
1
142
GL
2
1
M6
1
2
1
M5
1
143
WB
2
1
M6
1
L
2
1
M5
1
155
R
2
M6
1
108
B
2
1
M5
1
164
BW
2
1
M5
1
109
G
2
1
M5
1
172
1.25BY
2
1
M5
1
110
R
2
1
M5
1
176
BY
2
1
M7
1
111
W
2
1
M5
1
181
L
3
1
M7
1
112
L
2
1
M5
1
183
LR
2
1
M7
1
113
P
3
1
1
M5
1
185
G
6
4
1
M7
1
114
Y
3
1
1
M5
1
186
L
6
4
1
M7
1
116
G
3
1
1
M5
1
187
LgR
2
1
M7
1
117
O
2
1
M5
1
189
BrG
2
1
M7
1
118
GB
4
3
M5
1
190
L
2
1
M7
1
119
LB
3
2
M5
1
193
GB
2
1
M7
1
120
WL
2
1
M6
1
195
W
2
1
M7
1
121
B
2
1
M6
1
197
B
3
2
M7
1
122
L
2
1
M6
1
199
2BR
2
1
M3
1
123
B
2
1
M6
1
204
G
3
2
M7
1
124
Br
2
1
M6
1
205
L
3
2
M7
1
125
BrW
2
1
M6
1
210
G
3
SPD
1
126
Lg
2
1
M6
1
240
2GW
2
1
M1
1
127
LgB
2
1
M6
1
241
2GR
2
1
ROLL (option)
1
131
GR
2
1
M5
1
243
L
2
M7
1
133
2B
4
2
M3
1
256
3R
2
ROPS (option)
1
81
2G
2
M2 , X1
2
82
2GW
2
M4 , CAB1 (option)
2
83
2L
2
M1 , ROLL (option), ROPS (option)
3
84
2LW
2
3
CAB1 (option)
1
91
1.25YR
2
1
2
CAB1 (option)
1
94
BrG
2
4
1
2
SPR
1
95
LY
Lg
2
1
M5
1
107
15
LgR
3
1
1
M5
1
17
Y
4
2
1
M6
1
23
GB
2
1
M6
1
25
BW, 2BW
9
6
1
M3 , RES2
2
32
G
3
1
1
RES1
1
33
L
3
1
1
RES1
1
34
Br
4
1
2
RES1
1
35
YB
3
1
1
RES1
1
36
GB
3
1
1
RES1
1
37
YL
3
1
1
RES1
1
38
GY
3
1
1
RES1
1
39
BrR
3
1
1
RES1
1
40
GW
3
1
1
RES1
1
41
LW
3
1
1
RES1
1
42
BrW
3
1
1
RES1
1
47
LgB
3
2
M6
1
49
5L
2
1
M2
1
52
1.25BY
3
1
M6
1
65
WY
2
1
RES2
1
66
WR
2
1
M6
1
67
WL
2
1
M6
1
73
Lg
4
M6
1
1
1
3
CONNECTION and NUMBER CONTACT OF CONTACT POINTS POINTS TOTAL (1) (2) Main Harness (3)
1
2
7
SIZE, COLOR
M4
M4 , RES1
6
No.
1 1 1 1
1
1
1
2
1 1
5-014
ELECTRICAL SYSTEM
4-2. Fuse · Relay Harness
3 5
2 STARTER SW. RELAY
EXACT METER RELAY
MID SPEED CONTROL RELAY
HORN RELAY
15
163
166 GB
164 BW X 163 15 165 243 B LgY LgR LgB L
44 Br 53 G
7 WG 8
LgR
52 1.25BY
1
LgY
2
3
THROTTLE RELAY
DEF SUPPLY STARTER MODULE RELAY LOCKOUT RELAY
178 75 30 1.25BY G 2L 190 132 199 Lg 1.25BR L Br 181 181 7 9 192 189 X 75 112 183 GR RW BrG B 2L L WG L L LR 4 RELAY BOX 1
5
PROPULSION PUMP PROPULSION PUMP PROPULSION PUMP AFTERTREATMENT PARKING NEUTRAL RELAY(1) NEUTRAL RELAY(2) NEUTRAL HOLDING RELAY RELAY INTERLOCK RELAY
15 LgR
71 LY 72 Br
72 Br X 74 73 X 73 B BrY Lg B Lg
8
71 LY 13 WL
9
10
6
7
STARTER RELAY
INTERLOCK RELAY
4
1
Relay Pin Position
69 153 56 12 1.25LB 2W 1.25Y BW 134 4 153 161 2WR 1.25GY 1.25Y P 133 74 X 68 X 161 X 162 X 2B BrY B 2G B P B Gr B 11 12 RELAY BOX 2
13
28 GB
15
X 167 B GR
76 2LB 80 2Y 16
20A
17
18 19 RELAY BOX 3
15A
20A
20A
15A
15A
15A
F2
F3
F4
F5
F6
F7
F8
10A
172 1.25BY 10A
174 1.25W
F13
10 5WR
20A
76 29 242 3 2LB 2WB 1.25Br 2WR F1
10A
70 2W
7 WG
68 2G
F14
5A
5W
10A
69 2W
F15
15A
75 2L
F16
20A
13 WL
14 WY
FUSE BOX 1
60
5A
58Y-2M
100 Tape
62 60 FU8 5WR 5W
58Y-2F
100 Tape
FU10 255 254
58X-4F
130 Tape
89 90 FU11 3WR 3R
58X-2M
160 Tape
251 FU12 5WR
58Y-1M
15A
63 2Br
F17
30A
89 3WR
F18
62 5WR
30A
90 3R
F19
FUSE BOX 2
20
15A
20A
F9
F10
31 YW
15A
19 2W
21
20A
5A
SWP-14F
130 Tape
6 7 12 112 RY WG BW L 132 28 52 56 FU2 Br GB 1.25BY 1.25LB 242 74 152 162 1.25Br BrY G Gr
SWP-12M
100 Tape
8 9 13 14 Lg GR WL WY 15 31 44 73 LgR YW Br Lg FU3 78 163 164 165 O LgY BW LgB 167 172 174 176 GR 1.25BY W BY
F11
F12
SWP-16F
(P.5-043)
30 176 1.25BY BY 15A
*2
Fuse box 2
252 3L
F20
5WR
20A
20A
15A
253 254 255 3LW 3GW 3G
F21
20A
F22
F23
270 Corrugate
200 Corrugate
30 Tape 161 6 P RY 71 78 LY O
Main harness (1) (P.5-009)
157 159 2LR 2RG
130 Tape
FU4 168 169
100 Tape
FU5 79 80
58X-4F
130 Tape
FU7
82 84 2GW 2LW 199 2BR
58X-3F
450 Corrugate
25
18
170 Tape
FU9 2WR192B
58X-3M
100 Tape
19 OPT. 2W
58X-1F
58X-4M
2LW 2LY
30A
*1
DIO
ECM harness (2) (P.5-021)
(P.5-044)
251 20A
3G 3GW
130 Tape
Fuse box 1
4 166 1.25GY GB
253 252 3LW 3L
113 243 53 P L G 178 117 116 114 FU1 G189O183G181Y BrG LR L X 192 190 1.25B RW L
63 63 63 82 84 2GW 2LW Br Br Br 168 169 113 114 116 2LW 2LY P Y G X 152 159 X 152 157 X 63 117 63 117 63 117 B G 2RG B G 2LR B Br O Br O Br O
93
5WL
10 93 FU6 5WR 5WL
14
WATER SPRAY PUMP WATER SPRAY PUMP WATER SPRAY PUMP WATER SPRAY PUMP PRESS.LINE BACKFLOW LINE SUCTION LINE RELAY(PUMP 1) RELAY(PUMP 2) RELAY(F, 2) RELAY(R, 2) HEATER RELAY HEATER RELAY HEATER RELAY
29 2WB 79 2W
120 Tape
3 70 2WR 2W
2W 2Y
134 133 2W
Roll light (option)
58X-1M (CAP)
7319-3090 Diode unit · The earth wire "X" between "*1" and "*2" use "AVS2". · Where the numbers differ, wires of same color must not be united.
5-015
1568-09309-0-12320-0
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
X
B, 1.25B
13
3
2WR
4
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
69
2W
2
70
2W
2
FU1 , Relay box 1-1-2, 1-5-2, 2-8-2, 2-9-2, 2-10-2, 2-12-2, 2-13-2, 2-14-2, 3-15-2, 3-16-2, 3-17-2, 3-18-2 FU5 , Fuse box 1-F4
Fuse box 2-F15, Relay box 2-11-3
159
2RG
2
FU4 , Relay box 3-17-4
2
FU5 , Fuse box 1-F5
161
P
3
DIO , Relay box 2-13-1, 2-14-5
71
LY
3
DIO , Relay box 2-8-3, 2-10-3
162
Gr
2
FU2 , Relay box 2-14-1
1.25GY
2
Fuse box 1-F11, Relay box 2-12-5
72
Br
2
Relay box 2-8-5, 2-9-3
163
LgY
3
FU3 , Relay box 1-2-1, 3
6
RY
2
DIO , FU2
73
Lg
3
FU3 , Relay box 2-9-4, 2-10-1
164
BW
2
FU3 , Relay box 1-2-5
7
WG
4
FU2 , Fuse box 1-F6, Relay box 1-4-1, 3
74
BrY
3
FU2 , Relay box 2-9-1, 2-12-1
165
LgB
2
FU3 , Relay box 1-2-2
8
Lg
2
FU3 , Relay box 1-4-5
75
2L
3
Fuse box 2-F16, Relay box 1-6-1, 3
166
GB
2
Fuse box 1-F12, Relay box 1-1-5
9
GR
2
FU3 , Relay box 1-4-2
76
2LB
2
Fuse box 1-F1, Relay box 3-16-3
167
GR
2
FU3 , Relay box 3-16-1
10
5WR
2
FU6 , Fuse box 1-F7
78
O
2
DIO , FU3
168
2LW
2
FU4 , Relay box 3-17-5
12
BW
2
FU2 , Relay box 2-14-3
79
2W
2
FU5 , Relay box 3-15-5
169
2LY
2
FU4 , Relay box 3-18-5
13
WL
3
FU3 , Fuse box 1-F7, Relay box 2-10-5
80
2Y
2
FU5 , Relay box 3-16-5
172
1.25BY
2
FU3 , Fuse box 2-F13
14
WY
2
FU3 , Fuse box 1-F8
82
2GW
2
FU7 , Relay box 3-17-3
174
W, 1.25W
2
FU3 , Fuse box 2-F13
15
LgR
4
FU3 , Relay box 1-1-3, 1-2-4, 2-8-1
84
2LW
2
FU7 , Relay box 3-18-3
176
BY
2
FU3 , Fuse box 1-F12
19
2W
3
FU9 , Fuse box 1-F10, OPT. (option)
89
3WR
2
FU11 , Fuse box 2-F18
178
G
2
FU1 , Relay box 1-5-3
28
GB
2
FU2 , Relay box 3-15-1
90
3R
2
FU11 , Fuse box 2-F19
181
L
3
FU1 , Relay box 1-3-2, 1-7-2
29
2WB
2
Fuse box 1-F2, Relay box 3-15-3
93
5WL
2
FU6 , Fuse box 1-F2
183
LR
2
FU1 , Relay box 1-7-1
30
1.25BY
2
Fuse box 1-F11, Relay box 1-7-3
112
L
2
FU2 , Relay box 1-6-2
189
BrG
2
FU1 , Relay box 1-5-4
31
YW
2
FU3 , Fuse box 1-F9
113
P
2
FU1 , Relay box 3-19-5
190
L
2
FU1 , Relay box 1-5-5
44
Br
2
FU3 , Relay box 1-3-3
114
Y
2
FU1 , Relay box 3-20-5
192
RW
2
FU1 , Relay box 1-5-1
52
1.25BY
2
FU2 , Relay box 1-1-1
116
G
2
FU1 , Relay box 3-21-5
199
1.25BR, 2BR
2
FU7 , Relay box 1-7-5
53
G
2
FU1 , Relay box 1-3-5
117
O
4
FU1 , Relay box 3-19-2, 3-20-2, 3-21-2
242
1.25Br
2
FU2 ,Fuse box 1-F3
56
1.25LB
2
FU2 , Relay box 2-13-3
132
Br
2
FU2 , Relay box 1-6-5
243
L
2
FU1 , Relay box 1-3-1
60
5W
2
FU8 , Fuse box 2-F15
133
2B
2
FU9 , Relay box 2-11-2
251
5WR
2
FU12 , Fuse box 2-F21
62
5WR
2
63
Br, 2Br
7
68
2G
2
FU8 , Fuse box 2-F19 Fuse box 2-F17, Relay box 3-19-1, 3, 3-20-1, 3, 3-21-1, 3 Fuse box 2-F14, Relay box 2-11-1
134
2WR
2
FU9 , Relay box 2-11-5
252
3L
2
FU10 , Fuse box 2-F20
152
G
3
FU2 , Relay box 3-17-1, 3-18-1
253
3LW
2
FU10 , Fuse box 2-F21
153
1.25Y
2
Relay box 2-12-3, 2-13-5
254
3GW
2
FU10 , Fuse box 2-F22
157
2LR
2
FU4 , Relay box 3-18-4
255
3G
2
FU10 , Fuse box 2-F23
CONNECTION
CONNECTION
5-016
ELECTRICAL SYSTEM
4-3. Engine Harness
50
15 Cor 0 ruga
5BW,50
Co 200 (H rrug -C at OT e )
1270 Corrugate 15 (H-COT)
100
5B,150
5B,150
5B,150
B,150
te
5B,150
120 Tape
30
150 Corrugate 15 (H-COT)
450 Corrugate 15 (H-COT)
B+
B+
B+
B+
L
STD
STD
STD
STD
STD
203
86
58
46
47
215
175
133
1
197
LA308 (B+)
LA308 (B+)
LA308 (B+)
LA308 (B+)
LA106 (L)
LA312
LA312
LA312
LA312
R1.25-12
LgB,30
E10
209
5R,120
47 91 197 LgB 1.25YR B
208
5R,120
SWP-3M
600 Corrugate 13 (H-COT)
120 Tape
ECM harness (1) (P.5-019)
LA305
Marking tape (color:white)
1 Co 80 (H- rruga CO te T)
E9
LA312
5R,150
175 133 3B 2B
58X-2M
1.25YR,20
CL
91
180 ate rug Cor COT) (H-
Compressor magnet clatch CB104 (option) (Insulation protection)
5B,20
ECM
1
LE306
(50)
5R,150
Ground
(30)
5W,150
Starter motor
100 Tape
B1
46 58 5R 5R
58Y-2M
100 Tape
B2
86 203 5R 5R
58Y-2M
80 Tape
B3
209 208 5BW 5W
58Y-2F
80 Tape
B4
215 5B
58Y-1F
Engine stud bolt
Alternator (150A)
· Where the numbers differ, wires of same color must not be united. · Make use of heat resistannce wire "AEX" equivalency product.
No.
SIZE, COLOR
CONTACT POINTS
1
5B
2
46
5R
47
1568-09297-2-12261-B
No.
SIZE, COLOR
CONTACT POINTS
ECM , STD
175
3B, 5B
2
E9 , STD
2
B1 , B+
197
B
2
E10 , STD
LgB
2
E10 , L
203
5R
2
B2 , B+
58
5R
2
B1 , B+
208
5W
2
30 , B3
86
5R
2
B2 , B+
209
5BW
2
50 , B3
91
1.25YR
2
CL , E10
215
5B
2
B4 , STD
133
2B, 5B
2
E9 , STD
5-017
Battery harness (P.5-023)
CONNECTION
CONNECTION
ELECTRICAL SYSTEM
4-4. Hydraulic Pump Harness
120 Tape 211 212 213 214
Battery harness (P.5-023)
212 b 211 G B 2
(b:Forward)
DT06-2S-CE05
1
G B L B
124 125 126 127
SWP-16M
Br BrW Lg LgB X 103 187 15 B W LgR LgR 15
250 Corrugate (H-COT)
100 Corrugate (H-COT)
350 Corrugate 10 (H-COT)
PRO
Propulsion pump proportional solenoid
LgR
RVa
RVb
126 X Lg B 2 1 *(a:Hi/Normal)
124 X 2 Br B 1 *(b:Lo/Oscillation)
127 X LgB B 2 1 *(a:Hi/Normal)
125 X 2 BrW B 1 *(b:Lo/Oscillation)
DT06-2S-CE05
DT06-2S-CE05
DT06-2S-CE05
DT06-2S-CE05
DT06-2S-CE05
WIF sensor
2
(a:Reverse)
DT06-2S-CE05
1
120 Tape
FVb
187 103 LgR W 1
2
214 a 213 L B
300 Corrugate (H-COT)
FVa
120 Tape
350 Corrugate (H-COT)
WIF
400 Corrugate (H-COT)
300 Corrugate (H-COT)
Vibrator pump (F) proportional solenoid
Vibrator pump (R) proportional solenoid
· Where the numbers differ, wires of same color must not be united. · Make use of heat resistannce wire "AEX" equivalency product. * · Hi, Lo : STD type Normal, Oscillation : ND type
No.
SIZE, COLOR
CONTACT POINTS
X
B
5
15
LgR
103
1568-09292-0-22244-A
No.
SIZE, COLOR
CONTACT POINTS
FVa , FVb , PRO , RVa , RVb
127
LgB
2
PRO , RVa
2
PRO × 2
187
LgR
2
PRO , WIF
W
2
PRO , WIF
211
G
2
b , PRO
124
Br
2
FVb , PRO
212
B
2
b , PRO
125
BrW
2
PRO , RVb
213
L
2
a , PRO
126
Lg
2
FVa , PRO
214
B
2
a , PRO
CONNECTION
CONNECTION
5-018
ELECTRICAL SYSTEM
4-5. ECM Harness
Terminating resistor DT06-3S-E008 With DT04-3P-P006 Twist cable
72 71
70
69
47
43
42
20
19
18
85 84 83 82 81 80 79 78 77 118 118 183 131 110 107 97 GB GB LR GR R L BY 187 119 108 96 LgR LB B GB 63 62 61 60 59 58 57 56 55 54 53
40 39 38 37 36 35 34 116 114 113 194 G Y P YB 111 103 W W 17 16 15 14 13 12 11 10
X7 240 2B 2GW
ROLL
DT06-3S-CE05
27 171 BW 117 O 3
4
175 B 50 26 171 BW
175 73 B 175 49 B
*3
E9
120 Tape
197 91 47 B 1.25YR LgB
E10
120 Tape
A 141 142 B YW GL THR 143 WB C
100 Tape
12110293
*1
*3 CONNECTION STATUS
2
50 Tape
Marking tape (color:white)
400 Corrugate (H-COT)
250 Corrugate (H-COT)
90 °
FP
100 Tape 12
11
10 9
8
7
6
5
4
3
2
1
243
Engine ECM (CM2350) /J4(24PIN)
L 205 204 G L 22 21 20 19 18 17 16 15 24 23
30 Tape 14
150 Corrugate (H-COT)
49
E1 5WR 5L
80 Tape
E2 5W 5WR
58Y-2F
100 Tape
E3
25 2BW 133 134 2B 2WR
58X-4M
80 Tape
E4 3BW 2BR
58Y-2M
200 Corrugate (H-COT)
100 Tape
120 Tape
100 Tape
ECM Harness (2) (P.5-021) · Where the numbers differ, wires of same color must not be united. · Change only harness of No. 171 and 175 in "*3" position from "AVS3" to 4×"AVS0.85", and connect, and do the insuolation processing. · The earth wire "X" between "*1" (ECM harness (1)) and "*2" (ECM harness (2)) use "AVS3". · Make use of heat resistannce wire "AEX" equivalency product.
200 Corrugate (H-COT)
60 62
171 199
58X-2F Battery harness (P.5-023)
E8
15 164 LgR BW 17 66 67 73 Y WR WL Lg 120 121 122 123 WL B L B 124 125 126 127 Br BrW Lg LgB
SWP-16F
E7
23 52 96 97 GB 1.25BY GB BY 103 155 172 187 W R 1.25BY LgR 177 181 204 205 G L G L
SWP-12M
Twist pair cable with shield
13
Twist pair cable with shield
5-019
10
100 Tape
∞
82 81 2GW 2G 8 Lg
250 Corrugate 28 (H-COT)
58X-3F
B B B B B 175 175 175 175 175
171 25 BW 171 1 BW
DT04-3P-CE02 (CAP)
Frame (F) harness (P.5-032)
BW BW BW BW BW 171 171 171 171 171
3B
330
133 175 2B 3B
193 194 195 GB YB W
175
171 3W
100 Tape
180 Corrugate 10 (H-COT)
Thermometer (option)
28 171 BW
74
Three wires twist cable
100 Tape
Coolant level sensor
Engine harness (P.5-017) SWP-3F
9
32 31 30 29 193 GB 195 112 109 176 W L G BY 8 7 6 5
75 177 G 175 B 51
Three wires twist cable
58X-2M (CAP)
58X-2F
33
76 181 L 175 B 52
170 Corrugate 28 (H-COT)
58X-2F
86
41
Twist pair cable with shield Roll light (option)
64
87 95 LY
°
24
44
88
90
48
46 45 186 L 185 G 23 22 21
91 90 89 94 BrG 189 BrG 68 67 66 65
900 Corrugate 25 (H-COT)
Engine ECM (CM2250)/J2(96PIN)
92
B
120 Tape
Twist pair cable with shield
E6
93 251 5WL 5WR
58Y-2F
E5
134 133 2WR 2B 205 204 L G
58X-4M
∞
96
94 93 190 L
185 186 G L X B C
Twist pair cable with shield
480
95
A
100 Tape
4-5-1. ECM harness (1)
Twist pair cable with shield
SCR harness (P.5-035)
1568-09311-0-12324-0
ELECTRICAL SYSTEM
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
X
B, 3B
3
Terminating resistor-C
1
2
X7
2B, 3B
3
ROLL (option)
1
8
Lg
2
FP
10
5WR
2
15
LgR
17
CONNECTION and NUMBER OF CONTACT POINTS
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
172
1.25BY
2
175
B, 3B
6
176
BY
2
E9 , Engine ECM (96pin)-49, 50, 51, 52, 73 Engine ECM (96pin)-5
177
G
2
E7 , Engine ECM (96pin)-75
2
181
L
3
E7 , Engine ECM (96pin)-76
2
1
183
LR
2
1
1
185
G
3
2
1
186
L
3
2
1
1
187
LgR
3
Engine ECM (96pin)-83 Engine ECM (96pin)-22, Terminating resistor-A Engine ECM (96pin)-46, Terminating resistor-B E7 , Engine ECM (96pin)-62
2
1
1
1
189
BrG
2
Engine ECM (96pin)-66
1
1
E8
1
1
190
L
2
1
1
2
E8
1
1
193
GB
3
2
1
Br
2
E8
1
1
125
BrW
2
E8
1
1
194
YB
2
1
126
Lg
2
E8
1
1
195
W
3
1
1
127
LgB
2
E8
1
1
E10
1
1
131
GR
2
Engine ECM (96pin)-82
1
1
197
B
2
Engine ECM (96pin)-94 Coolant level sensor, Engine ECM (96pin)-32 Coolant level sensor, Engine ECM (96pin)-35 Coolant level sensor, Engine ECM (96pin)-8 E10
2
E6
1
1
133
2B
4
E3 , E5 , E9
3
1
199
2BR
2
E4
BrG
2
Engine ECM (96pin)-91
1
1
134
2WR
3
E3 , E5
2
1
204
G
4
95
LY
2
Engine ECM (96pin)-87
1
1
141
YW
2
THR -A (option)
1
1
96
GB
2
E7 , Engine ECM (96pin)-53
2
142
GL
2
THR -B (option)
1
1
205
L
4
97
BY
2
E7 , Engine ECM (96pin)-77
2
143
WB
2
THR -C (option)
1
1
240
2GW
2
E5 , E7 , Engine ECM J4 (24pin)-22 E5 , E7 , Engine ECM J4 (24pin)-23 ROLL (option)
103
W
2
E7 , Engine ECM (96pin)-13
2
155
R
2
E7
1
1
243
L
2
107
L
2
Engine ECM (96pin)-79
1
1
164
BW
2
E8
1
1
251
5WR
2
108
B
2
Engine ECM (96pin)-54
1
1
171
BW, 3BW
6
E4 , Engine ECM (96pin)-1, 25, 26, 27, 28
6
SIZE, COLOR
CONTACT POINTS TOTAL
109
G
2
Engine ECM (96pin)-6
1
1
2
110
R
2
Engine ECM (96pin)-81
1
1
1
1
111
W
2
Engine ECM (96pin)-16
1
1
E1
1
1
112
L
2
Engine ECM (96pin)-7
1
1
2
E8
1
1
113
P
2
Engine ECM (96pin)-38
1
1
Y
2
E8
1
1
114
Y
2
Engine ECM (96pin)-39
1
1
23
GB
2
E7
1
1
116
G
2
Engine ECM (96pin)-40
1
1
25
2BW
2
E3
1
1
117
O
2
Engine ECM (96pin)-3
1
1
47
LgB
2
E10
1
1
118
GB
3
Engine ECM (96pin)-84, 85
2
1
49
1.25L, 5L
3
E1
1
1
119
LB
2
Engine ECM (96pin)-57
1
1
52
1.25BY
2
E7
1
1
120
WL
2
E8
1
60
5W
2
E2
1
1
121
B
2
E8
62
5WR
2
E2
1
1
122
L
2
66
WR
2
E8
1
1
123
B
67
WL
2
E8
1
1
124
73
Lg
2
E8
1
1
81
2G
2
FP
1
82
2GW
2
FP
91
1.25YR
2
93
5WL
94
No.
ECM Harness (1)
No. (2)
ECM Harness (1)
No. (2)
ECM Harness (1) E7
(2) 1
1
6 1
1
2 2
1
1
1
1
1
3
1
3
1
1
1
Engine ECM J4 (24pin)-7
1
1
E6
1
1
5-020
ELECTRICAL SYSTEM
4-5-2. ECM harness (2)
58X-2F
58X-4M
58Y-2M
58Y-2F
251 5WR
90 89 3R 3WR
252 253 3L 3LW 254 255 3GW 3G
60 62 5W 5WR
93 10 5WL 5WR
FU12
FU11
FU10
FU8
FU6
180 Corrugate (H-COT)
150 Tape
170 Tape
170 Tape
150 Tape
Fuse・relay harness (P.5-015)
58X-2F
58X-4F (CAP)
58X-4M
58X-3F (CAP)
58X-3M
58Y-2M (CAP)
58Y-2F
Cabin and air conditioner (option)
89 90 3WR 3R
CAB2
100 Tape
CAB3
120 Tape
X3 X4 3B 3B 49 1.25L
CAB4
120 Tape
X5 X6 5B 5B
CAB5
100 Tape
252 253 3L 3LW 254 255 3GW 3G
500 Corrugate (H-COT)
58X-2M (CAP)
450 Corrugate (H-COT)
58Y-1F
Twist pair cable with shield
∞
∞
183 181 176 91 LR L BY 1.25YR 189 187 186 185 BrG LgR L G 197 195 193 190 B W GB L 243 205 204 L L G
Twist pair cable with shield SWP-16M
200 Corrugate (H-COT)
200 Corrugate (H-COT)
50
120 Tape
100 Tape
M5
100 Tape
M6
Marking tape (color:white)
120 Tape
M7
350 Corrugate 28 (H-COT)
180 Tape
180 Tape
200 Tape
350 Corrugate 28 (H-COT)
M4
M3
M2
M1
52 47 23 17 1.25BY LgB GB Y 155 73 67 66 R Lg WL WR 123 122 121 120 B L B WL 127 126 125 124 LgB Lg BrW Br 143 142 141 WB GL YW
95 94 15 8 LY BrG LgR Lg 110 109 108 107 R B G L 114 113 112 111 Y P L W 119 118 117 116 LB GB O G 172 164 131 1.25BY BW GR
81 82 2G 2GW
040DL-20PM
040DL-20PF
58X-4M
X2 X 3B 3B
25 199 2BW 2BR
X1 5B
49 5L
134 133 2WR 2B
58X-4F
58Y-2M
240 2GW X7 3B
Marking tape (color:white)
*2
800 Corrugate 28 (H-COT)
LA208
X
E
3B,120
LA308
X1
E
5B,120
LA208
X2
E
3B,120
LA208
X3
E
3B,120
LA208
X4
E
3B,180
LA308
X5
E
5B,180
LA308
X6
E
5B,180
LA208
X7
E
3B,180
Ground
100
ECM Harness (1) (P.5-019)
500
58X-3F
Main harness (3) (P.5-013)
· Where the numbers differ, wires of same color must not be united. · The earth wire "X" between "*1" (ECM harness (1)) and "*2" (ECM harness (2)) use "AVS3". · Make use of heat resistannce wire "AEX" equivalency product.
5-021
1568-09311-0-12324-0
ELECTRICAL SYSTEM
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
(1)
X
B, 3B
3
1
X1
5B
X2
No.
No.
ECM Harness (2)
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
(1)
No.
ECM Harness (2)
CONNECTION and NUMBER OF CONTACT POINTS
SIZE, COLOR
CONTACT POINTS TOTAL
(1)
ECM Harness (2)
E , M4
2
93
5WL
2
1
FU6
1
142
GL
2
1
M6
1
2
E , M2
2
94
BrG
2
1
M5
1
143
WB
2
1
M6
1
3B
2
E , M4
2
95
LY
2
1
M5
1
155
R
2
1
M6
1
X3
3B
2
CAB4 , E
2
107
L
2
1
M5
1
164
BW
2
1
M5
1
X4
3B, 5B
2
CAB4 , E
2
108
B
2
1
M5
1
172
1.25BY
2
1
M5
1
X5
5B
2
CAB5 , E
2
109
G
2
1
M5
1
176
BY
2
1
M7
1
X6
5B
2
CAB5 , E
2
110
R
2
1
M5
1
181
L
3
2
M7
1
X7
2B, 3B
3
1
E , M1
2
111
W
2
1
M5
1
183
LR
2
1
M7
1
8
Lg
2
1
M5
1
112
L
2
1
M5
1
185
G
3
2
M7
1
10
5WR
2
1
FU6
1
113
P
2
1
M5
1
186
L
3
2
M7
1
15
LgR
2
1
M5
1
114
Y
2
1
M5
1
187
LgR
3
2
M7
1
17
Y
2
1
M6
1
116
G
2
1
M5
1
189
BrG
2
1
M7
1
23
GB
2
1
M6
1
117
O
2
1
M5
1
190
L
2
1
M7
1
25
2BW
2
1
M3
1
118
GB
3
2
M5
1
193
GB
3
2
M7
1
47
LgB
2
1
M6
1
119
LB
2
1
M5
1
195
W
3
2
M7
1
49
1.25L, 5L
3
1
CAB4 , M2
1
120
WL
2
1
M6
1
197
B
2
1
M7
1
52
1.25BY
2
1
M6
1
121
B
2
1
M6
1
199
2BR
2
1
M3
1
60
5W
2
1
FU8
1
122
L
2
1
M6
1
204
G
4
3
M7
1
62
5WR
2
1
FU8
1
123
B
2
1
M6
1
205
L
4
3
M7
1
66
WR
2
1
M6
1
124
Br
2
1
M6
1
240
2GW
2
1
M1
1
67
WL
2
1
M6
1
125
BrW
2
1
M6
1
243
L
2
1
M7
1
73
Lg
2
1
M6
1
126
Lg
2
1
M6
1
251
5WR
2
1
FU12
1
81
2G
2
1
M4
1
127
LgB
2
1
M6
1
252
3L
2
CAB3 , FU10
2
82
2GW
2
1
M4
1
131
GR
2
1
M5
1
253
3LW
2
CAB3 , FU10
2
89
3WR
2
CAB2 , FU11
2
133
2B
4
3
M3
1
254
3GW
2
CAB3 , FU10
2
90
3R
2
CAB2 , FU11
2
134
2WR
3
2
M3
1
255
3G
2
CAB3 , FU10
2
91
1.25YR
2
M7
1
141
YW
2
1
M6
1
1
5-022
ELECTRICAL SYSTEM
4-6. Battery Harness
300 Corrugate (H-COT)
LA105
LA105
(BR) LE104
X
177
181
(NO)
59
(NO)
92
52
NO
11
5WR,130
160
NO
61
(NO)
2W,120
250
(NO)
BR
LA208
5Y,200
CO
85
LA308 (COM)
5WL,170
CO
51
LA308 (COM)
5Y,170
CO
45
LA308 (COM)
3BY,150
CO
172
LA208 (COM)
RL,200
CO
156
LA108 (COM)
Battery relay
230 Corrugate 28 (H-COT)
Marking tape (color:white)
130
1.25BY,200
LA308 (COM)
5W,150
202
300
CO
3B,30
5Y,200
2-1418390-1 NOx sensor (P.3-004)
(Combination meter)
(Controllers) (Engine ECM)
140
120
140
180
5
4
3
2
1
7123-2128-60 DIODE
180
FUSE 30A
210
FUSE 15A
6
FUSE 5A
7
30A
170
15A
8
5A
X B 52 1.25BY
150
171
220 Corrugate
150 172
170
160
9
25
210
1
155
10 156
Tape
SWP-4F Solenoid harness (P.5-034)
3
3BY,50
SWP-16F Hydraulic pump harness (P.5-018)
4
205 204 L G 133 134 2B 2WR
3BW,50
SWP-16F
2
150
23 17 GB Y X 73 B Lg
Tape
123 122 121 120 B L B WL 127 126 125 124 LgB Lg BrW Br 15 187 103 X LgR LgR W B 15 LgR
2W,50
X 67 X 66 B WL B WR 127 126 125 124 LgB Lg BrW Br 15 187 103 X LgR LgR W B 164 BW
Twist pair cable with shield
2BW,50
150 Tape
LA308 (COM)
180
INJ
57
Tape
97 96 BY GB
CO
R,50
SWP-2F
40
5Y,200
RL,50
150 Tape
(NO)
LA308 LA308 LA308 LA208 LA308 LA308
(NO)
Ground
Battery (-)
Marking tape (color:white) 190 Tape
E6
LA310
Battery relay
80
1.25B,200
550 Corrugate 28 (H-COT)
HYD
251 93 5WR 5WL
215
E
230 Corrugate 15 (H-COT)
E
200 Tape
58Y-2M
SWP-16M (CAP)
5-023
X
130 Tape
Twist pair cable with shield
· Where the numbers differ, wires of same color must not be united. · Make use of heat resistannce wire "AEX" equivalency product.
5B,50
120 Corrugate (H-COT)
160 Tape
Battery relay LE104 Ground
200 D_NOx Tape
E8
Grid heater relay
Marking tape (color:white)
150
120 Tape
97 96 52 23 BY GB 1.25BY GB 187 172 155 103 LgR 1.25BY R W E7 205 204 181 177 L G L G
Twist pair cable with shield
DRT harness (P.5-036)
E4
LA205
0 22 ate g rru T) Co -CO (H
SWP-12F
164 15 BW LgR 73 67 66 17 Lg WL WR Y 123 122 121 120 B L B WL 127 126 125 124 LgB Lg BrW Br
100 Tape
PRO
SWP-16M
199 171 2BR 3BW
E3
Corrugate 19 (H-COT)
ECM harness (1) (P.5-019)
134 133 2WR 2B
160 Tape
220 Tape
58X-2M
25 2BW
E2
120 Tape
EMR
58X-4F
62 60 5WR 5W
E1
X
0 15 gate ) rru T Co H-CO (
58Y-2M
49 10 5L 5WR
LA205
NO
2B,100 58Y-2F
199
Starter relay
2BR,140
Corrugate 15 (H-COT)
58Y-1M
215 5B
LA308
NO
B4
200 Tape
58Y-2M
Corrugate 10 (H-COT)
209
5WR,130
B3
150 Tape
208 209 5W 5BW
5BW,100 250
NO
200 Tape
LA308
5WL,150
B2
208
NO
203 86 5R 5R
5W,150
5W,150
150 Tape
L,70
58Y-2F
B1
230 Corrugate (H-COT)
Engine harness (P.5-017)
58 46 5R 5R
G,70
58Y-2F
251 5WR 250 5W
93 5WL 92 5WR
62 5WR 61 5WL
60 5W 59 5WR
10 5WR 11 5W
203 5R 202 5Y
86 5R 85 5Y
58 5R 57 5Y
46 5R 45 5Y
49 5L 51 5WL
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
7322-4123-30 F.L.65A
1568-09312-0-12341-A
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
X
B, 1.25B, 2B, 3B
9
10
5WR
11
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
67
WL
2
2
E × 2, EMR × 3, HYD , PRO , Diode, Starter relay 6 , E1
73
Lg
5W
2
6 , NO
85
15
LgR
4
E8 , EMR , PRO × 2
17
Y
2
E8 , HYD
23
GB
2
E7 , HYD
25
2BW
2
E3 , Fuse 15A
45
5Y
2
2 , CO
46
5R
2
2 , B1
49
5L
2
1 , E1
51
5WL
2
1 , CO
52
1.25BY
3
BR , E7 , Diode
57
5Y
2
3 , CO
58
5R
2
3 , B1
59
5WR
2
7 , NO
60
5W
2
7 , E2
61
5WL
2
8 , NO
62
5WR
2
8 , E2
66
WR
2
E8 , EMR
No.
SIZE, COLOR
CONTACT POINTS
E8 , EMR
155
R
2
E7 , Fuse 5A
2
E8 , HYD
156
RL
2
CO , Fuse 5A
5Y
2
4 , CO
160
2W
2
NO , Fuse 15A
86
5R
2
4 , B2
164
BW
2
E8 , EMR
92
5WR
2
9 , NO
171
3BW
2
E4 , Fuse 30A
93
5WL
2
9 , E6
172
1.25BY, 3BY
3
CO , E7 , Fuse 30A
96
GB
2
E7 , INJ
177
G
2
E7 , Grid heater relay
97
BY
2
E7 , INJ
181
L
2
E7 , Grid heater relay
103
W
3
E7 , EMR , PRO
187
LgR
3
E7 , EMR , PRO
120
WL
2
E8 , PRO
199
2BR
2
E4 , Starter relay
121
B
2
E8 , PRO
202
5Y
2
5 , CO
122
L
2
E8 , PRO
203
5R
2
5 , B2
123
B
2
E8 , PRO
204
G
2
D_NOX , E7
124
Br
3
E8 , EMR , PRO
205
L
2
D_NOX , E7
125
BrW
3
E8 , EMR , PRO
208
5W
2
B3 , Starter relay
126
Lg
3
E8 , EMR , PRO
209
5BW
2
B3 , Starter relay
127
LgB
3
E8 , EMR , PRO
215
5B
2
B4 , Battery(-)
133
2B
2
D_NOX , E3
250
5W
2
10 , NO
134
2WR
2
D_NOX , E3
251
5WR
2
10 , E6
CONNECTION
CONNECTION
5-024
ELECTRICAL SYSTEM
4-7. F-R Lever Harness
2
4
5
151
152
167
151
GL,50
1
28
GR,50
151
G,50
78
GL,50
151
GB,50
2Y,50
2RG,50
2G,50
2W,50
2LW,50
2Y,50
2LR,50
2L,50
77
Water spray timer RB4B-SL X 152 B G 28 152 GB G
100 Tape WL,50
BW,50
O,50
FCOM
FNC
FNO
162
13
12
78
CB104
CA104
CA104
CB104
CA104
CA104
Backup buzzer switch
· Where the numbers differ, wires of same color must not be united.
F-R lever switch
138 206 140 R WR B
30 Tape
30 Tape 31 YW 31 YW 31 YW
35 YB 38 GY 43 GR
P/O
Gr,50
RNC
6
138 145 140 R W B
LVR
RY,50
RNO
70 Tape
WG,50
RCOM 7
Tape
50 Tape
L4
30
SWP-12M
13 12 7 6 WL BW WG RY 145 140 138 78 W B R O 242 206 167 162 1.25Br WR GR Gr
POT2
100 Tape
POT1
38 35 31 28 GY YB YW GB X 152 77 43 L3 1.25B G GW GR
50 Tape
SWP-8F
120 Corrugate
1050 Corrugate
Main harness (2) (P.5-011)
5-025
80
TIM
50 Tape
159
100 Tape
L2
81
TIM
159 81 2RG 2G 157 83 2LR 2L
79
100 Tape
58X-4M
168
FP
100 Tape
80
100 Tape
L1
157
RP
80 79 2Y 2W 169 168 2LY 2LW
83
110 Tape
58X-4F
79
2W,50
2LY,50
169
(5) (1) (2) (3) (4) LE204 LE204 LE204 LE204 LE204
GL,50
(5) (1) (2) (3) (4) LE204 LE204 LE204 LE204 LE204
O,50
(5) (1) (2) (3) (4) LE204 LE204 LE204 LE204 LE204
Water spray timer switch
Water spray mode select switch
GL,50
Water spray pump switch (F)
GW,50
Water spray pump switch (R)
242 X 1.25Br 1.25B
174357-2
174357-2
DT06-6S-CE05
DT04-2P-E005
Potentiometer 1 (P.5-039)
Potentiometer 2 (P.5-039)
Lever switch (P.5-042)
Sub power
1568-09298-0-12262-0
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
X
B, 1.25B
3
L3 , P/O , TIM
83
2L
2
L2 , RP
6
RY
2
L4 , RNO
138
R
3
L4 , POT1 , POT2
7
WG
2
L4 , RCOM
140
B
3
L4 , POT1 , POT2
12
BW
2
FNC , L4
145
W
2
L4 , POT1
13
WL
2
FCOM , L4
151
GL
4
2 , 5 , TIM (LE204) × 2
28
GB
3
L3 , TIM (LE204), TIM (RB4B)
152
G
4
L3 , TIM (LE204), TIM (RB4B) × 2
31
YW
4
L3 , LVR × 3
157
2LR
2
L2 , RP
35
YB
2
L3 , LVR
159
2RG
2
FP , L2
38
GY
2
L3 , LVR
162
Gr
2
L4 , RNC
43
GR
2
L3 , LVR
167
GR
2
L4 , TIM
77
GW
2
1 , L3
168
2LW
2
FP , L1
78
O
3
4 , FNO , L4
169
2LY
2
L1 , RP
79
2W
3
FP , L1 , RP
206
WR
2
L4 , POT2
80
2Y
3
FP , L1 , RP
242
1.25Br
2
L4 , P/O
81
2G
2
FP , L2
CONNECTION
CONNECTION
5-026
ELECTRICAL SYSTEM
4-8. Panel (L) Harness
31
1
YW,100
(2) R1.25-3.5
40
2
GW,100
(3) R1.25-3.5
31
3
YW,100
4
LW,100
IPF select switch (4) R1.25-3.5
41 31
5
(6) R1.25-3.5
42
6
BrW,100
(3)
(4)
(6)
(1)
(2)
(4)
(5)
31
34
170
31
36
31
37
31
32
31
33
31
26
31
27
1
2
3
1
3
4
5
1
3
4
6
1
2
4
5
GR,70
YW,70
GB,70
YW,70
YL,70
YW,70
G,70
YW,70
L,70
YW,70
BrB,70
YW,70
LB,70
F/R
(1)
100 Tape
(5)
FRQ
(4)
100 Tape
(3)
C/A
(1)
50 Tape
(3)
L/H
(2)
50 Tape
(1)
Br,70
Vibratory drum select switch
IPF
80 Tape
250 Corrugate 25
Marking tape (color:white)
15
LH
32 31 27 26 G YW LB BrB 37 36 34 33 YL GB Br L 137 42 41 40 GB BrW LW GW X 170 B GR
SWP-16M Main harness (2) (P.5-011)
X
CA104
B,50
137
CB104
GB,50
AUT
(5) R1.25-3.5
YW,100
Vibration frequency select switch
50 Tape
(1) R1.25-3.5
Vibration mode select switch
YW,70
Vibration switch
Auto speed indicator
· Where the numbers differ, wires of same color must not be united.
5-027
1568-09190-0-21386-A
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
X
B
2
26
BrB
27
No.
SIZE, COLOR
CONTACT POINTS
AUT , LH
36
GB
2
C/A - 3 , LH
2
F/R - 2 , LH
37
YL
2
C/A - 5 , LH
LB
2
F/R - 5 , LH
40
GW
2
IPF - 2 , LH
31
YW
11
C/A - 1 , - 4 , F/R - 1 , - 4 , FRQ - 1 , - 4 , IPF - 1 , - 3 , - 5 , LH , L/H - 1
41
LW
2
IPF - 4 , LH
32
G
2
FRQ - 3 , LH
42
BrW
2
IPF - 6 , LH
33
L
2
FRQ - 6 , LH
137
GB
2
AUT , LH
34
Br
2
L/H - 2 , LH
170
GR
2
LH , L/H - 3
CONNECTION
CONNECTION
5-028
ELECTRICAL SYSTEM
4-9. Panel (R) Harness
Speed change switch
65
67
15
74
17
18
X
1
3
3
2
1
1
2
3
4
5
L,70
B,70
60 Tape
SPE
70 Tape
50 Tape
PAR
EME
66
Y,70
(5)
BrY,70
(4)
LgR,70
(3)
WL,70
(2)
WY,70
(1)
WR,70
(3) LA104
39
S/M 150 Tape
(2) LA104
31
60 Tape
SWP-12M
31 18 17 15 YW L Y LgR X 56 52 39 B 1.25LB 1.25BY BrR RH1
(1) LA104
BrR,70
(3)
YW,70
(1)
Parking brake switch
Emergency switch
L,70
1
181
(1)
G,70
3
178
(3)
YW,70
4
31
(4)
RW,70
5
192
(5)
Br,70
6
44
(6)
B
49
LE305 (B)
BR
52
LE205 (BR)
5L,70
Marking tape (color:white)
RH4
100 Tape
49 5L
80 Tape
100 Tape
LgR,70
LY,70
BrG,70
LgR,70
BrY,70
B,70
2
3
1
2
1
2
187
95
94
187
196
X
(1)
(2)
(2)
(3)
Regen. disable switch
5-029
Starter switch LgW,70
ACC
64
LE105 (ACC)
1.25LB,70
C
56
LE105 (C)
LIT
2WR,70
1
3
(1)
2RW,70
3
2
(3)
2W,70
4
70
(4)
2RL,70
5
5
(5)
Lighting switch
LA104 LA104
LA104 LA104
· Where the numbers differ, wires of same color must not be united.
80 Tape
DIA
70 3 2W 2WR 5 2 RH3 2RL 2RW
KEY
25
INH
58Y-1M
80 Tape
18
80 Tape
58X-4M
150 Tape
MAN
SWP-14M
1.25BY,70 250 Corrugate
110 Tape
Main harness (2) (P.5-011)
66 65 64 WR WY LgW 95 94 74 67 LY BrG BrY WL 44 187 178 RH2 Br LgR G 196 192 181 BrY RW L
Throttle switch
Regen. manual switch
(1)
(2)
Diagnostic switch
1568-09295-2-12247-B
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
X
B
3
2
2RW
3
No.
SIZE, COLOR
CONTACT POINTS
DIA - 2 , PAR - 5 , RH1
64
LgW
2
KEY - ACC , RH2
2
LIT - 3 , RH3
65
WY
2
EME - 2 , RH2
2WR
2
LIT - 1 , RH3
66
WR
2
EME - 3 , RH2
5
2RL
2
LIT - 5 , RH3
67
WL
2
EME - 1 , RH2
15
LgR
2
PAR - 1 , RH1
70
2W
2
LIT - 4 , RH3
17
Y
2
PAR - 3 , RH1
74
BrY
2
PAR - 2 , RH2
18
L
2
PAR - 4 , RH1
94
BrG
2
MAN - 1 , RH2
31
YW
3
RH1 , S/M - 1 , SPE - 4
95
LY
2
INH - 3 , RH2
39
BrR
2
RH1 , S/M - 3
178
G
2
RH2 , SPE - 3
44
Br
2
RH2 , SPE - 6
181
L
2
RH2 , SPE - 1
49
5L
2
KEY - B , RH4
187
LgR
3
INH - 2 , MAN - 2 , RH2
52
1.25BY
2
KEY - BR , RH1
192
RW
2
RH2 , SPE - 5
56
1.25LB
2
KEY - C , RH1
196
BrY
2
DIA - 1 , RH2
CONNECTION
CONNECTION
5-030
ELECTRICAL SYSTEM
4-10. Water Spray Pump (R) Harness
Main harness (3) (P.5-013) 58Y-1F
139 138 W R 210 140 G B
84 83 2LW 2L 6 RY
X1 5B
SPR
X1 *1
2L,50
1700 Corrugate
50 Tape
SPD
5B,50
58X-3M
50 Tape
SWP-4M
2200 Corrugate
CB104 (+)
RP1
83
2B,50
2B1
X1
CA104 (-)
2B,50
2B2
X1
CA104 (-)
2LW,50
RP2
84
CB104 (+)
30 Tape
6 X1 BUZ RY 3B
58X-2F
Water spray pump (R, 1)
150 Corrugate
750 Corrugate
*2
400 Corrugate
Water spray pump (R, 2)
Backup buzzer harness (P.5-037)
210 140 G B 139 138 W R
DTM06-6S Speed sensor (P.4-011)
· The earth wire "X1" between "*1" and "*2" use "AVS5".
No.
SIZE, COLOR
CONTACT POINTS
X1
2B, 3B, 5B
4
6
RY
83 84
5-031
1568-09304-0-22298-0
No.
SIZE, COLOR
CONTACT POINTS
2B1 , 2B2 , BUZ , X1
138
R
2
SPD , Speed sensor
2
BUZ , SPR
139
W
2
SPD , Speed sensor
2L
2
RP1 , SPR
140
B
2
SPD , Speed sensor
2LW
2
RP2 , SPR
210
G
2
SPD , Speed sensor
CONNECTION
CONNECTION
ELECTRICAL SYSTEM
4-11. Frame (F) Harness
Ground LA308 X1
5B,150
E
ECM harness (1) 58X-3M (P.5-019)
81 82 2G 2GW 8 Lg
FP
80
3600 Corrugate
150 Corrugate
400 Corrugate
2G,50
FP1
81
CB104 (+)
2B,50
2B1
X1
CA104 (-)
2B,50
2B2
X1
CA104 (-)
82
CB104 (+)
X1 2B
58X-2F
2GW,50
FP2
30 Tape
HORN
8 Lg
Water spray pump (F, 1)
Water spray pump (F, 2)
Horn harness (P.5-038)
1568-09285-1-22235-A
No.
SIZE, COLOR
CONTACT POINTS
X1
5B, 2B
4
2B1 , 2B2 , E , HORN
8
Lg
2
FP , HORN
81
2G
2
FP , FP1
82
2GW
2
FP , FP2
CONNECTION
5-032
ELECTRICAL SYSTEM
4-12. Floor Board Harness
*2
DT06-2S-EP06
X2 5 2B 2RL
50 Tape
2070 Corrugate
2250 Corrugate
50 Tape
X2 2 2B 2RW
DT06-2S-EP06
Head lamp (L)
2250 Corrugate
50 Tape
X2 2 2B 2RW
DT06-2S-EP06
Head lamp (R)
300 Corrugate
Flood lamp (L)
58X-3M
5 2 2RL 2RW
X2 3B
FL1
100 Tape 200 Corrugate
Main harness (1) (P.5-009)
Flood lamp (R)
DT06-2S-EP06
X2 5 2B 2RL
50 Tape
2070 Corrugate
*1
· The earth wire "X2" between "*1" and "*2" use "AVS3".
1568-09274-0-22057-0
No.
SIZE, COLOR
CONTACT POINTS
X2
2B
5
FL1 , Flood lamp (L), (R), Head lamp (L), (R)
2
2RW
3
FL1 , Head lamp (L), (R)
5
2RL
3
FL1 , Flood lamp (L), (R)
5-033
CONNECTION
ELECTRICAL SYSTEM
4-13. Solenoid Harness
17 23 Y GB 73 X Lg B
110 Corrugate
HYD
200 Corrugate
BRA
X 17 B Y
SWP-2F
Parking brake solenoid
180 Corrugate
NEU
X 73 B Lg
SWP-2F
Neutral solenoid
100 Corrugate
Battery harness SWP-4M (P.5-023)
Hydraulic oil filter switch 2 LE105
23
Hydraulic oil filter switch 1 LE105
23
GB,50
120 Corrugate
220 Corrugate
GB,100
1568-09286-1-32236-0
No.
SIZE, COLOR
CONTACT POINTS
X
B
3
HYD , BRA , NEU
17
Y
2
HYD , BRA
23
GB
3
HYD , Hydraulic oil filter switch1, 2
73
Lg
2
HYD , NEU
CONNECTION
5-034
ELECTRICAL SYSTEM
4-14. SCR Harness
Twist pair cable with shield 2 NOx sensor (P.3-004)
1-1418390-1 4
205 204 L G 133 134 2B 2WR
3 120 Corrugate (H-COT)
S_NOx 1
Twist pair cable with shield 2 SCR in out temp (P.3-004)
2-1418390-1 4
250 Corrugate 13 (H-COT)
133 134
2B 2WR E5 204 205
1
200 Corrugate 13 (H-COT)
· Make use of heat resistannce wire "AEX" equivalency product.
ECM harness (1) (P.5-019)
1568-09294-1-32246-B
No.
SIZE, COLOR
CONTACT POINTS
133
2B
3
S_NOx -4, S_TEMP -4, E5
134
2WR
3
S_NOx -1, S_TEMP -1, E5
204
G
3
S_NOx -3, S_TEMP -3, E5
205
L
3
S_NOx -2, S_TEMP -2, E5
5-035
58X-4F
Twist pair cable with shield
3
205 204 L G 133 134 S_TEMP 2WR 2B
G L
CONNECTION
ELECTRICAL SYSTEM
4-15. DRT Harness
DEF dosing injector valve (P.3-005)
1928403874 1
97 96 BY GB
INJ
2
240 Corrugate (H-COT)
96 97
INJ GB BY
SWP-2M
· Make use of heat resistannce wire "AEX" equivalency product.
Battery harness (P.5-023)
1568-09293-0-32245-A
No.
SIZE, COLOR
CONTACT POINTS
96
GB
2
INJ -2, INJ (SWP)
97
BY
2
INJ -1, INJ (SWP)
CONNECTION
5-036
ELECTRICAL SYSTEM
4-16. Backup Buzzer Harness
3B,50 Water spray pump (R) harness (P.5-031)
58X-2M
X1 6 3B RY
BUZ
30
NEG
X1
LA204
(-NEG)
80 Corrugate
Backup buzzer RY,50
HI
6
LA104
(+HI)
1568-09272-0-32053-0
No.
SIZE, COLOR
CONTACT POINTS
X1
3B
2
BUZ , NEG
6
RY
2
BUZ , HI
5-037
CONNECTION
ELECTRICAL SYSTEM
4-17. Horn Harness
Lg,50
Frame (F) harness (P.5-032)
58X-2M
X1 3B
8
Lg
HORN
30
8
PB104
Horn
X1
LA208
Ground
80 Corrugate 3B,50
1568-09271-0-32052-0
No.
SIZE, COLOR
CONTACT POINTS
X1
3B
2
HORN , Ground
8
Lg
2
HORN , Horn
CONNECTION
5-038
ELECTRICAL SYSTEM
5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Potentiometer Harness side
POT2
A
POT1
(P.5-025)
138 145 140 R W B
138 206 140 R WR B
Schematic Pot. +V X
OUT White Vin Red
OUT GND
Red White Black
R
Vin W
OUT
RL
B
・Red, white and black indicate harness colors
GND Black
VIEW A Starting shaft position CW
CW
120° ±５° Mechanical travel
Stop position with return spring
Output characteristics Output (％)
Output voltage ratio
90
50
（％） 10
CW -45
0
+45
Angle (°)
Electrical travel Total electrical travel Shaft return direction SW880-1-05018
5-039
ELECTRICAL SYSTEM
5-2. Exact Meter
SWP-8M 4 3 2 1 8 7 6 5 * * * *
* * * *
* * * *
SWP-6F SWP-6M (Cap)
Harness side (P.5-011)
128 129 130 141 GW B B YW
DIS 25 X 165 BW B LgB
* *
SWP-8F SW884-05003
Pin NO.
Wire NO.
1
128
CAN +
2
129
CAN -
3
130
CAN GND
4
141
+12 V OUT
5
25
+12 V
6
X
GND
7
165
Exact meter relay
8
—
—
Function
5-040
ELECTRICAL SYSTEM
5-3. Resistor Unit
3W
3W
3
3W
3W
3W
3W
L Pu Gy P Lg O
Br
3W
3W
Y
3W
3W
3W
10W
10W
2
G
W R
10W
W
1
B
B
Shunt resistance output harness VCTF 0.5 12 wires
Resistor harness for emergency propulsion VCTF 0.75 2 wires
Harness side
Harness side
(P.5-013)
(P.5-013)
65 B
* *
25 W
25 * RES2 BW *
SWP-3F
65 WY
SWP-3M
35 34 33 32 Y G R W 39 38 37 36 Gy Pu L Br 44 42 41 40 B O Lg P
32 33 34 35 G L Br YB 36 37 38 39 RES1 GB YL GY BrR 40 41 42 X GW LW BrW B
SWP-12F
SWP-12M
Internal circuit 300Ω 300Ω 300Ω 300Ω 300Ω
25 SWP3F-1
300Ω 5.6Ω
300Ω 300Ω
5.6Ω
65 SWP3F-3
5.6Ω
300Ω 300Ω 300Ω
SWP12F-1
32
SWP12F-2
33
SWP12F-3
34
SWP12F-4
35
SWP12F-5
36
SWP12F-6
37
SWP12F-7
38
SWP12F-8
39
SWP12F-9
40
SWP12F-10
41
SWP12F-11
42
SWP12F-12
X
SW884-05004
(1) Case (2) Cement resistor : 5.6 Ω 10 W (3) Resistor : 300 Ω 3 W
5-041
ELECTRICAL SYSTEM
5-4. Lever Switch 1
2
3
4
Harness side (P.5-025)
1
L
O
B
G
R
Y
DT04-6P
2
LVR
31 YW 31 YW 31 YW
35 YB 38 GY 43 GR
DT06-6S
Y
R
G
B
O
L
3
Electrical circuit SW880-1-05019
(1) F-R lever auto speed set switch (White) (2) F-R lever vibration switch (Green) (3) F-R lever water spray switch (Blue) (4) Handle
5-042
ELECTRICAL SYSTEM
5-5. Fuse Box (1) Foot brake switch (WY)
(WL) F-R lever switch Propulsion pump neutral holding relay
Throttle switch (YW) F-R lever vibration switch F-R lever water spray switch Vibration switch Vibration frequency select switch (STD only) Vibratory drum select switch Vibration mode select switch F-R lever AUTO speed set switch Speed change switch IPF select switch Display change switch (option)
(WG) Backup buzzer switch Horn relay CIS (option) (W) Lighting switch (WR) Lighting switch
Power supply (option) (W) Roll light (option)
(Br) Sub power
Starter lockout relay (BY)
(WB) Water spray pump relay (pump 1) (LB) Water spray pump relay (pump 2)
Engine ECM (BR)
12
11
10
9
8
7
6
5
4
3
2
1
5A 20A 20A 15A 15A 15A 15A 20A 20A 15A 20A 20A
(WL) Battery relay (WR) Battery relay (GY) Parking interlock relay (GB) Starter switch relay
· For the relay box, refer to “4-2. Fuse · Relay Harness” (P.5-015).
SW884-05001
Harness color codes W : White Br : Brown BY : Black/Yellow stripe BR : Black/Red stripe WR : White/Red stripe WB : White/Black stripe WL : White/Blue stripe
5-043
WY : White/Yellow stripe WG : White/Green stripe GY : Green/Yellow stripe GB : Green/Black stripe YW : Yellow/White stripe LB : Blue/Black stripe
ELECTRICAL SYSTEM
5-6. Fuse Box (2)
Pressure line heater relay (Br) Backflow line heater relay Suction line heater relay
(L) DEF supply module relay (W) Aftertreatment relay
Air conditioner unit (WR) (option)
(G) Aftertreatment relay
Air conditioner unit (R) (option)
(W) Data link interface
19
18
17
5A 20A 5A
16
15
14
13
5A 15A 5A 20A
(BY) Engine ECM Battery relay (W) Battery relay (WB) Battery relay
· For the relay box, refer to “4-2. Fuse · Relay Harness” (P.5-015).
SW884-05002
Harness color codes W : White R : Red G : Green Br : Brown
L : Blue BY : Black/Yellow stripe WR : White/Red stripe WB : White/Black stripe
5-044
ELECTRICAL SYSTEM
5-7. Combination Meter
A 1
12 186 185 47 L G LgB 64 196 23 LgW BrY 35 53 G
12 23 35
13 24
X 64 155 1 B LgW R 23 47 18 2 13 GB LgB L RW 148 5 28 24 YL RL GB
21 YB 2 RW
Harness side (P.5-011)
DETAIL A
PIN DESCRIPTION
NO.
1
Battery 24V (+)
155
2
Starter switch (ACC)
64
3
Ground
X
4
Turn signal (R)
5
Engine stop
6
Over heat
7
REV. ratio SEL.1
8
REV. ratio SEL.3
9
Buzzer
10
Lamp check
47
11
CAN(+)
185
Illumination LED
12
CAN(-)
186
Engine oil pressure indicator
13
Head lamp
2
14
Parking brake
18
15
Charge warning
47
16
HYD. oil filter warning
23
17
Engine warning
18
Fuel meter
19
REV. ratio SEL.2
System configuration diagram +BAT Battery 24V (+)
+ -
DC/DC Converter
5V LDO
TACHO
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
TEMP
CAN Transceiver
Fuel meter
REV. ratio SEL.1
FUEL
Pull up Resistor 31KΩ x4
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD Dot Matrix LCD
REV. ratio SEL.2 REV. ratio SEL.3 REV. ratio SEL.4 Lamp check DTC display LYS pin
Preheating
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
Charge warning
DEF (SCR) Quality (Green) DEF (SCR) Quality (Red) CPU
DEF Tampering
Over heat Manual regeneration
Buzzer
DEF low level
20
REV. ratio SEL.4
Water splay
21
DTC display
196
Liquid spray
22
Hour meter
64
Vibrator
23
Turn signal (L)
24
Preheating
25
Water splay
26
Flood lamp
5
27
Vibrator
148
28
Liquid spray
29
High beam
30
COMBI. meter ILLUMI.
31
Exhaust system high temperature
32
DEF low level
33
Manual regeneration
34
LYS pin
35
ECO mode
Engine warning +BAT
Engine stop HYD. oil filter warning Parking brake
Flood lamp
+BAT
High beam
Exhaust system high temperature
Turn signal (R)
Head lamp
Turn signal (L)
ECO mode COMBI. meter ILLUMI. Hour meter Pull down Resistor 4.7KΩ x5
Pull down Resistor 4.7KΩ x7
21
28
2
53
SW884-05005
5-045
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) Prior to disassembly of vibratory drum, completely drain water spray tank. Water spray tank : 600 L×2 ( 158.5 gal.×2 ) 2) Joint front frame and rear frame with steering lock bar (1).
1
SW880-06001
WARNING When lifting the vehicle 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 vehicle body, use a support stand of sufficient strength. 3) Lift frames with a crane. • With drum lifted a little off ground, place support stands under both sides of each frame to hold vehicle body in place. (The front and rear frames are structurally identical.)
Lift with crane.
Support stand
Support stand SW880-06002
Front frame SW884 : 6,350 kg (14,000 lbs.) SW994 : 6,530 kg (14,395 lbs.) SW884ND : 6,520 kg (14,375 lbs.) SW994ND : 6,690 kg (14,750 lbs.)
Rear frame 6,540 kg (14,420 lbs.) 6,740 kg (14,860 lbs.) 6,710 kg (14,795 lbs.) 6,900 kg (15,210 lbs.)
4) Remove guard pipes (2).
2 SW880-06003
6-003
VIBRATORY DRUM 5) Loosen hose clamps (3) and remove water spray hoses (4). 3
4
SW880-06004
6) Remove two bolts (5) (left and right). • Pull out tank stoppers (6) (left and right).
5
6
SW884-06004
7) Loosen hose clamp (7) at outlet of water tank. • Disconnect water spray hose (8).
8
7 SW884-06002
6-004
VIBRATORY DRUM 8) Remove bolt (9) fixing drain cap chain. • Remove four cover fixing bolts (10) (left and right). • Remove covers (11) (left and right).
11
9
10 SW884-06003
9) Remove two bolts (12) (left and right). • Pull out tank stoppers (13) (left and right).
13
12 SW884-06014
10) Lift water tank (14) with a crane and remove it from frame.
14
Water supply port
(NOTICE) • Lift the water tank at the water supply port so as not to damage the tank. (14) Water tank : 50 kg (110 lbs.)
SW884-06005
6-005
VIBRATORY DRUM 11) Lift cross member (15) with a crane and hold it. • Remove three bolts (16) (left and right). • Remove bolts (17) and nuts (18) (left and right). • Lift cross member (15) and remove it from frame. (15) Cross member SW884/884ND : 295 kg (650 lbs.) SW994/994ND : 345 kg (761 lbs.)
16
15
17,18 SW884-06006
WARNING
19
The hydraulic oil in the vehicle is hot and compressed immediately after the vehicle is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work.
20
21
22
23
12) Disconnection of piping ① Propulsion motor piping • Remove hydraulic hose clamp (23). • Disconnect four hydraulic hoses (19), (20), (21) and (22) connecting to propulsion motor. (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter.
Propulsion motor
28
25
27
24
SW884-06015
26
② Vibrator motor piping • Remove hydraulic hose clamp (28). • Disconnect four hydraulic hoses (24), (25), (26) and (27) connecting to the vibrator motor. (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter. Vibrator motor
6-006
SW884-06016
VIBRATORY DRUM 13) Remove twelve bolts (30). • Lift off vibratory drum (29) from frame. (29) Drum SW884 : 3,380 kg (7,452 lbs.) SW994 : 3,505 kg (7,727 lbs.) SW884ND : 3,640 kg (8,025 lbs.) SW994ND : 3,755 kg (8,278 lbs.)
29
30 SW884-06017
14) Put chocks or like under removed drum (29) to prevent it
29
from moving.
Chock SW884-06018
6-007
VIBRATORY DRUM
2-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torques for bolts where particular care is required when installing vibratory drum. (16) Bolts M20× 70 : 539 N·m (398 lbf·ft) (SW884/884ND : Cross member) (16) Bolts M20×110 : 539 N·m (398 lbf·ft) (SW994/994ND : Cross member) (30) Nuts M22 : 685 N·m (505 lbf·ft) (Vibratory drum)
N•m
2) Upon installing vibratory drum, pay particular attention to following precaution.
WARNING If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed, the piston packing or other items may be damaged by air entering into the cylinder. (NOTICE) • Fill the hydraulic oil tank to the specified level to make up for any oil leakage. • Start the engine and circulate the oil through the piping. Then check the oil level again, ensuring that the oil is at the specified level.
6-008
VIBRATORY DRUM
3. Vibratory Drum ASSY (SW884/994) 3-1. Vibratory Drum ASSY 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
60 18 59
19
58
20
57
21
B
A
22 23
56
C
55
24
54
25 26
53
27 28
C
52
29
51
B
50
A
30
(1) Bolt :M20×60 (2) Housing (3) Vibrator bearing (4) Eccentric shaft (5) Vibrator bearing (6) Sleeve (7) Spring pin (8) Housing (9) Bolt :M16×50 (10) Vibrator bearing (11) Eccentric shaft (12) Vibrator bearing (13) Axle shaft (14) Bolt :M16×50 (15) Housing (16) Bracket (17) Bolt :M12×45 (18) Damper (19) Bolt :M12×45 (20) Shim (21) Bolt :M22×90 (22) Bracket (23) Bolt :M20×60 (24) Breather (25) Oil seal (26) Shim (27) Vibrator motor (28) Bolt :M14×40 (29) Cover (30) Bolt :M10×30
(31) Bolt :M22×90 (32) Bracket (33) Shim (34) O-ring (35) Cover (36) Bolt :M12×40 (37) Roller bearing (38) Oil seal (39) Plug (40) O-ring (41) O-ring (42) Sleeve (43) Spring pin (44) Spring pin (45) Retaining ring (46) Drum (47) O-ring (48) Bracket (49) Bolt :M22×90 (50) Bolt :M20×60 (51) Bolt :M10×100 (52) O-ring (53) Propulsion motor (54) Bolt :M20×60 (55) Plate (56) Bracket (57) Bolt :M22×90 (58) Bolt :M12×45 (59) Damper (60) Bolt :M12×45
31 49
32 33
48
47
46
45
44
42,43 41
39-1 (Oil filler plug)
39,40 38
37
36
35
34
39-1 (Oil filler plug)
10 Bar Vibration mode: Low Counterclockwise rotation
Vibration mode: High Clockwise rotation
SECTION C-C
SECTION B-B
39-2 (Oil level and drain plug)
10 Bar
SECTION A-A
39-2 (Oil level and drain plug) 0568-43808-0-11410-E
6-009
SW884/994
VIBRATORY DRUM
3-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in illustrations for the following vibratory drum disassembly and reassembly procedures are constant with part numbers of vibratory drum ASSY shown on page 6-009.
39-1
3-2-1. Disassembly of vibratory drum 1) Remove plugs (39-1) and (39-2). • Drain gear oil. • Quantity of gear oil : 22 L (5.8 gal.) • Install plugs.
39-2 SW880-06017
WARNING
Vibratory drum ASSY
27
When standing the drum, use wooden blocks of sufficient strength to securely support the drum. 2) Lift vibratory drum ASSY with a crane and stand it with its vibrator motor (27) side facing up as shown on the right.
Wooden block
Vibratory drum ASSY SW884 : 3,360 kg (7,407 lbs.) SW994 : 3,485 kg (7,683 lbs.) Wooden block
SW884-06019
WARNING
24
30
27
Carry out the work in an unstrained posture using a work stool or the like. 3) Remove bolts (30). • Remove vibrator motor (27). • Remove breather (24). (27) Vibrator motor : 6 kg (13 lbs.)
SW880-06019
6-010
VIBRATORY DRUM
WARNING When installing lifting bolts, screw them with nuts.
SW884/994 Lifting bolt
32
22
4) Install lifting bolts (M22) to brackets (22) and (32) with nuts.
Nut SW884-06020
5) Remove bolts (23). • Remove bracket SUBASSY.
Bracket SUBASSY
23
(NOTICE) • Since parts cannot be lifted in a level position in the illustrated state, lift them using a support or like until spigot joint of housing is disengaged. Bracket SUBASSY SW884 : 285 kg (628 lbs.) SW994 : 290 kg (639 lbs.)
SW884-06021
6) Remove sleeve (42). • Remove bolts (14).
42
14
SW880-06022
6-011
SW884/994
VIBRATORY DRUM
7) Lift axle shaft SUBASSY using two pulling bolts (M16×50).
Axle shaft SUBASSY
Pulling bolt
SW884-06022
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt 13
8) Install lifting bolts (M16) to axle shaft (13).
SW800-06019
9) Remove axle shaft SUBASSY. Axle shaft SUBASSY : 135 kg (298 lbs.) (NOTICE) • In order not to lift eccentric shaft together with axle shaft SUBASSY, tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting.
Lift with crane.
Wooden hammer Wooden bar
Axle shaft SUBASSY
(To step 25))
SW880-06023
6-012
VIBRATORY DRUM
WARNING Take care not to get your fingers caught in movable weights.
SW884/994
Lift with crane. Lifting bolt 11
10) Install a lifting bolt (M8) to eccentric shaft (11). • Remove eccentric shaft. (11) Eccentric shaft : 55 kg (121 lbs.) (NOTICE) • Put the movable weight at its outmost position. SW800-06022
11) Remove bolts (9). 9
SW800-06023
12) Lift housing (8) using two pulling bolts (M16×50).
Pulling bolt
8
SW800-06024
6-013
SW884/994
VIBRATORY DRUM
13) Install lifting bolts (M16) to housing (8). Lifting bolt
8
SW800-06025
14) Remove housing SUBASSY. Lift with crane.
Housing SUBASSY : 90 kg (198 lbs.) (To step 30)) Housing SUBASSY
SW884-06023
WARNING Be careful because reversing the drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
Drum SUBASSY
15) Reverse drum SUBASSY. Drum SUBASSY SW884 : 2,780 kg (6,129 lbs.) SW994 : 2,900 kg (6,393 lbs.) Wooden block SW884-06024
6-014
VIBRATORY DRUM 16) Install lifting bolts (M22) to brackets (48) and (56) with nuts.
SW884/994
56
Lifting bolt
48
Nut SW884-06025
17) Remove bolts (54). • Remove bracket SUBASSY.
Bracket SUBASSY
54
(NOTICE) • Since parts cannot be lifted in a level position in the illustrated state, lift them using a support or like until spigot joint of housing is disengaged. Bracket SUBASSY SW884 : 230 kg (507 lbs.) SW994 : 240 kg (529 lbs.)
SW884-06026
18) Remove bolts (50).
50
SW880-06027
6-015
SW884/994
VIBRATORY DRUM
19) Install lifting bolts (M20) to propulsion motor (53). Lifting bolt 53
SW880-06028
20) Remove propulsion motor (53).
Lift with crane.
(53) Propulsion motor : 215 kg (474 lbs.)
53
SW880-06029
21) Remove bolts (1). 1
SW880-06030
6-016
VIBRATORY DRUM 22) Lift housing SUBASSY using two pulling bolts (M20×50).
SW884/994 Housing SUBASSY
Pulling bolt
SW884-06027
23) Install lifting bolts (M20) to housing (2). 2
Lifting bolt
SW880-06032
24) Remove housing SUBASSY. Housing SUBASSY : 75 kg (165 lbs.) Housing SUBASSY
SW884-06028
6-017
SW884/994
VIBRATORY DRUM
25) Disassembly of axle shaft SUBASSY (From step 9)) • Remove bolts (36). • Remove cover (35).
36
35
SW800-06037
26) Remove bolts (28). • Remove cover (29). • Remove shim (26).
28 29 26
SW800-06038
27) Put a piece of wooden board on end of axle shaft (13). • Set a puller on housing (15). • Remove housing SUBASSY with roller bearing from axle shaft SUBASSY.
Wooden board Puller
13
15
SW800-06039
6-018
VIBRATORY DRUM
SW884/994
28) Install lifting bolts (M12) to housing (15). 15
Lifting bolt
SW800-06040
29) Remove housing SUBASSY from axle shaft SUBASSY. Housing SUBASSY : 45 kg (99 lbs.)
Housing SUBASSY
Axle shaft SUBASSY
SW884-06029
30) Put housing SUBASSY on a stand as shown. (From step 14)) Housing SUBASSY : 90 kg (198 lbs.)
Housing SUBASSY
Stand
SW884-06030
6-019
SW884/994
VIBRATORY DRUM
31) Set up a bearing puller.
50
Nut M16 4- 18
t 16
Plate
Nut M16
Puller
4-
C
15 30
Two tabs
110
3 C
2 50
8
φ16
M16 2.0
270
110
157
75 162
C
2
2
M16 2.0
C
M16 2.0
Bearing puller
Nut M16
300 250 54
C
2
Two shafts
SW800-06043
SW880-06059
32) Turn nuts of bearing puller counterclockwise to remove vibrator bearing (10).
10
Bearing puller
(NOTICE) • To prevent the inner race of the vibrator bearing from tilting, alternately turn the nuts on both sides of the puller.
Nut
SW800-06044
33) Remove sleeve (6).
6
SW800-06045
6-020
VIBRATORY DRUM
SW884/994
34) Install lifting bolts (M16) to housing (8). • Remove housing.
Lift with crane.
(8) Housing : 85 kg (187 lbs.) Lifting bolt 8
SW800-06046
35) Put housing (8) and eccentric shaft (4) lifted with a crane on wooden blocks.
8 4
Wooden block
SW884-06031
36) Remove retaining ring (45). 45
SW800-06048
6-021
SW884/994
VIBRATORY DRUM
37) Remove housing (8) from eccentric shaft (4). (8) Housing : 40 kg (88 lbs.)
Lift with crane.
8
4
SW880-06034
38) Put housing (8) on wooden blocks.
8
Wooden block SW800-06050
39) Tap on the bearing (5) with a hammer via a wooden bar or like to remove it from housing (8). Hammer (NOTICE) • Be careful not to damage the bearing.
Wooden bar
8
5
SW800-06051
6-022
VIBRATORY DRUM
SW884/994
3-2-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality.
WARNING • When standing the 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.
46
1) Lift drum (46) with a crane and put it with propulsion motor side facing up. (NOTICE) • The side on which no
10 round bar is installed is the
propulsion motor side. (46) Drum SW884 : 2,245 kg (4,949 lbs.) SW994 : 2,355 kg (5,192 lbs.)
Wooden block SW800-06054
O-ring fitting groove
47
3
2) Reassembly of housing SUBASSY • Apply a coat of gear oil to housing (2) at where vibrator bearing will be press-fitted. • Drive vibrator bearing (3).
2
(NOTICE) • Take care not to damage the bearing when installing it. • Apply grease to O-ring (47). • Install O-ring to housing.
Wooden block SW800-06052
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
• Reverse housing SUBASSY. Housing SUBASSY : 75 kg (165 lbs.) • Install lifting bolts (M20) to housing (2).
Housing SUBASSY SW800-06053
6-023
SW884/994
VIBRATORY DRUM
3) Install housing SUBASSY. Housing SUBASSY : 75 kg (165 lbs.) (NOTICE) • Take care not to let O-ring to protrude from its groove. Housing SUBASSY
SW800-06055
4) Secure housing SUBASSY with sixteen bolts (1) and washers. N•m
(1) Bolts M20×60 : 540 N·m (398 lbf·ft)
Housing SUBASSY
1
SW800-06056
5) Attach a bearing inner race fixture to housing SUBASSY with two bolts (M20×35) and washers.
Bearing inner race fixture Bolt
470
0
81 -0.2
120
60
420
9
SW800-06057
Bearing inner race fixture SW880-06060
6-024
VIBRATORY DRUM
SW884/994
6) Shown on right is a sectional view of housing SUBASSY to which bearing inner race fixture is attached.
Bearing inner race fixture
Secure bearing inner race.
SW800-06058
WARNING Be careful because reversing the drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
46 10mm round bar
7) Reverse drum SUBASSY. (NOTICE) • The side on which a vibrator motor side.
10 round bar is installed is the
Drum SUBASSY SW884 : 2,335 kg (5,148 lbs.) SW994 : 2,440 kg (5,379 lbs.) 8) Put eccentric shaft (11) (vibrator motor side) on wooden blocks with its splined portion facing up. • Drive spring pin (44).
Wooden blcok SW800-06059
44 11
Wooden block SW880-06035
6-025
SW884/994
VIBRATORY DRUM
9) Reassembly of eccentric shaft SUBASSY ① Apply a coat of gear oil to housing (8) at where bearing will be press-fitted. • Drive vibrator bearing (5). • Apply a coat of gear oil to inner surface of vibrator bearing.
5
8
(NOTICE) • Take care not to damage the bearing when installing it.
SW800-06060
② Reverse housing SUBASSY and install lifting bolts (M16) to housing (8).
Lifting bolt
Housing SUBASSY SW800-06061
③ Put eccentric shaft (4) (propulsion motor side) on wooden blocks with its splined position facing up. 4
Wooden block SW880-06036
6-026
VIBRATORY DRUM
SW884/994
④ Apply a coat of gear oil to eccentric shaft (4) at where bearing will be installed. • Install housing SUBASSY. (NOTICE) • Install the housing SUBASSY taking care not to tilt the vibrator bearing inner race. Housing SUBASSY : 40 kg (88 lbs.)
Lift with crane.
Housing SUBASSY
4
SW880-06037
⑤ Install retaining ring (45). 45
(NOTICE) • Confirm that the retaining ring is securely fitted in the groove.
SW884-06032
⑥ Drive spring pin (7) into sleeve (6). • Apply gear oil to inner surface of sleeve. • Apply gear oil to splined portion of eccentric shaft (4). • Install sleeve.
7
6
Positioning hole 4
(NOTICE) • When installing the sleeve, take care not to plug the positioning hole in the eccentric shaft with the spring pin.
SW880-06039
6-027
SW884/994
VIBRATORY DRUM
⑦ Apply a coat of gear oil to housing (8) at where bearing will be press-fitted. • Drive vibrator bearing (10). (NOTICE) • Take care not to damage the bearing when installing it.
10
8
SW800-06066
⑧ Install a lifting bolt (M8) to eccentric shaft (11). • Apply a coat of gear oil to eccentric shaft at where bearing will be installed. • Install eccentric shaft. (NOTICE) • Install the eccentric shaft taking care not to tilt the vibrator bearing (10) inner race.
Lifting bolt 11
10 8
(11) Eccentric shaft : 55 kg (121 lbs.)
SW880-06040
⑨ When installing eccentric shaft (11) in housing (8), insert spring pin (44) on shaft into positioning hole in eccentric shaft (4). 11 8
44
4
SW880-06041
6-028
VIBRATORY DRUM
SW884/994
10) Attach a lifting jig to eccentric shaft SUBASSY. Nut 2-M16 2.0 22 30
Eyebolt (M16 2.0)
80 250 300
4- 18
Eccentric shaft SUBASSY
Lifting jig
710
Nut 24
40
9
22 30
75
75
Bracket L75 75 9
Two shafts
Lifting jig SW800-06069 SW880-06061
11) Apply a coat of gear oil to eccentric shaft SUBASSY at where bearing will be installed. • Slowly lift eccentric shaft SUBASSY with a crane and install it to drum SUBASSY. Eccentric shaft SUBASSY
Eccentric shaft SUBASSY : 155 kg (342 lbs.)
SW884-06033
12) Secure eccentric shaft SUBASSY to drum with twelve bolts (9) and washers. N•m
9
Eccentric shaft SUBASSY
(9) Bolts M16×50 : 265 N·m (195 lbf·ft)
SW800-06072
6-029
SW884/994
VIBRATORY DRUM
13) Reassembly of axle shaft SUBASSY 13-1) Apply a coat of gear oil to axle shaft (13) at where bearing will be press-fitted. • Drive vibrator bearing (12).
12
13
(NOTICE) • Take care not to damage the bearing when installing it.
SW800-06074
WARNING Wear heat resistant gloves when handling heated parts to avoid burns.
37
Axle shaft SUBASSY
13-2) R everse axle shaft SUBASSY. Axle shaft SUBASSY : 75 kg (165 lbs.) • Heat up roller bearing (37) 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. • Apply sufficient amount of lithium-based grease to rollers of roller bearing inner race. 13-3) Apply grease to O-rings for plugs (39). • Install plugs.
Wooden block SW800-06075
39
Axle shaft SUBASSY SW884-06034
6-030
VIBRATORY DRUM
SW884/994
13-4) Apply a coat of gear oil to roller bearings (37) outer race mounting surface of housing (15). • Drive roller bearing outer races. • Apply liquid packing to periphery of oil seal (38). • Drive oil seal. • Apply grease to lip of oil seal.
37
38
15
37 SW800-06073
13-5) I nstall lifting bolts (M12). Housing SUBASSY
Lifting bolt
SV414-06064
13-6) I nstall housing SUBASSY to axle shaft SUBASSY. Housing SUBASSY : 40 kg (88 lbs.)
Housing SUBASSY
Axle shaft SUBASSY
SW884-06035
6-031
SW884/994
VIBRATORY DRUM
13-7) Apply sufficient amount of lithium-based grease to rollers of roller bearing (37) inner race. • Drive in roller bearing inner race until rollers come in contact with outer race.
37
SW800-06078
13-8) Preload adjustment of roller bearing
28
① Install a shim of about 1 mm (0.04 in.) and secure cover (29) to axle shaft (13) with four bolts (28) and washers.
29 Shim 13
SW884-06007
② A gap will remain between end of axle shaft (13) and inside of cover (29). • Tighten bolts (28) to a torque of 30 N·m (22 lbf·ft). • Give housing (15) two to three turns. • Tighten bolts to a torque of 30 N·m (22 lbf·ft) again. • Repeat this work several times until tightening torque of bolts no longer fluctuates.
15
Shim
29
28
Gap
(NOTICE) • Tighten the bolts alternately in diagonal directions.
13 SW884-06036
6-032
VIBRATORY DRUM (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.
SW884/994
End of rollers in close contact with inner race shoulder
Gap Gap
(1) Bearing not seated
(2) Bearing correctly seated
SW800-06080
③ Remove bolts (28). • Remove cover (29). • Remove shim. (NOTICE) • Do not turn the housing after the cover is removed.
28 29 Shim
SW884-06037
④ Without inserting shim, install cover (29). • Install washers to four bolts (28) and tighten.
28 29 13
SW884-06008
6-033
SW884/994
VIBRATORY DRUM
⑤ Using a thickness gauge, measure clearance “A”.
No gap
A
★ Preload adjusting = A + 0.2 mm (0.008 in.) shim thickness
SW850ND- -06092
⑥ Remove bolts (28). • Remove cover (29).
28 29
SW884-06009
⑦ Install shim (26) of preload adjusting shim thickness = “A + 0.2 mm (0.008 in.)”. • Secure cover (29) to axle shaft (13) with eight bolts (28) and washers. N•m
(28) Bolts M14×40 : 170 N·m (125 lbf·ft)
28 29 26 13
SW884-06010
6-034
VIBRATORY DRUM
SW884/994
13-9) Apply liquid packing to periphery of oil seal (25). • Drive in oil seal to cover (35). • Apply grease to lip of oil seal.
35
25 SW800-06084
(NOTICE) • The four holes in housing (15), breather mounting hole in cover (35), and cover mounting bolt holes must be arranged as shown on the right.
15
Hole 1
Breather mounting hole 35
Hole 4
Hole 2
Cover mounting bolt hole Hole 3
SW884-06011
13-10) Apply a coat liquid packing to housing (15) at where cover (35) will be installed. • Secure cover to housing with six bolts (36) and spring washers.
36 35 15
N•m
(36) Bolts M12×40 : 110 N·m (81 lbf·ft)
SW800-06085
6-035
SW884/994
VIBRATORY DRUM
14) Install lifting bolts (M16) to axle shaft (13). Lifting bolt
13 SW884-06038
15) Lift axle shaft SUBASSY. Axle shaft SUBASSY : 135 kg (298 lbs.) • Apply grease to O-ring (40). • Install O-ring.
40
Axle shaft SUBASSY SW800-06087
16) Lower axle shaft SUBASSY on mounting surface of drum (46). (NOTICE) • Support the eccentric shaft (11) with a pipe or the like, to prevent tilting of the vibrator bearing inner race during installation. • Take care not to let O-ring to protrude from its groove.
Pipe
Axle shaft SUBASSY
11
SW800-06088
6-036
VIBRATORY DRUM
SW884/994
(NOTICE) • When installing the axle shaft SUBASSY, pay attention to the positional relationship between the 10 round bar on the drum and the plugs (39-1) and (39-2).
10 round bar
39-1
60
39-2
SW800-06089
17) Secure axle shaft SUBASSY with sixteen bolts (14) and washers. N•m
(14) Bolts M16×50 : 265 N·m (195 lbf·ft) Axle shaft SUBASSY
14
SW800-06090
18) Install a lifting bolt (M8) to end of eccentric shaft (11). 11
Lifting bolt
SW800-06091
6-037
SW884/994
VIBRATORY DRUM
19) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 2 mm (0.04 to 0.08 in.).
Lift with crane.
SW800-06092
WARNING When installing lifting bolts, screw them with nuts.
32
Lifting bolt
22
20) Install lifting bolts (M22) to brackets (22) and (32) with nuts.
Nut SW884-06039
21) Lift bracket SUBASSY. Bracket SUBASSY SW884 : 285 kg (628 lbs.) SW994 : 290 kg (639 lbs.)
Bracket SUBASSY SW884-06040
6-038
VIBRATORY DRUM 22) Lower bracket SUBASSY while keeping it level and install it on spigot joint of housing. (NOTICE) • Since the bracket SUBASSY cannot be lowered in a level position, lower them using a support or like. • Be sure to install the bracket SUBASSY correctly in relation to the position of the breather mounting hole in the cover.
SW884/994 Breather mounting hole
Align gap with hole.
SW880-06044
23) Secure bracket SUBASSY with sixteen bolts (23) and washers. N•m
24
(23) Bolts M20×60 : 540 N·m (398 lbf·ft)
23
• Wind seal tape around threaded portion of breather (24). • Install breather.
SW880-06045
24) Drive two spring pins (43) into sleeve (42). 42
43
SW884-06012
6-039
SW884/994
VIBRATORY DRUM
25) Apply molybdenum-based grease to splined portion of sleeve (42). • Fit sleeve to splined portion on eccentric shaft end.
42
SW880-06046
26) Apply grease to O-ring (34). • Install O-ring to vibrator motor (27). 34
27
SW880-06047
27) Secure vibrator motor (27) to cover (29) with four bolts (30).
30
27
(27) Vibrator motor : 6 kg (13 lbs.) N•m
(30) Bolts M10×30 : 60 N·m (44 lbf·ft)
(NOTICE) • Take care not to let O-ring to protrude from its groove.
SW880-06048
6-040
VIBRATORY DRUM
SW884/994
WARNING
Drum SUBASSY
Be careful because reversing the drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 28) Reverse drum SUBASSY. Drum SUBASSY SW884 : 2,910 kg (6,415 lbs.) SW994 : 3,025 kg (6,669 lbs.)
Wooden block
SW884-06041
29) Remove bearing inner race fixture. Bearing inner race fixture
SW800-06101
30) Install a lifting bolt (M10) to end of eccentric shaft (4). Lifting bolt 4
SW880-06049
6-041
SW884/994
VIBRATORY DRUM
31) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 2 mm (0.04 to 0.08 in.). Lift with crane.
SW800-06103
32) Apply grease to O-ring (52). • Install O-ring to propulsion motor (53).
52
53
SW800-06104
33) Reverse propulsion motor (53).
Lifting bolt
(53) Propulsion motor : 215 kg (474 lbs.) • Install lifting bolts (M20).
53 SW880-06050
6-042
VIBRATORY DRUM
SW884/994
34) Install propulsion motor (53). Lift with crane.
(53) Propulsion motor : 215 kg (474 lbs.) (NOTICE) • Take care not to let O-ring to protrude from its groove.
53
SW880-06051
35) Secure propulsion motor (53) with sixteen bolts (50) and washers. N•m
(50) Bolts M20×60 : 540 N·m (398 lbf·ft)
53
50
SW880-06052
36) Install lifting bolts (M22) to brackets (48) and (56) with nuts.
56
Lifting bolt
48
Nut SW884-06042
6-043
SW884/994
VIBRATORY DRUM
37) Lift bracket SUBASSY. Bracket SUBASSY SW884 : 230 kg (507 lbs.) SW994 : 240 kg (529 lbs.)
Bracket SUBASSY SW884-06043
38) Lower bracket SUBASSY while keeping it level and install it on spigot joint of propulsion motor (53).
53
(NOTICE) • Since the bracket SUBASSY cannot be lowered in a level position, lower them using a support or like. • Be sure to install the bracket SUBASSY correctly in relation to the position of the propulsion motor.
SW880-06055
39) Secure bracket SUBASSY with sixteen bolts (54) and washers. 54 N•m
53
(54) Bolts M20×60 : 540 N·m (398 lbf·ft)
SW880-06056
6-044
VIBRATORY DRUM 40) Lift vibratory drum ASSY with a crane and lay it with 10 round bar on vibrator motor side facing down. • Hold with chocks.
SW884/994 Oil supply plug
Gauge port (drain plug)
Vibratory drum ASSY SW884 : 3,360 kg (7,407 lbs.) SW994 : 3,485 kg (7,683 lbs.) φ10 round bar
Chock
Chock
SW880-06057
41) Remove plugs (39-1) and (39-2). • Supply gear oil from oil supply port. • Check that oil drips from gauge port.
Oil supply port 39-1
Gauge port (drain port)
• Gear oil : 22 L (5.8 gal.) • Install plugs.
39-2 SW880-06058
6-045
VIBRATORY DRUM
4. VIBRATORY DRUM ASSY (SW884ND/994ND) 4-1. Vibratory Drum ASSY 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
83
29
B
82
A
C
81
30 31 32
33
80
34 35
79
36
78
37
77
38
76
39,40
75
42 43
41
74
44
73
C
B
72
71
70
69
68 67 66
65 64 63
62
61
A
60 59 58 57 56
55 54 53 52 51
50 49
48
47
46
45
68-1 (Oil filler plug)
Vibration mode: Normal Counterclockwise rotation
SECTION C-C
Vibration mode: Horizontal Clockwise rotation 68-3 (Level plug)
SECTION B-B
(47) Plate (48) Roller bearing (49) Housing (50) Oil seal (51) Cover (52) Bolt : M10×30 (53) Plug (54) Bolt : M16×45 (55) Housing (56) O-ring (57) Vibrator bearing (58) Retaining ring (59) Gear (60) Sunk key (61) O-ring (62) Eccentric shaft (63) O-ring (64) Vibrator bearing (65) O-ring (66) Housing (67) Bolt : M16×45 (68) Plug (69) Bolt : M10×30 (70) Cover (71) Housing (72) Plate (73) Bracket (74) Bolt : M20× 60 (75) Bolt : M10×100 (76) O-ring (77) Propulsion motor (78) Bolt : M20×60 (79) Plate (80) Bracket (81) Bolt : M12×45 (82) Damper (83) Bolt : M12×45
53-1 (Oil filler plug)
53-3 (Level plug) 68-2 (Drain plug)
(1) Drum (2) Bolt : M16×50 (3) Cover (4) Bolt : M10×30 (5) Pin (6) Vibrator bearing (7) O-ring (8) O-ring (9) Eccentric shaft (10) Retaining ring (11) Shaft (12) Sunk key (13) Retaining ring (14) Gear (15) O-ring (16) Sunk key (17) Gear (18) Retaining ring (19) Vibrator bearing (20) Pin (21) Bolt : M10×30 (22) Cover (23) Bolt : M16×50 (24) O-ring (25) Axle shaft (26) Ball bearing (27) Ball bearing (28) Bracket (29) Bolt : M12×45 (30) Damper (31) Bolt : M12×45 (32) Bracket (33) Bolt : M20×60 (34) Breather (35) Oil seal (36) Shim (37) Bolt : M14×40 (38) Vibrator motor (39) Sleeve (40) Spring pin (41) Cover (42) O-ring (43) Bolt : M12×40 (44) Bracket (45) Cover (46) Bolt : M12×40
53-2 (Drain plug)
SECTION A-A
0568-43810-0-11872-D
6-046
SW884ND/994ND
VIBRATORY DRUM
4-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in illustrations for the following vibratory drum disassembly and reassembly procedures are constant with part numbers of vibratory drum ASSY shown on page 6-046.
Supply port
53-1
4-2-1. Disassembly of vibratory drum 1) Remove plugs (53-1) and (53-2). • Drain gear oil. • Quantity of gear oil : 75 L (19.8 gal.) • Install plugs.
Drain port
53-2 SW884ND-06002
WARNING When standing the drum, use wooden blocks of sufficient strength to securely support the drum.
Vibratory drum ASSY
38
2) Lift vibratory drum ASSY with a crane and stand it with its vibrator motor (38) side facing up as shown on the right. Vibratory drum ASSY SW884ND : 3,490 kg (7,694 lbs.) SW994ND : 3,610 kg (7,959 lbs.)
Wooden block
Wooden block SW884ND-06003
WARNING Carry out the work in an unstrained posture using a work stool or the like.
34 38
43
3) Remove bolts (43). • Remove vibrator motor (38). • Remove breather (34). (38) Vibrator motor : 15 kg (33 lbs.)
SW884ND-06004
6-047
SW884ND/994ND
VIBRATORY DRUM
WARNING When installing lifting bolts, screw them with nuts.
Lifting bolt
44
32
4) Install lifting bolts (M22) to brackets (32) and (44) with nuts.
Nut SW884ND-06032
5) Remove bolts (33).
33
Bracket SUBASSY SW884ND-06006
6) Remove bracket SUBASSY.
Bracket SUBASSY
(NOTICE) • Since parts cannot be lifted in a level position in the illustrated state, lift them using a support or like until spigot joint of housing is disengaged. Bracket SUBASSY SW884ND : 290 kg (639 lbs.) SW994ND : 295 kg (650 lbs.)
SW884ND-06007
6-048
SW884ND/994ND 7) Remove sleeve (39). • Remove bolts (23).
VIBRATORY DRUM 39
23
SW850ND- -06008
8) Lift axle shaft SUBASSY using two pulling bolts (M16×50). Pulling bolt
SW850ND- -06009
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
9) Install lifting bolts (M16).
SW850ND- -06010
6-049
SW884ND/994ND
VIBRATORY DRUM 10) Remove axle shaft SUBASSY. Axle shaft SUBASSY : 185 kg (408 lbs.)
Axle shaft SUBASSY
(To step 26))
SW850ND- -06011
11) Remove bolts (21) and (52). • Remove covers (22) and (51). • Remove bolts (54).
22
21
54
52
51
SW850ND- -06013
12) Install lifting bolts (M16) to housing (55). 55
Lifting bolt
SW850ND- -06014
6-050
SW884ND/994ND
VIBRATORY DRUM
13) Remove housing SUBASSY. Housing SUBASSY : 220 kg (485 lbs.)
Housing SUBASSY
Wooden hammer
(NOTICE) • In order not to lift eccentric shaft together with housing SUBASSY, tap on the eccentric shaft ends alternately with a wooden hammer during lifting.
SW850ND- -06015
14) Install a lifting bolt (M8) to eccentric shaft (9). Lifting bolt
9
SW850ND- -06016
WARNING Take care not to get your fingers caught in movable weights.
Eccentric shaft SUBASSY
Movable weight
15) Remove eccentric shaft SUBASSY. Eccentric shaft SUBASSY : 95 kg (209 lbs.) (NOTICE) • Put the movable weight at its outmost position.
SW850ND- -06017
6-051
SW884ND/994ND
VIBRATORY DRUM 16) Install a lifting bolt (M8) to eccentric shaft (62).
Lifting bolt
62
SW850ND- -06018
17) Remove eccentric shaft SUBASSY. Eccentric shaft SUBASSY : 95 kg (209 lbs.)
Movable weight
Eccentric shaft SUBASSY
(NOTICE) • Put the movable weight at its outmost position.
SW850ND- -06019
WARNING
Propulsion motor
Drum SUBASSY
Be careful because reversing the drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 18) Reverse drum SUBASSY. Drum SUBASSY SW884ND : 2,575 kg (5,677 lbs.) SW994ND : 2,685 kg (5,919 lbs.)
Wooden block
SW884ND-06008
6-052
SW884ND/994ND 19) Install lifting bolts (M22) to brackets (73) and (80) with nuts.
VIBRATORY DRUM
80
Lifting bolt
73
Nut SW884ND-06009
20) Lift plate SUBASSY. • Remove bolts (78).
Plate SUBASSY
78
(NOTICE) • Since parts cannot be lifted in a level position in the illustrated state, lift them using a support or like until spigot joint of housing is disengaged.
SW884ND-06010
21) Remove plate SUBASSY. Plate SUBASSY SW884ND : 230 kg (507 lbs.) SW994ND : 240 kg (529 lbs.)
Plate SUBASSY
SW884ND-06011
6-053
SW884ND/994ND
VIBRATORY DRUM 22) Install lifting bolts (M20) to propulsion motor (77). • Remove bolts (74).
74
Lifting bolt
77
SW884ND-06021
23) Remove propulsion motor (77). (77) Propulsion motor : 215 kg (474 lbs.)
77
SW884ND-06022
24) Install lifting bolts (M20) to housing (71). • Remove bolts (67).
Lifting bolt
67
71 SW850ND- -06026
6-054
SW884ND/994ND
VIBRATORY DRUM
25) Remove housing SUBASSY.
Housing SUBASSY
Housing SUBASSY : 280 kg (617 lbs.)
SW850ND- -06027
26) Disassembly of axle shaft SUBASSY (From step 10)) • Remove bolts (46). • Remove cover (45).
45
46
SW850ND- -06028
27) Remove bolts (37). • Remove cover (41). • Remove shim (36).
37 41 36
SW850ND- -06029
6-055
SW884ND/994ND
VIBRATORY DRUM 28) Put a piece of wooden board on end of axle shaft (25). • Set a puller on housing (49). • Remove housing SUBASSY with roller bearing from axle shaft SUBASSY.
Puller
Wooden board 49
25 SW850ND- -06030
29) Install lifting bolts (M12). Lifting bolt
SW850ND- -06031
30) Remove housing SUBASSY from axle shaft SUBASSY. Housing SUBASSY : 45 kg (99 lbs.)
Housing SUBASSY
Axle shaft SUBASSY
SW850ND- -06032
6-056
SW884ND/994ND 31) Put a piece of wooden board on end of axle shaft (25). • Set a puller on roller bearing (48) inner race. • Remove roller bearing inner race from axle shaft SUBASSY.
VIBRATORY DRUM 25
Puller Wooden board 48
SW850ND- -06033
32) Reverse axle shaft SUBASSY. Axle shaft SUBASSY : 125 kg (276 lbs.)
Axle shaft SUBASSY
SW850ND- -06034
33) Remove retaining ring (13). • Remove gear (14). 14
13
SW850ND- -06035
6-057
SW884ND/994ND
VIBRATORY DRUM 34) Remove sunk key (12). • Remove retaining ring (10).
10
12
SW850ND- -06036
35) Reverse axle shaft SUBASSY. Axle shaft SUBASSY : 105 kg (231 lbs.)
Axle shaft SUBASSY
SW850ND- -06037
36) Strike on ball bearing (27) inner race by using a steel bar, and remove shaft SUBASSY.
Steel bar
27
Hammer
SW850ND- -06038
6-058
SW884ND/994ND
VIBRATORY DRUM
4-2-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality.
1
WARNING • When standing the 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) Lift drum (1) with a crane and put it in an upright position. (1) Drum
SW884ND : 1,840 kg (4,056 lbs.) SW994ND : 1,940 kg (4,277 lbs.)
2) Reassembly of housing SUBASSY 2-1) Apply a coat of gear oil to housing (66) at where vibrator bearings will be press-fitted. • Drive vibrator bearings (6) and (64).
SW850ND- -06039
6
66
64
(NOTICE) • Take care not to damage the bearings when installing them.
2-2) Stop driving in vibrator bearings (6) and (64) when they come to a position slightly protruding from the boss surface of housing (66) to avoid driving in too much.
Protruding
SW850ND- -06040
6,64
66
SW850ND- -06041
6-059
SW884ND/994ND
VIBRATORY DRUM 2-3) Apply grease to O-rings (7) and (63). • Install O-rings to covers (3) and (70). 7,63
3,70
SW850ND- -06042
2-4) Apply a coat liquid packing to housing SUBASSY at where covers (3) and (70) will be installed. • Place covers while making sure to orient them in the correct direction. • Install four bolts (4), (69) to press in bearings.
4
3,70
69
(NOTICE) • Take care not to let O-ring to protrude from its groove. • Bolts are treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
SW850ND- -06043
N•m
4,69
3,70
Press fit with cover
2-5) Press in and secure bearings (6) and (64) with covers (3) and (70). (4) and (69) Bolts M10×30 : 59 N·m (44 lbf·ft)
6,64
Protruding
Fitted into position SW850ND- -06044
6-060
SW884ND/994ND
VIBRATORY DRUM
WARNING
Lifting bolt
When installing lifting bolts, screw in the threads fully before using.
71
2-6) Install lifting bolts (M20) to housing (71).
SW850ND- -06045
2-7) Lift housing (71). • Apply grease to O-ring (8). • Install O-ring to housing. 71
8 SW850ND- -06046
2-8) Apply a coat of liquid packing to housing (66) at where housing SUBASSY will be installed. • Install housing SUBASSY. Housing SUBASSY : 45 kg (99 lbs.)
Housing SUBASSY 66
(NOTICE) • Take care not to let O-ring to protrude from its groove.
SW850ND- -06047
6-061
SW884ND/994ND
VIBRATORY DRUM 2-9) Secure housing SUBASSY with sixteen bolts (2) and washers. N•m
Housing SUBASSY
2
(2) Bolts M16×50 : 265 N·m (195 lbf·ft)
(NOTICE) • Bolts are treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
SW850ND- -06048
3) Apply grease to O-rings for plugs (68-1), (68-2), and (68-3). • Install plugs.
68-1
68-2
68-3
SW850ND- -06049
4) Lift housing SUBASSY. • Apply grease to O-ring (65). • Install O-ring.
Housing SUBASSY
65 SW850ND- -06050
6-062
SW884ND/994ND 5) Install housing SUBASSY. Housing SUBASSY : 275 kg (606 lbs.)
VIBRATORY DRUM Housing SUBASSY
(NOTICE) • Take care not to let O-ring to protrude from its groove. 1
SW850ND- -06051
6) Drive in two locating pins (5) for housing SUBASSY and drum (1) temporarily.
Housing SUBASSY
1 5
SW850ND- -06052
7) Secure housing SUBASSY with sixteen bolts (67) and washers. N•m
5
67
Housing SUBASSY
(67) Bolts M16×45 : 265 N·m (195 lbf·ft)
• Drive in locating pins (5) again.
SW850ND- -06053
6-063
SW884ND/994ND
VIBRATORY DRUM 8) Apply grease to O-ring (76). • Install O-ring to propulsion motor (77).
76
77
SW884ND-06023
9) Reverse propulsion motor (77).
Lifting bolt
(77) Propulsion motor : 215 kg (474 lbs.) • Install lifting bolts (M20).
77 SW884ND-06024
10) Install propulsion motor (77). (77) Propulsion motor : 215 kg (474 lbs.)
77
(NOTICE) • Take care not to let O-ring to protrude from its groove.
SW884ND-06025
6-064
SW884ND/994ND
VIBRATORY DRUM
11) Secure propulsion motor (77) with sixteen bolts (74) and washers. N•m
77
74
(74) Bolts M20×60 : 539 N·m (398 lbf·ft)
SW884ND-06026
WARNING When installing lifting bolts, screw them with nuts.
80
Lifting bolt, Nut
73
12) Install lifting bolts (M22) to brackets (73) and (80) with nuts.
SW884ND-06012
13) Lift plate SUBASSY. Plate SUBASSY SW884ND : 230 kg (507 lbs.) SW994ND : 240 kg (529 lbs.)
Plate SUBASSY SW884ND-06013
6-065
SW884ND/994ND
VIBRATORY DRUM 14) Lower plate SUBASSY while keeping it level and install it on spigot joint of propulsion motor (77).
77
(NOTICE) • Since the plate SUBASSY cannot be lowered in a level position, lower them using a support or like. • Be sure to install the plate SUBASSY correctly in relation to the position of the propulsion motor.
SW884ND-06014
15) Secure plate SUBASSY with sixteen bolts (78) and washers. N•m
Plate SUBASSY
78
(78) Bolts M20×60 : 539 N·m (398 lbf·ft)
SW884ND-06015
WARNING Be careful because reversing the drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
Drum SUBASSY
16) Reverse drum SUBASSY. Drum SUBASSY SW884ND : 2,575 kg (5,677 lbs.) SW994ND : 2,685 kg (5,919 lbs.)
SW850ND- -06062
6-066
SW884ND/994ND
VIBRATORY DRUM
WARNING Wear heat resistant gloves when handling heated parts to avoid burns.
18 17
17) Heat up gear (17) by using a ring heater or the like. • Drive sunk key (16) into eccentric shaft (9). • Install heated gear. • Install retaining ring (18).
16
(NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
9
SW850ND- -06063
18) Install a lifting bolt (M8). Lifting bolt
SW850ND- -06064
WARNING Take care not to get your fingers caught in movable weights. 19) Apply a coat of gear oil to eccentric shaft SUBASSY at where bearing will be installed. • Install eccentric shaft SUBASSY to drum SUBASSY.
Eccentric shaft SUBASSY Movable weight
Eccentric shaft SUBASSY : 95 kg (209 lbs.) (NOTICE) • Put the movable weight at its outmost position. SW850ND- -06065
6-067
SW884ND/994ND
VIBRATORY DRUM (NOTICE) • Insert eccentric shaft SUBASSY into vibrator bearing (6) while taking care not to tilt vibrator bearing inner race. • After inserting the eccentric shaft SUBASSY into the bearing, lay the eccentric shaft SUBASSY against the inner wall of the drum so that it will not fall down.
Eccentric shaft SUBASSY
6
Inner race SW850ND- -06066
20) Heat up gear (59) by using a ring heater or the like. • Drive sunk key (60) into eccentric shaft (62). • Install heated gear. • Install retaining ring (58).
58 59
(NOTICE) • Make sure that the retaining ring is fitted completely in its groove. 60
62
SW850ND- -06067
21) Install a lifting bolt (M8).
Lifting bolt
SW850ND- -06068
6-068
SW884ND/994ND
VIBRATORY DRUM
22) Apply a coat of gear oil to eccentric shaft SUBASSY at where bearing will be installed. • Install eccentric shaft SUBASSY to drum SUBASSY.
Eccentric shaft SUBASSY
Movable weight
Eccentric shaft SUBASSY : 95 kg (209 lbs.) (NOTICE) • Put the movable weight at its outmost position.
SW850ND- -06069
(NOTICE) • Insert eccentric shaft SUBASSY into vibrator bearing (57) while taking care not to tilt vibrator bearing inner race. • After inserting the eccentric shaft SUBASSY into the vibrator bearing, lay the eccentric shaft SUBASSY against the inner wall of the drum so that it will not fall down.
Eccentric shaft SUBASSY 57
Inner race
SW850ND- -06070
23) Apply grease to O-rings for plugs (53-1), (53-2), and (53-3). • Install plugs to housing (55).
53-3
53-2
53-1
55
SW850ND- -06071
6-069
SW884ND/994ND
VIBRATORY DRUM 24) Install lifting bolts (M10). Lifting bolt
SW850ND- -06072
25) Lift housing (55). (55) Housing : 215 kg (474 lbs.)
55
• Apply grease to O-ring (56). • Install O-ring to housing.
56 SW850ND- -06073
26) Install housing (55). 55 (NOTICE) • Take care not to let O-ring to protrude from its groove.
SW850ND- -06074
6-070
SW884ND/994ND 27) Drive in two locating pins (20) for housing SUBASSY and drum (1) temporarily.
VIBRATORY DRUM 1 20
Housing SUBASSY
SW850ND- -06075
28) Secure housing SUBASSY to drum (1) with sixteen bolts (54) and washers. N•m
1 20
Housing SUBASSY 54
(54) Bolts M16×45 : 265 N·m (195 lbf·ft)
• Drive in locating pins (20) again.
SW850ND- -06076
29) Reassembly of axle shaft SUBASSY 29-1) Fix axle shaft (25) with wooden blocks. 25
Wooden blocks
SW850ND- -06077
6-071
SW884ND/994ND
VIBRATORY DRUM 29-2) Apply a coat of gear oil to axle shaft (25) at where bearing will be press-fitted. • Drive ball bearing (27).
27
25
SW850ND- -06078
29-3) Apply a coat of gear oil to bearing mounting surface of shaft (11). • Drive in shaft.
11
SW850ND- -06079
29-4) Apply a coat of gear oil to axle shaft (25) at where bearing will be press-fitted and to drive shaft (11) at where bearing will be installed. • Drive ball bearing (26). • Install retaining ring (10).
10 26
25 (NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
11
SW850ND- -06080
6-072
SW884ND/994ND
VIBRATORY DRUM
29-5) H eat up gear (14) by using a ring heater or the like. • Drive sunk key (12) to shaft (11). • Install heated gear. • Install retaining ring (13). (NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
13 14
12
11
SW850ND- -06081
29-6) Reverse axle shaft SUBASSY. Axle shaft SUBASSY
Axle shaft SUBASSY : 125 kg (276 lbs.)
Wooden blocks SW850ND- -06082
29-7) H eat up roller bearing (48) inner race by using a ring heater or the like. • Apply a coat of gear oil to axle shaft at where bearing
48
inner race will be press-fitted. • Drive in heated roller bearing inner race. • Apply sufficient amount of lithium-based grease to rollers of roller bearing inner race.
SW850ND- -06083
6-073
SW884ND/994ND
VIBRATORY DRUM 29-8) Apply a coat of gear oil to roller bearings (48) outer race mounting surface of housing (49). • Drive roller bearing outer races. • Apply liquid packing to periphery of oil seal (50). • Drive oil seal. • Apply grease to lip of oil seal.
48
50
49
48 SW884ND-06027
29-9) Install lifting bolts (M12). Housing SUBASSY
Lifting bolt
SV414-06064
29-10) Install housing SUBASSY to axle shaft SUBASSY. Housing SUBASSY : 40kg (88 lbs.) Housing SUBASSY Axle shaft SUBASSY
SW850ND- -06086
6-074
SW884ND/994ND
VIBRATORY DRUM
29-11) Apply sufficient amount of lithium-based grease to rollers of roller bearing (48) inner race. • Drive in roller bearing inner race until rollers come in contact with outer race.
48
SW884ND-06028
29-12) P reload adjustment of roller bearing ① Install a shim of about 1 mm (0.04 in.) and secure cover (41) to axle shaft (25) with four bolts (37) and washers.
37 41 Shim 25
SW850ND- -06088
② A gap will remain between end of axle shaft (25) and inside of cover (41). • Tighten bolts (37) to a torque of 30 N·m (22 lbf·ft). • Give housing (49) two to three turns. • Tighten bolts to a torque of 30 N·m (22 lbf·ft) again. • Repeat this work several times until tightening torque of bolts no longer fluctuates.
49
Shim
41
37
Gap
(NOTICE) • Tighten the bolts alternately in diagonal directions.
25 SW850ND- -06089
6-075
SW884ND/994ND
VIBRATORY DRUM (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
③ Remove bolts (37). • Remove cover (41). • Remove shim.
37
(NOTICE) • Do not turn the housing after the cover is removed.
Shim
41
SW850ND- -06090
④ Without inserting shim, install cover (41). • Install washers to four bolts (37) and tighten. 37 41
25
SW850ND- -06093
6-076
SW884ND/994ND
VIBRATORY DRUM
⑤ Using a thickness gauge, measure clearance “A”.
No gap
A
★ Preload adjusting = A + 0.1 mm (0.004 in.) shim thickness
SW850ND- -06092
⑥ Remove bolts (37). • Remove cover (41). 37 41
25
SW850ND- -06091
⑦ Install shim (36) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (41) to axle shaft (25) with eight bolts (37) and washers. N•m
(37) Bolts M14×40 : 170 N·m (125 lbf·ft)
37 41 36 25
SW850ND- -06094
6-077
SW884ND/994ND
VIBRATORY DRUM 29-13) Apply liquid packing to periphery of oil seal (35). • Drive in oil seal to cover (45). • Apply grease to lip of oil seal.
45
35
SW884ND-06029
(NOTICE) • The four holes in housing (49), breather mounting hole in cover (45), and vibrator motor mounting bolt holes must be arranged as shown on the right.
49
Hole 1
Breather mounting hole 45
Hole 4
Vibrator motor mounting bolt hole
Hole 2
Hole 3 SW850ND- -06096
29-14) Apply a coat liquid packing to housing (49) at where cover (45) will be installed. • Secure cover to housing with six bolts (46) and washers. N•m
46
(46) Bolts M12×40 : 110 N·m (81 lbf·ft) 49
45
SW850ND- -06097
6-078
SW884ND/994ND
VIBRATORY DRUM
30) Install lifting bolts (M16) to axle shaft (25). Lifting bolt
25
SW850ND- -06098
31) Lift axle shaft SUBASSY. Axle shaft SUBASSY : 185 kg (408 lbs.) • Apply grease to O-ring (24). • Install O-ring.
Axle shaft SUBASSY 24 SW850ND- -06099
32) Apply a coat of liquid packing to housing (55) at where axle shaft SUBASSY will be installed. • Lower axle shaft SUBASSY on mounting surface of
Axle shaft SUBASSY
housing. (NOTICE) • Take care not to let O-ring to protrude from its groove.
55
SW850ND- -06100
6-079
SW884ND/994ND
VIBRATORY DRUM 33) Secure axle shaft SUBASSY with sixteen bolts (23) and washers. N•m
(23) Bolts M16×50 : 265 N·m (195 lbf·ft)
Axle shaft SUBASSY
23
(NOTICE) • Bolts are treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
Near
Far
shafts (9) and (62) are as shown right.
Far
34) Make sure that punch marks on shaft (11) of eccentric
Near
SW850ND- -06101
9
11
62
SW850ND- -06102
35) Apply a coat of gear oil to housing (55) at where bearings will be press-fitted and to eccentric shafts at where bearings will be installed. • Drive in vibrator bearings (19) and (57).
57
55
19
(NOTICE) • Take care not to damage the bearings when installing them.
SW850ND- -06103
6-080
SW884ND/994ND
19,57
Protruding
36) Stop driving in vibrator bearings (19) and (57) when they come to a position slightly protruding from the boss surface of housing (55) to avoid driving in too much.
VIBRATORY DRUM
55
SW884ND-06030
21,52
19,57
22,51
Press fit with cover
37) Press fit slightly protruding vibrator bearings (19) and (57) into place by securing covers (22) and (51) with four bolts (21), (52), and washers. • After press fitting, remove covers to make sure that vibrator bearings are not protruding.
Protruding
Fitted into position SW850ND- -06105
38) Install lifting bolts (M8) to end of eccentric shafts. Lifting bolt
SW850ND- -06106
6-081
SW884ND/994ND
VIBRATORY DRUM 39) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1.6 to 4 mm (0.06 to 0.16 in.).
SW850ND- -06107
40) Apply grease to O-rings (15) and (61). • Install O-rings to covers (22) and (51). 15,61
22,51
SW850ND- -06108
41) Apply a coat liquid packing to housing SUBASSY at where covers (22) and (51) will be installed. • Secure covers to four bolts (21), (52), and washers. N•m
52
22,51
21
(21) and (52) Bolts M10×30 : 59 N·m (44 lbf·ft)
(NOTICE) • Take care not to let O-ring to protrude from its groove. • Bolts are treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
SW850ND- -06109
6-082
SW884ND/994ND 42) Install lifting bolts (M22) to brackets (32) and (44) with nuts.
VIBRATORY DRUM
44
Lifting bolt, Nut
32
SW884ND-06016
43) Lift bracket SUBASSY. Bracket SUBASSY SW884ND : 290 kg (639 lbs.) SW994ND : 295 kg (650 lbs.)
Bracket SUBASSY
SW884ND-06017
44) Lower bracket SUBASSY while keeping it level and install it on spigot joint of housing.
Breather mounting hole
Align gap with hole.
(NOTICE) • Since the bracket SUBASSY cannot be lowered in a level position, lower them using a support or like. • Be sure to install the bracket SUBASSY correctly in relation to the position of the breather mounting hole in the cover.
SW884ND-06018
6-083
SW884ND/994ND
VIBRATORY DRUM 45) Secure bracket SUBASSY with sixteen bolts (33) and washers. N•m
(33) Bolts M20×60 : 539 N·m (398 lbf·ft)
Bracket SUBASSY 33
SW884ND-06019
46) Drive two spring pins (40) into sleeve (39). 39
40
SW850ND- -06114
47) Apply molybdenum-based grease to splined portion of sleeve (39). • Fit sleeve (39) to splined portion on drive shaft end.
39
SW884ND-06020
6-084
SW884ND/994ND
VIBRATORY DRUM
48) Apply grease to O-ring (42). • Install O-ring (42) to vibrator motor (38).
38
42 SW884ND-06031
49) Wind seal tape around threaded portion of breather (34). • Install breather. • Secure vibrator motor (38) to cover (45) with two bolts (43) and washers.
34 38
43
(38) Vibrator motor : 15 kg (33 lbs.) N•m
(43) Bolts M12×40 : 108 N·m (80 lbf·ft)
(NOTICE) • Take care not to let O-ring to protrude from its groove.
SW884ND-06004
50) Lay vibratory drum ASSY with plugs (53-1), (53-2), and (53-3) positioned as shown on the right. • Hold with chocks.
Vibratory drum ASSY
Vibratory drum ASSY SW884ND : 3,490 kg (7,694 lbs.) SW994ND : 3,610 kg (7,959 lbs.)
53-1
53-3
53-2
Chock SW884ND-06001
6-085
SW884ND/994ND
VIBRATORY DRUM 51) Remove plugs (53-1) and (53-3). • Supply gear oil from oil supply port. • Check that oil drips from gauge port.
Supply port
53-1
• Quantity of gear oil : 75 L (19.8 gal.) • Install plugs.
Gauge port
6-086
53-3 SW884ND-06033
BRAKE
BRAKE
1. BRAKE PEDAL 1
2
5
4
3 0568-51803-0-11251-C
(1) Brake pedal (2) Foot brake switch (3) Stopper bolt : M10×25 P=1.25 (4) Nut : M10 P=1.25 (5) Return spring
7-001
BRAKE Fig.: Brake circuit
(1) EXACT meter relay 4 5 2
3 1
(2) Parking brake switch (Brake OFF condition) 1 4
3 2 5
Propulsion motor (F)
b a NC NO COM
15A Fuse
(3) Foot brake switch (Condition in which brake pedal pressed)
(5) Brake (Brake ON condition) Propulsion motor (R)
b a
(5) Brake (Brake ON condition)
Parking brake solenoid valve when brake is OFF. (with solenoid excited)
(4) Parking brake solenoid valve when brake is ON. (without solenoid excited)
Steering・charge pump
࣭The arrow (
) symbol shows the direction of the hydraulic oil flow. SW880-1-07001
7-002
BRAKE
2. BRAKE SYSTEM 2-1. Description and Operation of Brake Circuit Description • Made up of EXACT meter relay (1), parking brake switch (2), foot brake switch (3), parking brake solenoid valve (4) and brake (5). The foot brake switch is ON with the brake pedal released and OFF if pushed down on.
Operation To release parking brake: • When parking brake switch (2) is set to the OFF position, the contacts of parking brake switch (2) close the circuit to parking brake solenoid valve (4) and breaks the circuit to the brake indicator lamp. • This leads the pressurized fluid through parking brake solenoid valve (4) to pistons (a) of brake (5) to compress springs (b). Brake is freed. To apply parking brake (Brake pedal not depressed): • If parking brake switch (2) is put in the ON position, the contacts of parking brake switch (2) break the circuit to parking brake solenoid valve (4) and close the brake indicator lamp circuit. • This stops feeding the fluid from parking brake solenoid valve (4) to brake (5). Springs (b) move pistons (a) toward the brake discs and plates so that they make a close contact with each other. The brake is applied.The indicator lamp comes on simultaneously. When brake pedal is pushed down on: • If brake pedal is depressed, foot brake switch (3) is switched off to break the circuit to parking brake switch (2). This applies the brake even if parking brake switch is in the OFF position. To disengage the brake when towing: • Turn the bypass valve clockwise to engage the drive. • For the bypass valve location refer to page 4-005.
7-003
OPERATOR STATION
OPERATOR STATION
1. FLOORBOARD 1-1. Structure of Operator Station
1
2
3
B A
C
C
B 4
5
6 8
7
Fill grease
DETAIL A 10
11
D
17
SECTION B-B
12
124 mm (4.9 in.)
9
D
16
15
14
13
VIEW D-D
SECTION C-C (1) (2) (3) (4) (5) (6) (7) (8) (9)
Dashboard Lever Pin Swing bearing Bolt : M10×50 Bolt : M10×50 Pin Spring Bolt (pedal stopper) : M10×40
0568-62811-0-11992-0
(10) Nut (11) Pedal (12) Bolt (13) Rod end (14) Nut (15) Rod (16) Nut (17) Rod end
: M10 : M10×20 : M10 (left-hand thread) : M10 (left-hand thread) : M10 : M10
N•m
(12) Bolt M10×20 : 49 N∙m (36 lbf∙ft) 8-001
OPERATOR STATION
1-2. Adjustment of Swivel Lock Release Pedal ① Loosen the nuts (14) and (16). ② Insert the pin (7) into the fixing hole to lock the pedal. ③ Using the rod (15), adjust the pedal height in the locked condition. ★ Pedal height: 124 mm (4.9 in.) ④ With the pedal still locked, check that there is no looseness in the dashboard. ⑤ Depress the pedal (11) and check that the lock is smoothly released. ⑥ If the above checks ( ④ and ⑤ ) show no problem, tighten the nuts (14) and (16) to fix the pedal. 11
14
7
16 Locked Pedal released
15 Released SW880-08002
SW880-08003
Pedal depressed
• The numbers in parentheses that appear in the above sentences and the numbers in the above illustrations are consistent with the lead line numbers shown in “1-1. Structure of Operator Station” (page 8-001).
8-002
WATER SPRAY SYSTEM
WATER SPRAY SYSTEM
1. WATER SPRAY PIPING
Pipe 1
Pump 2 IN
Pipe 2
Pump 2 OUT
Pump 1 OUT Pump 2 (Water spray pump 2)
Drain valve
Pump 1 IN
Drain valve Pipe 2 (Water spray pipe 2)
Hose (Tee
VIEW A-A
Pipe 1 (Water spray pipe 1)
Filter IN
Filter OUT
Hose (Tee
Tee
Pump 1 (Water spray pump 1)
Pump 1 IN)
Pump 2 IN)
Filter
Filter IN)
Pump 2 Drain Hose (Pump 2 Drain
Hose (Pump 1 Drain
3 way valve
DETAIL C
VIEW B
Water spray tank
Filler cap
A
Strainer
D Hose (Pump 2 OUT
A
Cover Nozzle
Pipe 2)
D
VIEW D-D
Stopper
Bolt : M10×20
B
Pipe 1)
Water spray tank Filter
Drain valve
Drain valve
The letters and numbers in the figure such as “Pump 2 OUT” and “Pipe 2” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the water.
P
Tee IN
Hose (Pump 1 OUT
Drain valve
IN
3 way valve
Stopper
Drain cap
Nozzle
Water spray pump 1 Bolt : M10×20
C
Drain valve)
OUT
OUT Drain
Drain valve Drain valve Drain IN
P
OUT
Drain valve Water spray pipe 1
Level gauge
Pump 1 Drain
Drain valve)
Water spray pipe 2
Hose (3 way valve
Hose (Tee Pump 1 IN) Hose (Tee Pump 2 IN)
Water spray pump 2 Water spray diagram 0568-75804-0-12194-C
9-001
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. 10-001
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 couplings (1) and (2). Attach pressure gauge with hose ⓢ and connector ⓤ . • Coupling : 7/16-20UNF×M16 • Adapter for hose ⓢ : M16 P=2.0 • Pressure gauge connector ⓤ : M16×G3/8 • High pressure gauge port (Forward) : (2) • High pressure gauge port (Reverse) : (1) • 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 vibration frequency select switch to “2,500 vpm”. ⑥ Start the engine and set throttle switch to “Full”. ⑦ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.)
Bypass valve
1 2
SW884-10001
s
u
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) : 40.2 ± 1.0 MPa (5,829 ± 145 psi)
10-002
PG003163
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.
1-4
2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value ① Check nut (3) of cut off valve (1-4) 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 (4). 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
SW884-10002
4
3
RLV-BR-001
(3) Nut : 22 N·m (16 lbf·ft) (1-4) 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 “1-4” 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).
10-003
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 (1-8) or (1-9) for evidence of having loosened. • High pressure relief valve (Forward) : (1-8) • High pressure relief valve (Reverse) : (1-9) 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.
1-8
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 : 28 MPa/turn (4,060 psi/turn) 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.
1-9
SW884-10003
3 4
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 : 20 N·m (14.8 lbf·ft) (1-8) High pressure relief valve (1-9) : 200 N·m (148 lbf·ft)
RLV-BR-004
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. • The number “1-8” and “1-9” 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).
10-004
INSPECTION AND ADJUSTMENT
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION 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 ASSY 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 : 7/16-20UNF×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 switch to “Full”. ⑤ Read pressure indicated by pressure gauge.
1
Hydraulic oil filter 2
★ Standard charge relief valve setting : 2.5 ± 0.2 MPa (363 ± 29 psi)
SW884-10004
s
u
PG003163
10-005
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 nut (1) of charge relief valve (1-15) for evidence of having loosened. ② If there is evidence of nut having loosened, adjust charge relief valve so that pressure becomes within standard charge relief valve setting 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 : 0.4 MPa/turn (58 psi/turn) ③ If there is no evidence of nut 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
SW884-10006
1
(1) Nut : 44 N·m (32 lbf·ft) (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.
2 Charge relief valve RLV-BR-006
• 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).
10-006
INSPECTION AND ADJUSTMENT
4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hoses (1) and (3) from propulsion pump (2). Attach pressure gauge through adapter ⓦ . • Adapter ⓦ : 4-4LOHL6G5TP (Parker part number) • 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 switch to “Full”. ⑤ Operate F-R lever and then read pressure indicated by pressure gauge. • With parking brake applied (ON), measured pressures of (1-1) and (1-11) are same. • With parking brake released (OFF), measured pressures of (1-1) and (1-11) are different. ★ Standard charge relief pressure setting : 2.5 ± 0.2 MPa (362 ± 29 psi)
1-1 3 1-11
1
2
SW884-10007
w
PG002060
• The numbers “1-1” and “1-11” 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).
10-007
INSPECTION AND ADJUSTMENT
5. M EASUREMENT OF PARKING BRAKE RELEASE PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement.
5-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion motor. Attach pressure gauge through adapter ⓦ . • Adapter ⓦ : 4-4LOHL6G5TP (Parker part number) • 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 switch to “Full”. ⑤ Release parking brake by pressing parking brake switch button. ⑥ Read brake release pressure indicated by pressure gauge.
1
Propulsion motor SW880-10008
★ Brake release pressure : More than 1.5 MPa (218 psi) w
PG002060
10-008
INSPECTION AND ADJUSTMENT
6. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE 6-1. 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 (2-3),(2-11),(3-3) and (3-11) of vibrator pump (F),(R).
2-3
3-3
2-11
3-11 SW884-10008
Attach pressure gauge with adapter ⓨ . : 7/16-20UNF • Adapter ⓨ • High pressure gauge port : (2-3),(3-3) (Low amplitude/Oscillation) • High pressure gauge port : (2-11),(3-11) (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 vibratory drum select switch to “
”.
⑤ Set vibration mode change switch to “
”.
⑥ Start the engine and set throttle switch to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ Read pressure gauge for maximum value of vibrator circuit pressure.
y
⑨ Press F-R lever vibration switch OFF as soon as measurement is finished. ★ Maximum circuit pressure (cut off valve setting) : 31.5 ± 1.0 MPa (4,568 ± 145 psi) PG001011
• The numbers “2-3”, “2-11”, “3-3” and “3-11” 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).
10-009
INSPECTION AND ADJUSTMENT
6-2. Adjustment • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① Check high pressure relief valve (2-7), (2-10), (3-7), or (3-10) for evidence of having loosened. • High pressure relief valve : (2-7),(3-7) (High amplitude/Normal) • High pressure relief valve : (2-10),(3-10) (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. 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)
2-7
3-7
2-10
3-10 SW884-10009
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) (2-7),(2-10) High pressure relief valve (3-7),(3-10) : 160 N·m (118 lbf·ft)
RLV-BR-005
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. • The numbers “2-7”, “2-10”, “3-7”, and “3-10” 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).
10-010
INSPECTION AND ADJUSTMENT
7. MEASUREMENT AND ADJUSTMENT OF 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 ASSY are aligned.
7-1. 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 switch to “Full”. ⑤ Read pressure indicated by pressure gauge.
Hydraulic oil filter 1
1
SW884-10005
★ Standard charge relief valve setting : 2.5 ± 0.2 MPa (363 ± 29 psi) s
u
PG003163
10-011
INSPECTION AND ADJUSTMENT
7-2. 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 Remove charge relief valve (2-9). ② Check removed charge relief valve for trapped dirt and other abnormalities. ③ If trapped dirt is present, disassemble and clean charge relief valve. ④ If pressure still deviates from standard charge pressure setting range after valve is disassembled and cleaned, replace charge relief valve. ⑤ After adjustment, measure pressure again and check that pressure reaches standard charge relief valve setting range. N•m
(2-9) Charge relief valve : 90 N·m (66 lbf·ft)
2-9 SW884-10010
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
Charge relief valve RLV-BR-007
• 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).
10-012
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 ⓧ :6 -4LOHL6G5TP (Parker part number) • 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 switch 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) : 17.5 ± 1.0 MPa (2,538 ± 145 psi)
SW884-10011
x
PG002090
10-013
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.
10-014
2
ORB-SD-09150
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 (1-3). Attach pressure gauge through adapter ⓚ . • Adapter ⓚ : 12-4LOHL6G5TF (Parker part number) • 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
”. ④ Set speed change switch to “ ⑤ SW884/994 : Set vibration frequency select switch to “2,500 vpm”. ⑥ Start the engine and set throttle switch 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
SW884-10012
1-3
2
” and
★ Allowable pump case pressure : 0.4 MPa (58.0 psi) or less
1
SW884-10013
k
PG002190
• The number “1-3” 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).
10-015
INSPECTION AND ADJUSTMENT
9-2. Measurement of Vibrator Pump (F) Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (2) from vibrator pump (F) (1) drain port (3-12). Attach pressure gauge through adapter ⓚ . • Adapter ⓚ : 12-4LOHL6G5TF (Parker part number) • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”.
2
③ Apply parking brake by pressing parking brake switch button. ”.
④ Set vibratory drum select switch to “ ⑤ Set vibration mode select switch to “
”.
⑥ Start the engine and set throttle switch to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ ・SW884/994 : Measure pressure when vibration switch is “
” and “
1
” and vibration frequency select switch
3-12 SW884-10014
“2,500”, “3,000”, and “4,000”, respectively. ・SW884ND/994ND : Measure pressure when vibration switch is “
”and “
”, respectively.
k
⑨ Press F-R lever vibration switch OFF as soon as measurement is finished. ★ Allowable pump case pressure : 0.4 MPa (58.0 psi) or less
PG002190
• The number “3-12” 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).
10-016
INSPECTION AND ADJUSTMENT
9-3. Measurement of Vibrator Pump (R) Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plug from vibrator pump (R) (1) drain port (2-15). Attach pressure gauge with adapter ⓙ . 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”.
2-15
③ Apply parking brake by pressing parking brake switch button. ”.
④ Set vibratory drum select switch to “ ⑤ Set vibration mode select switch to “
”.
⑥ Start the engine and set throttle switch to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ ・SW884/994 : Measure pressure when vibration switch is “
” and “
1
” and vibration frequency select switch
SW884-10016
“2,500”, “3,000”, and “4,000”, respectively. ・SW884ND/994ND : Measure pressure when vibration switch is “ ”and “ ”, respectively. ⑨ Press F-R lever vibration switch OFF as soon as
j
measurement is finished. ★ Allowable pump case pressure : 0.4 MPa (58.0 psi) or less
PG001022
• 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).
10-017
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 speed change switch to “ ⑤ SW884/994 : Set vibration frequency select switch to “2,500 vpm”. ⑥ Start the engine and set throttle switch 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 SW880-1-10006
j
★ Allowable motor case pressure : 0.3 MPa (43.5 psi) or less
PG001022
10-018
INSPECTION AND ADJUSTMENT
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11-1. Measurement (SW884/994)
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 Disconnect hose (1) from vibrator motor. Attach pressure gauge through adapter ⓥ . • Adapter ⓥ : 8-4LOHL6G5TP (Parker part number) • 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 vibratory drum select switch to “
”.
⑤ Set vibration mode change switch to “
”.
1
⑥ Start the engine and set throttle switch to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ Measure pressure when vibration switch is “ “
” and
” and vibration frequency select switch “2,500”,
“3,000”, and “4,000”, respectively. ⑨ Press F-R lever vibration switch OFF as soon as measurement is finished.
SW880-1-10007
v
★ Allowable motor case pressure : 0.15 MPa (21.6 psi) or less
PG002120
10-019
INSPECTION AND ADJUSTMENT
11-2. Measurement (SW884ND/994ND)
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 Disconnect hose (1) from vibrator motor. Attach pressure gauge through adapter ⓥ . • Adapter ⓥ : 8-4LOHL6G5TP (Parker part number) • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”.
1
③ Apply parking brake by pressing parking brake switch button. ④ Set vibratory drum select switch to “
”.
⑤ Set vibration mode change switch to “
”.
⑥ Start the engine and set throttle switch to “Full”. ⑦ Press F-R lever vibration switch ON. ” and ⑧ Measure pressure when vibration switch is “ “ ”, respectively. ⑨ Press F-R lever vibration switch OFF as soon as measurement is finished.
SW884-10018
v ★ Allowable motor case pressure : 0.15 MPa (21.6 psi) or less
PG002120
10-020
INSPECTION AND ADJUSTMENT
12. Adjustment of F-R lever potentiometer • When replacing potentiometer, make adjustments in accordance with procedures described below.
12-1. Adjustment of F-R Lever Operating Force (NOTICE) • After tightening adjusting bolt or nut, move F-R lever (2) in both directions to its full stroke positions several times before measuring F-R lever operating force. • When taking measurements, always pull F-R lever with a spring balance, etc. fastened to lever at a right angle.
4
5
6
SECTION A-A
12-1-1. Adjustment of disc spring tension (NOTICE) • Ends of F-R lever switch (1) and backup buzzer switch (3) must not be in contact with F-R lever cam. • Screw (7) must not be in contact with F-R lever. • Apply lithium-based grease to shaft of potentiometer 1 (4) and potentiometer 2 (6).
7
SECTION B-B
① Place F-R lever in the temporary neutral position. ② Adjust with nut (5) so that F-R lever operating force reading becomes the following standard value when F-R lever is moved toward forward position.
2
1
N F
★ F-R lever operating force standard value : 1.0 ± 0.2 N (0.22 ± 0.05 lbf)
A
A B
B
3 N
90 SW880-1-10010
10-021
INSPECTION AND ADJUSTMENT
12-1-2. Adjustment of steel ball thrust (NOTICE) • F-R lever switch (1) and backup buzzer switch (3) must be placed in contact with F-R lever cam. • Apply lithium-based grease to F-R lever switch and backup buzzer switch at their surfaces that slide on F-R lever cam. • Apply molybdenum-based grease to screw.
4
① Temporarily adjust with screw (7) so that F-R lever operating force reading becomes the following standard value when F-R lever (2) is moved from neutral toward forward position and screw rides out of detent in F-R lever cam.
6
5
SECTION A-A
★ F-R lever operating force standard value when steel ball rides out of detent: 40.0 ± 0.2 N (9.0 ± 0.05 lbf)
7
SECTION B-B 2
1
② Adjust with screw (7) so that F-R lever operating force reading becomes the following standard value when F-R lever is moved further toward forward position after screw rides out of detent.
N F
★ F-R lever operating force standard value : 18.0 ± 2 N (4.0 ± 0.45 lbf)
A
A B
B
3 N
N F
90
In neutral
F
90
When screw rides out of detent SW880-1-10011
10-022
INSPECTION AND ADJUSTMENT
12-2. Adjustment of Potentiometer • Voltage at potentiometer must be measured with connector connected. For details about taking measurements, refer to TROUBLESHOOTING, 2-1-2 Inspection procedures using a tester, 2) Measuring voltage using tester (page 11-006). • Connect positive probe of tester to W (white) wire and negative probe to B (black) wire of potentiometer.
POTENTIOMETER 1
X
138 R
R
+V OUT GND
TO CONTROL BOX
145 W
W
140 B
B
12-2-1. Adjustment of potentiometer 1 voltage when F-R lever is in “N” • Prior to taking measurements, make sure that potentiometer 1 (6) is seated in notch of F-R lever (2), and operate F-R lever in both directions to its full stroke positions several times.
SW880-1-10012
① Set starter switch to ON. ② Operate F-R lever as follows and then take a measurement of voltage at potentiometer 1 when F-R lever is placed in “N”. • Move F-R lever in both directions to its full stroke positions and then quickly return lever to “N”. • Move F-R lever toward reverse until screw rides out of detent, and then release lever slowly (reverse direction only). ③ Adjust angle of potentiometer 1 so that middle value between maximum and minimum voltages becomes 2.500 V, and range (difference) between maximum and minimum voltages becomes 0.010 V.
4
5
6
SECTION A-A
Example: When maximum voltage is 2.505 V and minimum voltage is 2.495 V Middle value
7
: (2.505 V + 2.495 V) ÷ 2 = 2.500 V
SECTION B-B
Range between maximum : 2.505 – 2.495 = 0.010 V and minimum voltages
1
R
2
N
Adjust the voltage at potentiometer 2 (4) when F-R lever is placed in “N” in the same manner. (NOTICE) • Range between maximum and minimum voltages must not be wider than 0.020 V (acceptable range for midvalue: 2.485 to 2.515 V). If range extends beyond limits, make an adjustment by loosening disc spring tension adjusting nut (5) and tightening screw (7). F-R lever operating force must not deviate from standard value. • Voltage values should be rounded off to three decimal places.
F
A
A B 3
B SW880-1-10013
10-023
INSPECTION AND ADJUSTMENT
12-2-2. Adjustment of potentiometer 1 voltage when F-R lever switch operates • The moment that F-R lever switch turns ON/OFF can be monitored on water spray indicator lamp in combination meter. Water spray mode select switch must be placed in “AUTO”, and water spray timer switch must be turned OFF (placed in “
5
”).
① Set starter switch to ON. ② Move F-R lever (2) in forward direction. ③ Adjust with nut (8) of F-R lever switch (1) so that water spray indicator lamp in combination meter illuminates when voltage reaches a value 0.080 V higher than middle value measured in 12-2-1. Example: Middle value
4
8
Centerlines must be aligned
SECTION A-A
: 2.500 V
Voltage when F-R lever switch : 2.500 – 0.080 = 2.420 V operates (NOTICE) • Acceptable range for voltage when F-R lever switch operates is 2.415 to 2.425 V. • F-R lever switch must be installed with its centerline aligned with centerline of F-R lever cam. ④ After adjustments are made, make sure about following points. • F-R lever cam must not push in F-R lever switch until it bottoms when F-R lever is moved toward forward position. • F-R lever must automatically return to neutral when F-R lever is released at a position slightly beyond F-R lever switch operating point. If lever does not return automatically, make an adjustment by loosening disc spring tension adjusting nut (5) and tightening screw (7). F-R lever operating force must not deviate from standard value.
10-024
6
7
SECTION B-B 2
1
N F
A A B
B
SW880-1-10014
INSPECTION AND ADJUSTMENT
12-2-3. Adjustment of potentiometer 1 voltage when backup buzzer switch operates • The moment that backup buzzer switch turns ON/OFF can be monitored on water spray indicator lamp in combination meter. Water spray mode select switch must be placed in “AUTO”, and water spray timer switch must be turned OFF (placed in “
5
”).
① Set starter switch to ON. ② Move F-R lever (2) in reverse direction. ③ Adjust with nut (9) of backup buzzer switch (3) so that water spray indicator lamp in combination meter illuminates when voltage reaches a value 0.080 V lower than middle value measured in 12-2-1. Example: Middle value
4
9
Centerlines must be aligned 6
SECTION A-A
: 2.500 V
Voltage when backup buzzer : 2.500 + 0.080 = 2.580 V switch operates (NOTICE) • Acceptable range for voltage when backup buzzer switch operates is 2.575 to 2.585 V. • Backup buzzer switch must be installed with its centerline aligned with centerline of F-R lever cam. ④ After adjustments are made, make sure about following points. • F-R lever cam must not push in backup buzzer switch until it bottoms when F-R lever is moved toward reverse position. • F-R lever must automatically return to neutral when F-R lever is released at a position slightly beyond backup buzzer switch operating point. If lever does not return automatically, make an adjustment by loosening disc spring tension adjusting nut (5) and tightening screw (7). F-R lever operating force must not deviate from standard value.
7
SECTION B-B 3
R
2
N
A A
B
B
SW880-1-10015
10-025
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.
11-001
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.
11-002
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).
11-003
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.
11-004
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. 11-005
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.
11-006
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. 11-007
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.
11-008
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.
11-009
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.
11-010
TROUBLESHOOTING
2-2. Engine Diagnosis Trouble Code 2-2-1. Description of fault code (SPN,FMI) • When a fault code (SPN,FMI) occurs, display a fault code on the display monitor in the combination meter. Display monitor
SV544-09001
• Fault codes can be accessed in at least two different ways; using the electronic service tool or a method of displaying it on a display monitor in a combination meter. • To check the fault code occurring in the electronic fuel system / protection system of the engine on the display monitor, set the diagnostic switch to “ON” and set the start switch to “ON”. • After the diagnosis is ended, set the diagnostic switch to “OFF”. Diagnostic switch ON OFF
DETAIL A A No fault code.
Self-diagnosis in progress.
Occurrence of fault code.
SW884-11010
11-011
TROUBLESHOOTING
2-2-2. Fault code list SPN
FMI
Cummins Description
27
4
EGR Valve Position Circuit • Voltage below normal or shorted to low source.
3
Engine Intake Throttle Actuator Position Sensor Circuit • Voltage above normal or shorted to high source.
4
Engine Intake Throttle Actuator Position Sensor Circuit • Voltage below normal or shorted to low source.
2
Wheel-Based Vehicle Speed • Data erratic, intermittent, or incorrect.
9
Wheel-Based Vehicle Speed • Abnormal update rate.
10
Wheel-Based Vehicle Speed Sensor Circuit tampering has been detected • Abnormal change rate.
19
Wheel-Based Vehicle Speed • Received network data in error.
0
Accelerator Pedal or Lever Position Sensor 1 • Data valid but above normal operation range. • Most severe level.
1
Accelerator Pedal or Lever Position 1 Sensor Circuit Frequency • Data valid but below normal operation range. • Most severe level.
2
Accelerator Pedal or Lever Position Sensor 1 • Data erratic, intermittent, or incorrect.
3
Accelerator Pedal or Lever Position Sensor 1 Circuit • Voltage above normal or shorted to high source.
4
Accelerator Pedal or Lever Position Sensor 1 Circuit • Voltage below normal or shorted to low source.
9
SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System • Abnormal update rate.
19
SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System • Received network data in error.
51
84
91
11-012
Effect
• Possible reduced engine performance.
• Engine speed limited to maximum engine speed without VSS parameter value. • Cruise control, gear-down protection, and road speed governor will not work.
• The engine will operate in limp home mode.
• Engine will only idle.
• The engine will operate in limp home mode.
• Engine will only idle.
TROUBLESHOOTING SPN
FMI 3
WIF Indicator Sensor Circuit • Voltage above normal or shorted to high source.
4
WIF Indicator Sensor Circuit • Voltage below normal or shorted to low source.
15
WIF Indicator • Data valid but above normal operation range. • Least severe level.
16
WIF Indicator • Data valid but above normal operation range. • Moderately severe level.
1
Engine Oil Rifle Pressure • Data valid but below normal operation range. • Most severe level.
2
Engine Oil Rifle Pressure • Data erratic, intermittent, or incorrect.
3
Engine Oil Rifle Pressure 1 Sensor Circuit • Voltage above normal or shorted to high source.
4
Engine Oil Rifle Pressure 1 Sensor Circuit • Voltage below normal or shorted to low source.
18
Engine Oil Rifle Pressure • Data valid but below normal operation range. • Moderately severe level.
2
Intake Manifold 1 Pressure • Data erratic, intermittent, or incorrect.
3
Intake Manifold 1 Pressure Sensor Circuit • Voltage above normal or shorted to high source.
4
Intake Manifold 1 Pressure Sensor Circuit • Voltage below normal or shorted to low source.
18
Intake Manifold 1 Pressure • Data valid but below normal operation range. • Moderately severe level.
97
100
Cummins Description
102
Effect
• None on performance.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
• None on performance.
• Possible reduced engine performance.
11-013
TROUBLESHOOTING SPN
FMI
Cummins Description
Effect
0
Intake Manifold 1 Temperature • Data valid but above normal operation range. • Most severe level.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
3
Intake Manifold 1 Temperature Sensor Circuit • Voltage above normal or shorted to high source.
4
Intake Manifold 1 Temperature Sensor Circuit • Voltage below normal or shorted to low source.
15
Intake Manifold 1 Temperature • Data valid but above normal operation range. • Least severe level.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
16
Intake Manifold 1 Temperature • Data valid but above normal operation range. • Moderately severe level.
• Progressive power derate increasing in severity from time of alert.
18
Intake Manifold 1 Temperature • Data valid but below normal operation range. • Moderately severe level.
15
Engine Air Filter Differential Pressure • Data valid but above normal operation range. • Least severe level.
16
Engine Air Filter Differential Pressure • Data valid but above normal operation range. • Moderately severe level.
3
Barometric Pressure Sensor Circuit • Voltage above normal or shorted to high source.
4
Barometric Pressure Sensor Circuit • Voltage below normal or shorted to low source.
0
Engine Coolant Temperature • Data valid but above normal operation range. • Most severe level.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
2
Engine Coolant Temperature • Data erratic, intermittent, or incorrect.
• None on performance.
3
Engine Coolant Temperature 1 Sensor Circuit • Voltage above normal or shorted to high source.
4
Engine Coolant Temperature 1 Sensor Circuit • Voltage below normal or shorted to low source.
16
Engine Coolant Temperature • Data valid but above normal operation range. • Moderately severe level.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
31
Engine Coolant Temperature • Engine coolant temperature was above a threshold.
• Possible reduced engine performance.
105
107
108
110
11-014
• Fan will stay ON if controlled by the ECM.
• None on performance.
• Possible reduced engine performance.
• Fan will stay ON if controlled by the ECM.
TROUBLESHOOTING SPN
111
157
FMI
Cummins Description
1
Coolant Level • Data valid but below normal operation range. • Most severe level.
3
Coolant Level Sensor 1 Circuit • Voltage above normal or shorted to high source.
4
Coolant Level Sensor 1 Circuit • Voltage below normal or shorted to low source.
9
Coolant Level Sensor • Abnormal update rate.
• Possible reduced engine performance.
17
Coolant Level • Data valid but below normal operation range. • Least severe level.
• None on performance.
18
Coolant Level • Data valid but below normal operation range. • Moderately severe level.
19
Coolant Level Sensor • Received network data in error.
0
Injector Metering Rail 1 Pressure • Data valid but above normal operation range. • Most severe level.
3
Injector Metering Rail 1 Pressure Sensor Circuit • Voltage above normal or shorted to high source.
4
Injector Metering Rail 1 Pressure Sensor Circuit • Voltage below normal or shorted to low source.
16
Injector Metering Rail 1 Pressure • Data valid but above normal operation range. • Moderately severe level.
• Possible reduced engine performance.
18
Injector Metering Rail 1 Pressure • Data valid but below normal operation range. • Moderately severe level.
• Engine will not run or engine will run poorly.
15
Battery 1 Voltage • Data valid but above normal operation range. • Least severe level.
16
Battery 1 Voltage • Data valid but above normal operation range. • Moderately severe level.
17
Battery 1 Voltage • Data valid but below normal operation range. • Least severe level.
• Engine may stop running or be difficult to start. • Possible reduced engine performance.
18
Battery 1 Voltage • Data valid but below normal operation range. • Moderately severe level.
• Engine may stop running or be difficult to start.
168
Effect • Engine will be shut down.
• None on performance.
• Possible reduced engine performance.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
• None on performance.
11-015
TROUBLESHOOTING SPN
190
FMI
Cummins Description
0
Engine Crankshaft Speed/Position • Data valid but above normal operation range. • Most severe level.
411
Engine Crankshaft Speed/Position • Data erratic, intermittent, or incorrect.
16
Engine Crankshaft Speed/Position • Data valid but above normal operation range. • Moderately severe level.
• Engine will be shut down.
9
Transmission Output Shaft Speed • Abnormal update rate.
• None on performance.
16
Transmission Output Shaft Speed • Data valid but above normal operation range. • Moderately severe level.
• Engine power derate.
18
Transmission Output Shaft Speed • Data valid but below normal operation range. • Moderately severe level.
• Possible reduced engine performance.
19
Transmission Output Shaft Speed • Received network data in error.
13
Vehicle Identification Number • Out of calibration.
2
EGR Valve Differential Pressure • Data erratic, intermittent, or incorrect.
3
EGR Valve Differential Pressure Sensor Circuit • Voltage above normal or shorted to high source.
4
EGR Valve Differential Pressure Sensor Circuit • Voltage below normal or shorted to low source.
3
EGR Valve Temperature Sensor Circuit • Voltage above normal or shorted to high source.
4
EGR Valve Temperature Sensor Circuit • Voltage below normal or shorted to low source.
15
EGR Valve Temperature • Data valid but above normal operation range. • Least severe level.
16
EGR Valve Temperature • Data valid but above normal operation range. • Moderately severe level.
3
Auxiliary Temperature Sensor Input 1 Circuit • Voltage above normal or shorted to high source.
4
Auxiliary Temperature Sensor Input 1 Circuit • Voltage below normal or shorted to low source.
14
Auxiliary Temperature Sensor Input 1 • The input has exceeded the calibrated limit. • Out of calibration.
412
441
11-016
• Possible reduced engine performance.
2
191
237
Effect
• None on performance.
• Possible reduced engine performance.
• None on performance.
• Engine power derate.
TROUBLESHOOTING SPN
FMI
Cummins Description
Effect
3
Auxiliary Temperature Sensor Input 2 Circuit • Voltage above normal or shorted to high source.
4
Auxiliary Temperature Sensor Input 2 Circuit • Voltage below normal or shorted to low source.
2
Brake Pedal Position • Data erratic, intermittent, or incorrect.
2
Accelerator Pedal or Lever Idle Validation Switch • Engine will only idle. • Data erratic, intermittent, or incorrect.
13
Accelerator Pedal or Lever Idle Validation Switch Circuit • Engine will be shut down. • Out of calibration.
19
Accelerator Pedal or Lever Idle Validation Switch • Engine will only idle. • Received network data in error.
31
Anti-Lock Braking (ABS) Active
3
Brake Switch Circuit • Voltage above normal or shorted to high source.
4
Brake Switch Circuit • Voltage below normal or shorted to low source.
611
2
Auxiliary Intermediate (PTO) Speed Switch Validation • Data erratic, intermittent, or incorrect.
• One or more multiplexed devices will not operate properly.
612
2
Engine Magnetic Speed/Position Lost Both of Two Signals • Data erratic, intermittent, or incorrect.
• Engine will be shut down or not start.
625
9
Proprietary Datalink Error (OEM/Vehicle Datalink) • Abnormal update rate.
• The immobilizer anti-theft system will not operate properly. • Engine not start.
629
12
Engine Control Module Warning Internal Hardware Failure • Bad intelligent device or component. • Critical internal failure.
• Engine may not start or may be difficult to start. • Possible reduced engine performance.
630
12
Engine Control Module Calibration Memory • Bad intelligent device or component.
• Engine may not start or may be difficult to start.
31
Electronic Fuel Injection Control Valve Circuit • Fuel pump actuator circuit resistance is too high • Possible reduced engine performance. or too low, or an intermittent connection has been detected.
9
SAE J1939 Multiplexing PGN Timeout Error • Abnormal update rate.
13
SAE J1939 Multiplexing Configuration Error • Out of calibration.
14
Auxiliary Commanded Dual Output Shutdown • Engine will be shut down. • The engine protection limit has been exceeded.
442
521
558
563
597
633
639
640
• None on performance.
• Adaptive cruise control will not operate. • Standard cruise control may not operate.
• None on performance.
• One or more multiplexed devices will not operate properly.
11-017
TROUBLESHOOTING SPN
FMI 3
Fan Control Circuit • Voltage above normal or shorted to high source.
4
Fan Control Circuit • Voltage below normal or shorted to low source.
3
Engine Exhaust Back Pressure Regulator Control Circuit • Voltage above normal or shorted to high source.
4
Engine Exhaust Back Pressure Regulator Control Circuit • Voltage below normal or shorted to low source.
5
Engine Exhaust Back Pressure Regulator Control Circuit • Current below normal or open circuit.
5
Injector Solenoid Driver Cylinder 1 Circuit • Current below normal or open circuit.
13
Injector Solenoid Driver Cylinder 1 • Out of calibration.
5
Injector Solenoid Driver Cylinder 2 Circuit • Current below normal or open circuit.
13
Injector Solenoid Driver Cylinder 2 • Out of calibration.
5
Injector Solenoid Driver Cylinder 3 Circuit • Current below normal or open circuit.
13
Injector Solenoid Driver Cylinder 3 • Out of calibration.
5
Injector Solenoid Driver Cylinder 4 Circuit • Current below normal or open circuit.
13
Injector Solenoid Driver Cylinder 4 • Out of calibration.
3
Engine Starter Motor Relay Circuit • Voltage above normal or shorted to high source.
647
649
651
652
653
654
677 4
Engine Starter Motor Relay Circuit • Voltage below normal or shorted to low source.
3
Auxiliary PWM Driver 1 Circuit • Voltage above normal or shorted to high source.
4
Auxiliary PWM Driver 1 Circuit • Voltage below normal or shorted to low source.
14
Auxiliary Input/Output 1 Circuit • No communications on the J1939 data link.
697
701
11-018
Cummins Description
Effect
• The fan can be ON or OFF all the time.
• Possible reduced engine performance.
• Engine will not start or the engine will not have starter lockout protection.
• None on performance.
• Engine power derate.
TROUBLESHOOTING SPN
702
703
FMI 3
Auxiliary Input/Output 2 Circuit • Voltage above normal or shorted to high source.
5
Auxiliary Input/Output 2 Circuit • Current below normal or open circuit.
6
Auxiliary Input/Output 2 Circuit • Current above normal or ground circuit.
3
Auxiliary Input/Output 3 Circuit • Voltage above normal or shorted to high source.
2
Engine Camshaft Speed / Position Sensor • Data erratic, intermittent, or incorrect.
7
Engine Speed / Position Camshaft and Crankshaft Misalignment • Mechanical system not responding properly or out of adjustment.
3
Engine Intake Air Heater 1 Circuit • Voltage above normal or shorted to high source.
723
729
974
976
4
Engine Intake Air Heater 1 Circuit • Voltage below normal or shorted to low source.
3
Remote Accelerator Pedal or Lever Position Sensor 1 Circuit • Voltage above normal or shorted to high source.
4
Remote Accelerator Pedal or Lever Position Sensor 1 Circuit • Voltage below normal or shorted to low source.
19
SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Position Sensor System • Received network data in error.
2
PTO Governor State • Data erratic, intermittent, or incorrect.
3
Electric Lift Pump for Engine Fuel Supply • Voltage above normal or shorted to high source.
4
Electric Lift Pump for Engine Fuel Supply • Voltage below normal or shorted to low source.
9
Engine Wait to Start Lamp • Abnormal update rate.
1075
1081
Cummins Description
Effect
• None on performance.
• Possible reduced engine performance.
• The intake air heaters can be ON or OFF all the time.
• Remote accelerator will not operate.
• At least one multiplexed device will not operate properly.
• Engine may stop running or be difficult to start.
• None on performance.
11-019
TROUBLESHOOTING SPN
FMI
Cummins Description
3
Turbocharger 1 Compressor Intake Temperature Circuit • Voltage above normal or shorted to high source.
4
Turbocharger 1 Compressor Intake Temperature Circuit • Voltage below normal or shorted to low source.
2
Turbocharger 1 Compressor Intake Pressure • Data erratic, intermittent, or incorrect.
3
Turbocharger 1 Compressor Intake Pressure Circuit • Voltage above normal or shorted to high source.
4
Turbocharger 1 Compressor Intake Pressure Circuit • Voltage below normal or shorted to low source.
13
Anti-theft Encryption Seed • Out of calibration.
2
Antitheft Password Valid Indicator • Data erratic, intermittent, or incorrect.
2
Exhaust Gas Pressure 1 • Data erratic, intermittent, or incorrect.
3
Exhaust Gas Pressure Sensor 1 Circuit • Voltage above normal or shorted to high source.
4
Exhaust Gas Pressure Sensor 1 Circuit • Voltage below normal or shorted to low source.
3
Idle Shutdown Vehicle Accessories Relay Driver Circuit • Voltage above normal or shorted to high source.
1172
1176
1194 1195
1209
1267
Effect
• Possible reduced engine performance.
• Engine will not start.
• Possible reduced engine performance.
• Vehicle accessories or ignition bus loads controlled by the idle shutdown relay will not power up.
4
Idle Shutdown Vehicle Accessories Relay Driver Circuit • Voltage below normal or shorted to low source.
3
Engine Fuel Pump Pressurizing Assembly 1 Circuit • Voltage above normal or shorted to high source.
• Engine will not run or engine will run poorly.
4
Engine Fuel Pump Pressurizing Assembly 1 Circuit • Voltage below normal or shorted to low source.
• Possible reduced engine performance.
1377
2
Multiple Unit Synchronization Switch • Data erratic, intermittent, or incorrect.
• Various optional switch inputs to the ECM may not operate correctly.
1378
31
Engine Oil Change Interval
• None on performance.
1347
11-020
TROUBLESHOOTING SPN
FMI
1569
1623
1639
1675
Effect
3
Auxiliary Pressure Sensor Input 1 Circuit • Voltage above normal or shorted to high source.
4
Auxiliary Pressure Sensor Input 1 Circuit • Voltage below normal or shorted to low source.
3
Auxiliary Pressure Sensor Input 2 Circuit • Voltage above normal or shorted to high source.
4
Auxiliary Pressure Sensor Input 2 Circuit • Voltage below normal or shorted to low source.
14
Auxiliary Pressure Sensor Input 2 • Engine power derate. • The engine protection limit has been exceeded.
31
Engine Protection Torque Derate • Critical fault codes related to engine operation are active.
9
Tachograph Output Shaft Speed • Abnormal update rate.
13
Tachograph Output Shaft Speed • Out of calibration.
19
Tachograph Output Shaft Speed • Received network data in error.
0
Fan Speed • Data valid but above normal operation range. • Most severe level.
1
Fan Speed • Data valid but below normal operation range. • Most severe level.
2
Fan Speed • Data erratic, intermittent, or incorrect.
15
Fan Speed • Data valid but above normal operation range. • Least severe level.
17
Fan Speed • Data valid but below normal operation range. • Least severe level.
31
Engine Starter Mode Overcrank Protection • Starter operation is prohibited until the starter • The starter motor has been temporarily disabled motor has adequately cooled. in order to prevent starter damage.
1387
1388
Cummins Description
• None on performance.
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
• The fan can be ON or OFF all the time.
• Possible reduced engine performance.
11-021
TROUBLESHOOTING SPN
1761
FMI
Cummins Description
1
Aftertreatment 1 Diesel Exhaust Fluid Tank Level • Data valid but below normal operation range. • Most severe level.
3
Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit • Voltage above normal or shorted to high • Possible reduced engine performance. source.
4
Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor Circuit • Voltage below normal or shorted to low source.
9
Aftertreatment 1 Diesel Exhaust Fluid Tank Level • One or more multiplexed devices will not • Abnormal update rate. operate properly.
10
Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor • Abnormal change rate.
11
Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor • Root cause not known.
13
Aftertreatment 1 Diesel Exhaust Fluid Tank Level Sensor • Out of calibration.
17
Aftertreatment Diesel Exhaust Fluid Tank Level • Data valid but below normal operation range. • Least severe level.
18
Aftertreatment Diesel Exhaust Fluid Tank Level • Data valid but below normal operation range. • Moderately severe level.
3
Accelerator Pedal or Lever Position Sensor 2 Circuit • Voltage above normal or shorted to high source.
4
Accelerator Pedal or Lever Position Sensor 2 Circuit • Voltage below normal or shorted to low source.
3
Engine Charge Air Cooler Outlet Temperature • Voltage above normal or shorted to high source.
4
Engine Charge Air Cooler Outlet Temperature • Voltage below normal or shorted to low source.
15
Turbocharger Turbine Intake Temperature • Data valid but above normal operation range. • Least severe level.
2623
2630
2789
11-022
Effect
• Possible reduced engine performance.
• None on performance.
• The engine will operate in limp home mode.
• None on performance.
• Possible reduced engine performance.
TROUBLESHOOTING SPN
2791
2797
FMI 5
EGR Valve Control Circuit • Current below normal or open circuit.
6
EGR Valve Control Circuit • Current above normal or ground fault.
7
EGR Valve Control Circuit • Mechanical system not responding properly or out of adjustment.
13
EGR Valve Controller • Out of calibration.
15
EGR Valve Control Circuit Calculated Over Temperature • Data valid but above normal operation range. • Least severe level.
13
Engine Injector Bank 1 Barcodes • Out of calibration.
2
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature • Data erratic, intermittent, or incorrect.
3
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor • Voltage below normal or shorted to low source.
9
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature • Abnormal update rate.
11
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature • Root cause not known.
13
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor • Out of calibration.
2
Aftertreatment 1 Intake NOx Sensor • Data erratic, intermittent, or incorrect.
4
Aftertreatment 1 Intake NOx Sensor Circuit • Voltage below normal or shorted to low source.
9
Aftertreatment 1 Intake NOx Sensor • Abnormal update rate.
10
Aftertreatment 1 Intake NOx Sensor • Abnormal change rate.
13
Aftertreatment 1 Intake NOx • Out of calibration.
20
Aftertreatment 1 Intake NOx Sensor • Data not rational. • Drifted high.
3031
3216
Cummins Description
Effect
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
• Engine power derate.
• Possible reduced engine performance.
• None on performance.
11-023
TROUBLESHOOTING SPN
FMI
3218
2
Aftertreatment 1 Intake NOx Sensor Power Supply • Data erratic, intermittent, or incorrect.
2
Aftertreatment 1 Outlet NOx Sensor • Data erratic, intermittent, or incorrect.
4
Aftertreatment 1 Outlet NOx Sensor Circuit • Voltage below normal or shorted to low source.
9
Aftertreatment 1 Outlet NOx Sensor • Abnormal update rate.
10
Aftertreatment 1 Outlet NOx Sensor • Abnormal change rate.
13
Aftertreatment 1 Outlet NOx Sensor • Out of calibration.
20
Aftertreatment 1 Outlet NOx Sensor • Data not rational. • Drifted high.
• Possible reduced engine performance.
2
Aftertreatment 1 Outlet NOx Sensor Power Supply • Data erratic, intermittent, or incorrect.
• None on performance.
3
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature Sensor Circuit • Voltage above normal or shorted to high source.
2
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Temperature • Data erratic, intermittent, or incorrect.
3
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit • Voltage below normal or shorted to low source.
31
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Input Lines • Aftertreatment diesel exhaust fluid dosing unit is unable to prime.
3
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater Circuit • Voltage below normal or shorted to low source.
7
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater • Mechanical system not responding properly or out of adjustment.
3226
3228
3246
3361
3362
3363
11-024
Cummins Description
Effect • None on performance.
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
TROUBLESHOOTING SPN
FMI
Cummins Description
16
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater • Data valid but above normal operation range. • Moderately severe level.
• None on performance.
18
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater • Data valid but below normal operation range. • Moderately severe level.
• Possible reduced engine performance.
2
Aftertreatment Diesel Exhaust Fluid Quality • Data erratic, intermittent, or incorrect.
• Engine power derate.
3
Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit • Voltage below normal or shorted to low source.
7
Aftertreatment Diesel Exhaust Fluid Quality Sensor • Mechanical system not responding properly or out of adjustment.
9
Aftertreatment Diesel Exhaust Fluid Quality • Abnormal update rate.
10
Aftertreatment Diesel Exhaust Fluid Quality • Abnormal change rate.
11
Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit • Root cause not known.
12
Aftertreatment Diesel Exhaust Fluid Quality Sensor • Bad intelligent device or component.
13
Aftertreatment Diesel Exhaust Fluid Quality • Out of calibration.
15
Aftertreatment Diesel Exhaust Fluid Quality • Data valid but above normal operation range. • Least severe level.
18
Aftertreatment Diesel Exhaust Fluid Quality • Data valid but below normal operation range. • Moderately severe level.
19
Aftertreatment Diesel Exhaust Fluid Quality • Received network data in error.
3
Sensor Power Supply 1 Circuit • Voltage above normal or shorted to high source.
4
Sensor Power Supply 1 Circuit • Voltage below normal or shorted to low source.
3363
3364
3509
Effect
• Possible reduced engine performance.
• Engine power derate.
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
11-025
TROUBLESHOOTING SPN
FMI 3
Sensor Power Supply 2 Circuit • Voltage above normal or shorted to high source.
4
Sensor Power Supply 2 Circuit • Voltage below normal or shorted to low source.
3
Sensor Power Supply 3 Circuit • Voltage above normal or shorted to high source.
4
Sensor Power Supply 3 Circuit • Voltage below normal or shorted to low source.
3
Sensor Power Supply 4 Circuit • Voltage above normal or shorted to high source.
4
Sensor Power Supply 4 Circuit • Voltage below normal or shorted to low source.
3
Sensor Power Supply 5 • Voltage above normal or shorted to high source.
4
Sensor Power Supply 5 • Voltage below normal or shorted to low source.
3
Sensor Power Supply 6 Circuit • Voltage above normal or shorted to high source.
4
Sensor Power Supply 6 Circuit • Voltage below normal or shorted to low source.
10
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 • Abnormal change rate.
11
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 • Root cause not known.
11
Aftertreatment 1 Diesel Exhaust Fluid Property • Root cause not known.
2
Power Supply Lost With Ignition On • Data erratic, intermittent, or incorrect.
12
Injector Power Supply • Bad intelligent device or component.
17
ECU Power Output Supply Voltage 1 • Data valid but below normal operation range. • Least severe level.
18
ECU Power Output Supply Voltage 1 • Data valid but below normal operation range. • Moderately severe level.
3510
3511
3512
3513
3514
3515
3521
3597
11-026
Cummins Description
Effect
• Possible reduced engine performance.
• Engine will not run or engine will run poorly.
• Engine will only idle.
• The engine will operate in limp home mode.
• Possible reduced engine performance.
• Engine power derate.
• Possible reduced engine performance.
TROUBLESHOOTING SPN
FMI
3695
2
Aftertreatment Regeneration Inhibit Switch • Data erratic, intermittent, or incorrect.
14
Aftertreatment 1 Diesel Particulate Filter Conditions Not Met for Active Regeneration • Aftertreatment temperatures are not warm enough for aftertreatment injection.
31
NOx Limits Exceeded Due to Insufficient Reagent Quality • Diesel exhaust fluid quality is not sufficient enough to provide adequate NOx reduction.
3750
4094
Cummins Description
Effect
• Possible frequent need for aftertreatment regeneration.
• Possible reduced engine performance.
4096
31
Aftertreatment Diesel Exhaust Fluid Tank Empty
4185
31
Overspeed Shutdown Relay Driver Diagnostic Has Detected an Error
• The overspeed shutdown lamp will not turn on.
4186
31
Low Oil Pressure (LOP) Shutdown Relay Driver Diagnostic Has Detected an Error
• The low oil pressure (LOP) shutdown lamp will not turn on.
2
Aftertreatment 1 Diesel Exhaust Fluid Pressure • Data erratic, intermittent, or incorrect.
3
Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Pressure • Possible reduced engine performance. Sensor Circuit • Voltage below normal or shorted to low source.
16
Aftertreatment 1 Diesel Exhaust Fluid Pressure • Data valid but above normal operation range. • Moderately severe level.
18
Aftertreatment 1 Diesel Exhaust Fluid Pressure • Data valid but below normal operation range. • Moderately severe level.
10
Aftertreatment 1 Diesel Exhaust Fluid Dosing Temperature • Abnormal change rate.
3
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Circuit • Voltage below normal or shorted to low source.
5
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Circuit • Current below normal or open circuit.
4334
4337
4340
• None on performance.
• Possible reduced engine performance.
11-027
TROUBLESHOOTING SPN
4342
4344
FMI
3
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Circuit • Voltage below normal or shorted to low source.
5
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Circuit • Current below normal or open circuit.
3
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 3 Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 3 Circuit • Voltage below normal or shorted to low source.
5
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 3 Circuit • Current below normal or open circuit.
0
Aftertreatment 1 SCR Intake Temperature • Data valid but above normal operation range. • Most severe level.
2
Aftertreatment 1 SCR Intake Temperature Sensor • Data erratic, intermittent, or incorrect.
3
Aftertreatment 1 SCR Intake Temperature Sensor Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 SCR Intake Temperature Sensor Circuit • Voltage below normal or shorted to low source.
15
Aftertreatment 1 SCR Intake Temperature • Data valid but above normal operation range. • Least severe level.
16
Aftertreatment 1 SCR Intake Temperature • Data valid but above normal operation range. • Moderately severe level.
4360
11-028
Cummins Description
Effect
• Possible reduced engine performance.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
• Possible reduced engine performance.
• Progressive power derate increasing in severity from time of alert. • If engine protection shutdown feature is enabled, engine will shut down.
TROUBLESHOOTING SPN
FMI
Cummins Description
0
Aftertreatment 1 SCR Outlet Temperature • Data valid but above normal operation range. • Most severe level.
2
Aftertreatment 1 SCR Outlet Temperature Sensor • Data erratic, intermittent, or incorrect.
3
Aftertreatment 1 SCR Outlet Temperature Sensor Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 SCR Outlet Temperature Sensor Circuit • Voltage below normal or shorted to low source.
16
Aftertreatment 1 SCR Outlet Temperature • Data valid but above normal operation range. • Moderately severe level.
17
Aftertreatment SCR Catalyst Conversion Efficiency • Data valid but below normal operation range. • Least severe level.
18
Aftertreatment SCR Catalyst Conversion Efficiency • Data valid but below normal operation range. • Moderately severe level.
3
Aftertreatment Diesel Exhaust Fluid Return Valve • Voltage above normal or shorted to high source.
4
Aftertreatment Diesel Exhaust Fluid Return Valve • Voltage below normal or shorted to low source.
7
Aftertreatment Diesel Exhaust Fluid Return Valve • Mechanical system not responding properly or • None on performance. out of adjustment.
4792
14
Aftertreatment 1 SCR Catalyst System • The incorrect SCR system has been installed.
• Engine will be shut down.
4794
31
Aftertreatment 1 SCR Catalyst System Missing
• Possible reduced engine performance.
5024
10
Aftertreatment 1 Intake NOx Sensor Heater • Abnormal change rate.
10
Aftertreatment 1 Outlet NOx Sensor Heater • Abnormal change rate.
5245
31
Aftertreatment 1 SCR Operator Inducement Active • Critical SCR related fault codes have been active.
• Possible reduced engine performance.
5246
-
Aftertreatment 1 SCR Operator Inducement • Data valid but above normal operation range. • Most severe level.
• Engine power derate.
4363
4364
4376
5031
Effect
• Possible reduced engine performance.
• None on performance.
11-029
TROUBLESHOOTING SPN
FMI
Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 Circuit • Current below normal or open circuit.
7
Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 • Mechanical system not responding properly or out of adjustment.
3
Engine Fan Clutch 2 Control Circuit • Voltage above normal or shorted to high source.
4
Engine Fan Clutch 2 Control Circuit • Voltage below normal or shorted to low source.
3
Aftertreatment Diesel Exhaust Fluid Line Heater Relay Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment Diesel Exhaust Fluid Line Heater Relay Circuit • Voltage below normal or shorted to low source.
0
High Pressure Common Rail Fuel Pressure Relief Valve • Data valid but above normal operation range. • Most severe level.
7
High Pressure Common Rail Fuel Pressure Relief Valve • Mechanical system not responding properly or out of adjustment.
15
High Pressure Common Rail Fuel Pressure Relief Valve • Data valid but above normal operation range. • Least severe level.
9
Cruise Control Disable Command • Abnormal update rate.
2
Engine Exhaust Back Pressure Regulator Position • Data erratic, intermittent, or incorrect.
3
Engine Exhaust Back Pressure Regulator Position Sensor Circuit • Voltage above normal or shorted to high source.
4
Engine Exhaust Back Pressure Regulator Position Sensor Circuit • Voltage below normal or shorted to low source.
7
Engine Exhaust Back Pressure Regulator • Mechanical system not responding properly or out of adjustment.
• None on performance.
13
Engine Exhaust Back Pressure Regulator • Out of calibration.
• Possible reduced engine performance.
5484
5491
5603
5625
5626
11-030
Effect
5 5394
5571
Cummins Description
• Possible reduced engine performance.
• The fan can be ON or OFF all the time.
• Possible reduced engine performance.
• Engine may stop running or be difficult to start.
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
TROUBLESHOOTING SPN
5743
FMI 3
Aftertreatment SCR Temperature Sensor • Voltage above normal or shorted to high source.
4
Aftertreatment SCR Temperature Sensor • Voltage below normal or shorted to low source.
9
Aftertreatment SCR Temperature Sensor • Abnormal update rate.
11
Aftertreatment SCR Temperature Sensor • Root cause not known.
12
Aftertreatment SCR Temperature Sensor • Bad intelligent device or component.
16
Aftertreatment SCR Temperature Sensor • Data valid but above normal operation range. • Moderately severe level.
3
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Heater Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Heater Circuit • Voltage below normal or shorted to low source.
17
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Heater • Data valid but below normal operation range. • Least severe level.
18
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Heater • Data valid but below normal operation range. • Moderately severe level.
3
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Relay Circuit • Voltage above normal or shorted to high source.
4
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Relay Circuit • Voltage below normal or shorted to low source.
10
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater Temperature • Abnormal change rate.
3
Engine Coolant Level 2 Sensor • Voltage above normal or shorted to high source.
4
Engine Coolant Level 2 Sensor • Voltage below normal or shorted to low source.
5745
5746
5798
Cummins Description
6303
Effect
• Possible reduced engine performance.
• None on performance.
• Possible reduced engine performance.
• None on performance.
11-031
TROUBLESHOOTING SPN
FMI
Maintain ECU Power Lamp Circuit • Voltage above normal or shorted to high source.
4
Maintain ECU Power Lamp Circuit • Voltage below normal or shorted to low source.
2
Engine Fan Blade Pitch • Data erratic, intermittent, or incorrect.
3
Engine Fan Blade Pitch Position Sensor Circuit • Voltage above normal or shorted to high source.
4
Engine Fan Blade Pitch Position Sensor Circuit • Voltage below normal or shorted to low source.
7
Engine Fan Blade Pitch • Mechanical system not responding properly or out of adjustment.
31
Aftertreatment 1 Diesel Exhaust Fluid Dosing System Frozen • Diesel exhaust fluid dosing system was unable • Engine power derate. to prime when the ambient air temperature was low.
9
SCR Operator Inducement Override Switch • Abnormal update rate.
13
SCR Operator Inducement Override Switch • Out of calibration.
31
SCR System Cleaning Inhibited Due to Inhibit Switch • Cleaning of the SCR system has been prevented due to the permit switch being disabled.
6799
6881
6918
6928
Effect
3 6655
6802
Cummins Description
31
• None on performance.
• One or more multiplexed devices will not operate properly.
• None on performance.
SCR System Cleaning Inhibited Due to System Timeout
(NOTICE) • For details, refer to “Service information” of engine manufacturer.
11-032
TROUBLESHOOTING
2-3. Error Codes 2-3-1. Description of error codes • The traveling/working controller constantly monitors the input and output status to control each system. • The traveling/working controller performs the system diagnostics function. When any system problem is detected, it displays the corresponding error code like as “E01” on the EXACT METER.
-
SLOW
SPEED
+
FAST
MPH( °F )
SW884-11009
2-3-2. Error code list Error code
Description
E01, E02
Faulty potentiometer inside F-R lever.
E03, E04
Faulty F-R lever switch.
E05, E06
Faulty buckup buzzer switch.
E07
Faulty speed sensor or traveling controller. (auto speed abnormality)
Symptom
Engine stop.
An error code is displayed. Engine stop (only auto speed mode).
E11
Faulty speed sensor. (speed sensor pulse is not detected)
Impact frequency lamp does not light. Automatic speed function does not operate. Vehicle speed is not displayed.
E12
Faulty speed sensor. (when F-R lever is “N”, it detected a speed sensor Engine stop. pulse)
E15
Faulty road surface temperature sensor.
E21
Faulty frequency or amplitude selector switch (three input signals).
Display does not switch to temperature indication. Automatic speed function does not operate. Vibration amplitude or frequency cannot be changed (Fixed in 4000 vpm). 11-033
TROUBLESHOOTING Error code
Description
E22
Faulty IPF selector switch (three input signals).
E31
Faulty propulsion pump proportional solenoid (F) output current.
E32
Faulty propulsion pump proportional solenoid (R) output current.
E33
Faulty vibrator pump (F) proportional solenoid a (Hi) output current.
E34
Faulty vibrator pump (F) proportional solenoid b (Lo) output current.
E35
Faulty vibrator pump (R) proportional solenoid a (Hi) output current.
E36
Faulty vibrator pump (R) proportional solenoid b (Lo) output current.
Symptom Automatic speed function does not operate. IPF number cannot be changed (Fixed in IPF12).
Engine stop.
Vibration does not occur.
Vibration does not occur.
Engine stop (only auto speed mode). E41
Faulty CAN communication.
Automatic speed function does not operate. Tachometer in combination meter does not work.
E42
Faulty traveling controller.
E43
Faulty exact meter.
E44 E45 E88 E00
11-034
Engine stop.
Faulty working controller. Mismatch of parameter values of the traveling controller and working controller.
Running stop.
Parking brake switch is OFF and F-R lever is in “F” Engine does not start. or “R” or brake pedal is depressed.
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-035
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4. Engine 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.11-006 to P.11-008). • Check any ground circuit which belongs to components to be checked. • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer.
2-4-1. Engine will not start (Starter motor does not run) 1/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code Pon
Check/Cause
Action
1. Connector
Check point
• Check F-R lever switch connector, buckup buzzer switch connector and traveling controller connector terminal 19, 20, working controller connector terminal 11, 12 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistances between switches and traveling Repair or replace controller terminal wires. harness. • F-R lever switch terminal NC wire BW and traveling controller terminal 19 wire BW, working controller terminal 11 wire BW • Buckup buzzer switch terminal NC wire Gr and traveling controller terminal 20 wire Gr, working controller terminal 12 wire Gr Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • F-R lever switch terminal COM wire WL and fuse box terminal 7 wire WL • Buckup buzzer switch terminal COM wire WG and fuse box terminal 6 wire WG Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. F-R lever switch
• When starter switch is OFF, check continuity between F-R Replace F-R lever lever switch terminal COM and terminal NC. switch. There is continuity in normal condition. • If there is no continuity, F-R lever switch is faulty.
4. Buckup buzzer • When starter switch is OFF, check continuity between switch buckup buzzer switch terminal COM and terminal NC. There is continuity in normal condition. • If there is no continuity, buckup buzzer switch is faulty.
Replace buckup buzzer switch.
11-036
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-037
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 2/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code Pon
Check point
Check/Cause
Action
5. T raveling/ Working Controller
• If error code Pon is displayed and no abnormality is Replace traveling/ found in connector, harness, F-R lever switch and buckup working controller. buzzer switch in above inspection, traveling/working controller is faulty.
6. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, place F-R lever “F” or “N”. ② Set starter switch to ON. ③ When F-R lever is “F” or “N”, traveling/working controller cannot be initialized. Exact meter will continuously display Pon. ④ Return F-R lever to “N”. ⑤ When traveling/working controller initialization is completed, display will change from Pon to vehicle speed. Machine is in normal state.
11-038
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-039
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 3/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E01 or E02 1. Connector
2. Harness
Check/Cause
Action
• Check F-R lever potentiometer 1, 2 connector and Replace connector traveling controller connector terminal 8, 9, 47, 48, or terminal. working controller connector terminal 29, 30 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty. • Measure resistances between F-R lever potentiometer Repair or replace and traveling/working controller terminal wires. harness. • F-R lever potentiometer 1 terminal wire R and traveling controller terminal 8 wire R • F-R lever potentiometer 1 terminal wire W and traveling controller terminal 47 wire W, working controller terminal 29 wire W • F-R lever potentiometer 1 terminal wire B and traveling controller terminal 9 wire B • F-R lever potentiometer 2 terminal wire R and traveling controller terminal 8 wire R • F-R lever potentiometer 2 terminal wire WR and traveling controller terminal 48 wire WR, working controller terminal 30 wire WR • F-R lever potentiometer 2 terminal wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
(1) W hen starter switch is ON, measure voltage between 3. F -R Lever Potentiometer 1 F-R lever potentiometer 1 terminal inlet wire R and ground terminal wire B. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between F-R lever potentiometer 1 terminal outlet wire W and ground terminal wire B. ① When F-R lever is “N” Standard voltage : 2.5 ± 0.015 V ② When F-R lever is “F” Standard voltage : 1.2 ± 0.02 V ③ When F-R lever is “R” Standard voltage : 3.8 ± 0.02 V • If above item (1) is OK and any of measurements in item (2) is NG, F-R lever potentiometer 1 adjustment is faulty.
Adjust F-R lever potentiometer 1 or replace it even if measurement is out of standard after adjustment.
11-040
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-041
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 4/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
Check/Cause
E01 or E02 4. F-R Lever (1) W hen starter switch is ON, measure voltage between Potentiometer 2 F-R lever potentiometer 2 terminal inlet wire R and ground terminal wire B. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between F-R lever potentiometer 2 terminal outlet wire WR and ground terminal wire B. ① When F-R lever is “N” Standard voltage : 2.5 ± 0.015 V ② When F-R lever is “F” Standard voltage : 3.8 ± 0.02 V ③ When F-R lever is “R” Standard voltage : 1.2 ± 0.02 V • If above item (1) is OK and any of measurements in item (2) is NG, F-R lever potentiometer 2 adjustment is faulty. 5. T raveling Controller
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between traveling controller terminal 8 outlet wire R (positive side) and 9 wire B (ground side). Standard voltage : 5 ± 0.5 V • If above item (1) is OK and item (2) is NG, traveling controller is faulty.
6. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed (0.0). If E01 or E02 is displayed, check above items again. ④ Place F-R lever “F” or “N”. ⑤ Exact meter will still display vehicle speed (0.0). Machine is in normal state. If display changes to E01 or E02, check above items again.
Action Adjust F-R lever potentiometer 2 or replace it even if measurement is out of standard after adjustment.
Replace traveling controller.
11-042
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-043
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 5/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E03 or E04 1. Connector
Check/Cause
Action
• Check F-R lever switch connector and traveling controller connector terminal 19, working controller connector terminal 11 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistance between F-R lever switch connector Repair or replace terminal NC wire BW and traveling controller terminal harness. 19 wire BW, working controller terminal 11 wire BW. Standard resistance : 10 Ω or less (2) M easure resistance between F-R lever switch connector terminal COM wire WL and fuse box terminal 7 wire WL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. F-R lever switch
(1) W hen starter switch is OFF, check continuity between F-R lever switch terminal COM and terminal NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “F”, check continuity between F-R lever switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, F-R lever switch is faulty.
Replace F-R lever switch.
4. T raveling/ Working Controller
• If error code E03 or E04 is displayed and no abnormality is found in connector, harness and F-R lever switch in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E03 or E04. When E03 is displayed: ③ Move F-R lever in “F”. Exact meter display will change from E03 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state. When E04 is displayed: ③ Place F-R lever “N”. Exact meter display will change from E04 to vehicle speed (0.0). Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-044
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-045
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 6/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E05 or E06 1. Connector
2. Harness
Check/Cause
Action
• Check buckup buzzer switch connector and traveling controller connector terminal 20, working controller connector terminal 12 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
(1) M easure resistance between buckup buzzer switch terminal NC wire Gr and traveling controller terminal 20 wire Gr, working controller terminal 12 wire Gr. Standard resistance : 10 Ω or less (2) M easure resistance between buckup buzzer switch terminal COM wire WG and fuse box terminal 6 wire WG. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
hen starter switch is OFF, check continuity between Replace buckup 3. Buckup buzzer (1) W switch buckup buzzer switch terminal COM and terminal NC. buzzer switch. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “R”, check continuity between buckup buzzer switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, buckup buzzer switch is faulty. 4. T raveling/ Working Controller
• If error code E05 or E06 is displayed and no abnormality is found in connector, harness and buckup buzzer switch in above inspection, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E05 or E06. When E05 is displayed: ③ Place F-R lever “N”. Exact meter display will change from E05 to vehicle speed (0.0). Machine is in normal state. If display does not change to vehicle speed, check above items again. When E06 is displayed: ③ Move F-R lever in “R”. Exact meter display will change from E06 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state.
Replace traveling/ working controller.
11-046
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-047
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 7/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E31 or E32 1. Connector
2. Harness
Check/Cause
Action
• Check propulsion pump proportional solenoid connector Replace connector and traveling controller connector terminal 40, 50, or terminal. working controller connector terminal 37, 38 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty. • Measure resistances between propulsion pump proportional solenoid and traveling controller terminal wires. • Propulsion pump proportional solenoid b wire G and traveling controller terminal 40 wire G • Propulsion pump proportional solenoid a wire L and traveling controller terminal 50 wire L • Propulsion pump proportional solenoid a, b wire B and working controller terminal 37 and 38 wires B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
• Disconnect connectors and check continuity between propulsion pump proportional solenoid terminal wires. • Terminal wire No.120 wire G and terminal wire No.121 wire B • Terminal wire No.122 wire L and terminal wire No.123 wire B • If there is continuity, harness is faulty. • Disconnect harness and measure resistance of coils. 3. Propulsion Pump Standard resistance: 5.5 Ω Proportional • If resistance is abnormal, propulsion pump proportional Solenoid a (R) solenoid a (R) or b (F) is faulty. or b (F)
Replace propulsion pump proportional solenoid.
11-048
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-049
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 8/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E31 or E32 4. Traveling/ Working Controller
Check/Cause
Action
(1) W hen starter switch is ON, measure voltage between Replace traveling/ traveling/working controller terminal wires and ground working controller. terminal wire. • Traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B • Working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B Standard voltage : 12 V or more (2) W hen starter switch is “ON” and speed change switch is “ ”, measure current between propulsion pump proportional solenoid terminal wires (positive side) and B (ground side). • Propulsion pump proportional solenoid b (F) wire G (positive side) and wire B (ground side) • Propulsion pump proportional solenoid a (R) wire L (positive side) and wire B (ground side) • While measuring current, operate F-R lever from “N” to “F” or “R”. Standard current: 0 mA (“N”) Standard current: 3 90 mA or more (at vehicle start moving) Standard current: 1,350 mA or less (“F” or “R”) • If item (1) is OK and item (2) is NG, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed. If display does not change to vehicle speed, check above items again. In case of E31: ④ Move F-R lever in “F”. Exact meter will still display vehicle speed. Machine is in normal state. If E31 is displayed again, check above items again. In case of E32: ④ Move F-R lever in “R”. Exact meter will still display vehicle speed. Machine is in normal state. If E32 is displayed again, check above items again.
11-050
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-051
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 9/15 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E42
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. T raveling Controller
• When starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more • If voltage is normal, traveling controller is faulty.
Replace traveling controller.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 0.5 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-052
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-053
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 10/15 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E43
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter
• When starter switch is ON, measure voltage between exact meter terminal 5 inlet wire WB and ground terminal 6 wire B. Standard voltage : 12 V or more • If voltage is normal, exact meter is faulty.
Replace exact meter.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 1 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-054
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-055
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 11/15 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E44, E45
Check point 1. Connector
2. Harness
Check/Cause
Action
• Check exact meter connector terminal 1, 2, 7 and working Replace connector controller connector terminal 3, 4, 39, for corrosion, or terminal. breakage, bending and looseness. • If any abnormality is found, connector is faulty.
• Measure resistances between exact meter and working controller terminal wires. • Exact meter terminal 1 wire GW and working controller terminal 3 wire GW • Exact meter terminal 2 wire B and working controller terminal 4 wire B • Exact meter terminal 3 wire B and working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. (1) W hen starter switch is ON, measure voltage between 3. W orking Controller working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between working controller terminal 39 inlet wire LgB and working controller ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) is OK and (2) is NG, working controller is faulty. • A normally operating working controller sends connection 4. C AN Communication verification signals to exact meter every 0.1 second. Exact (E44 only) meter cannot receive connection verification signals that are regularly sent from working controller for 1 continuous second while operating. • Working controller is faulty. 5. Clearing ① When repair is complete, set starter switch to ON. Error Code ② Place F-R lever “N”. and Judging Exact meter will display vehicle speed. Machine is in OK/NG after normal state. Repair If display does not change to vehicle speed, check above items again.
Replace harness.
Replace working controller.
Replace working controller.
11-056
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
W
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-057
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 12/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-4-2 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 30 and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter motor terminal 50 and chassis ground. Standard voltage : 12 V or more • If starter motor does not run even though above items (1) and (2) are OK, starter motor is faulty.
4. Battery Relay
(1) W hen starter switch is OFF, measure voltage between Replace battery relay. battery relay primary terminal COM and chassis ground. Standard resistance : 12 V or more (2) W hen starter switch is ON, measure voltage between battery relay coil terminal BR inlet wire BR 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.
5. Starter Relay
(1) W hen starter switch is START, measure voltage Replace starter relay. between starter relay terminal inlet wire BR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between starter relay terminal inlet wire W and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between starter relay terminal 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 motor.
11-058
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-059
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 13/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-4-2 Check point
Check/Cause
Action
6. F-R lever switch
(1) W hen starter switch is ON, measure voltage between F-R lever switch terminal COM inlet wire WL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal NC 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.
7. Buckup buzzer switch
(1) W hen starter switch is ON, measure voltage between Replace buckup buzzer buckup buzzer switch terminal COM inlet wire WG and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between buckup buzzer switch terminal NC outlet wire Gr and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, buckup buzzer switch is faulty.
8. 14 Interlock Relay
(1) W hen starter switch is ON, measure voltage between interlock relay terminal 1 inlet wire Gr and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between 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 interlock relay terminal 5 outlet wire P and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, interlock relay is faulty.
Replace F-R lever switch.
Replace interlock relay.
hen starter switch is ON, measure voltage between Replace starter motor 9. 13 Starter Motor Relay (1) W starter motor relay terminal 1 inlet wire P and chassis relay. ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between Starter motor relay terminal 3 inlet wire LB and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between starter motor relay terminal 5 outlet wire Y and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, starter motor relay is faulty. 11-060
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
W
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-061
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 14/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-4-2 Check point 10. Foot Brake Switch
Check/Cause (1) W hen starter switch is ON, measure voltage between foot brake switch terminal COM inlet wire WY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal NC outlet wire LgY 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.
Action Replace foot brake switch.
hen starter switch is ON, measure voltage between Replace exact meter 11. 2 Exact Meter Relay (1) W exact meter relay terminal 1, 3 inlet wire LgY and relay. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage of coil between exact meter relay terminal 1 and terminal 2. There is no electricity in normal condition. (3) W hen starter switch is ON, measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, exact meter relay is faulty. 12. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between parking brake switch terminal 1 inlet wire LgR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking brake switch terminal 2 outlet wire BrY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, parking brake switch is faulty.
Replace parking brake switch.
13. 12 Parking Interlock Relay
(1) W hen starter switch is ON, measure voltage between parking interlock relay terminal 1 inlet wire BrY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between parking interlock relay terminal 3 inlet wire Y and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between parking interlock relay terminal 5 outlet wire GY 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 parking interlock relay.
11-062
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
W
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-063
TROUBLESHOOTING
2-4-1. Engine will not start (Starter motor does not run) 15/15 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-4-2 Check point
Check/Cause
Action
14. 7 Starter Lockout Relay
(1) W hen starter switch is ON, measure voltage between Replace starter switch starter lockout relay terminal 1 inlet wire LR and 2 outlet relay. wire GW. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter lockout relay terminal 3 inlet wire Y and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between starter lockout relay terminal 5 outlet wire BR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, starter lockout relay is faulty.
15. 1 Starter Switch Relay
(1) W hen starter switch is ON, measure voltage between Replace starter switch starter switch relay terminal 1 inlet wire BR and chassis relay. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between starter switch relay terminal 3 inlet wire LgR and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between starter switch relay terminal 5 outlet wire GB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, starter switch relay is faulty.
16. 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.
11-064
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-065
TROUBLESHOOTING
2-4-2. No charging Reference Fig.: 2-4-2 Check point 1. Alternator
Check/Cause
Action
• After starting engine, measure voltage between alternator Replace alternator or terminal + wire R 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.
2-4-3. Grid heater does not work (Engine starting performance is bad in cold weather) Reference Fig. : 2-4-2 Check point
Check/Cause
Action
1. Grid Heater Relay
Replace grid heater (1) W hen starter switch is ON, measure voltage between grid heater relay terminal 1 inlet wire Y and 2 outlet wire relay. GW. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between grid heater relay terminal 3 inlet wire L and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between grid heater relay terminal 5 outlet wire B and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, grid heater relay is faulty.
2. Grid Heater
• When starter switch is ON, measure voltage between grid Replace grid heater. heater inlet wire B and chassis ground. Standard voltage : 12 V or more • If voltage is normal, grid heater 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) • If any abnormality is found in shielded twisted wires, repair is not approved. Be sure to replace them.
11-066
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-067
TROUBLESHOOTING
2-4-4. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied Reference Fig.: 2-4-2 Check point
Check/Cause
Action
1. F-R lever switch
• When starter switch is OFF and F-R lever is “F”, check continuity between F-R lever switch terminal COM and terminal NC. There is no continuity in normal condition. • If there is continuity, F-R lever switch is faulty.
Replace F-R lever switch.
2. Buckup buzzer switch
• When starter switch is OFF and F-R lever is “R”, check continuity between buckup buzzer switch terminal COM and terminal NC. There is no continuity in normal condition. • If there is continuity, buckup buzzer switch is faulty.
Replace buckup buzzer switch.
3. Parking Brake Switch
• When starter switch is OFF and parking brake switch is Replace parking brake released position, check continuity between parking brake switch. switch terminal 1 and 2. There is no continuity in normal condition. • If there is continuity, parking brake switch is faulty.
11-068
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-069
TROUBLESHOOTING
2-4-5. Engine speed cannot be switched Reference Fig. : 2-4-2 Check point
Check/Cause
Action
1. Throttle Switch
(1) W hen throttle switch is “IDLE”, check continuity between Replace throttle switch. throttle switch terminals 1 and 2, 4 and 6. There is continuity in normal condition. (2) W hen throttle switch is “MID”, check continuity between throttle switch terminals 1 and 3, 4 and 6. There is continuity in normal condition. (3) W hen throttle switch is “FULL”, check continuity between throttle switch terminals 1 and 3, 4 and 5. There is continuity in normal condition. • If above item (1), (2) or (3) is NG, throttle switch is faulty.
2. 5 Throttle Relay
Replace throttle relay. (1) W hen starter switch is ON, measure voltage between throttle relay terminal 1 inlet wire RW and terminal 2 outlet wire B. There is no electricity in normal condition. (2) W hen starter switch is ON, check continuity between throttle relay terminal 3 and terminal 4. There is continuity in normal condition. • If above item (1) is OK and item (2) is NG, throttle relay is faulty.
3. 3 Mid Speed Control Relay
Replace mid speed (1) W hen starter switch is ON, measure voltage between control relay. mid speed control relay terminal 1 inlet wire L and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and throttle switch is “ECO”, check continuity between throttle relay terminal 3 and terminal 5. There is continuity in normal condition. • If above item (1) is OK and item (2) is NG, throttle relay 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.
11-070
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-071
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5. Propulsion 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.11-006 to P.11-008). • Check any ground circuit which belongs to components to be checked.
2-5-1. Machine and engine suddenly stops 1/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E01 or E02 1. Connector
2. Harness
Check/Cause
Action
• Check F-R lever potentiometer 1, 2 connector and Replace connector traveling controller connector terminal 8, 9, 47, 48, or terminal. working controller connector terminal 29, 30 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty. • Measure resistances between F-R lever potentiometer Repair or replace and traveling controller terminal wires. harness. • F-R lever potentiometer 1 terminal wire R and traveling controller terminal 8 wire R • F-R lever potentiometer 1 terminal wire W and traveling controller terminal 47 wire W, working controller terminal 29 wire W • F-R lever potentiometer 1 terminal wire B and traveling controller terminal 9 wire B • F-R lever potentiometer 2 terminal wire R and traveling controller terminal 8 wire R • F-R lever potentiometer 2 terminal wire WR and traveling controller terminal 48 wire WR, working controller terminal 30 wire WR • F-R lever potentiometer 2 terminal wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
(1) W hen starter switch is ON, measure voltage between 3. F -R Lever Potentiometer 1 F-R lever potentiometer 1 terminal inlet wire R and ground terminal wire B. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between F-R lever potentiometer 1 terminal outlet wire W and ground terminal wire B. ① When F-R lever is “N” Standard voltage : 2.5 ± 0.015 V ② When F-R lever is “F” Standard voltage : 1.2 ± 0.02 V ③ When F-R lever is “R” Standard voltage : 3.8 ± 0.02 V • If above item (1) is OK and any of measurements in item (2) is NG, F-R lever potentiometer 1 adjustment is faulty.
Adjust F-R lever potentiometer 1 or replace it even if measurement is out of standard after adjustment.
11-072
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-073
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 2/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
Check/Cause
E01 or E02 4. F-R Lever (1) W hen starter switch is ON, measure voltage between Potentiometer 2 F-R lever potentiometer 2 terminal inlet wire R and ground terminal wire B. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between F-R lever potentiometer 2 terminal outlet wire WR and ground terminal wire B. ① When F-R lever is “N” Standard voltage : 2.5 ± 0.015 V ② When F-R lever is “F” Standard voltage : 3.8 ± 0.02 V ③ When F-R lever is “R” Standard voltage : 1.2 ± 0.02 V • If above item (1) is OK and any of measurements in item (2) is NG, F-R lever potentiometer 2 adjustment is faulty. 5. T raveling Controller
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between traveling controller terminal 8 outlet wire R (positive side) and 9 wire B (ground side). Standard voltage : 5 ± 0.5 V • If above item (1) is OK and item (2) is NG, traveling controller is faulty.
6. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed (0.0). If E01 or E02 is displayed, check above items again. ④ Place F-R lever “F” or “N”. ⑤ Exact meter will still display vehicle speed (0.0). Machine is in normal state. If display changes to E01 or E02, check above items again.
Action Adjust F-R lever potentiometer 2 or replace it even if measurement is out of standard after adjustment.
Replace traveling controller.
11-074
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-075
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 3/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E03 or E04 1. Connector
Check/Cause
Action
• Check F-R lever switch connector and traveling controller connector terminal 19, working controller connector terminal 11 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistance between F-R lever switch connector Repair or replace terminal NC wire BW and traveling controller terminal harness. 19 wire BW, working controller terminal 11 wire BW. Standard resistance : 10 Ω or less (2) M easure resistance between F-R lever switch connector terminal COM wire WL and fuse box terminal 7 wire WL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. F-R lever switch
(1) W hen starter switch is OFF and F-R lever is “N”, check continuity between F-R lever switch terminal COM and terminal NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “F”, check continuity between F-R lever switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, F-R lever switch is faulty.
Replace F-R lever switch.
4. T raveling/ Working Controller
• If error code E03 or E04 is displayed and no abnormality is found in connector, harness and F-R lever switch in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E03 or E04. When E03 is displayed: ③ Move F-R lever in “F”. Exact meter display will change from E03 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state. When E04 is displayed: ③ Place F-R lever “N”. Exact meter display will change from E04 to vehicle speed (0.0). Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-076
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-077
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 4/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E05 or E06 1. Connector
2. Harness
Check/Cause
Action
• Check buckup buzzer switch connector and traveling controller connector terminal 20, working controller connector terminal 12 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
(1) M easure resistance between buckup buzzer switch terminal NC wire Gr and traveling controller terminal 20 wire Gr, working controller terminal 12 wire Gr. Standard resistance : 10 Ω or less (2) M easure resistance between buckup buzzer switch terminal COM wire WG and fuse box terminal 6 wire WG. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
hen starter switch is OFF and F-R lever is “N”, check Replace buckup 3. Buckup buzzer (1) W switch continuity between buckup buzzer switch terminal COM buzzer switch. and terminal NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “R”, check continuity between buckup buzzer switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, buckup buzzer switch is faulty. 4. T raveling/ Working Controller
• If error code E05 or E06 is displayed and no abnormality is found in connector, harness and buckup buzzer switch in above inspection, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E05 or E06. When E05 is displayed: ③ Place F-R lever “N”. Exact meter display will change from E05 to vehicle speed (0.0). Machine is in normal state. If display does not change to vehicle speed, check above items again. When E06 is displayed: ③ Move F-R lever in “R”. Exact meter display will change from E06 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state.
Replace traveling/ working controller.
11-078
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-079
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 5/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E31 or E32 1. Connector
2. Harness
Check/Cause
Action
• Check propulsion pump proportional solenoid connector Replace connector and traveling controller connector terminal 40, 50, or terminal. working controller connector terminal 37, 38 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty. • Measure resistances between propulsion pump proportional solenoid and traveling controller terminal wires. • Propulsion pump proportional solenoid b wire G and traveling controller terminal 40 wire G • Propulsion pump proportional solenoid a wire L and traveling controller terminal 50 wire L • Propulsion pump proportional solenoid a, b wire B and working controller terminal 37 and 38 wires B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
• Disconnect connectors and check continuity between propulsion pump proportional solenoid terminal wires. • Terminal wire No.120 wire G and terminal wire No.121 wire B • Terminal wire No.122 wire L and terminal wire No.123 wire B • If there is continuity, harness is faulty. • Disconnect harness and measure resistance of coils. 3. Propulsion Pump Standard resistance: 5.5 Ω Proportional • If resistance is abnormal, propulsion pump proportional Solenoid a (R) solenoid a (R) or b (F) is faulty. or b (F)
Replace propulsion pump proportional solenoid.
11-080
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-081
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 6/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code
Check point
E31 or E32 4. Traveling/ Working Controller
Check/Cause
Action
(1) W hen starter switch is ON, measure voltage between Replace traveling/ traveling/working controller terminal wires and ground working controller. terminal wire. • Traveling controller terminal power supply terminal 2 inlet wire WB and ground terminal 1 wire B • Working controller terminal power supply terminal 2 inlet wire WB and ground terminal 1 wire B Standard voltage : 12 V or more (2) W hen starter switch is “ON” and speed change switch is “ ”, measure current between propulsion pump proportional solenoid terminal wires (positive side) and B (ground side). • Propulsion pump proportional solenoid b (F) wire G (positive side) and wire B (ground side) • Propulsion pump proportional solenoid a (R) wire L (positive side) and wire B (ground side) • While measuring current, operate F-R lever from “N” to “F” or “R”. Standard current: 0 mA (“N”) Standard current: 3 90 mA or more (at vehicle start moving) Standard current: 1,350 mA or less (“F” or “R”) • If item (1) is OK and item (2) is NG, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed. If display does not change to vehicle speed, check above items again. In case of E31: ④ Move F-R lever in “F”. Exact meter will still display vehicle speed. Machine is in normal state. If E31 is displayed again, check above items again. In case of E32: ④ Move F-R lever in “R”. Exact meter will still display vehicle speed. Machine is in normal state. If E32 is displayed again, check above items again.
11-082
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-083
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 7/9 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E42
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. T raveling Controller
• When starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more • If voltage is abnormal, traveling controller is faulty.
Replace traveling controller.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 0.5 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-084
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-085
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 8/9 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E43
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter
• When starter switch is ON, measure voltage between exact meter terminal 5 inlet wire WB and ground terminal 6 wire B. Standard voltage : 12 V or more • If voltage is abnormal, exact meter is faulty.
Replace exact meter.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 1 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-086
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-087
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-1. Machine and engine suddenly stops 9/9 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E44, E45
Check point 1. Connector
2. Harness
Check/Cause
Action
• Check exact meter connector terminal 1, 2, 7 and working Replace connector controller connector terminal 3, 4, 39, for corrosion, or terminal. breakage, bending and looseness. • If any abnormality is found, connector is faulty.
• Measure resistances between exact meter and working controller terminal wires. • Exact meter terminal 1 wire GW and working controller terminal 3 wire GW • Exact meter terminal 2 wire B and working controller terminal 4 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. (1) W hen starter switch is ON, measure voltage between 3. W orking Controller working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more • If above item (1) is OK and (2) is NG, working controller is faulty. (2) W hen starter switch is ON, measure voltage between working controller terminal 39 inlet wire LgB and working controller ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) is OK and (2) is NG, working controller is faulty. 4. C AN • A normally operating working controller sends connection Communication verification signals to exact meter every 0.1 second. Exact (E44 only) meter cannot receive connection verification signals that are regularly sent from working controller for 1 continuous second while operating. • Working controller is faulty. 5. Clearing ① When repair is complete, set starter switch to ON. Error Code ② Place F-R lever “N”. and Judging Exact meter will display vehicle speed. Machine is in OK/NG after normal state. Repair If display does not change to vehicle speed, check above items again.
Replace harness.
Replace working controller.
Replace working controller.
11-088
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-089
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-2. Machine and engine suddenly stops in automatic speed mode 1/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. • If error code E11 is displayed while running manual speed mode, machine will be movable regardless of the display. Reference Fig.: 2-4-1 Error code E11
Check point
Check/Cause
Action
1. Connector
• Check speed sensor connector and traveling controller connector terminal 8, 9, 26, 46, working controller connector terminal 24, 25 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between speed sensor and traveling Repair or replace controller terminal wires. harness. • Speed sensor terminal 2 wire G and traveling controller terminal 26 wire G, working controller terminal 24 wire G • Speed sensor terminal 3 wire W and traveling controller terminal 46 wire W, working controller terminal 25 wire W • Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R • Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. Speed Sensor
(1) W hen starter switch is ON, measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 wire B. Standard voltage : 5 ± 0.25 V (2) S tart engine and rotate vibratory drum. Measure pulse between speed sensor terminal 3 outlet wire W and ground terminal 5 wire B with a pulse meter. Standard pulse : 21 pulses/rotation • If above item (1) is OK and item (2) is NG, speed sensor is faulty.
Replace speed sensor.
4. T raveling/ Working Controller
• If error code E11 is displayed and no abnormality is found in connector, harness and speed sensor in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, start engine. ② Exact meter will display E11. ③ Move F-R lever “F” or “R” and run machine. ④ Exact meter display will change from E11 to vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-090
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-091
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-2. Machine and engine suddenly stops in automatic speed mode 2/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. • If error code E41 is displayed while running manual speed mode, machine will be movable but tachometer will not operate. Reference Fig.: 2-4-1 Error code E41
Check point
Check/Cause
Action
1. Connector
• Check engine ECM connector terminal 22, 46 and traveling controller connector terminal 6, 7 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between engine ECM and traveling Replace harness. controller terminal wires. • Engine ECM terminal 22 wire RB and traveling controller terminal 6 wire RB • Engine ECM terminal 46 wire RY and traveling controller terminal 7 wire RY Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. (NOTICE) • Since shielded twist wires are used for traveling controller terminal harness, repair is not approved. Be sure to replace them.
• Faulty CAN communication. 3. CAN Communication (NOTICE) • Check if any CAN-related blink code for engine is issued. If no blink code is issued, traveling controller is faulty. 4. Clearing Error Code and Judging OK/NG after Repair
Replace traveling controller.
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-092
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-093
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 1/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code Pon
Check/Cause
Action
1. Connector
Check point
• Check F-R lever switch connector, buckup buzzer switch connector and traveling controller connector terminal 19, 20, working controller connector terminal 11, 12 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistances between switches and traveling Repair or replace controller terminal wires. harness. • F-R lever switch terminal NC wire BW and traveling controller terminal 19 wire BW, working controller terminal 11 wire BW • Buckup buzzer switch terminal NC wire Gr and traveling controller terminal 20 wire Gr, working controller terminal 12 wire Gr Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • F-R lever switch terminal COM wire WL and fuse box terminal 7 wire WL • Buckup buzzer switch terminal COM wire WG and fuse box terminal 6 wire WG Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. F-R lever switch
• When starter switch is OFF and F-R lever is “N”, check continuity between F-R lever switch terminal COM and terminal NC. There is continuity in normal condition. • If there is no continuity, F-R lever switch is faulty.
4. Buckup buzzer • When starter switch is OFF and F-R lever is “N”, check switch continuity between buckup buzzer switch terminal COM and terminal NC. There is continuity in normal condition. • If there is no continuity, buckup buzzer switch is faulty.
Replace F-R lever switch.
Replace buckup buzzer switch.
5. T raveling/ Working Controller
• If error code Pon is displayed and no abnormality is Replace traveling/ found in connector, harness, F-R lever switch and buckup working controller. buzzer switch in above inspection, traveling/working controller is faulty.
6. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, place F-R lever “F” or “N”. ② Set starter switch to ON. ③ When F-R lever is “F” or “N”, traveling/working controller cannot be initialized. Exact meter will continuously display Pon. ④ Return F-R lever to “N”. ⑤ When traveling/working controller initialization is completed, display will change from Pon to vehicle speed. Machine is in normal state.
11-094
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-095
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 2/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E03
Check/Cause
Action
1. Connector
Check point
• Check F-R lever switch connector and traveling controller connector terminal 19, working controller connector terminal 11 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistance between F-R lever switch connector Repair or replace terminal NC wire BW and traveling controller terminal harness. 19 wire BW, working controller terminal 11 wire BW. Standard resistance : 10 Ω or less (2) M easure resistance between F-R lever switch connector terminal COM wire WL and fuse box terminal 7 wire WL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. F-R lever switch
(1) W hen starter switch is OFF and F-R lever is “N”, check continuity between F-R lever switch terminal COM and terminal NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “F”, check continuity between F-R lever switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, F-R lever switch is faulty.
4. T raveling/ Working Controller
• If error code E03 is displayed and no abnormality is found Replace traveling/ in connector, harness and F-R lever switch in above working controller. inspection, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E03. ③ Move F-R lever in “F”. Exact meter display will change from E03 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state.
Replace F-R lever switch.
11-096
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-097
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 3/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E06
Check point
Check/Cause
Action
1. Connector
• Check buckup buzzer switch connector and traveling controller connector terminal 20, working controller connector terminal 12 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistance between buckup buzzer switch Repair or replace terminal NC wire Gr and traveling controller terminal 20 harness. wire Gr. Standard resistance : 10 Ω or less (2) M easure resistance between buckup buzzer switch terminal COM wire WG and fuse box terminal 6 wire WG. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
hen starter switch is OFF and F-R lever is “N”, check Replace buckup 3. Buckup buzzer (1) W switch continuity between buckup buzzer switch terminal COM buzzer switch. and terminal NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “F”, check continuity between buckup buzzer switch terminal COM and terminal NC. There is no continuity in normal condition. • If above item (1) or (2) is NG, buckup buzzer switch is faulty. 4. T raveling/ Working Controller
• If error code E06 is displayed and no abnormality is found Replace traveling/ in connector, harness and buckup buzzer switch in above working controller. inspection, traveling/working controller is faulty.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display E06. ③ Move F-R lever in “R”. Exact meter display will change from E06 to vehicle speed (0.0). If display does not change to vehicle speed, check above items again. ④ Return F-R lever to “N”. Machine is in normal state.
11-098
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-099
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 4/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-4-1 Error code E43
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter
• When starter switch is ON, measure voltage between exact meter terminal 5 inlet wire WB and ground terminal 6 wire B. Standard voltage : 12 V or more • If voltage is abnormal, exact meter is faulty.
Replace exact meter.
• A normally operating exact meter sends connection Replace exact meter 4. CAN Communication verification signals to traveling/working controller every or traveling/working 0.1 second. Traveling/working controller could not receive controller. connection verification signals that were regularly sent from exact meter for 1 continuous second. • Exact meter on transmission side or traveling/working controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever in “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-100
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-101
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 5/6 • F-R lever must be in “N”. • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Neutral Solenoid
• Disconnect harness and measure resistance of coil. Standard resistance : 12.3 Ω • If resistance is abnormal, neutral solenoid is faulty.
Replace neutral solenoid.
2. 8 Propulsion Pump Neutral Relay (1)
(1) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (1) terminal 1 inlet wire LgR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (1) terminal 3 inlet wire LY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (1) terminal 5 outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, propulsion pump neutral relay (1) is faulty.
Replace propulsion pump neutral relay (1).
3. 9 Propulsion Pump Neutral Relay (2)
(1) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (2) terminal 1 inlet wire BrY and chassis ground. There is no current in normal condition. (2) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (2) terminal 3 inlet wire Br and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between propulsion pump neutral relay (2) terminal 4 outlet wire Lg and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, propulsion pump neutral relay (2) is faulty.
Replace propulsion pump neutral relay (2).
4. 10 Propulsion Pump Neutral Holding Relay
(1) W hen starter switch is ON, measure voltage between propulsion pump neutral holding relay terminal 1 inlet wire Lg and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between propulsion pump neutral holding relay terminal 5 inlet wire WL and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between propulsion pump neutral holding relay terminal 3 outlet wire LY and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, propulsion pump neutral relay (2) is faulty.
Replace propulsion pump neutral holding relay.
11-102
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-103
TROUBLESHOOTING
2-5-3. Machine moves neither forward nor backward 6/6 • F-R lever must be in “N”. • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-5-1 Check point
Check/Cause
Action
• A normally operating exact meter sends connection Replace exact meter 5. Exact Meter (CAN Communication) verification signals to traveling/working controller every or traveling/working 0.1 second. Traveling/working controller could not receive controller. connection verification signals that were regularly sent from exact meter for 1 continuous second. • Exact meter on transmission side or traveling/working controller is faulty. (NOTICE) • See check procedures for error code E43. 6. 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) • If standard voltage cannot be measured with terminals of neutral relay (1), (2) and neutral holding relay, in particular, check relevant harness.
11-104
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-105
TROUBLESHOOTING
2-5-4. Machine speed cannot be changed • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Speed Change Switch
Replace speed change (1) W hen starter switch is ON, measure voltage between speed change switch terminal 1 inlet wire YW and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and speed change switch is “ ”, measure voltage between speed change switch terminal 3 outlet wire BrR and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and speed change switch is “ ”, measure voltage between speed change switch terminal 3 outlet wire BrR and chassis ground. There is no electricity in normal condition. • If above item (1) is OK and item (2) or (3) is NG, speed change switch is faulty.
2. Resistor Unit
• Measure resistance between resistor unit wire No. 39 wire Replace resistor unit. BrR and ground wire. Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty. (NOTICE) • Resistor unit is used to stabilize contact of switch.
3. Traveling Controller
(1) W hen starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and speed change switch is “ ”, measure voltage between traveling controller terminal 25 inlet wire BrR and ground terminal 1 wire B. Standard voltage : 12 V or more • If items (1) and (2) are OK, traveling controller 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.
11-106
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-107
TROUBLESHOOTING
2-5-5. Auto speed function does not work 1/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code E11
Check point
Check/Cause
Action
1. Connector
• Check speed sensor connector and traveling controller connector terminal 8, 9, 26, 46, working controller connector terminal 24, 25 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between speed sensor and Repair or replace traveling/working controller terminal wires. harness. • Speed sensor terminal 2 wire G and traveling controller terminal 26 wire G, working controller terminal 24 wire G • Speed sensor terminal 3 wire W and traveling controller terminal 46 wire W, working controller terminal 25 wire W • Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R • Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. Speed Sensor
(1) W hen starter switch is ON, measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 wire B. Standard voltage : 5 ± 0.25 V (2) S tart engine and rotate vibratory drum. Measure pulse between speed sensor terminal 3 outlet wire W and ground terminal 5 wire B with a pulse meter. Standard pulse : 21 pulses/rotation • If above item (1) is OK and item (2) is NG, speed sensor is faulty.
Replace speed sensor.
4. T raveling/ Working Controller
• If error code E11 is displayed and no abnormality is found in connector, harness and speed sensor in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, start engine. ② Exact meter will display E11. ③ Move F-R lever “F” or “R” and run machine. ④ Exact meter display will change from E11 to vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-108
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-109
TROUBLESHOOTING
2-5-5. Auto speed function does not work 2/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). ”. • Set speed change switch to “ (Automatic speed function is disabled when speed change switch is “ ”.) ”) and traveling • Check that speed can be changed by speed change switch between operation speed (“ speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code Check point Check/Cause Action E21 1. Connector • Check vibration frequency select switch, vibration switch Replace connector and traveling controller connector terminal 31, 32, 33 for or terminal. corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty. 2. Harness (1) M easure resistances between switches and traveling Repair or replace controller terminal wires. harness. • Vibration frequency select switch terminal 3 wire G and traveling controller terminal 31 wire G • Vibration frequency select switch terminal 6 wire L and traveling controller terminal 32 wire L • Vibration switch terminal 2 wire Br and traveling controller terminal 33 wire Br Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • Vibration frequency select switch terminal 1, 4 wires YW and fuse box terminal 9 wire YW • Vibration switch terminal 1 wire YW and fuse box terminal 9 wire YW Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. 3. Vibration (1) W hen starter switch is ON, measure voltage between Replace vibration vibration frequency select switch terminal 1, 4 inlet Frequency frequency select wires YW and chassis ground. Select Switch switch. Standard voltage : 12 V or more (SW884/994 (2) W hen starter switch is ON and vibration frequency only) select switch is “2500”, measure voltage between vibration frequency select switch terminal 6 outlet wire L and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration frequency select switch is “3000”, measure voltage between vibration frequency select switch terminal wires and chassis ground. • Vibration frequency select switch terminal 3 outlet wire G and chassis ground • Vibration frequency select switch terminal 6 outlet wire L and chassis ground Standard voltage : 12 V or more (4) W hen starter switch is ON and vibration frequency select switch is “4000”, measure voltage between vibration frequency select switch terminal 3 outlet wire G and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibration frequency select switch is faulty. 11-110
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-111
TROUBLESHOOTING
2-5-5. Auto speed function does not work 3/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code
Check point
Check/Cause
Action
E21
4. Vibration Switch (SW884/994)
(1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire YW and chassis ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 3 outlet wire GR and chassis ground. Standard voltage : 12 V or more (3) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, vibration switch is faulty.
Replace vibration switch.
5. Vibration Switch (SW884ND/ 994ND)
(1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire YW and chassis ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 3 outlet wire GR and chassis ground. Standard voltage : 12 V or more (3) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, vibration switch is faulty.
Replace vibration switch.
6. Resistor Unit
• Measure resistances between resistor unit wires and ground wire. • Resistor unit wire No. 32 wire G and ground wire (SW884/994 only) • Resistor unit wire No. 33 wire L and ground wire (SW884/994 only) • Resistor unit wire No. 34 wire Br and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch.
11-112
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-113
TROUBLESHOOTING
2-5-5. Auto speed function does not work 4/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code
Check point
Check/Cause
E21
7. T raveling Controller (SW884/994)
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration frequency select switch is “2500”, measure voltage between traveling controller terminal 32 inlet wire L and ground terminal 1 wire B. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration frequency select switch is “3000”, measure voltage between traveling controller terminal wires. • Traveling controller terminal 31 inlet wire G and ground terminal 1 wire B • Traveling controller terminal 32 inlet wire L and ground terminal 1 wire B Standard voltage : 12 V or more (4) W hen starter switch is ON and vibration frequency select switch is “4000”, measure voltage between traveling controller terminal 31 inlet wire G and ground terminal 1 wire B. Standard voltage : 12 V or more (5) When starter switch is ON and vibration switch is “ ”, measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1), (2), (3), (4) and (5) are OK, traveling controller is faulty.
Action Replace traveling controller.
11-114
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-115
TROUBLESHOOTING
2-5-5. Auto speed function does not work 5/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code
Check point
Check/Cause
E21
8. T raveling Controller (SW884ND/ 994ND)
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) and (2) are OK, traveling controller is faulty.
9. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all combinations of vibration frequency select switch and vibration switch positions. Exact meter will still display vehicle speed. Machine is in normal state. If display changes form vehicle speed to E21, check above items again.
Action Replace traveling controller.
11-116
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-117
TROUBLESHOOTING
2-5-5. Auto speed function does not work 6/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code E22
Check point
Check/Cause
Action
1. Connector
• Check IPF select switch connector and traveling controller Replace connector connector terminal 37, 38, 39 for corrosion, breakage, or terminal. bending and looseness. • If any abnormality is found, connector is faulty.
2. Harness
(1) M easure resistances between IPF select switch and Repair or replace traveling controller terminal wires. harness. • IPF select switch terminal 2 wire GW and traveling controller terminal 37 wire GW • IPF select switch terminal 4 wire LW and traveling controller terminal 38 wire LW • IPF select switch terminal 6 wire BrW and traveling controller terminal 39 wire BrW Standard resistance : 10 Ω or less (2) M easure resistances between IPF select switch terminal 1, 3, 5 wires YW and fuse box terminal 9 wire YW. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
11-118
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-119
TROUBLESHOOTING
2-5-5. Auto speed function does not work 7/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). ”. • Set speed change switch to “ (Automatic speed function is disabled when speed change switch is “ ”.) ”) and traveling • Check that speed can be changed by speed change switch between operation speed (“ speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code E22
Check point
Check/Cause
Action
3. IPF Select Switch
(1) When starter switch is ON, measure voltage between Replace IPF select IPF select switch terminal 1, 3, 5 inlet wires YW and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and IPF select switch is “10”, measure voltage between IPF select switch terminal 2 outlet wire GW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and IPF select switch is “11”, measure voltage between IPF select switch terminal 4 outlet wire LW and chassis ground. Standard voltage : 12 V or more (4) W hen starter switch is ON and IPF select switch is “12”, measure voltage between IPF select switch terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (5) W hen starter switch is ON and IPF select switch is “13”, measure voltage between IPF select switch terminal 2 outlet wire GW, terminal 4 outlet wire LW and chassis ground. Standard voltage : 12 V or more (6) W hen starter switch is ON and IPF select switch is “14”, measure voltage between IPF select switch terminal 4 outlet wire LW, terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (7) W hen starter switch is ON and IPF select switch is “15”, measure voltage between IPF select switch terminal 2 outlet wire GW, terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and any of items (2) through (7) is NG, IPF select switch is faulty.
4. Resistor Unit
• Measure resistances between resistor unit wires and ground wire. • Resistor unit wire No.40 wire GW and ground wire • Resistor unit wire No.41 wire LW and ground wire • Resistor unit wire No.42 wire BrW and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch. 11-120
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-121
TROUBLESHOOTING
2-5-5. Auto speed function does not work 8/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). ”. • Set speed change switch to “ (Automatic speed function is disabled when speed change switch is “ ”.) ”) and traveling • Check that speed can be changed by speed change switch between operation speed (“ speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code Check point E22 5. T raveling Controller
6. Clearing Error Code and Judging OK/NG after Repair
Check/Cause Action (1) W hen starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and IPF select switch is “10”, measure voltage between traveling controller terminal 37 inlet wire GW and ground terminal 1 wire B. Standard voltage : 12 V or more (3) W hen starter switch is ON and IPF select switch is “11”, measure voltage between traveling controller terminal 38 inlet wire LW and ground terminal 1 wire B. Standard voltage : 12 V or more (4) W hen starter switch is ON and IPF select switch is “12”, measure voltage between traveling controller terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more (5) W hen starter switch is ON and IPF select switch is “13”, measure voltage between traveling controller terminal 37 inlet wire GW, terminal 38 inlet wire LW and ground terminal 1 wire B. Standard voltage : 12 V or more (6) W hen starter switch is ON and IPF select switch is “14”, measure voltage between traveling controller terminal 38 inlet wire LW, terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more (7) W hen starter switch is ON and IPF select switch is “15”, measure voltage between traveling controller terminal 37 inlet wire GW, terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more • If all of items (1) through (7) are OK, traveling controller is faulty. ① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all positions of IPF select switch. Exact meter will still display vehicle speed. Machine is in normal state. If display changes form vehicle speed to E22, check above items again.
11-122
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-123
TROUBLESHOOTING
2-5-5. Auto speed function does not work 9/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-5-1 Error code E41
Check point
Check/Cause
Action
1. Connector
• Check engine ECM connector terminal 22, 46 and traveling controller connector terminal 6, 7 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between engine ECM and traveling Replace harness. controller terminal wires. • Engine ECM terminal 22 wire RB and traveling controller terminal 6 wire RB • Engine ECM terminal 46 wire RY and traveling controller terminal 7 wire RY Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. (NOTICE) • Since shielded twist wires are used for traveling controller terminal harness, repair is not approved. Be sure to replace them.
• Faulty CAN communication. 3. CAN Communication (NOTICE) • Check if any CAN-related blink code for engine is issued. If no blink code is issued, traveling controller is faulty. 4. Clearing Error Code and Judging OK/NG after Repair
Replace traveling controller.
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-124
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-125
TROUBLESHOOTING
2-5-5. Auto speed function does not work 10/10 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) • Check that speed can be changed by speed change switch between operation speed (“ ”) and traveling speed (“ ”). • Set throttle switch to “FULL”. (Automatic speed function is disabled when throttle switch is in any other position than “FULL”.) • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. F-R Lever Auto Speed Set Switch
(1) W hen starter switch is ON, measure voltage between Replace F-R lever auto F-R lever auto speed set switch terminal COM inlet wire speed set switch. YW and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and F-R lever auto speed set switch is ON, measure voltage between F-R lever auto speed set switch terminal NO outlet wire GY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, F-R lever auto speed set switch is faulty.
2. Resistor Unit
• Measure resistance between resistor unit wire No.38 wire Replace resistor unit. GY and ground wire. Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty. (NOTICE) • Resistor unit is used to stabilize contact of switch.
3. Traveling Controller
(1) W hen starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and F-R lever auto speed set switch is ON, measure voltage between traveling controller terminal 21 inlet wire GY and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) and (2) are OK and no error code is displayed, traveling controller 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.
11-126
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-127
TROUBLESHOOTING
2-5-6. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows no error code. Reference Fig.: 2-4-2 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard voltage : 12.3 Ω • If measured resistance is abnormal, parking brake solenoid is faulty.
Replace parking brake solenoid.
2. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between parking brake switch terminal 1 inlet wire LgR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking brake switch terminal 3 outlet wire Y and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, parking brake switch is faulty.
Replace parking brake switch.
3. 2 Exact Meter Relay
(1) W hen starter switch is ON, measure voltage between Replace exact meter exact meter relay terminal 1, 3 inlet wire LgY and relay. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage of coil between exact meter relay terminal 1 and terminal 2. There is no electricity in normal condition. (3) W hen starter switch is ON, measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, exact meter relay is faulty.
4. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal COM inlet wire WY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal NC outlet wire LgY 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.
11-128
TROUBLESHOOTING
Fig.: 2-4-2 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC 3
NO 14 WY
B COM
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY TO EXACT METER
M
F-R LEVER
NC
NO
CO
F
F-R LEVER SWITCH W
R
B
18 L
78 O
17 Y
SOL
2 74 BrY
4
12 BW
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
M
CO
W
7 WG
6 RY
162 Gr
R
NO
NC
R
3 17 Y
15 LgR 1 13 WL
B
BACKUP BUZZER SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6 RY
15 LgR
X2 3B
52 1.25BR
BACKUP BUZZER
4 166 GB
3
5
1
X B
2
STARTER SWITCH RELAY
1
56 1.25LB
7 WG
9
13 WL
12 11 10
14 WY
64 LgW
STARTER SWITCH
31 YW
49 5L 52 1.25BR
19 2W
B
30 1.25BY
C
176 BR
R2
R1 BR ACC
8
7
6
5
4
3
2
1
FUSE BOX
166 GB
ON ST
10 5WR
OFF
4 1.25GY
HEAT
5 2020151515152020152020 A A A A A A A A A A A A
B A CC B R C
TO COMBINATION METER
TO COMBINATION METER 161 P 4 X B 5 2
ECM. (CM2250) /J2(96PIN)
162 Gr
1
14 INTERLOCK RELAY 153 1.25Y 74 BrY
3 1
12
49
22
25
50
23
4
4 1.25GY
26
51
5
X B
27
52
28
73
5
66
2
PARKING INTERLOCK RELAY
176 BR
3 1
13
4
153 1.25Y
5
X B
243 L
B X
3
5 2
1
22
76
46
75
183 LR
4
53 G
5
181 GW
30 1.25Y
1
2
199 1.25BR
5
181 GW
2
7 STARTER LOCKOUT
RELAY
4 31 YW
192 RW 5
192 RW
4
1 181 GW
2 44 Br 6
1
3
183 LR
CONTROL RELAY
THROTTLE SWITCH
5 THROTTLE 83
3
3 MID SPEED
178 G
4
190 L
62
2
STARTER MOTOR RELAY
44 Br 243 L
178 G 3 189 BrR
13
56 1.25LB 161 P
7
1
94
TO PROPULSION PUMP NEUTRAL RELAY (1)
ECM. (CM2350) /J4(24PIN)
12 BW 3
RELAY
THROTTLE SWITCH
181 GW
POSITION IDLE ECO FULL
177 Y
79
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
54 91
6
GRID HEATER
81 16 87
AV30,B
7 38
53
39
77
40
32
3
35
84
8
85
5
3
1
2
AV30,B
177 Y
181 GW
GRID HEATER RELAY
STARTER RELAY
57
AV30,B
AV30,B
FUSE (250A)
52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
50 COM E
208 5W
X 2B
209 5BW
F.L.65A
45 5Y
46 5R
F.L.65A 57 5Y
58 5R
F.L.65A 85 5Y
86 5R
F.L.65A 202 5Y
203 5R
F.L.65A
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
BATTERY RELAY
AV60,R
11 5W
F.L.65A
AV60,B
10 5WR
199 2BR
82
BATTERY -
12V
+
SW884-11003
11-129
TROUBLESHOOTING
2-5-7. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed) • Check whether exact meter multiple display shows no error code. Reference Fig.: 2-4-2 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard voltage : 12.3 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 Y and chassis ground. There is no electricity in normal condition. • If there is electricity, parking brake switch is faulty.
Replace parking brake switch.
3. Exact Meter Relay
• When starter switch is ON, measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground. There is no electricity in normal condition. • If there is electricity, exact meter relay is faulty.
Replace exact meter relay.
4. Foot Brake Switch
• When starter switch is ON, measure voltage between Replace foot brake foot brake switch terminal NC outlet wire LgY and chassis switch. ground. There is no electricity in normal condition. • If there is electricity, foot brake 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.
11-130
TROUBLESHOOTING
Fig.: 2-4-1 EMERGENCY CONNECTOR
163 LgY 15 LgR
R NC
3
15 LgR
1
4
72 Br
5
X B
14 WY
B COM
3 17 Y
15 LgR 1
73 Lg 3
5
X B
TO COMBINATION METER
72 Br
4 2
1
4
164 BW
5
165 LgB
PRO EMR
2
FOOT BRAKE 2 EXACT METER SWITCH RELAY
2
PROPULSION PUMP NEUTRAL RELAY (1)
8
3
NO
71 LY
18 L
17 Y
2 74 BrY
4
F
X B
PARKING BRAKE SOLENOID
5 X B
PARKING BRAKE SWITCH
74 BrY
SOL
EMERGENCY SWITCH POSITION CONNECTION -
R
2-3
RESISTOR UNIT 25 WB
1
2-1
N
65 WY
EMERGENCY SWITCH
71 LY 3
71 LY
73 Lg
1 10
4
13 WL
5
X B
120Ω 25 0.5WB 128 0.5GW
161 P
138 0.5R
SPEED SENSOR
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
140 0.5B X 0.5B
210 G 139 W 138 R
12 0.5BW
140 B
162 0.5Gr
210 0.5G
F-R LEVER SWITCH
M CO
F-R LEVER
NC
NO
F
B
W
R
+V X
13 WL
R
OUT W GND B
78 O
138 R
139 0.5W
145 W
145 0.5W
140 B
206 0.5WR
F-R LEVER POTENTIOMETER 1
12 BW
130 0.5B
W
B
162 0.5Gr
BACKUP BUZZER SWITCH
210 0.5G 139 0.5W +V
7 WG
6 RY
162 Gr
R
NO CO M
NC
R
214 B
TERMINATING RESISTOR
130 0.5B
2
PRO
213 L
EMERGENCY CONNECTOR
129 0.5B
OUT(DIRECTION SIG.)
212 B
122 L
123 B
PROPULSION PUMP NEUTRAL HOLDING RELAY
1
EMR
X B
2
OUT(SIGNAL1)
PRO
a(R)
211 G
66 WR
165 LgB
X B
25 WB
129 B
128 GW
SOL
NEUTRAL SOLENOID
130 B
X B
b(F)
120 WL
121 B
EXACT METER 73 Lg
EMR
X B 3
PROPULSION PUMP 9 NEUTRAL RELAY (2)
PROPULSION PUMP PROPORTIONAL SOLENOID
EMERGENCY CONNECTOR
1 67 WL
2
X
TO WATER SPRAY MODE SELECT SWITCH
6 RY X2 3B
BACKUP BUZZER
R
OUT W GND B
138 R
145 0.5W
206 WR
206 0.5WR
140 B
121 0.5B 123 0.5B
F-R LEVER POTENTIOMETER 2
165 0.5LgB
2
1
3
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
23
35
24
36
26
37
30
38
46
39
47
27
48
40
X 0.5B 185 0.5RB 186 0.5RY
ECM. (CM2250) /J2(96PIN)
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
50 5
1
6
2
7
3
12
4
24
11
25
31
29
32
1
49
25
50
26
51
27
52
28
73
5
66 94
13
120 0.5WL
62
122 0.5L X 0.5B
TERMINATING RESISTOR
25 0.5WB
83 76
120Ω
128 0.5GW 129 0.5B
75
185 RB
12 0.5BW
186 RY
22
79
46
54
91
13
39
44
47
45
48
14
49
15
6 81
WORKING CONTROLLER 42 37 MC050-110 43 30 38
183 LR 181 GW
16 87
7 38
50
53
39
77
40
32
3
35
84
8
85 57 82
30 1.25Y
1
3 1
4
4 1.25GY
5
X B
2
PARKING INTERLOCK RELAY
56 1.25LB 161 P
3 1
11-131
5
4
3
2
1
4
153 1.25Y
5
X B
FUSE BOX
10 5WR F.L.65A
51 5WG
BATTERY RELAY
11 5W 52 1.25BR
NO BR
49 5L
F.L.65A
STARTER RELAY
COM 45 5Y E
46 5R
F.L.65A 57 5Y 58 5R
208 5W
6
160 2WL
X 2B
7
2
F.L.65A 85 5Y 86 5R X 1.25B
F.L.65A 202 5Y 203 5R F.L.65A
50
ALTERNATOR (150A) W D
AV60,R
30
+
B
E
STARTER MOTOR AV30,B
AV60,B
74 BrY
13
8
181 GW
AV60,R
153 1.25Y
10 5WR
4 1.25GY
ST
12
9
5 2020151515152020152020 A A A A A A A A A A A A
ON
15A
199 1.25BR
5
RELAY
209 5BW
12 11 10
OFF
25 2WR
4
7 STARTER LOCKOUT
199 2BR
B A CC B R C
FUSE
AV60,B
STARTER SWITCH HEAT
3
183 LR
52 1.25BR
7 WG
R1 BR ACC
49 5L
13 WL
B
14 WY
C
30 1.25BY
R2
BATTERY -
12V
+
2
STARTER MOTOR RELAY
SW884-11001
TROUBLESHOOTING
2-5-8. Emergency exit propulsion switch does not work • Disconnect SWP-6F PRO (P.5-005, 006) connector from engine harness side and connect emergency switch connector SWP-6F EMR (P.5-005, 006). Reference Fig.: 2-4-1 Check point
Check/Cause
• Disconnect harness for propulsion pump proportional 1. Propulsion Pump Proportional Solenoid a solenoid a (R) or b (F) and measure resistance of coils. (R) or b (F) Standard voltage : 5.5 Ω • If measured resistance is abnormal, propulsion pump proportional solenoid a (R) or b (F) is faulty.
Action Replace propulsion pump proportional solenoid.
2. Emergency Switch
Replace emergency (1) W hen starter switch is ON, measure voltage between emergency switch terminal 2 inlet wire WY and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and emergency switch is “F”, measure voltage between emergency switch terminal 1 outlet wire WL and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and emergency switch is “R”, measure voltage between emergency switch terminal 3 outlet wire WR and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, emergency switch is faulty.
3. Resistor Unit
• Measure resistance between resistor unit terminal wire WB and terminal wire WY. Standard resistance : 15 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
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.
11-132
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-133
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6. Vibration 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.11-006 to P.11-008). • Check any ground circuit which belongs to components to be checked. • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Throttle switch to “FULL”.
2-6-1. No vibration occurs 1/5 • F-R lever must be in “N”. • Parking brake switch must be released. • Vibration mode select switch to “ ” (continuous mode). • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-6-1 Error code
Check point
E33, E34, 1. Connector E35 or E36
Check/Cause
Action
• Check vibrator pump (F) proportional solenoid connector, vibrator pump (R) proportional solenoid connector and working controller connector terminal 42, 43, 44, 45, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between vibrator pump (F) Replace harness. proportional solenoid, vibrator pump (R) proportional solenoid and working controller terminal wires. • Vibrator pump (F) proportional solenoid b (Lo) wire Br and working controller terminal 42 wire Br • Vibrator pump (F) proportional solenoid a (Hi) wire Lg and working controller terminal 43 wire Lg • Vibrator pump (R) proportional solenoid b (Lo) wire BrW and working controller terminal 44 wire BrW • Vibrator pump (R) proportional solenoid a (Hi) wire LgB and working controller terminal 45 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. Vibrator Pump (F) Proportional Solenoid a (Hi), b (Lo)
(1) D isconnect harness and measure resistance of coils. Replace vibrator Standard resistance: 5.5 Ω pump (F) (2) C heck vibrator pump (F) proportional solenoid a (Hi) proportional solenoid and b (Lo) terminal wire B is grounded. • If above item (1) or (2) is NG, vibrator pump (F) proportional solenoid a (Hi) or b (Lo) is faulty.
4. Vibrator Pump (R) Proportional Solenoid a (Hi), b (Lo)
(1) D isconnect harness and measure resistance of coils. Standard resistance: 5.5 Ω (2) C heck vibrator pump (R) proportional solenoid a (Hi) and b (Lo) terminal wire B is grounded. • If above item (1) or (2) is NG, vibrator pump (R) proportional solenoid a (Hi) or b (Lo) is faulty.
Replace vibrator pump (R) proportional solenoid
11-134
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-135
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-1. No vibration occurs 2/5 • F-R lever must be in “N”. • Parking brake switch must be released. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-6-1 Error code Check point E33, E34, 5. Traveling/ E35 or E36 Working Controller (SW884/994)
Check/Cause (1) W hen starter switch is ON, measure voltage between traveling/working controller terminal wires and ground terminal wire. • Traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B • Working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and measure current between vibrator pump (F)/(R) proportional solenoid terminal wires (positive side) and B (ground side). • Vibrator pump (F) proportional solenoid a (Hi) wire Lg (positive side) and wire B (ground side) • Vibrator pump (F) proportional solenoid b (Lo) wire Br (positive side) and wire B (ground side) • Vibrator pump (R) proportional solenoid a (Hi) wire LgB (positive side) and wire B (ground side) • Vibrator pump (R) proportional solenoid b (Lo) wire BrW (positive side) and wire B (ground side)
Action Replace traveling/ working controller.
While measuring current, operate vibration frequency select switch, vibration mode select switch and vibration switch as below. • Vibration mode select switch is “ ” (continuous mode) and depress F-R lever vibration switch more than 0.05 second, vibration frequency select switch is 3000 vpm and vibration switch is “ ”. Standard current: Solenoid a (Hi): 960 mA Solenoid b (Lo): 200 mA • Vibration mode select switch is “ ” (continuous mode) and depress F-R lever vibration switch more than 0.05 second, vibration frequency select switch is 4000 vpm and vibration switch is “ ”. Standard current: Solenoid a (Hi): 200 mA Solenoid b (Lo): 1150 mA • Vibration mode select switch is “ ” (Vibration is OFF). Standard current: Solenoid a (Hi): 200 mA Solenoid b (Lo): 200 mA • If item (1) is OK and item (2) is NG, traveling/working controller is faulty. (NOTICE) • Since current value is output in PWM, standard value shown above represent a maximum instantaneous value.
11-136
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-137
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-1. No vibration occurs 3/5 • F-R lever must be in “N”. • Parking brake switch must be released. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-6-1 Error code Check point E33, E34, 5. Traveling/ E35 or E36 Working Controller (SW884ND/ 994ND)
Check/Cause Action (1) W hen starter switch is ON, measure voltage between Replace traveling/ traveling/working controller terminal wires and ground working controller. terminal wire. • Traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B • Working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and measure current between vibrator pump (F)/(R) proportional solenoid terminal wires (positive side) and B (ground side). • Vibrator pump (F) proportional solenoid a (NORMAL) wire Lg (positive side) and wire B (ground side) • Vibrator pump (F) proportional solenoid b (OSCILLATION) wire Br (positive side) and wire B (ground side) • Vibrator pump (R) proportional solenoid a (NORMAL) wire LgB (positive side) and wire B (ground side) • Vibrator pump (R) proportional solenoid b (OSCILLATION) wire BrW (positive side) and wire B (ground side) While measuring current, operate vibration mode select switch and vibration switch as below. • Vibration mode select switch is “ ” (continuous mode) and depress F-R lever vibration switch more than 0.05 second and vibration switch is “ ”. Standard current: Solenoid a (NORMAL): 960 mA Solenoid b (OSCILLATION): 200 mA • Vibration mode select switch is “ ” (continuous mode) and depress F-R lever vibration switch more than 0.05 second and vibration switch is “ ”. Standard current: Solenoid a (NORMAL): 200 mA Solenoid b (OSCILLATION): 1150 mA • Vibration mode select switch is “ ” (Vibration is OFF) Standard current: Solenoid a (NORMAL): 200 mA Solenoid b (OSCILLATION): 200 mA • If item (1) is OK and item (2) is NG, traveling/working controller is faulty. (NOTICE) • Since current value is output in PWM, standard value shown above represent a maximum instantaneous value.
11-138
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-139
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-1. No vibration occurs 4/5 • F-R lever must be in “N”. • Parking brake switch must be released. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig.: 2-6-1 Error code Check point E33, E34, 6. Clearing E35 or E36 Error Code and Judging OK/NG after Repair
Check/Cause ① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. ③ Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
Action
11-140
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-141
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO CO M
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-1. No vibration occurs 5/5 • F-R lever must be in “N”. • Parking brake switch must be released. • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig.: 2-6-1 Check point
Check/Cause
Action
1. Vibration Mode Select Switch
(1) W hen starter switch is ON, measure voltage between vibration mode select switch terminal 1, 4 inlet wires YW and chassis ground. Standard voltage: 12 V or more (2) W hen starter switch is ON and vibration mode select
Replace vibration mode select switch.
switch to “ ” (continuous mode), measure voltage between vibration mode select switch terminal wires and chassis ground. • Vibration mode select switch terminal 3 outlet wire GB and chassis ground • Vibration mode select switch terminal 5 outlet wire YL and chassis ground There is no electricity in normal condition. • If above item (1) is OK and electricity is found in item (2), vibration mode select switch is faulty. 2. F-R Lever Vibration Switch
• Depress F-R lever vibration switch and check continuity Replace F-R vibration between F-R lever vibration switch terminal COM and NO. lever switch. There is continuity in normal condition. • If there is no continuity, F-R lever vibration switch is faulty. (NOTICE) • Pressing F-R lever vibration switch turns on vibration and vibration is turned off when switch is pressed again.
3. Resistor Unit
• Measure resistance between resistor unit wire No.35 wire Replace resistor unit. YB and ground wire. Standard resistance: 300 Ω • If resistance is abnormal, the resistor unit is faulty. (NOTICE) • Resistor unit is used to stabilize contact of switch.
4. Traveling Controller
• When starter switch is ON and depress F-R lever vibration Replace traveling switch, measure voltage between traveling controller controller. terminal 34 inlet wire YB and ground terminal 1 wire B. Standard voltage: 12 V or more • If display shows no error code and the above item is OK, traveling controller 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.
11-142
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-143
TROUBLESHOOTING
2-6-2. Vibration frequency cannot be switched (SW884/994) 1/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration switch is “ switched. • Check whether exact meter multiple display shows any error code. Reference Fig.: 2-5-1 Error code E21
Check point
” when frequency cannot be
Check/Cause
Action
1. Connector
• Check vibration frequency select switch, vibration switch and traveling controller connector terminal 31, 32, 33 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistances between switches and traveling controller terminal wires. • Vibration frequency select switch terminal 3 wire G and traveling controller terminal 31 wire G • Vibration frequency select switch terminal 6 wire L and traveling controller terminal 32 wire L • Vibration switch terminal 2 wire Br and traveling controller terminal 33 wire Br Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • Vibration frequency select switch terminal 1, 4 wires YW, vibration switch terminal 1 wire YW and fuse box terminal 9 wire YW Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
3. Vibration Frequency Select Switch
(1) W hen starter switch is ON, measure voltage between Replace vibration vibration frequency select switch terminal 1, 4 inlet frequency select wires YW and chassis ground. switch. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration frequency select switch is “2500”, measure voltage between vibration frequency select switch terminal 6 outlet wire L and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration frequency select switch is “3000”, measure voltage between vibration frequency select switch terminal wires and chassis ground. • Vibration frequency select switch terminal 3 outlet wire G and chassis ground • Vibration frequency select switch terminal 6 outlet wire L and chassis ground Standard voltage : 12 V or more (4) W hen starter switch is ON and vibration frequency select switch is “4000”, measure voltage between vibration frequency select switch terminal 3 outlet wire G and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and any of items (2) through (4) is NG, vibration frequency select switch is faulty.
11-144
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-145
TROUBLESHOOTING
2-6-2. Vibration frequency cannot be switched (SW884/994) 2/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration switch is “ switched. • Check whether exact meter multiple display shows any error code. Reference Fig.: 2-5-1 Error code E21
Check point
” when frequency cannot be
Check/Cause
Action
4. Vibration switch
(1) W hen starter switch is ON, measure voltage between Replace vibration vibration switch terminal 1 inlet wire YW and chassis switch ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration 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 switch is faulty.
5. Resistor Unit
• Measure resistance between resistor unit wires and ground wire. • Resistor unit wire No.32 wire G and ground wire • Resistor unit wire No.33 wire L and ground wire • Resistor unit wire No.34 wire Br and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch.
11-146
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-147
TROUBLESHOOTING
2-6-2. Vibration frequency cannot be switched (SW884/994) 3/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration switch is “ switched. • Check whether exact meter multiple display shows any error code. Reference Fig.: 2-5-1 Error code E21
Check point
” when frequency cannot be
Check/Cause
6. Traveling Controller
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration frequency select switch is “2500”, measure voltage between traveling controller terminal 32 inlet wire L and ground terminal 1 wire B. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration frequency select switch is “3000”, measure voltage between traveling controller terminal wires. • Traveling controller terminal 31 inlet wire G and ground terminal 1 wire B • Traveling controller terminal 32 inlet wire L and ground terminal 1 wire B Standard voltage : 12 V or more (4) W hen starter switch is ON and vibration frequency select switch is “4000”, measure voltage between traveling controller terminal 31 inlet wire G and ground terminal 1 wire B. Standard voltage : 12 V or more (5) When starter switch is ON and vibration switch is “ ”, measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1), (2), (3), (4) and (5) are OK, traveling controller is faulty.
7. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all combinations of vibration frequency select switch and vibration switch positions. Exact meter will still display vehicle speed. Machine is normal state. If display changes form vehicle speed to E21, check above items again.
Action Replace traveling controller.
11-148
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-149
TROUBLESHOOTING
2-6-3. Vibration type cannot be switched (SW884ND/994ND) 1/2 • Set vibration mode select switch to “ ” (continuous mode). • Vibration switch is “ ” when vibration type cannot be switched. • Check whether exact meter multiple display shows any error code. Reference Fig.: 2-5-1 Error code E21
Check point
Check/Cause
Action
1. Connector
• Check vibration frequency select switch, vibration switch and traveling controller connector terminal 33 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
(1) M easure resistances between switches and traveling controller terminal wires. • Vibration switch terminal 2 wire Br and traveling controller terminal 33 wire Br Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • Vibration switch terminal 1 wire YW and fuse box terminal 9 wire YW Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
4. Vibration switch
(1) W hen starter switch is ON, measure voltage between Replace vibration vibration switch terminal 1 inlet wire YW and chassis switch ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration 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 switch is faulty.
5. Resistor Unit
• Measure resistance between resistor unit wire No.34 wire Br Replace resistor and ground wire. unit. Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty. (NOTICE) • Resistor unit is used to stabilize contact of switch.
11-150
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-151
TROUBLESHOOTING
2-6-3. Vibration type cannot be switched (SW884ND/994ND) 2/2 ” (continuous mode). • Set vibration mode select switch to “ • Vibration switch is “ ” when vibration type cannot be switched. • Check whether exact meter multiple display shows any error code. Reference Fig.: 2-5-1 Error code E21
Check point
Check/Cause
6. Traveling Controller
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) and (2) are OK, traveling controller is faulty.
7. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all combinations of vibration frequency select switch and vibration switch positions. Exact meter will still display vehicle speed. Machine is normal state. If display changes form vehicle speed to E21, check above items again.
Action Replace traveling controller.
11-152
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-153
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-4. Continuous/automatic vibration mode cannot be switched 1/2 Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Vibration Mode Select Switch
(1) W hen starter switch is ON and vibration mode select switch is “ ”, measure voltage between vibration mode select switch terminal 1, 4 inlet wires YW and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and vibration mode select switch is “ ”, measure voltage between vibration mode select switch terminal wires and chassis ground. • Vibration mode select switch terminal 3 outlet wire GB and chassis ground • Vibration mode select switch terminal 5 outlet wire YL and chassis ground There is no electricity in normal condition. (3) W hen starter switch is ON and vibration mode select switch is “AUTO”, measure voltage between vibration mode select switch terminal wires and chassis ground. • Vibration mode select switch terminal 3 outlet wire GB and chassis ground • Vibration mode select switch terminal 5 outlet wire YL and chassis ground Standard voltage : 12 V • If above item (1) is OK and item (2) or (3) is NG, vibration mode select switch is faulty.
Replace vibration mode select switch.
2. Resistor Unit
• Measure resistance between resistor unit wires and ground wire. • Resistor unit wire No.36 inlet wire GB and ground wire • Resistor unit wire No.37 wire YL and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch.
11-154
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
M
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-155
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
CO
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-4. Continuous/automatic vibration mode cannot be switched 2/2 Reference Fig. : 2-6-1 Check point
Check/Cause
Action
3. Traveling Controller
(1) W hen starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration mode select switch is “ ”, measure voltage between traveling controller terminal wires and ground terminal 1 wire B. • Traveling controller terminal 36 inlet wire GB and ground terminal 1 wire B • Traveling controller terminal 35 inlet wire YL and ground terminal 1 wire B There is no electricity in normal condition. (3) W hen starter switch is ON and vibration mode select switch is “AUTO”, measure voltage between traveling controller terminal wires and ground terminal 1 wire B. • Traveling controller terminal 36 inlet wire GB and ground terminal 1 wire B • Traveling controller terminal 35 inlet wire YL and ground terminal 1 wire B Standard voltage : 12 V or more • If above item (1), (2) or (3) is OK, traveling controller 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.
11-156
TROUBLESHOOTING
Fig.: 2-6-1
35
24
36
26
37
30
38
46
39
47
27
48
40
162 0.5Gr
5
1
6
2
7
3
12
4
24
11
25
31
29
32
WORKING
30 CONTROLLER 42
165 0.5LgB
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
R NC NO
41 0.5LW 42 0.5BrW
M CO
NO
NC
W
25 0.5WB 128 0.5GW
TO PROPULSION PUMP NEUTRAL RELAY (2)
12 0.5BW
124 0.5Br
VIBRATORY DRUM SELECT SWITCH
126 0.5Lg
POSITION
125 0.5BrW
R2
C
B
52 1.25BR
3
66 94
6
13 WL
75
31 YW
BACKUP BUZZER SWITCH
6 RY
25 2WR
FUSE
15A
9
ECM. (CM2350) /J4(24PIN)
8
7
6
5
4
3
2
7
7 WG
22 23
243 L
3 1
4 5
TO COMBINATION 53 G 181 GW METER
2
3 MID SPEED
CONTROL RELAY
7
4
38 77
40
32
3
35
84
8
85 57 82
11-157
B X
5 2
178 G 3 1
192 RW
5 THROTTLE
RELAY
165 LgB
X B
25 WB
130 B
49 5L
F.L.65A
AV60,B
52 1.25BR
SW884/994 only
VIBRATION FREQUENCY SELECT SWITCH POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
178 G 3
16
35 YB
NO
COM E
BATTERY -
12V
+
1
FUSE BOX
44 Br 243 L
4 31 YW
X 1.25B
5 2020151515152020152020 A A A A A A A A A A A A
181 GW
1 31 YW
VIBRATION MODE SELECT SWITCH
51 5WG
11 5W
31 YW
12 11 10
189 BrR
L
BATTERY RELAY
BR
190 L
37 YL 5
NC
160 2WL
F.L.65A
81
39
O COM
F-R LEVER NO VIBRATION SWITCH
TO WATER SPRAY MODE SELECT SWITCH
6
53
1-3,4-5
36 GB 3
54
87
1-3,4-6 AUTO
ST
79 91
CONNECTION 1-2,4-6
ON
10 5WR 76
46
VIBRATION MODE SELECT SWITCH POSITION
VIBRATORY DRUM SELECT SWITCH
OFF
62
22
RESISTOR UNIT
4 31 YW
27 LB 5
HEAT
13
83
PARKING BRAKE SOLENOID
5 X B
1 31 YW
26 BrB 2
B A CC B R C
13 WL
73
5
4
X B
1-3,4-5
49 5L
STARTER SWITCH
14 WY
52
28
SOL
1-3,4-6
26 0.5BrB
10 5WR
27
17 Y
2 74 BrY
NC
B
EMR
1-2,4-6
27 0.5LB
ECM. (CM2250) /J2(96PIN)
51
3 17 Y
6
NO CO M
7 WG
6 RY
162 Gr
W
PRO
2 EXACT METER RELAY
CONNECTION
127 0.5LgB
BACKUP BUZZER
50
165 LgB
2
PARKING BRAKE SWITCH
129 0.5B
B
X2 3B
26
18 L
164 BW
5
2 R
25
1
4
12 BW
R
49
B COM
15 LgR 1
78 O
1
3
TO COMBINATION METER
X 0.5B
F-R LEVER SWITCH
R
14 WY
15 LgR
FOOT BRAKE SWITCH
R1 BR ACC
F
128 GW
36 0.5GB
50
F-R LEVER
EMERGENCY CONNECTOR
163 LgY
40 0.5GW
50
130 0.5B
a(Hi/ NORMAL)
37 0.5YL
42 BrW
23
b(Lo/ OSCILLATION)
35 0.5YB
41 LW
34
34 0.5Br
40 GW
20 MC050-155
VIBRATOR PUMP (R) PROPORTIONAL SOLENOID
33 0.5L
39 BrR
TRAVELING
19 CONTROLLER 33
32 0.5G
38 GY
32
36 GB
31
17
37 YL
14
38 0.5GY 39 0.5BrR
35 YB
25
34 Br
21
13
33 L
22
9
32 G
18
8
a(Hi/ NORMAL)
X B
5
b(Lo/ OSCILLATION)
126 Lg
7
X B
4
VIBRATOR PUMP (F) PROPORTIONAL SOLENOID
X 0.5B
X B
6
127 LgB
162 0.5Gr
1
3
124 Br
129 0.5B 130 0.5B
2
X B
128 0.5GW
125 BrW
25 0.5WB
129 B
EXACT METER
2 44 Br 6 192 RW 5
1 181 GW 31 YW 4 4 31 YW
THROTTLE SWITCH THROTTLE SWITCH POSITION IDLE ECO FULL
CONNECTION 1-2,4-6 1-3,4-6 1-3,4-5
SW884/994
VIBRATION SWITCH POSITION
CONNECTION 1-3 1-2
SW884ND/994ND VIBRATION SWITCH POSITION
3 32 G 2
1-2
(NORMAL)
31 YW 1
X B
1-3
(OSCILLATION)
6 33 L 5
CIS (OPTION)
CONNECTION
34 Br 170 GR
3 170 GR 2 34 Br
VIBRATION SWITCH
SW884-11004
TROUBLESHOOTING
2-6-5. Front and rear vibratory drums cannot perform one-drum vibration Reference Fig. : 2-6-1 Check point 1. Vibratory Drum Select Switch
2. Harness Connecting Between Terminals
Check/Cause Action , (1) W hen starter switch is ON measure voltage between Replace vibratory drum vibratory drum select switch terminal 1, 4 inlet wires YW select switch. and chassis ground. Standard voltage: 12 V (2) W hen starter switch is ON and vibratory drum select switch is “ ”, measure voltage between vibratory drum select switch terminal wires and chassis ground. • Vibratory drum select switch terminal 2 outlet wire BrB and chassis ground • Vibratory drum select switch terminal 5 outlet wire LB and chassis ground There is no electricity in normal condition. (3) W hen starter switch is ON and vibratory drum select switch is “ ”, measure voltage between vibratory drum select switch terminal 2 outlet wire BrB and chassis ground. Standard voltage : 12 V (4) W hen starter switch is ON and vibratory drum select switch is “ ”, measure voltage between vibratory drum select switch terminal 5 outlet wire LB and chassis ground. Standard voltage : 12 V • If above item (1) is OK and any of items (2) through (4) is NG, vibratory drum select switch is faulty. • Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
11-158
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-159
TROUBLESHOOTING
2-7. Exact Meter Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. (NOTICE) • If any abnormality is found in shielded twisted wires, be sure to replace them.
2-7-1. Exact meter indicator lamp does not illuminate while driving 1/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E11
Check point
Check/Cause
Action
1. Connector
• Check speed sensor connector and traveling controller connector terminal 8, 9, 26, 46, working controller connector terminal 24, 25 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between speed sensor and Repair or replace traveling/working controller terminal wires. harness. • Speed sensor terminal 2 wire G and traveling controller terminal 26 wire G, working controller terminal 24 wire G • Speed sensor terminal 3 wire W and traveling controller terminal 46 wire W, working controller terminal 25 wire W • Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R • Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. Speed Sensor
(1) W hen starter switch is ON, measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 wire B. Standard voltage : 5 ± 0.25 V (2) S tart engine and rotate vibratory drum. Measure pulse between speed sensor terminal 3 outlet wire W and ground terminal 5 wire B with a pulse meter. Standard pulse : 21 pulses/rotation • If above item (1) is OK and item (2) is NG, speed sensor is faulty.
Replace speed sensor.
4. T raveling/ Working Controller
• If error code E11 is displayed and no abnormality is found in connector, harness and speed sensor in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, start engine. ② Exact meter will display E11. ③ Move F-R lever “F” or “R” and run machine. ④ Exact meter display will change from E11 to vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-160
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-161
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 2/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E21
Check point 1. Connector
Check/Cause • Check vibration frequency select switch, vibration switch and traveling controller connector terminal 31, 32, 33 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Action Replace connector or terminal.
2. Harness
(1) M easure resistances between switches and traveling controller terminal wires. • Vibration frequency select switch terminal 3 wire G and traveling controller terminal 31 wire G (SW884/994 only) • Vibration frequency select switch terminal 6 wire L and traveling controller terminal 32 wire L (SW884/994 only) • Vibration switch terminal 2 wire Br and traveling controller terminal 33 wire Br Standard resistance : 10 Ω or less (2) M easure resistances between switches and fuse box terminal wires. • Vibration frequency select switch terminal 1, 4 wires YW and fuse box terminal 9 wire YW (SW884/994 only) • Vibration switch terminal 1 wire YW and fuse box terminal 9 wire YW Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. (1) W hen starter switch is ON, measure voltage between vibration frequency select switch terminal 1, 4 inlet wires YW and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, vibration frequency select switch is “2500”, measure voltage between vibration frequency select switch terminal 6 outlet wire L and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, vibration frequency select switch is “3000”, measure voltage between vibration frequency select switch terminal wires and chassis ground. • Vibration frequency select switch terminal 3 outlet wire G and chassis ground • Vibration frequency select switch terminal 6 outlet wire L and chassis ground Standard voltage : 12 V or more (4) W hen starter switch is ON, vibration frequency select switch is “4000”, measure voltage between vibration frequency select switch terminal 3 outlet wire G and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibration frequency select switch is faulty.
Repair or replace harness.
3. Vibration Frequency Select Switch (SW884/994 only)
Replace vibration frequency select switch.
11-162
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-163
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 3/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code
Check point
Check/Cause
E21
4. Vibration Switch (SW884/994)
(1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire YW and chassis ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 3 outlet wire GR and chassis ground. Standard voltage : 12 V or more (3) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, vibration switch is faulty.
Replace vibration switch.
Action
5. Vibration Switch (SW884ND/ 994ND)
(1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire YW and chassis ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 3 outlet wire GR and chassis ground. Standard voltage : 12 V or more (3) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, vibration switch is faulty.
Replace vibration switch.
6. Resistor Unit
• Measure resistances between resistor unit wires and ground wire. • Resistor unit wire No. 32 wire G and ground wire (SW884/994 only) • Resistor unit wire No. 33 wire L and ground wire (SW884/994 only) • Resistor unit wire No. 34 wire Br and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch.
11-164
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-165
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 4/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code
Check point
Check/Cause
E21
6. T raveling Controller (SW884/994)
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration frequency select switch is “2500”, measure voltage between traveling controller terminal 32 inlet wire L and ground terminal 1 wire B. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration frequency select switch is “3000”, measure voltage between traveling controller terminal wires. • Traveling controller terminal 31 inlet wire G and ground terminal 1 wire B • Traveling controller terminal 32 inlet wire L and ground terminal 1 wire B Standard voltage : 12 V or more (4) W hen starter switch is ON and vibration frequency select switch is “4000”, measure voltage between traveling controller terminal 31 inlet wire G and ground terminal 1 wire B. Standard voltage : 12 V or more (5) When starter switch is ON and vibration switch is “ ” measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1), (2), (3), (4) and (5) are OK, traveling controller is faulty.
Action Replace traveling controller.
11-166
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-167
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 5/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code
Check point
Check/Cause
E21
8. T raveling Controller (SW884ND/ 994ND)
(1) W hen starter switch is ON, measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is “ ”, measure voltage between traveling controller terminal 33 inlet wire Br and ground terminal 1 wire B. Standard voltage : 12 V or more • If above items (1) and (2) are OK, traveling controller is faulty.
9. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all combinations of vibration frequency select switch and vibration switch positions. Exact meter will still display vehicle speed. Machine is in normal state. If display changes form vehicle speed to E21, check above items again.
Action Replace traveling controller.
11-168
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-169
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 6/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E22
Check point
Check/Cause
Action
1. Connector
• Check IPF select switch connector and traveling controller Replace connector connector terminal 37, 38, 39 for corrosion, breakage, or terminal. bending and looseness. • If any abnormality is found, connector is faulty.
2. Harness
(1) M easure resistances between IPF select switch and Repair or replace traveling controller terminal wires. harness. • IPF select switch terminal 2 wire GW and traveling controller terminal 37 wire GW • IPF select switch terminal 4 wire LW and traveling controller terminal 38 wire LW • IPF select switch terminal 6 wire BrW and traveling controller terminal 39 wire BrW Standard resistance : 10 Ω or less (2) M easure resistances between IPF select switch terminal 1, 3, 5 wires YW and fuse box terminal 9 wire YW. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
11-170
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-171
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 7/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E22
Check point
Check/Cause
Action
3. IPF Select Switch
(1) W hen starter switch is ON, measure voltage between Replace IPF select IPF select switch terminal 1, 3, 5 inlet wires YW and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and IPF select switch is “10”, measure voltage between IPF select switch terminal 2 outlet wire GW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and IPF select switch is “11”, measure voltage between IPF select switch terminal 4 outlet wire LW and chassis ground. Standard voltage : 12 V or more (4) W hen starter switch is ON and IPF select switch is “12”, measure voltage between IPF select switch terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (5) W hen starter switch is ON and IPF select switch is “13”, measure voltage between IPF select switch terminal 2 outlet wire GW, terminal 4 outlet wire LW and chassis ground. Standard voltage : 12 V or more (6) W hen starter switch is ON and IPF select switch is “14”, measure voltage between IPF select switch terminal 4 outlet wire LW, terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (7) W hen starter switch is ON and IPF select switch is “15”, measure voltage between IPF select switch terminal 2 outlet wire GW, terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and any of items (2) through (7) is NG, IPF select switch is faulty.
4. Resistor Unit
• Measure resistances between resistor unit wires and ground wire. • Resistor unit wire No.40 wire GW and ground wire • Resistor unit wire No.41 wire LW and ground wire • Resistor unit wire No.42 wire BrW and ground wire Standard resistance : 300 Ω • If resistance is abnormal, resistor unit is faulty.
Replace resistor unit.
(NOTICE) • Resistor unit is used to stabilize contact of switch.
11-172
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-173
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 8/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E22
Check point 5. Traveling Controller
6. Clearing Error Code and Judging OK/NG after Repair
Check/Cause Action (1) W hen starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and IPF select switch is “10”, measure voltage between traveling controller terminal 37 inlet wire GW and ground terminal 1 wire B. Standard voltage : 12 V or more (3) W hen starter switch is ON and IPF select switch is “11”, measure voltage between traveling controller terminal 38 inlet wire LW and ground terminal 1 wire B. Standard voltage : 12 V or more (4) W hen starter switch is ON and IPF select switch is “12”, measure voltage between traveling controller terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more (5) W hen starter switch is ON and IPF select switch is “13”, measure voltage between traveling controller terminal 37 inlet wire GW, terminal 38 inlet wire LW and ground terminal 1 wire B. Standard voltage : 12 V or more (6) W hen starter switch is ON and IPF select switch is “14”, measure voltage between traveling controller terminal 38 inlet wire LW, terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more (7) W hen starter switch is ON and IPF select switch is “15”, measure voltage between traveling controller terminal 37 inlet wire GW, terminal 39 inlet wire BrW and ground terminal 1 wire B. Standard voltage : 12 V or more • If all of items (1) through (7) are OK, traveling controller is faulty. ① When repair is complete, set starter switch to ON. ② Exact meter will display vehicle speed. ③ Check all positions of IPF select switch. Exact meter will still display vehicle speed. Machine is in normal state. If display changes form vehicle speed to E22, check above items again.
11-174
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-175
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 9/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E43
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter
• When starter switch is ON, measure voltage between exact meter terminal 5 inlet wire WB and ground terminal 6 wire B. Standard voltage : 12 V or more • If voltage is abnormal, exact meter is faulty.
Replace exact meter.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 1 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-176
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-177
TROUBLESHOOTING
2-7-1. Exact meter indicator lamp does not illuminate while driving 10/10 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig. : 2-5-1 Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter Multiple Display
• If no abnormality is found in connector and harness in above inspections and error code E43 is not displayed, exact meter multiple display or traveling controller is faulty.
Replace exact meter multiple display or traveling controller.
11-178
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-179
TROUBLESHOOTING
2-7-2. No vehicle speed indication on display 1/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E11
Check point
Check/Cause
Action
1. Connector
• Check speed sensor connector and traveling controller connector terminal 8, 9, 26, 46, working controller connector terminal 24, 25 for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between speed sensor and Repair or replace traveling/working controller terminal wires. harness. • Speed sensor terminal 2 wire G and traveling controller terminal 26 wire G, working controller terminal 24 wire G • Speed sensor terminal 3 wire W and traveling controller terminal 46 wire W, working controller terminal 25 wire W • Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R • Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
3. Speed Sensor
(1) W hen starter switch is ON, measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 outlet wire B. Standard voltage : 5 ± 0.25 V (2) S tart engine and rotate vibratory drum. Measure pulse between speed sensor terminal 3 outlet wire W and terminal 5 outlet wire B with a pulse meter. Standard pulse : 21 pulses/rotation • If above item (1) is OK and item (2) is NG, speed sensor is faulty.
Replace speed sensor.
4. T raveling/ Working Controller
• If error code E11 is displayed and no abnormality is found in connector, harness and speed sensor in above inspection, traveling/working controller is faulty.
Replace traveling/ working controller.
5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, start engine. ② Exact meter will display E11. ③ Move F-R lever “F” or “R” and run machine. ④ Exact meter display will change from E11 to vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-180
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-181
TROUBLESHOOTING
2-7-2. No vehicle speed indication on display 2/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) When display shows any error code Reference Fig. : 2-5-1 Error code E43
Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter
• When starter switch is ON, measure voltage between Replace exact exact meter terminal 5 outlet wire WB and ground terminal meter. 6 wire B. Standard voltage : 12 V or more • If voltage is abnormal, exact meter is faulty.
4. C AN • A normally operating traveling controller sends connection Replace traveling Communication verification signals to exact meter every 0.1 second. controller. Exact meter cannot receive connection verification signals that are regularly sent from traveling controller for 1 continuous second while operating. • Traveling controller is faulty. 5. Clearing Error Code and Judging OK/NG after Repair
① When repair is complete, set starter switch to ON. ② Place F-R lever “N”. Exact meter will display vehicle speed. Machine is in normal state. If display does not change to vehicle speed, check above items again.
11-182
TROUBLESHOOTING
Fig.: 2-5-1
B COM
1
PRO EMR
2
2 EXACT METER RELAY
FOOT BRAKE SWITCH
25 0.5WB
SPEED SENSOR
1
72 Br
5
X B
2
PROPULSION PUMP 8 NEUTRAL RELAY (1)
OUT(SIGNAL1)
1
OUT(DIRECTION SIG.)
2
OUT(SIGNAL2)
3
+5V
4
0V(GND)
5
NO USE
6
3 17 Y
15 LgR 1
73 Lg
72 Br
4
3
5
X B
2
18 L
74 BrY
PROPULSION PUMP NEUTRAL RELAY (2)
73 Lg
2 74 BrY
4
5 X B
PARKING TO COMBINATION BRAKE SWITCH METER
1
17 Y
128 0.5GW 210 G
129 0.5B
139 W
130 0.5B
138 R
138 0.5R
140 B
140 0.5B
SOL
3 1
10
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
TRAVELING 19 CONTROLLER 33 20 MC050-155 34
X B
PARKING BRAKE SOLENOID 210 0.5G 139 0.5W
23
35
24
36
26
37
30
38
46
39
47
27
48
40
4
13 WL
5
X B
210 0.5G
SW884/994 only
139 0.5W
VIBRATION FREQUENCY SELECT SWITCH
2
PROPULSION PUMP NEUTRAL HOLDING RELAY
POSITION
CONNECTION
2500
1-2,4-6
3000
1-3,4-6
4000
1-3,4-5
165 0.5LgB
1
6
2
7
3
12
4
24
11
25
31
29
32
38
13
TERMINATING RESISTOR 38 0.5GY 39 0.5BrR 32 0.5G 33 0.5L 34 0.5Br 35 0.5YB 37 0.5YL 36 0.5GB 40 0.5GW 41 0.5LW 42 0.5BrW
X 0.5B 25 0.5WB 128 0.5GW 129 0.5B
IPF SELECT SWITCH 5 6
44
3
47
45
1
48
14
49
15
39
50
39 BrR
38 GY
36 GB
37 YL
35 YB
34 Br
32 G
5
33 L
2 6 33 L
40 GW
3 32 G
31 YW 4
186 0.5RY
WORKING 30 CONTROLLER 42 37 MC050-110 43
VIBRATION FREQUENCY SELECT SWITCH 31 YW 1
5
120Ω
X 0.5B 185 0.5RB
50
130 0.5B
NEUTRAL SOLENOID
73 Lg
1
3
X B
SOL
71 LY
2
42 BrW
3
15 LgR
4
41 LW
71 LY
9
X B
165 LgB
25 WB
164 BW
5
129 B
4
130 B
3
NO
128 GW
15 LgR
R NC 14 WY
EXACT METER
EMERGENCY CONNECTOR
163 LgY
RESISTOR UNIT
4
2 10 11 12131415 (NOTCH POSITION) IPF SELECT SWITCH POSITION CONNECTION 10 1-2 11 3-4 12 5-6 13 1-2,3-4 14 3-4,5-6 1-2,5-6 15
SW884/994
VIBRATION SWITCH POSITION
1-3 VIBRATION MODE SELECT SWITCH POSITION
SW884ND/994ND VIBRATION SWITCH
1-2
(NORMAL)
31 YW 1
X B
1-3
1-3
1-3,4-5
6 37 YL 5
2 34 Br
POSITION CONNECTION
1-3,4-6 AUTO
2
170 GR 3 170 GR
IPF SELECT SWITCH SPEED CHANGE SWITCH
1-2,4-6
36 GB 3
34 Br
1-2 39 BrR 3
1 31 YW
NC 38 GY B NO
COM
ECM. (CM2250) /J2(96PIN)
1 31 YW
2
4 31 YW
VIBRATION MODE SELECT SWITCH
VIBRATION SWITCH
5 31 YW
42 BrW 6
CONNECTION
CIS (OPTION)
CONNECTION
(OSCILLATION)
3 31 YW
41 LW 4
1-2
POSITION
1 31 YW
40 GW 2
CONNECTION
SPEED CHANGE SWITCH G
31 YW
F-R LEVER AUTO SPEED SET SWITCH
1
49
25
50
26
51
27
52
28
73
5
66 94
13 62 120Ω
TERMINATING RESISTOR
185 RB 186 RY
83 22
76
46
75
STARTER SWITCH B A CC B R C HEAT OFF ON ST
12 11 10
9
8
7
54 91 6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A FUSE BOX
6 81 16
25 2WR
FUSE
15A
10 5WR F.L.65A
51 5WG
160 2WL
F.L.65A
BATTERY RELAY
11 5W 52 1.25BR
NO BR
X 1.25B
COM E
49 5L
AV60,B
52 1.25BR
13 WL
R1 BR ACC
31 YW
B
10 5WR
R2
49 5L
14 WY
79 C
87
7 38
53
39
77
40
32
3
35
84
8
85
BATTERY
57
12V
82
-
+
SW884-11005
11-183
TROUBLESHOOTING
2-7-2. No vehicle speed indication on display 3/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 2) When display shows no error code Reference Fig. : 2-5-1 Check point
Check/Cause
Action
1. Connector
• Check exact meter connector terminal 1, 2, 3, 7 and traveling controller connector terminal 3, 4, 5, working controller connector terminal 3, 4, 5, 39, for corrosion, breakage, bending and looseness. • If any abnormality is found, connector is faulty.
Replace connector or terminal.
2. Harness
• Measure resistances between exact meter and traveling controller terminal wires. • Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW, working controller terminal 3 wire GW • Exact meter terminal 2 wire B and traveling controller terminal 4 wire B, working controller terminal 4 wire B • Exact meter terminal 3 wire B and traveling controller terminal 5 wire B, working controller terminal 5 wire B • Exact meter terminal 7 wire LgB and working controller terminal 39 wire LgB Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Replace harness.
3. Exact Meter Multiple Display
• If no abnormality is found in connector and harness in above inspections and error code E43 is not displayed, exact meter multiple display or traveling controller is faulty.
Replace exact meter multiple display or traveling controller.
11-184
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-185
TROUBLESHOOTING
2-8. Water Spray Check following items before troubleshooting. • No blown fuses and power is applied up to fuses.
2-8-1. Continuous water spray does not operate 1/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point 1. Water Spray Pump (F, 1), (F, 2), (R, 1) or (R, 2)
Check/Cause
Action
(1) W hen starter switch is ON and depress F-R lever water Replace the water spray spray switch once, measure voltage between water pump (F, 1), (F, 2), (R, 1) spray pump terminal inlet wires and chassis ground. or (R, 2). • Water spray pump (F, 1) inlet wire: G • Water spray pump (F, 2) inlet wire: GW • Water spray pump (R, 1) inlet wire: L • Water spray pump (R, 2) inlet wire: LW Standard voltage: 12 V or more (2) Check if grounding of each water spray pump is normal. • If above items (1) and (2) are OK and water spray pump does not operate, water spray pump is faulty.
(NOTICE) • There are a total of four water spray pumps, two each for front and rear drums. • Pressing F-R lever water spray switch turns on power and power is turned off when switch is pressed again. Replace F-R lever water 2. F-R Lever Water Spray • Depress F-R lever water spray switch and check Switch continuity between F-R lever water spray switch terminal spray switch. COM and NO. There is continuity in normal condition. • If there is no continuity, F-R lever water spray switch is faulty.
3. Water Spray Mode Select Switch
(NOTICE) • Pressing F-R lever water spray switch turns on power and power is turned off when switch is pressed again. (1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water mode select switch. spray mode select switch terminal 1 inlet wire GW and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray mode select switch terminal 2 outlet wire GL and chassis ground. Standard voltage : 12 V • If above item (1) is OK and item (2) is NG, water spray mode select switch is faulty.
11-186
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-187
TROUBLESHOOTING
2-8-1. Continuous water spray does not operate 2/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point 4. Water Spray Timer Switch
Check/Cause
Action
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water timer switch. spray timer switch terminal 2, 5 inlet wires GL and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray timer switch terminal 1 outlet wire GB and chassis ground. Standard voltage : 12 V (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray timer switch terminal 4 outlet wire GR and chassis ground. Standard voltage: 12 V • If above item (1) is OK and item (2) or (3) is NG, water spray timer switch is faulty.
hen starter switch is ON and depress F-R lever water Replace water spray 5. 15 Water Spray Pump (1) W spray switch once, measure voltage between water pump relay (pump 1). Relay (Pump 1) spray pump relay (pump 1) terminal 1 inlet wire GB and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (pump 1) terminal 3 inlet wire WB and chassis ground. Standard voltage : 12 V (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (pump 1) terminal 5 outlet wire W and chassis ground. Standard voltage : 12 V • If above items (1) and (2) are OK and item (3) is NG, water spray pump relay (pump 1) is faulty. hen starter switch is ON and depress F-R lever water Replace water spray 6. 16 Water Spray Pump (1) W spray switch once, measure voltage between water pump relay (pump 2). Relay (Pump 2) spray pump relay (pump 2) terminal 1 inlet wire GR and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (pump 2) terminal 3 inlet wire LB and chassis ground. Standard voltage : 12 V (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (pump 2) terminal 5 outlet wire Y and chassis ground. Standard voltage : 12 V • If above items (1) and (2) are OK and item (3) is NG, water spray pump relay (pump 2) is faulty.
11-188
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-189
TROUBLESHOOTING
2-8-1. Continuous water spray does not operate 3/4 • Water spray mode select switch must be “
”.
• Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point
Check/Cause
Action
7. Water Spray Pump Switch (F)
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water pump switch (F). spray pump switch (F) terminal 2 inlet wire W, terminal 5 inlet wire Y and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump switch (F) terminal wires and chassis ground. • Center position (both pumps) Water spray pump switch (F) terminal 3 outlet wire G and chassis ground Water spray pump switch (F) terminal 4 outlet wire RG and chassis ground Standard voltage : 12 V • If above item (1) is OK and item (2) is NG, water spray pump switch (F) is faulty.
8. Water Spray Pump Switch (R)
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water pump switch (R). spray pump switch (R) terminal 2 inlet wire W, terminal 5 inlet wire Y and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump switch (R) terminal wires and chassis ground. • Center position (both pumps) Water spray pump switch (R) terminal 3 outlet wire L and chassis ground Water spray pump switch (R) terminal 4 outlet wire LR and chassis ground Standard voltage : 12 V • If above item (1) is OK and item (2) is NG, water spray pump switch (R) is faulty.
hen starter switch is ON and depress F-R lever water Replace water spray 9. 17 Water Spray Pump (1) W spray switch once, measure voltage between water pump relay (F, 2). Relay (F, 2) spray pump (F, 2) relay terminal 4 inlet wire RG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump (F, 2) relay terminal 3 outlet wire GW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray pump relay (F, 2) relay is faulty.
11-190
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-191
TROUBLESHOOTING
2-8-1. Continuous water spray does not operate 4/4 • Water spray mode select switch must be “
”.
• Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point
Check/Cause
Action
10. 18 Water Spray Pump Relay (R, 2)
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water pump relay (R, 2). spray pump relay (R, 2) terminal 4 inlet wire LR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (R, 2) terminal 3 outlet wire LW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray pump relay (R, 2) is faulty.
11. Traveling/Working Controller
(1) W hen starter switch is ON, measure voltage between Replace traveling/ traveling/working controller terminal wires and ground working controller. terminal wires. • Traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. • Working controller power supply terminal 2 inlet wire WB and ground terminal 1 wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between traveling controller terminal 22 inlet wire GR and chassis ground. Standard voltage : 12 V (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between working controller terminal 32 outlet wire GW and chassis ground. Standard voltage : 12 V • If above items (1) and (2) are OK and item (3) is NG, traveling controller is faulty.
12. H arness 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.
11-192
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-193
TROUBLESHOOTING
2-8-2. Continuous water spray works, but intermittent water spray does not operate 1/2 • Water spray mode select switch must be “ • Water spray timer switch must be “ I ”. • Set water spray pump switch to “PUMP 2”. Reference Fig. : 2-8-1 Check point
”.
Check/Cause
Action
1. Water Spray Timer
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water timer. spray timer terminal 1, 3 inlet wires G and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray timer terminal 4 outlet wire GB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG with no abnormality found in grounding of water spray timer, water spray timer is faulty.
2. Water Spray Timer Switch
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water timer switch. spray timer switch terminal 2 inlet wire GL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray timer switch terminal 3 outlet wire G and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray timer switch is faulty.
3. Water Spray Pump (F, 2)
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water pump (F, 2). spray pump relay (F, 2) terminal 1 inlet wire G and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (F, 2) terminal 5 inlet wire LW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (F, 2) terminal 3 outlet wire GW and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray pump (F, 2) is faulty.
11-194
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-195
TROUBLESHOOTING
2-8-2. Continuous water spray works, but intermittent water spray does not operate 2/2 • Water spray mode select switch must be “ • Water spray timer switch must be “ I ”. • Set water spray pump switch to “PUMP 2”. Reference Fig. : 2-8-1 Check point
”.
Check/Cause
Action
4. Water Spray Pump (R, 2)
(1) W hen starter switch is ON and depress F-R lever water Replace water spray spray switch once, measure voltage between water pump (R, 2). spray pump relay (R, 2) terminal 1 inlet wire G and chassis ground. Standard voltage: 12 V or more (2) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (R, 2) terminal 5 inlet wire LY and chassis ground. Standard voltage: 12 V or more (3) W hen starter switch is ON and depress F-R lever water spray switch once, measure voltage between water spray pump relay (R, 2) terminal 3 outlet wire LW and chassis ground. Standard voltage: 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray pump (R, 2) 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.
11-196
TROUBLESHOOTING
Fig.: 2-8-1 WATER SPRAY PUMP RELAY (PUMP 1)
15
29 2WB
CONNECTION
2-3,5-6
1-2,4-6
2-1,5-4
3
77 GW 1 78 O
151 GL
2
3
152 G
16
4
5
5
1
3
2
4
X B
M CO
F-R LEVER SWITCH
NO
NC
W
12 0.5BW
B
162 0.5Gr
13 WL
6
4
7
5
18
8
22
9
21
13
25
14
31
17
32
35
24
36
26
37
30
38
46
39
47
27
48
40
7 WG
6 RY
50 162 Gr
80 2Y
5
X B
1 168 2LW
2
2
WATER SPRAY PUMP RELAY (PUMP 2)
3 81 2G 4 159 2RG
5
6
6 RY X2 3B
162 0.5Gr
BACKUP BUZZER
5
1
6
2
7
3
12
4
24
11
25
31
29
32
1 169 2LY
2 3
1
4
2
3 83 2L 4 157 2LR
5
6
WATER SPRAY TIMER
X 0.5B
43 0.5GR
81 2G
TRAVELING 19 CONTROLLER 33 20 MC050-155 34 23
BACKUP BUZZER SWITCH
B
1
3
12 BW
M
NO
W
CO
R
2
78 O
NC
R
4
28 GB 152 G
25 0.5WB
R
3
WATER SPRAY PUMP SWITCH (R)
78 O
F
2-1,5-4
WATER SPRAY TIMER SWITCH
WATER SPRAY MODE SELECT SWITCH
F-R LEVER
2-3,5-4
PUMP 2
6
6
4
28 GB
2-3,5-6
(BOTH)
O
P
B
X1 2B
WATER SPRAY PUMP (F, 1) 159 2RG
82 2GW
168 2LW 4
3
5
X B
2
152 G
P
B
WATER SPRAY PUMP (F, 2)
1
WATER SPRAY PUMP RELAY (F, 2)
17
O
83 2L
O
P
B
X1 2B X1 5B
2
1
PUMP 1
WATER SPRAY PUMP SWITCH (F)
1
1-3,4-5
X B
2
76 2LB 167 GR
POSITION CONNECTION
79 2W
5
1
1-3,4-6 AUTO
4
3
X1 2B
WATER SPRAY PUMP (R, 1)
X 0.5B 25 0.5WB
157 2LR
84 2LW O
169 2LY 4
3
5
X B
2
12 0.5BW
152 G
1
WATER SPRAY PUMP RELAY (R, 2)
18 77 0.5GW
P
B
WATER SPRAY PUMP (R, 2)
X1 2B X1 5B
WATER SPRAY MODE SELECT SWITCH POSITION
28 GB
WATER SPRAY TIMER SWITCH POSITION CONNECTION
WATER SPRAY PUMP SWITCH (F), (R)
WORKING CONTROLLER 42 37 MC050-110 43 30 38
13
39
44
47
45
48
14
49
15
F-R LEVER WATER SPRAY SWITCH
50
NC
COM
43 GR R
Y
31 YW
NO
49 5L
B A CC B R C
12 11 10
9
8
7
6
5
4
3
76 2LB
STARTER SWITCH
29 2WB
52 1.25BR 7 WG
B
13 WL
C
31 YW
R2
R1 BR ACC
2
1
FUSE BOX
ST
25 2WR
93 5WL
ON
10 5WR
OFF
5 2020151515152020152020 A A A A A A A A A A A A
HEAT
93 5WL
FUSE
15A
160 2WL
92 5WB F.L.65A
BATTERY RELAY
11 5W F.L.65A 52 1.25BR
NO BR
X 1.25B
51 5WG
49 5L
F.L.65A
COM AV60,B
10 5WR
E
BATTERY -
12V
+
SW884-11006
11-197
TROUBLESHOOTING
2-8-3. Continuous water spray works, but automatic water spray does not operate • Water spray mode select switch must be “AUTO”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point
Check/Cause
Action
1. F-R lever switch
(1) W hen starter switch is OFF and F-R lever is “N”, check continuity between F-R lever switch terminal COM and NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “F”, check continuity between F-R lever switch terminal COM and NO. There is continuity in normal condition. • If above item (1) or (2) is NG, F-R lever switch is faulty.
2. Buckup buzzer switch
(1) W hen starter switch is OFF and F-R lever is “N”, check Replace buckup buzzer continuity between buckup buzzer switch terminal COM switch. and NC. There is continuity in normal condition. (2) W hen starter switch is OFF and F-R lever is “R”, check continuity between buckup buzzer switch terminal COM and NO. There is continuity in normal condition • If above item (1) or (2) is NG, buckup buzzer switch is faulty.
3. Water Spray Mode Select Switch
(1) W hen starter switch is ON and F-R lever is “F” or “R”, measure voltage between water spray mode select switch terminal 4 inlet wire O and chassis ground. Standard voltage : 12 V (2) W hen starter switch is ON and F-R lever is “F” or “R”, measure voltage between water spray mode select switch terminal 5 outlet wire GL 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.
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.
Replace F-R lever switch.
11-198
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-199
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “measuring voltage and current following using tester” (P. 11-006 to P. 11-008). • Check any ground circuit which belongs to components to be checked.
2-9-1. Head lamp and flood lamp do not light Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Each Bulb
• Check that none of the lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
2. Lighting Switch
(1) W hen starter switch is ON, measure voltage between Replace lighting switch. lighting switch terminal 1 inlet wire WR, terminal 4 inlet wire W and chassis ground. Standard voltage : 12 V or more ”, (2) W hen starter switch is ON and lighting switch is “ measure voltage between lighting switch terminal 3 outlet wire RW and chassis ground. Standard voltage : 12 V or more (3) When starter switch is ON and lighting switch is “ ”, measure voltage between lighting switch terminal 5 outlet wire RL 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.
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.
11-200
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-201
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-2. Illumination of combination meter does not light Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between combination meter and lighting switch. • Measure resistance between terminals and chassis ground. • Combination meter connector terminal wire No.2 wire RW and chassis ground Standard resistance: 100 kΩ or more • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Combination meter illumination)
• When starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B • Combination meter combination meter illumination terminal wire No.2 inlet wire RW and chassis ground Standard voltage : 12 V or more • If above items are OK and combination meter illumination does not turn on, combination meter is faulty.
11-202
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-203
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-3. Hour meter is abnormal Reference Fig. : 2-9-1 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 terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Replace combination meter.
2-9-4. Fuel meter is abnormal Reference Fig. : 2-9-1 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 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 terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X 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.
11-204
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-205
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-5. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between hydraulic oil filter switch Repair or replace 1, 2 and combination meter. harness. • Measure resistance between terminal and chassis ground. • Hydraulic oil filter switch 1 or 2 terminal wire GB and chassis ground • Combination meter connector terminal wire No. 23 wire GB and chassis ground Standard resistance : 100 kΩ or more • If resistance is abnormal, harness is faulty.
2. Hydraulic Oil Filter Switch 1 or 2
• When starter switch is OFF, check continuity between hydraulic oil filter switch 1 or 2 terminal inlet wire GB and chassis ground. There is no continuity in normal condition. • If there is continuity, hydraulic oil filter switch 1 or 2 is faulty.
Replace hydraulic oil filter switch 1 or 2.
3. Combination Meter (Hydraulic oil filter warning)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter hydraulic filter terminal outlet wire No.23 wire GB 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.
11-206
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-207
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-6. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Harness
• Measure resistance between working controller terminal Repair or replace 31 wire YL and combination meter connector terminal wire harness. No. 148 wire YL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
2. Combination Meter (Vibration indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration mode change switch is “CONT” and vibration select switch is not “ “, measure voltage between combination meter vibration terminal wire No.148 inlet wire YL and chassis ground. 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.
11-208
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-209
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-7. Water spray indicator lamp does not light • Check that water spray pump can be operated. Reference Fig. : 2-9-1 Check point 1. Harness
Check/Cause • Measure resistance between water spray timer switch terminal 1 wire GB and combination meter connector terminal wire No. 28 wire GB. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Action Repair or replace harness.
• Measure resistance between water spray timer terminal 4 Repair or replace wire GB and combination meter connector terminal wire harness. No. 28 wire GB. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty. 2. Combination Meter (Water spray indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery terminal wire No. 155 inlet wire R and ground terminal wire B • Starter switch terminal wire No. 64 inlet wire LgW and ground terminal wire B Standard voltage : 12 V or more (2) When starter switch is ON and water spray mode select switch is “ ” or “AUTO”, measure voltage between combination meter terminal wire No. 28 inlet wire GB (water spray terminal) and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK, combination meter is faulty.
11-210
TROUBLESHOOTING
Fig.: 2-9-1 TO STARTER SWITCH RELAY
18 L
1-2,4-6 1-3,4-6
TO F-R LEVER SWITCH
TO PARKING INTERLOCK RELAY
1-3,4-6
6
4
5 2RL 5
78 O
3 2WR
17 0.5Y
70 2W
LIGHTING SWITCH
25 0.5WB
12
4
24
11
25
31
29
32
WORKING
X2 2B
FLOOD LAMP(L) 55W 5 2RL
37 MC050-110
43
38
13
39
44
47
45
48
14
49
15
WATER SPRAY TIMER SWITCH POSITION CONNECTION
148 0.5YL 77 0.5GW
TO WATER SPRAY PUMP RELAY (PUMP1)
2-3,5-6 2-1,5-4
1
2
3
TO WATER SPRAY PUMP RELAY (PUMP2)
167 GR
4
5
50
6
TO WATER SPRAY PUMP RELAY (F,1) (R,2)
WATER SPRAY TIMER SWITCH 152 G
X2 2B
2 2RW
3
X2 2B
HEAD LAMP(L) 55W
2
7
30 CONTROLLER 42
5 2RL
X2 2B
2 2RW
FLOOD LAMP(R) 55W
1
6
5
WATER SPRAY MODE SELECT SWITCH
X 0.5B
5
2 6
4
151 GL
HEAD LAMP(R) 55W
3
77 GW 1
28 GB
1
2
1-3,4-5
AUTO
1-3,4-5
2 2RW 3
CONNECTION
5 X B
PARKING BRAKE SWITCH
1-2,4-6
POSITION
2 74 BrY
4
LIGHTING SWITCH POSITION CONNECTION
WATER SPRAY MODE SELECT SWITCH
3 17 Y
15 LgR 1
4
B
R1 BR ACC
3
1
4
2
WATER SPRAY TIMER
49 5L 52 1.25BR 12 11 10
64 LgW
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A
STARTER SWITCH
FUSE
15A
160 2WL
51 5WG
10 5WR
OFF
BATTERY RELAY
11 5W
F.L.65A
ON ST
49 5L
F.L.65A
FUSE BOX
10 5WR
B A CC B R C HEAT
25 2WR
52 1.25BR
NO BR
156 RG
5A
COM E
BATTERY -
COMBINATION METER Battery 24V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-) 1
2
13 14 15 16 17 18 19 20 21 22 23 24
Head lamp Parking brake Charge warning HYD. oil filter warning Engine warning Fuel meter REV. ratio SEL.2 REV. ratio SEL.4 DTC display Hour meter Turn signal (L) Preheating
+
X 1.25B
25 26 27 28 29 30 31 32 33 34 35
3
Water splay Flood lamp Vibrator Liquid spray High beam COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode
10 11 12
13 14 15 16
18
2 RW
148 YL
5 2RL
21 22
30 31
25 26 27
28 GB
12V
35
64 LgW
1 2 3 4 5 6 7 8 9 10 11 12
155 R
FUSE AV60,B
R2
3
2 X B
TO 56 1.25LB STARTER MOTOR RELAY C
1
53 G
18 L
21 YB
23 GB
X B
64 LgW
155 R
2 2RW
TO THROTTLE SWITCH TO ENGINE ECM. (CM2350)
23 GB B
21 YB
44 Br 243 L
3 1
4
53 G
5
181 GW
2
3 MID SPEED
TO ENGINE ECM. (CM2250)/J2(96PIN)
CONTROL RELAY
X B
HYDRAULIC OIL FILTER SWITCH 1 23 GB B
HYDRAULIC OIL FILTER SWITCH 2
11-211
FUEL GAUGE UNIT
SW884-11007
TROUBLESHOOTING
2-9-8. ECO mode indicator lamp does not light • Check that vibrator can be operated. • Vibration mode change switch must be “CONT”. • Vibration L-H change switch must not be “
”.
• Throttle switch must be “ECO”. Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Harness
• Measure resistance between Mid speed control relay terminal 5 wire G and combination meter connector terminal wire No.53 wire G. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (ECO lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Stater switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter vibration terminal wire No.53 inlet wire G and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and ECO lamp does not light, combination meter is faulty.
2-9-9. Parking brake indicator lamp does not light Reference Fig. : 2-9-1 Check point
Check/Cause
Action
1. Harness
• Measure resistance between parking brake switch terminal 4 wire L and combination meter connector terminal wire No.18 wire L. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Parking Brake Switch
• When parking brake is applied, check continuity between parking brake switch terminal 4 and 5. 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 terminal wire No.155 inlet wire R and ground terminal wire No.X wire B • Starter switch terminal wire No.64 inlet wire LgW and ground terminal wire No.X wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and parking brake is applied, check continuity between combination meter parking brake terminal wire No.18 inlet wire L 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. 11-212
TROUBLESHOOTING
Fig.: 2-9-2
F-R LEVER
F HORN
R
W
M
4 HORN RELAY
162 Gr
HORN SWITCH
R
7 WG
1
NC
2
NO
3
9 GR 5
CO
8 Lg
B
BACKUP BUZZER SWITCH
7 WG
X B
6 RY
X1 2B
BACKUP BUZZER
6 RY X2 3B
C
B
49 5L 52 1.25BR
STARTER SWITCH B A CC B R C HEAT
12 11 10
9
8
7
6
5
4
3
2
1
5 2020151515152020152020 A A A A A A A A A A A A 10 5WR
R2
R1 BR ACC
7 WG
TO WORKING CONTROLLER, TRAVELING CONTROLLER, INTERLOCK RELAY
FUSE BOX
OFF ON ST 11 5W
F.L.65A 52 1.25BR
BATTERY RELAY NO BR
51 5WG
49 5L
F.L.65A
COM E
BATTERY -
AV60,B
10 5WR
12V
+
X 1.25B
SW884-11008
11-213
TROUBLESHOOTING
2-9-10. Horn does not sound Reference Fig. : 2-9-2 Check point
Check/Cause
Action
1. Horn
• Disconnect horn and directly connect battery positive terminal to horn terminal wire Lg side and negative terminal to horn terminal wire B side. • If horn does not sound, horn is faulty.
Replace horn.
2. Horn Switch
• When horn switch is pressed, check continuity between horn switch terminals. There is continuity is normal condition. • If there is no continuity, horn switch is faulty.
Replace horn switch.
3. Horn Relay
(1) W hen starter switch is ON, measure voltage between horn relay terminal 1, 3 inlet wire WG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and horn switch is pressed, measure voltage between horn relay terminal 5 outlet wire Lg 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.
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.
2-9-11. Backup buzzer does not sound Reference Fig. : 2-9-2 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 RY side and negative terminal to backup buzzer terminal wire B side. • If backup buzzer does not sound, backup buzzer is faulty.
2. Buckup buzzer switch
Replace buckup buzzer (1) W hen starter switch is ON, measure voltage between buckup buzzer switch terminal COM inlet wire WG and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and F-R lever is “R”, measure voltage between buckup buzzer switch terminal NO outlet wire RY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, buckup 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.
11-214
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.
11-215
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. 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 propulsion charge pump discharge.
Repair propulsione charge pump or replace it if necessary.
4. Propulsion Pump Proportional Solenoid Valve
Propulsion pump cannot discharge oil • Measure pressure in servo cylinder because oil does not flow into servo cylinder chamber. chamber due to faulty propulsion pump • If low, repair propulsion pump proportional proportional solenoid valve. solenoid valve or replace it if necessary.
5. Neutral 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 Propulsion Charge Pump
Propulsion charge pump flow is reduced due to clogged filter.
Clean suction filter or replace it if necessary.
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
11-216
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 1. High Pressure Relief Valve
Cause
Check/Action
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. 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 propulsion charge pump discharge.
Repair propulsion charge pump or replace it if necessary.
Flow rate of propulsion charge pump decreases as well as charge pressure decreases due to clogged filter.
Clean suction filter or replace it if necessary.
3. Suction Filter for Propulsion Charge Pump
11-217
TROUBLESHOOTING
3-2-3. Slow machine speed or small drive force 2/2 Check point 4. Propulsion Motor
5. 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
1. Propulsion Pump Swash Plate Stroke Cylinder
Faulty propulsion pump swash plate stroke cylinder.
Check/Action Repair propulsion pump 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. Servo Control Valve
Servo control valve neutral position adjustment failure.
Check and adjust servo control valve or replace it if necessary.
2. Propulsion Pump Servo Cylinder
Faulty propulsion pump servo cylinder or faulty pump swash plate setting.
Repair propulsion pump or replace it if necessary.
11-218
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 Propulsion Charge Pump
Load of propulsion 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 2
Charge circuit pressure increases due to clogged filter.
Clean hydraulic oil filter 2 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 Propulsion Charge Pump
Cavitation is occurring in propulsion 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.
11-219
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 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. 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
• 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
Circuit does not obtain required pressure because setting pressure of high pressure relief is low.
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.
• Measure vibrator circuit pressure. • If low, check and adjust high pressure relief valve or replace them if necessary.
Output torque is not transmitted due to worn Replace vibrator motor. spline of vibrator motor output shaft. 7. Vibrator Pump
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.
11-220
TROUBLESHOOTING
3-3-2. V ibration wheel does not switch Check point
Cause
Check/Action
1. Vibrator Solenoid Valve
Vibrator pressure is bypassed because vibrator solenoid valve spool does not switch.
If the vibrator solenoid valve spool does not switch, repair vibrator solenoid valve or replace it if necessary.
2. Vibrator Motor
Vibrator circuit pressure is not held in vibrator motor case.
If pressure in vibrator motor case is not within allowable range, 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 pump. spline of vibrator motor output shaft.
3-3-3. Vibrator frequency is too low 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
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
• 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. Vibrator Solenoid Valve
Vibrator pressure is bypassed due to internal leakage of vibrator solenoid valve.
Repair vibrator solenoid valve or replace it if necessary.
4. Suction Filter for 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.
5. 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.
11-221
TROUBLESHOOTING
3-3-3. Vibrator frequency is too low 2/2 Check point 6. 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.
3-3-4. 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.
3-3-5. Vibratory drum does not changeover vibrating Check point
Cause
Check/Action
1. Vibrator Solenoid Valve
Vibratory drum does not changeover vibrating because spool of vibrator solenoid valve does not change.
Repair vibrator solenoid valve or replace it if necessary.
3-3-6. 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.
11-222
TROUBLESHOOTING
3-3-7. 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
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.
5. Suction Filter for Steering • Charge Pump
Fill tank until correct oil level is obtained.
• Measure vibrator circuit pressure. • If high, decrease vibration 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.
6. Hydraulic Oil Filter 1 Charge circuit pressure increases due to clogged filter.
Clean hydraulic oil filter 1 or replace it if necessary.
3-3-8. 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.
11-223
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 oil filter 1 or replace it if increases due to clogged charging hydraulic necessary. oil filter 1.
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.
11-224
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.
11-225
Check/Action
SW884/994 SHOP MANUAL
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 © 2020 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. 0 K.P Printed in Japan 2020.2 10 ○ 0568-99022-0-31971-C