SW/TW354 SW/TW504 SHOP MANUAL
3498-6446A-1
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.
1 SW/TW354,SW/TW504 ○
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. SW354 2-001 1-2. SW354 ROPS 2-003 1-3. TW354 2-005 1-4. TW354 ROPS 2-007 1-5. TW504 2-009 1-6. TW504 ROPS 2-011 1-7. Common Specifications 2-013 2. TABLE OF STANDARD VALUES 2-1. Engine 2-014 2-2. Propulsion 2-014 1 ○
2-3. Hydraulic System 2-015 2-4. Steering 2-015 2-5. Brakes 2-016 2-6. Capacities 2-016 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating 2-017 3-2. Recommended Lubricants 2-017 4. TIGHTENING TORQUE CHART 2-018
0-001
1 SW/TW354,SW/TW504 ○
5. SPECIFICATION DATA (SW504) 5-1. SW504 2-019 5-2. SW504 ROPS 2-021 5-3. Common Specifications 2-023 6. TABLE OF STANDARD VALUES (SW504) 6-1. Engine 2-024 1 ○
6-2. Propulsion 2-024 6-3. Hydraulic System 2-024 6-4. Steering 2-025 6-5. Brakes 2-025 6-6. Capacities 2-025 7. FUEL AND LUBRICANTS SPECIFICATION (SW504) 7-1. Rating 2-026 7-2. Recommended Lubricants 2-026
3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 3-001 2. CONTROL SYSTEM 2-1. Throttle Control 3-002 2-2. Forward-reverse Control 3-003 3. PUMP MOUNT 3-1. Pump Mount 3-004 3-1-1. Installation of pump 3-005 4. ENGINE (SW504) 4-1. Engine Mount 3-006 5. FUEL SYSTEM (SW504) 3-007 6. CONTROL SYSTEM (SW504) 1 ○
6-1. Throttle Control 3-009 6-2. Forward-reverse Control 3-010 7. PUMP MOUNT (SW504) 7-1. Pump Mount 3-011 7-1-1. Installation of pump 3-012
4. HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits 4-001
0-002
1 SW/TW354,SW/TW504 ○
1-2. Hydraulic Circuit Diagram 4-003 1-2-1. Hydraulic circuit diagram (SW354) 4-003 1-2-2. Hydraulic circuit diagram (TW354) 4-004 1-2-3. Hydraulic circuit diagram (TW504) 4-005 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping 4-006 2-1-1. Propulsion hydraulic piping (F) (SW/TW354) 4-006 2-1-2. Propulsion hydraulic piping (F) (TW504) 4-007 2-1-3. Propulsion hydraulic piping (R) (SW354) 4-008 2-1-4. Propulsion hydraulic piping (R) (TW354) 4-009 2-1-5. Propulsion hydraulic piping (R) (TW504) 4-010 2-2. Hydraulic Component Specifications 4-011 2-2-1. Propulsion hydraulic pump 4-011 2-2-2. Propulsion hydraulic motor (F) (SW/TW354) 4-013 2-2-3. Propulsion hydraulic motor (F) (TW504) 4-014 2-2-4. Propulsion hydraulic motor (R) (SW354) 4-015 2-2-5. Propulsion hydraulic motor (R) (TW354,504) 4-016 2-2-6. Differential lock valve (TW354,504) 4-017 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping 4-018 3-1-1. Vibrator hydraulic piping (SW354) 4-018 3-1-2. Vibrator hydraulic piping (TW354) 4-019 3-1-3. Vibrator hydraulic piping (TW504) 4-020 3-2. Hydraulic Component Specifications 4-021 3-2-1. Hydraulic pump assembly (vibrator (F) + steering • charge) 4-021 3-2-2. Vibrator hydraulic pump (R) (SW354) 4-022 3-2-3. Vibrator hydraulic motor 4-023 3-2-4. Cooling fan drive hydraulic motor 4-024 3-2-5. Vibrator solenoid valve (F), (R) (SW/TW354) 4-025 3-2-6. Vibrator solenoid valve (TW504) 4-026 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping 4-027 4-1-1. Steering hydraulic piping (SW/TW354) 4-027 4-1-2. Steering hydraulic piping (TW504) 4-028 4-2. Steering Wheel 4-029 4-3. Hydraulic Component Specifications 4-030 4-3-1. Orbitrol 4-030
0-003
1 SW/TW354,SW/TW504 ○
5. HYDRAULIC CIRCUIT DIAGRAM (SW504) 5-1. Hydraulic Circuit Diagram 4-031 6. PROPULSION HYDRAULIC SYSTEM (SW504) 6-1. Propulsion Hydraulic Piping 4-032 6-1-1. Propulsion hydraulic piping (F) 4-032 6-1-2. Propulsion hydraulic piping (R) 4-033 6-2. Hydraulic Component Specifications 4-034 6-2-1. Propulsion hydraulic pump 4-034 6-2-2. Propulsion hydraulic motor (R) 4-036 1 ○
7. VIBRATOR HYDRAULIC SYSTEM (SW504) 7-1. Vibrator Hydraulic Piping 4-037 7-2. Hydraulic Component Specifications 4-038 7-2-1. Hydraulic pump assembly (vibrator + steering • charge) 4-038 7-2-2. Cooling fan drive hydraulic motor 4-039 7-2-3. Vibrator solenoid valve assembly 4-040 8. STEERING SYSTEM (SW504) 8-1. Steering Hydraulic Piping 4-041 8-2. Hydraulic Component Specifications 4-042 8-2-1. Orbitrol 4-042
5. ELECTRICAL SYSTEM 1. Precautions for work 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses 5-001 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram (SW354) 5-003 2-2. Electrical Circuit Diagram (SW354 ROPS) 5-004 2-3. Electrical Circuit Diagram (TW354) 5-005 2-4. Electrical Circuit Diagram (TW354 ROPS) 5-006 2-5. Electrical Circuit Diagram (TW504) 5-007 2-6. Electrical Circuit Diagram (TW504 ROPS) 5-008 3. ELECTRICAL COMPONENTS 3-1. Wiring Harness Layout (SW354) 5-009 3-1-1. Wiring harness layout (1) 5-009 3-1-2. Wiring harness layout (2) 5-010 3-2. Wiring Harness Layout (TW354) 5-011 3-2-1. Wiring harness layout (1) 5-011 3-2-2. Wiring harness layout (2) 5-012
0-004
1 SW/TW354,SW/TW504 ○
3-3. Wiring Harness Layout (TW504) 5-013 3-3-1. Wiring harness layout (1) 5-013 3-3-2. Wiring harness layout (2) 5-014 4. WIRING HARNESSES 4-1. Engine Harness 5-015 4-2. Dashboard Harness 5-017 4-3. Frame (F) Harness 5-019 4-3-1. Frame (F) harness (SW/TW354) 5-019 4-3-2. Frame (F) harness (TW504) 5-021 4-4. Frame (R) Harness 5-023 4-5. Stater Switch Harness 5-025 4-6. Control Switch Harness 5-026 4-7. Working Switch Harness 5-027 4-7-1. Working switch harness (except ROPS) 5-027 4-7-2. Working switch harness (ROPS) 5-028 4-8. Parking Brake Switch Harness 5-029 4-9. Vibration Lo-Hi Change Switch Harness 5-030 4-9-1. Short harness (SW/TW354 : except SW354 ROPS) 5-030 4-9-2. Vibration Lo-Hi change switch harness (TW504) 5-031 4-10. Vibrator Solenoid (R) Harness 5-032 4-10-1. Vibrator solenoid (R) harness (SW354) 5-032 4-10-2. Cap (TW354,504) 5-033 4-11. Hazard Switch Harness 5-034 4-11-1. Cap (except ROPS) 5-034 4-11-2. Hazard switch harness (ROPS) 5-035 4-12. Mihaalu Harness 5-036 4-13. Liquid Spray Switch Harness (TW354,504) 5-037 4-14. Liquid Spray Pump Harness (TW354,504) 5-038 4-15. Short Harness 5-039 4-16. Vibratory Drum Select Switch Harness (SW354 ROPS) 5-040 4-17. F-R Lever Vibration Switch (L) Harness 5-041 4-18. F-R Lever Vibration Switch (R) Harness 5-042 5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Fuse Box (SW354) 5-043 5-2. Fuse Box (TW354) 5-044 5-3. Fuse Box (TW504) 5-045 5-4. Combination Meter 5-046
0-005
1 SW/TW354,SW/TW504 ○
6. SYSTEM CIRCUIT DIAGRAM (SW504) 6-1. Electrical Circuit Diagram (ROPS) 5-047 6-2. Electrical Circuit Diagram (except ROPS) 5-048 7. ELECTRICAL COMPONENTS (SW504) 7-1. Wiring Harness Layout (1) 5-049 7-2. Wiring Harness Layout (2) 5-050 8. WIRING HARNESSES (SW504) 8-1. Engine Harness 5-051 8-2. Dashboard Harness (1) 5-053 8-3. Dashboard Harness (2) 5-055 8-4. ECU Harness (Vihicle) 5-057 8-5. ECU Harness (Engine) 5-059 8-6. Frame (F) Harness 5-061 8-7. Frame (R) Harness 5-063 8-8. Stater Switch Harness 5-065 8-9. Control Switch Harness 5-066 8-10. Working Switch Harness 5-067 8-10-1. Working switch harness (ROPS) 5-067 8-10-2. Working switch harness (except ROPS) 5-068 1 ○
8-11. Vibration Switch Harness 5-069 8-11-1. Vibration switch harness (ROPS) 5-069 8-11-2. Vibration Lo-Hi change switch harness (except ROPS) 5-070 8-12. Vibrator Solenoid (F) Harness (1) 5-071 8-13. Vibrator Solenoid (F) Harness (2) 5-072 8-14. Vibrator Solenoid (R) Harness (1) 5-073 8-15. Vibrator Solenoid (R) Harness (2) 5-074 8-16. Vibrator Solenoid (R) Harness (3) 5-075 8-17. Vibrator Solenoid (R) Harness (4) 5-076 8-18. Hazard Switch Harness 5-077 8-18-1. Hazard switch harness (ROPS) 5-077 8-18-2. Cap (except ROPS) 5-078 8-19. DPF Switch Harness 5-079 8-20. Diagnostic Switch Harness 5-080 8-21. Parking Brake Switch Harness 5-081 8-22. Mihaalu Harness 5-082 8-23. Starter Relay Harness 5-083 8-24. F-R Lever Vibration Switch (L) Harness 5-084 8-25. F-R Lever Vibration Switch (R) Harness 5-085 8-26. Short Harness 5-086 8-27. Cord 5-087
0-006
1 SW/TW354,SW/TW504 ○
9. ELECTRICAL COMPONENT SPECIFICATIONS (SW504) 1 ○
9-1. Fuse Box 5-088 9-2. Combination Meter 5-089
6. VIBRATORY DRUM • REAR WHEEL 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 6-006 3. VIBRATORY DRUM ASSEMBLY 3-1. Vibratory Drum Assembly (SW/TW354) 6-007 3-2. Vibratory Drum Assembly (TW504) 6-008 3-3. Disassembly and Reassembly of Vibratory Drum 6-009 3-3-1. Disassembly of vibratory drum 6-009 3-3-2. Reassembly of vibratory drum 6-020 4. REAR AXLE 4-1. Rear Axle Assembly (TW types) 6-039 4-2. Removal and Installation of Rear Axle (TW types) 6-040 4-2-1. Removal of rear axle 6-041 4-2-2. Installation of rear axle 6-044 5. VIBRATORY DRUM (SW504) 1 ○
5-1. Removal and Installation of Vibratory Drum 6-045 5-2. Disassembly and Reassembly of Vibratory Drum 6-045
7. BRAKE 1. BRAKE PEDAL 7-001 2. BRAKE SYSTEM 2-1. Brake System (SW354) 7-002 2-2. Brake System (TW354, 504) 7-003
8. WATER SPRAY SYSTEM 1. WATER SPRAY PIPING 1-1. Water Spray Piping (SW354) 8-001 1-2. Water Spray Piping (TW354, 504) 8-002 2. LIQUID SPRAY SYSTEM 2-1. Liquid Spray Piping (TW354,504) 8-003
0-007
1 SW/TW354,SW/TW504 ○
9. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment 9-001 1-2. Preparation for Inspection and Adjustment 9-001 1-3. Precautions for Inspection and Adjustment 9-001 1-4. Warm-up 9-001 1-5. Inspection and Adjustment of Engine Related Items 9-001 2. MEASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement 9-002 2-2. Inspection 9-003 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3-1. Measurement 9-004 3-2. Adjustment 9-005 4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE 4-1. Measurement 9-006 5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5-1. Measurement 9-007 5-1-1. SW types: front and rear, TW types: front 9-007 5-1-2. TW types: rear 9-008 6. MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement 9-009 7. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 7-1. Measurement 9-010 7-2. Inspection 9-011 8. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 8-1. Measurement of Propulsion Pump Case Pressure 9-012 9. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 9-1. Measurement 9-013 9-1-1. SW types: front and rear, TW types: front 9-013 9-1-2. TW types: rear 9-014 10. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (EXCEPT TW504) 1 ○
10-1. Measurement 9-015 11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (TW504) 11-1. Measurement 9-016 12. ADJUSTMENT OF THROTTLE LEVER 12-1. Adjustment of Linkage 9-017 12-2. Adjustment of Operating Force 9-018 13. ADJUSTMENT OF F-R LEVER
0-008
13-1. Adjustment of Linkage 9-019
1 SW/TW354,SW/TW504 ○
13-2. Adjustment of Operating Force 9-020 14. PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) 14-1. Measurement 9-021 15. M EASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE (SW504) 15-1. Measurement 9-022 15-2. Inspection 9-023 16. M EASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE (SW504) 16-1. Measurement 9-024 16-2. Adjustment 9-025 17. M EASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE (SW504) 17-1. Measurement 9-026 1 ○
18. M EASUREMENT OF VIBRATOR CIRCUIT PRESSURE (SW504) 18-1. Measurement 9-027 19. M EASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE (SW504) 19-1. Measurement 9-028 19-2. Inspection 9-029 20. M EASUREMENT OF HYDRAULIC PUMP CASE PRESSURE (SW504) 20-1. Measurement of Propulsion Pump Case Pressure 9-030 21. ADJUSTMENT OF THROTTLE LEVER (SW504) 21-1. Adjustment of Potentiometer 9-031 21-2. Adjustment of Operating Force 9-032 22. ADJUSTMENT OF F-R LEVER (SW504) 22-1. Adjustment of Linkage 9-033
10. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting 10-001 1-2. Important Information for Troubleshooting 10-001 1-3. Before Starting 10-002 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis 10-003 2-1-1. Precautions to take during electrical circuit fault diagnosis 10-003 2-1-2. Inspection procedures using a tester 10-004 2-1-3. Inspection of electrical system 10-009 0-009
1 SW/TW354,SW/TW504 ○
2-2. Engine 10-012 2-2-1. Engine will not start (Starter motor does not run) 1/3 10-012 2-2-1. Engine will not start (Starter motor does not run) 2/3 10-014 2-2-1. Engine will not start (Starter motor does not run) 3/3 10-016 2-2-2. Engine will not start (But starter motor runs) 10-016 2-2-3. Engine does not stop running 10-018 2-2-4. No charging 10-018 2-2-5. Glow plugs is not heated (Engine starting performance is bad in cold weather) 10-018 2-2-6. Starter motor runs even when F-R lever is not at “N” 10-020 2-3. Propulsion 10-022 2-3-1. Machine moves neither forward nor backward 10-022 2-3-2. Machine speed cannot be changed 10-024 2-3-3. Brake cannot be released 10-026 2-3-4. Brake does not work 10-028 2-4. Vibration 10-030 2-4-1. No vibration occurs 1/2 10-030 2-4-1. No vibration occurs 2/2 10-032 2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not work) 10-034 2-4-3. Vibratory drum cannot be switched (SW354 ROPS) 10-036 2-4-4. Amplitude does not change (Remains either low or high) (TW504) 10-038 2-5. Water Spray 10-040 2-5-1. Continuous water spray does not operate 10-040 2-5-2. Continuous water spray works, but auto water spray does not operate 10-042 2-5-3. Liquid cannot be sprayed (TW354, 504) 10-044 2-6. Lighting 10-046 2-6-1. Head lamp and tail lamp do not light 10-046 2-6-2. Flood lamp does not light 10-046 2-6-3. Turn signal lamp does not blink 10-048 2-6-4. Hazard lamp does not light (Turn signal blinks) (ROPS type) 10-050 2-6-5. Stop lamp does not light 10-052 2-6-6. Illumination of combination meter does not light 10-054 2-6-7. Combination meter warning lamp or indicator lamp is abnormal 10-054 2-6-8. Tachometer reading is abnormal 10-056 2-6-9. Hour meter is abnormal 10-056 2-6-10. Temperature meter is abnormal 10-058 2-6-11. Fuel meter is abnormal 10-058 2-6-12. Hydraulic oil filter warning lamp remains ON 10-060 2-6-13. Charge warning lamp remains ON 10-060 0-010
1 SW/TW354,SW/TW504 ○
2-6-14. Engine oil pressure warning lamp remains ON 10-062 2-6-15. Vibration indicator lamp does not light 10-064 2-6-16. Water spray indicator lamp does not light 10-066 2-6-17. Liquid spray indicator lamp does not light (TW354, 504) 10-066 2-6-18. Flood lamp indicator lamp does not light 10-068 2-6-19. Parking brake indicator lamp does not light 10-068 2-6-20. Turn signal indicator lamp does not light 10-070 2-6-21. Horn does not sound 10-072 2-6-22. Backup buzzer does not sound 10-072 3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting 10-073 3-2. Propulsion System 10-074 3-2-1. Machine moves neither forward nor backward 1/2 10-074 3-2-1. Machine moves neither forward nor backward 2/2 10-075 3-2-2. Machine moves in one direction only (forward or backward) 10-075 3-2-3. Slow machine speed or small drive force 1/2 10-075 3-2-3. Slow machine speed or small drive force 2/2 10-076 3-2-4. Machine speed cannot be switched 10-076 3-2-5. Machine does not stop completely with F-R lever in “N” 10-076 3-2-6. Driving not possible with differential locked (TW354, 504) 10-077 3-2-7. Propulsion system is overheating 10-077 3-2-8. Abnormal noise from propulsion system 10-077 3-3. Vibrator System 10-078 3-3-1. No vibration 10-078 3-3-2. Vibrator frequency is too low 10-079 3-3-3. Vibratory drum does not changeover vibrating (SW354 ROPS) 10-079 3-3-4. Vibration mode does not switch (TW504) 10-079 3-3-5. Vibrator does not stop 10-079 3-3-6. Vibrator system is overheating 10-080 3-3-7. Abnormal noise from vibrator system 10-080 3-4. Steering System 10-081 3-4-1. Steering wheel is hard to turn 10-081 3-4-2. Steering response is slow 10-081 3-4-3. Steering wheel backlash or play is large 10-082 3-4-4. Steering system is overheating 10-082 3-4-5. Abnormal noise from steering system 10-082 3-5. Cooling System 10-083 3-5-1. Cooling fan does not rotate 10-083 3-5-2. Cooling system is overheating 10-083 0-011
1 SW/TW354,SW/TW504 ○
4. ELECTRICAL SYSTEM TROUBLESHOOTING (SW504) 4-1. Engine Diagnosis Trouble Code 10-084 4-1-1. Description of diagnostic trouble code (SPN, FMI) 10-084 4-1-2. Table of the diagnostic trouble code (DTC) 10-085 4-2. Engine 10-092 4-2-1. Engine will not start (Starter motor does not run) 1/3 10-092 4-2-1. Engine will not start (Starter motor does not run) 2/3 10-094 4-2-1. Engine will not start (Starter motor does not run) 3/3 10-096 4-2-2. Engine will not start (But starter motor runs) 10-096 4-2-3. Glow plugs is not heated (Engine starting performance is bad in cold weather) 10-098 4-2-4. Engine speed does not change when operating throttle lever 10-100 4-3. Propulsion 10-101 4-4. Vibration 10-103 4-4-1. No vibration occurs 1/3 10-103 4-4-1. No vibration occurs 2/3 10-105 1 ○
4-4-1. No vibration occurs 3/3 10-107 4-4-2. Vibratory drum cannot be switched (ROPS) 10-109 4-5. Water Spray 10-110 4-6. Lighting 10-112 4-6-1. Illumination of combination meter does not light 10-112 4-6-2. Combination meter warning lamp or indicator lamp is abnormal 10-114 4-6-3. Tachometer reading is abnormal 10-114 4-6-4. Hour meter is abnormal 10-116 4-6-5. Fuel meter is abnormal 10-116 4-6-6. Hydraulic oil filter warning lamp remains ON 10-118 4-6-7. Charge warning lamp remains ON 10-118 4-6-8. Vibration indicator lamp does not light 10-120 4-6-9. Water spray indicator lamp does not light 10-122 4-6-10. Flood lamp indicator lamp does not light 10-124 4-6-11. Parking brake indicator lamp does not light 10-124 4-6-12. Turn signal indicator lamp does not light 10-126 5. HYDRAULIC SYSTEM TROUBLESHOOTING (SW504) 10-127
0-012
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
SW354
1. SPECIFICATION DATA
67
1200
45
2000 2675
540
540
5
250
45
5
67
540
540
1575
1290
1-1. SW354
1200 0446-99024-0-10967-0
Model & Type
Model Type Operating weight
Weight
Dimensions
2-001
without ballast with ballast
Maximum weight Shipping weight Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width Overall height Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width
SAKAI SW354 VIBRATORY TANDEM ROLLER 2,900 kg ( 6,395 lbs. ) N/A kg ( N/A lbs. ) 3,020 kg ( 6,660 lbs. ) 2,710 kg ( 5,975 lbs. ) 1,470 kg ( 3,240 lbs. ) 1,430 kg ( 3,155 lbs. ) 2,675 mm ( 105 in. ) 1,290 mm ( 51 in. ) 1,575 mm ( 62 in. ) 2,000 mm ( 79 in. ) 1,200 mm ( 47 in. ) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 250 mm ( 10 in. ) 540 mm ( 21 in. ) 540 mm ( 21 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SW354
SPECIFICATIONS
Centrifugal force Frequency Amplitude Vibrator system Centrifugal force Rear Frequency Amplitude Front drum Operating weight Static linear pressure Rear drum Operating weight Linear pressure Dynamic linear Front drum Operating weight pressure Performance Rear drum Operating weight Number of speed shifts Traveling 1st speed Speed range 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 Front
29.0 kN ( 6,520 lbf ) 66.7 Hz ( 4,000 vpm ) 0.31 mm ( 0.012 in. ) 29.0 kN ( 6,520 lbf ) 66.7 Hz ( 4,000 vpm ) 0.31 mm ( 0.012 in. ) 120 N/cm ( 70 lbf./in. ) 117 N/cm ( 65 lbf./in. ) 362 N/cm ( 205 lbf./in. ) 358 N/cm ( 205 lbf./in. ) 2 speed ( 0 to 4.3 mile/h ) 0 to 7 km/h ( 0 to 6.2 mile/h ) 0 to 10 km/h 38 % ( 21 ° ) 2.5 m ( 99 in. ) 3.8 m ( 150 in. ) 2.6 m ( 103 in. ) 3.7 m ( 146 in. ) ± 35 ° / ± 4 °
2-002
SPECIFICATIONS
SW354 ROPS
5 2000
67
250
540
540 5
1200
67
45
540
540
1575
1875
2455
1290
1-2. SW354 ROPS
1200
2675 0446-99026-0-11005-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-003
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI SW354 with ROPS VIBRATORY TANDEM ROLLER 2,960 kg ( 6,525 lbs. ) N/A kg ( N/A lbs. ) 3,080 kg ( 6,790 lbs. ) 2,770 kg ( 6,105 lbs. ) 2,710 kg ( 5,795 lbs. ) 1,470 kg ( 3,240 lbs. ) 1,490 kg ( 3,285 lbs. ) 2,675 mm ( 105 in. ) 1,290 mm ( 51 in. ) 2,455 mm ( 97 in. ) 1,575 mm ( 62 in. ) 2,000 mm ( 79 in. ) 1,200 mm ( 47 in. ) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 250 mm ( 10 in. ) 540 mm ( 21 in. ) 540 mm ( 21 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SW354 ROPS
SPECIFICATIONS
Centrifugal force Frequency Amplitude Vibrator system Centrifugal force Rear Frequency Amplitude Front drum Operating weight Static linear pressure Rear drum Operating weight Linear pressure Dynamic linear Front drum Operating weight pressure Performance Rear drum Operating weight Number of speed shifts Traveling 1st speed Speed range 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 Front
29.0 kN ( 6,520 lbf ) 66.7 Hz ( 4,000 vpm ) 0.31 mm ( 0.012 in. ) 29.0 kN ( 6,520 lbf ) 66.7 Hz ( 4,000 vpm ) 0.31 mm ( 0.012 in. ) 120 N/cm ( 70 lbf./in. ) 121 N/cm ( 70 lbf./in. ) 362 N/cm ( 205 lbf./in. ) 363 N/cm ( 205 lbf./in. ) 2 speed ( 0 to 4.3 mile/h ) 0 to 7 km/h ( 0 to 6.2 mile/h ) 0 to 10 km/h 38 % ( 21 ° ) 2.5 m ( 99 in. ) 3.8 m ( 150 in. ) 2.6 m ( 103 in. ) 3.7 m ( 146 in. ) ± 35 ° / ± 4 °
2-004
SPECIFICATIONS
TW354
67
5
45
1200
250
9.
45
2000 2675
PR
540
540
1575
1290
1-3. TW354
5/ 65- 15
-6
279
398
279
0447-99021-0-10193-A
Model & Type
Model Type Operating weight
Weight
Dimensions
2-005
without ballast with ballast
Maximum weight Shipping weight Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width Overall height Wheelbase Compaction width Front drum width × dia. × thickness width × dia. Rear tyres (outer shell) Size Inflation pressure Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width
SAKAI TW354 VIBRATORY COMBINED ROLLER 2,600 kg ( 5,730 lbs. ) N/A kg ( N/A lbs. ) 2,720 kg ( 5,995 lbs. ) 2,410 kg ( 5,315 lbs. ) 1,470 kg ( 3,240 lbs. ) 1,130 kg ( 2,490 lbs. ) 2,675 mm ( 105 in. ) 1,290 mm ( 51 in. ) 1,575 mm ( 62 in. ) 2,000 mm ( 79 in. ) 1,200 mm ( 47 in. ) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 1,199 mm × 671 mm (47 in. × 26 in. ) 9.5/65-15-6PR 294 kPa ( 42.6 psi ) 250 mm ( 10 in. ) 540 mm ( 21 in. ) 540 mm ( 21 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
TW354
SPECIFICATIONS
Centrifugal force Frequency Amplitude Vibrator system Centrifugal force Rear Frequency Amplitude Front drum Operating weight Static linear pressure Rear drum Operating weight Linear pressure Dynamic linear Front drum Operating weight pressure Performance Rear drum Operating weight Number of speed shifts Traveling 1st speed Speed range 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 Front
20.6 kN ( 4,630 lbf ) 52.0 Hz ( 3,120 vpm ) 0.36 mm ( 0.014 in. ) N/A kN ( N/A lbf ) N/A Hz ( N/A vpm ) N/A mm ( N/A in. ) 120 N/cm ( 70 lbf./in. ) N/A N/cm ( N/A lbf./in. ) 292 N/cm ( 165 lbf./in. ) N/A N/cm ( N/A lbf./in. ) 2 speed ( 0 to 4.3 mile/h ) 0 to 7 km/h ( 0 to 6.2 mile/h ) 0 to 10 km/h 38 % ( 21 ° ) 2.5 m ( 99 in. ) 3.8 m ( 150 in. ) 2.6 m ( 103 in. ) 3.7 m ( 146 in. ) ± 35 ° / ± 4 °
2-006
SPECIFICATIONS
TW354 ROPS
45
5
1200
67
45
250
9.
2000
P
R
540
540
1575
1875
2455
1290
1-4. TW354 ROPS
5/ 65- 15
- 6
279 398
279
2675 0447-99023-0-10198-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-007
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness width × dia. Rear tyres (outer shell) Size Inflation pressure Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI TW354 with ROPS VIBRATORY COMBINED ROLLER 2,660 kg ( 5,865 lbs. ) N/A kg ( N/A lbs. ) 2,780 kg ( 6,130 lbs. ) 2,470 kg ( 5,445 lbs. ) 2,410 kg ( 5,315 lbs. ) 1,470 kg ( 3,240 lbs. ) 1,190 kg ( 2,625 lbs. ) 2,675 mm ( 105 in. ) 1,290 mm ( 51 in. ) 2,455 mm ( 97 in. ) 1,575 mm ( 62 in. ) 2,000 mm ( 79 in. ) 1,200 mm ( 47 in. ) 1,200 mm × 675 mm × 13 mm (47 in. × 27 in. × 0.5 in.) 1,199 mm × 671 mm (47 in. × 26 in. ) 9.5/65-15-6PR 294 kPa ( 42.6 psi ) 250 mm ( 10 in. ) 540 mm ( 21 in. ) 540 mm ( 21 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SPECIFICATIONS
TW354 ROPS Centrifugal force Frequency Amplitude Vibrator system Centrifugal force Rear Frequency Amplitude Front drum Operating weight Static linear pressure Rear drum Operating weight Linear pressure Dynamic linear Front drum Operating weight pressure Performance Rear drum Operating weight Number of speed shifts Traveling 1st speed Speed range 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 Front
20.6 kN ( 4,630 lbf ) 52.0 Hz ( 3,120 vpm ) 0.36 mm ( 0.014 in. ) N/A kN ( N/A lbf ) N/A Hz ( N/A vpm ) N/A mm ( N/A in. ) 120 N/cm ( 70 lbf./in. ) N/A N/cm ( N/A lbf./in. ) 292 N/cm ( 165 lbf./in. ) N/A N/cm ( N/A lbf./in. ) 2 speed ( 0 to 4.3 mile/h ) 0 to 7 km/h ( 0 to 6.2 mile/h ) 0 to 10 km/h 38 % ( 21 ° ) 2.5 m ( 99 in. ) 3.8 m ( 150 in. ) 2.6 m ( 103 in. ) 3.7 m ( 146 in. ) ± 35 ° / ± 4 °
2-008
SPECIFICATIONS
TW504
80
0
635
635
1705
1390
1-5. TW504
45
1300
280
10
45
2300 3105
.5
/ 80 - 16- 6
PR
295
430
295
0449-99014-0-10234-A
Model & Type
Model Type Operating weight
Weight
Dimensions
2-009
without ballast with ballast
Maximum weight Shipping weight Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width Overall height Wheelbase Compaction width Front drum width × dia. × thickness width × dia. Rear tyres (outer shell) Size Inflation pressure Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width
SAKAI TW504 VIBRATORY COMBINED ROLLER 3,440 kg ( 7,585 lbs. ) N/A kg ( N/A lbs. ) 3,620 kg ( 7,980 lbs. ) 3,190 kg ( 7,035 lbs. ) 1,980 kg ( 4,365 lbs. ) 1,460 kg ( 3,220 lbs. ) 3,105 mm ( 122 in. ) 1,390 mm ( 55 in. ) 1,705 mm ( 67 in. ) 2,300 mm ( 91 in. ) 1,300 mm ( 51 in. ) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 1,295 mm × 812 mm (51 in. × 32 in. ) 10.5/80-16-6PR 294 kPa ( 42.6 psi ) 280 mm ( 11 in. ) 635 mm ( 25 in. ) 635 mm ( 25 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SPECIFICATIONS
TW504 Low Centrifugal amplitude High force amplitude Low amplitude Front Frequency High amplitude Low amplitude Amplitude High amplitude Vibrator system Low Centrifugal amplitude High force amplitude Low amplitude Rear Frequency High amplitude Low amplitude Amplitude Performance High amplitude Static linear Front drum Operating weight pressure Rear drum Operating weight Low Operating amplitude Front drum weight Linear High Dynamic pressure amplitude linear Low pressure Operating amplitude Rear drum weight High amplitude Number of speed shifts Traveling 1st speed Speed range 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
26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
52 Hz
(
3,100 vpm
)
52 Hz
(
3,100 vpm
)
0.30 mm
(
0.012 in.
)
0.40 mm
(
0.016 in.
)
N/A kN
(
N/A lbf
)
N/A kN
(
N/A lbf
)
N/A Hz
(
N/A vpm
)
N/A Hz
(
N/A vpm
)
N/A mm
(
N/A in.
)
N/A mm
(
N/A in.
)
149 N/cm N/A N/cm
( (
85 lbf./in. ) N/A lbf./in. )
353 N/cm
(
202 lbf./in. )
413 N/cm
(
236 lbf./in. )
N/A N/cm
(
N/A lbf./in. )
N/A N/cm
(
N/A lbf./in. )
2 speed ( 0 to 4.3 mile/h 0 to 7 km/h ( 0 to 6.2 mile/h 0 to 10 km/h 38 % ( 21 ° 2.9 m ( 115 in. 4.4 m ( 174 in. 3.0 m ( 119 in. 4.3 m ( 170 in. ± 35 ° / ± 4 °
) ) ) ) ) ) )
2-010
SPECIFICATIONS
TW504 ROPS
635
635
1705
2565
1390
1-6. TW504 ROPS
45
0
1300
80
45
280
1
2300 3105
0.
5/ 80 16 - 6 -
PR
295
430
295
0449-99020-0-10260-A
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-011
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness width × dia. Rear tyres (outer shell) Size Inflation pressure Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI TW504 with ROPS VIBRATORY COMBINED ROLLER 3,510 kg ( 7,740 lbs. ) N/A kg ( N/A lbs. ) 3,680 kg ( 8,115 lbs. ) 3,260 kg ( 7,185 lbs. ) 3,190 kg ( 7,035 lbs. ) 1,980 kg ( 4,365 lbs. ) 1,530 kg ( 3,375 lbs. ) 3,105 mm ( 122 in. ) 1,390 mm ( 55 in. ) 2,565 mm ( 101 in. ) 1,705 mm ( 67 in. ) 2,300 mm ( 91 in. ) 1,300 mm ( 51 in. ) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 1,295 mm × 812 mm (51 in. × 32 in. ) 10.5/80-16-6PR 294 kPa ( 42.6 psi ) 280 mm ( 11 in. ) 635 mm ( 25 in. ) 635 mm ( 25 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SPECIFICATIONS
TW504 ROPS Low Centrifugal amplitude High force amplitude Low amplitude Front Frequency High amplitude Low amplitude Amplitude High amplitude Vibrator system Low Centrifugal amplitude High force amplitude Low amplitude Rear Frequency High amplitude Low amplitude Amplitude Performance High amplitude Static linear Front drum Operating weight pressure Rear drum Operating weight Low Operating amplitude Front drum weight Linear High Dynamic pressure amplitude linear Low pressure Operating amplitude Rear drum weight High amplitude Number of speed shifts Traveling 1st speed Speed range 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
26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
52 Hz
(
3,100 vpm
)
52 Hz
(
3,100 vpm
)
0.30 mm
(
0.012 in.
)
0.40 mm
(
0.016 in.
)
N/A kN
(
N/A lbf
)
N/A kN
(
N/A lbf
)
N/A Hz
(
N/A vpm
)
N/A Hz
(
N/A vpm
)
N/A mm
(
N/A in.
)
N/A mm
(
N/A in.
)
149 N/cm N/A N/cm
( (
85 lbf./in. ) N/A lbf./in. )
353 N/cm
(
202 lbf./in. )
413 N/cm
(
236 lbf./in. )
N/A N/cm
(
N/A lbf./in. )
N/A N/cm
(
N/A lbf./in. )
2 speed ( 0 to 4.3 mile/h 0 to 7 km/h ( 0 to 6.2 mile/h 0 to 10 km/h 38 % ( 21 ° 2.9 m ( 115 in. 4.4 m ( 174 in. 3.0 m ( 119 in. 4.3 m ( 170 in. ± 35 ° / ± 4 °
) ) ) ) ) ) )
2-012
SPECIFICATIONS
1-7. Common Specifications Model Type Bore × Stroke Displacement Rated speed Rated output Performance
Max. torque Fuel consumption rate
Engine
Fuel system
Lubrication system Air intake system Cooling system Electrical system
Fuel consumption Fuel Fuel injection pump Fuel injection time regulator Lubrication type Oil filter type Oil cooler type
Drive system
Vibration system
Steering system
Drums and tyres
Sprinkler system Others
2-013
Full forced pressure feed by gear pump Full flow paper element N/A Dry
Cooling type Cooling fan type Alternator Starter Battery
Pressurized water forced circulation Inhale 12 V 60 A 12 V 2.0 kW 12 V (78 Ah, CCA N/A) × 1 pc. (12 V) 169 kg (373 lbs.) Hydrostatic 2 speed shifts Switching the direction of flow delivered from the variable pump N/A N/A Direct drive Direct drive Hydraulic Single eccentric shaft Variable eccentric shaft Dynamic braking through hydrostatic drive system (F-N-R lever)
Type Speeds
Reverser Differential type
Front Rear Front Final drive Rear Power transmission type SW/TW354 Vibrator type TW504 Service brake
Brake system
Mechanical all speed governor
Air cleaner type
Dry weight Transmission
KUBOTA D1703-M-DI-EF03 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 3-cylinder in-line, vertical mounted, overhead valve, direct injection type 87.0 mm × 92.4 mm (3.425 in. × 3.638 in.) 1.647 L ( 100.5 cu.in. ) 2,200 min-1 18.2 kW ( 24 HP ) 96.0 N·m ( 71 lbf·ft ) at 1,500 min-1 256 g/kW·h ( 0.421 lb/HP·h ) at 2,200 min-1 5.6 L/h with full load ( 1.5 gal. with full load) Diesel (ASTM D975-2D) Inline injection pump
Secondary brake (Emergency brake) Parking brake Power transmission type Steering type Front Use SW354 Rear TW354,504 Front Suspension SW354 type Rear TW354,504 Water spray type SW354 Liquid spray type TW354,504 ECO mode ROPS
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 tyre / Drive / 4pcs. Rubber isolation Rubber isolation Rigid Pressurized N/A Pressurized Standard Option
SPECIFICATIONS
2. TABLE OF STANDARD VALUES 2-1. Engine Item Engine model Rated output Max. rpm under no load Min. rpm under no load Cylinder head tightening torque Intake manifold tightening torque Exhaust manifold tightening torque Fan belt tension
Standard value KUBOTA D1703-M-DI-E4B 17.7 kW 24 HP ( 2,470 min-1 1,050 to 1,150 min-1 93.2 to 98.0 N·m ( 68.8 to 72.3 lbf·ft 24 to 27 N·m 18 to 20 lbf·ft ( 24 to 27 N·m 18 to 20 lbf·ft ( 7.0 to 9.0 mm
Valve clearance (intake) Valve clearance (exhaust) Standard value Compression pressure Allowable limit
0.18 to 0.22 mm 0.18 to 0.22 mm 2.95 to 3.23 MPa 2.35 MPa
(
Remarks ) or less ) ) )
0.28 to 0.35 in.
)
( 0.0071 to 0.0086 in. ( 0.0071 to 0.0086 in. ( 427 to 469 psi ( 341 psi
) ) ) )
When midpoint of belt pressed at 98 N (22 lbf)
290 min-1 290 min-1
2-2. Propulsion Item 1st Travel speed (Forward/reverse) 2nd Hub bolt tightening torque (TW354,504) Tyre inflation pressure (TW354,504)
Standard value 0 to 7 km/h ( 0 to 4.3 mph 0 to 10 km/h ( 0 to 6.2 mph 167 N·m ( 123 lbf·ft 294 kPa ( 42.6 psi
Remarks ) ) ) )
2-014
SPECIFICATIONS
2-3. Hydraulic System Item
Standard value TW354
SW354
Propulsion
High pressure relief valve pressure setting Charge relief valve pressure setting Pump Case pressure Motor (F) Motor (R) Motor (F) Brake release pressure Motor (R) Motor (F) Drainage Motor (R) High pressure relief valve pressure setting
34.5 MPa (
Vibration
Motor (R)
3.7 L/min ( 1.0 gal./min )
Motor (R) Steering oil pressure
5,003 psi )
1.8 L/min ( 0.5 gal./min )
12.7 MPa ( 1,842 psi )
14.0 MPa ( 2,030 psi )
0.5 MPa ( 72.5 psi ) or less 0.5 MPa ( 72.5 psi ) or less
N/A 3.4 L/min ( 0.9 gal./min )
Motor (F) Drainage
Remarks
1.9 ± 0.7 MPa ( 276 ± 100 psi ) 0.25 MPa ( 36.3 psi ) or less 0.3 MPa ( 43.5 psi ) or less 0.3 MPa ( 43.5 psi ) or less More than 1.5 MPa ( 218 psi ) More than 1.5 MPa ( 218 psi ) 3.7 L/min 4.9 L/min ( 1.0 gal./min ) ( 1.3 gal./min )
Motor (F) Case pressure
TW504
3.4 L/min ( 0.9 gal./min )
N/A 13.5 MPa ( 1,958 psi )
2-4. Steering Item
Standard value 5 to 10 mm ( 0.2 to 0.4 in. )
Play in steering wheel 0.5 mm (
2-015
0.02 in. ) or less
Remarks Steering wheel circumference Steering column shaft direction
SPECIFICATIONS
2-5. Brakes Clearance between brake pedal and floorboard (as released)
Note 1: 119 mm (4.7 in.)
Clearance between brake pedal and floorboard (when pressed down)
Note 2: 79 mm (3.1 in.)
Remarks
Note 1
Standard value
Note 2
Item
SW354-02002
Brake lock condition
L1
Replacement standard brake stroke length
More than 3.5 mm (0.14 in.) (L2-L1)
Bolt Brake releasing condition
L2
SW300-1-02001
2-6. Capacities Item Engine oil pan Fuel tank Coolant Hydraulic oil tank Vibrator case Water spray tank Liquid spray tank
Standard value TW354 TW504 7.0 L ( 1.8 gal. ) 40 L 50 L ( 10.6 gal. ) ( 13.2 gal. ) 5.8 L 6.5 L ( 1.5 gal. ) ( 1.7 gal. ) 43 L ( 11.4 gal. ) 5.0 L × 2 5.0 L 6.0 L ( 1.3 gal. ) × 2 ( 1.3 gal. ) ( 1.6 gal. ) 200 L 310 L ( 52.8 gal. ) ( 81.9 gal. ) 10 L N/A ( 2.6 gal. ) SW354
Remarks
2-016
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 CF
SAE10W-30
SAE30
SAE40
MIL-L-2104D
Gear oil
API grade GL5
SAE75W-90
SAE75W-90
SAE140
MIL-L-2105
Hydraulic oil
Wear resisting
ISO-VG32 over VI 140
ISO-VG46 over VI 140
ISO-VG68 over VI 110
ISO-3448
Lubricant
Grease
Lithium type extreme pressure grease
Fuel
Ambient temp. -15 to -10°C
Ambient temp. -10 to 55°C
Diesel fuel ASTM D975 NO.1-D S15 or S500*1
Diesel fuel ASTM D975 NO.2-D S15 or S500*2
NLGI-2
*1: For EPA regulation:Diesel fuel ASTM D975 NO.1-D S15 only. *2: For EPA regulation:Diesel fuel ASTM D975 NO.2-D S15 only.
3-2. Recommended Lubricants Lubricant Engine oil API-CF
Gear oil API GL 5
Hydraulic oil VG 46
Grease NLGI-2
Chevron
DELO 400
RPM UNIVERSAL GEAR LUBRICANTS
RANDO HDZ
MULTIFAK EP
BP
Vanellus C-Extra
Energear HYPO-U
Bartran HV
Energrease LS-EP
CASTROL
CW 30
EPX GEAR OILS
Castrol Hyspin AWH
Castrol Spheerol EPL
Shell
Shell Rimura Super
Shell Spirax S2 A 90
Shell Tellus S2 V
Shell Alvania Grease EP
ExxonMobil
Mobil Delvac MX
Mobilude HD
Mobil DTE 10 Excel
Mobilux EP
Oil company
2-017
SPECIFICATIONS
4. TIGHTENING TORQUE CHART
Metric fine screw
Metric coarse screw
N·m 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)
2-018
SPECIFICATIONS
SW504
5. SPECIFICATION DATA (SW504)
1390 80
280 45
1300
0
635
0
45
2300 3100
635
80
635
635
1705
1390
5-1. SW504
1300 0448-99030-0-10639-0
Model & Type
Model Type Operating weight
Weight
Dimensions
2-019
without ballast with ballast
Maximum weight Shipping weight Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width Overall height Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width
SAKAI SW504 VIBRATORY TANDEM ROLLER 3,990 kg ( 8,800 lbs. ) N/A kg ( N/A lbs. ) 4,170 kg ( 9,195 lbs. ) 3,740 kg ( 8,250 lbs. ) 1,990 kg ( 4,390 lbs. ) 2,000 kg ( 4,410 lbs. ) 3,100 mm ( 122 in. ) 1,390 mm ( 55 in. ) 1,705 mm ( 67 in. ) 2,300 mm ( 91 in. ) 1,300 mm ( 51 in. ) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 280 mm ( 11 in. ) 635 mm ( 25 in. ) 635 mm ( 25 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SW504 Low Centrifugal amplitude High force amplitude Low amplitude Front Frequency High amplitude Low amplitude Amplitude High amplitude Vibrator system Low Centrifugal amplitude High force amplitude Low amplitude Rear Frequency High amplitude Low amplitude Amplitude Performance High amplitude Static linear Front drum Operating weight pressure Rear drum Operating weight Low Operating amplitude Front drum weight Linear High Dynamic pressure amplitude linear Low pressure Operating amplitude Rear drum weight High amplitude Number of speed shifts Traveling 1st speed Speed range 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 26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
55.0 Hz
(
3,300 vpm
)
55.0 Hz
(
3,300 vpm
)
0.27 mm
(
0.011 in.
)
0.35 mm
(
0.014 in.
)
26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
55.0 Hz
(
3,300 vpm
)
55.0 Hz
(
3,300 vpm
)
0.27 mm
(
0.011 in.
)
0.35 mm
(
0.014 in.
)
150 N/cm 151 N/cm
( (
85 lbf./in. ) 85 lbf./in. )
354 N/cm
(
200 lbf./in. )
414 N/cm
(
235 lbf./in. )
355 N/cm
(
205 lbf./in. )
415 N/cm
(
235 lbf./in. )
2 speed ( 0 to 4.7 mile/h 0 to 7.5 km/h ( 0 to 6.2 mile/h 0 to 10 km/h 38 % ( 21 ° 2.9 m ( 115 in. 4.4 m ( 174 in. 3.0 m ( 119 in. 4.3 m ( 170 in. ± 35 ° / ± 4 °
) ) ) ) ) ) )
2-020
SPECIFICATIONS
SW504 ROPS
45
0
1300
635
0
2300 3100
80
80
45
280
635
635
635
1705
1900
2565
1390
1390
5-2. SW504 ROPS
45
1300
45
0448-99032-0-10746-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-021
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI SW504 with ROPS VIBRATORY TANDEM ROLLER 4,060 kg ( 8,955 lbs. ) N/A kg ( N/A lbs. ) 4,240 kg ( 9,350 lbs. ) 3,810 kg ( 8,400 lbs. ) 3,740 kg ( 8,250 lbs. ) 1,990 kg ( 4,390 lbs. ) 2,070 kg ( 4,565 lbs. ) 3,100 mm ( 122 in. ) 1,390 mm ( 55 in. ) 2,565 mm ( 101 in. ) 1,705 mm ( 67 in. ) 2,300 mm ( 91 in. ) 1,300 mm ( 51 in. ) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 1,300 mm × 800 mm × 17 mm (51 in. × 31 in. × 0.7 in.) 280 mm ( 11 in. ) 635 mm ( 25 in. ) 635 mm ( 25 in. ) 45 mm ( 2 in. ) 45 mm ( 2 in. ) N/A mm ( N/A in. )
SW504 ROPS Low Centrifugal amplitude High force amplitude Low amplitude Front Frequency High amplitude Low amplitude Amplitude High amplitude Vibrator system Low Centrifugal amplitude High force amplitude Low amplitude Rear Frequency High amplitude Low amplitude Amplitude Performance High amplitude Static linear Front drum Operating weight pressure Rear drum Operating weight Low Operating amplitude Front drum weight Linear High Dynamic pressure amplitude linear Low pressure Operating amplitude Rear drum weight High amplitude Number of speed shifts Traveling 1st speed Speed range 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 26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
55.0 Hz
(
3,300 vpm
)
55.0 Hz
(
3,300 vpm
)
0.27 mm
(
0.011 in.
)
0.35 mm
(
0.014 in.
)
26.5 kN
(
5,955 lbf
)
34.3 kN
(
7,710 lbf
)
55.0 Hz
(
3,300 vpm
)
55.0 Hz
(
3,300 vpm
)
0.27 mm
(
0.011 in.
)
0.35 mm
(
0.014 in.
)
150 N/cm 156 N/cm
( (
85 lbf./in. ) 90 lbf./in. )
354 N/cm
(
200 lbf./in. )
414 N/cm
(
235 lbf./in. )
360 N/cm
(
205 lbf./in. )
420 N/cm
(
240 lbf./in. )
2 speed ( 0 to 4.7 mile/h 0 to 7.5 km/h ( 0 to 6.2 mile/h 0 to 10 km/h 38 % ( 21 ° 2.9 m ( 115 in. 4.4 m ( 174 in. 3.0 m ( 119 in. 4.3 m ( 170 in. ± 35 ° / ± 4 °
) ) ) ) ) ) )
2-022
SPECIFICATIONS
SW504
5-3. Common Specifications Model Type Bore × Stroke Displacement Rated speed Rated output Performance
Max. torque Fuel consumption rate
Engine
Fuel system
Lubrication system Air intake system Cooling system Electrical system
Fuel consumption Fuel Fuel injection pump Fuel injection time regulator Lubrication type Oil filter type Oil cooler type
Drive system
Vibration system
Steering system
Drums and tyres
Sprinkler system Others
2-023
Full forced pressure feed Full flow paper element Intergrated water cooled Dry
Cooling type Cooling fan type Alternator Starter Battery
Pressurized water forced circulation Inhale 12 V 60 A 12 V 2.0 kW 12 V (72 Ah, CCA 750 A) × 1 pc. (12 V) 200 kg (441 lbs.) Hydrostatic 2 speed shifts Switching the direction of flow delivered from the variable pump N/A N/A Direct drive Direct drive Hydraulic Single eccentric shaft Dynamic braking through hydrostatic drive system (F-N-R lever)
Type Speeds
Reverser Differential type
Front Rear Front Final drive Rear Power transmission type Vibrator type Service brake
Brake system
Electric speed control
Air cleaner type
Dry weight Transmission
KUBOTA D1803-CR-T-EF02 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 3-cylinder in-line, vertical mounted, overhead valve, direct injection type, with turbo charger 87.0 mm × 102.4 mm (3.425 in. × 4.031 in.) 1.826 L ( 111.4 cu.in. ) 2,400 min-1 32.3 kW ( 43 HP ) 148 N·m ( 109 lbf·ft ) at 1,500 min-1 232 g/kW·h ( 0.381 lb/HP·h ) at 2,400 min-1 9.0 L/h with full load ( 2.4 gal. with full load) Diesel (ASTM D975-2D) High pressure common rail
Secondary brake (Emergency brake) Parking brake Power transmission type Steering type Front Use Rear Front Suspension type Rear Water spray type Liquid spray type ECO mode ROPS CANOPY
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 Standard Option Option
SW504
SPECIFICATIONS
6. TABLE OF STANDARD VALUES (SW504) 6-1. Engine Item Engine model Rated output Max. rpm under no load Min. rpm under no load Cylinder head tightening torque Intake manifold tightening torque Exhaust manifold tightening torque Fan belt tension
Standard value KUBOTA D1803-CR-T-EF02 32.8 kW 44 HP ( 2,600 min-1 1,000 ± 25 min-1 93.2 to 98.0 N·m ( 68.8 to 72.3 lbf·ft 24 to 27 N·m 18 to 20 lbf·ft ( 24 to 27 N·m 18 to 20 lbf·ft ( 7.0 to 9.0 mm
Valve clearance (intake) Valve clearance (exhaust) Standard value Compression pressure Allowable limit
(
0.18 to 0.22 mm 0.18 to 0.22 mm 2.95 to 3.23 MPa 2.35 MPa
Remarks ) or less ) ) )
0.28 to 0.35 in.
)
( 0.0071 to 0.0086 in. ( 0.0071 to 0.0086 in. ( 427 to 469 psi ( 341 psi
) ) ) )
When midpoint of belt pressed at 98 N (22 lbf)
290 min-1 290 min-1
6-2. Propulsion Item
Standard value 0 to 7.5 km/h ( 0 to 4.7 mph 0 to 10 km/h ( 0 to 6.2 mph
1st 2nd
Travel speed (Forward/reverse)
Remarks ) )
6-3. Hydraulic System Item
Standard value
Vibration
Propulsion
High pressure relief valve pressure setting Charge relief valve pressure setting Pump Case pressure Motor (F) Motor (R) Motor (F) Brake release pressure Motor (R) Motor (F) Drainage Motor (R)
34.5 MPa (
5,003 psi )
1.8 ± 0.7 MPa ( 261 ± 100 psi ) 0.25 MPa ( 36.3 psi ) or less 0.3 MPa ( 43.5 psi ) or less 0.3 MPa ( 43.5 psi ) or less More than 1.5 MPa ( 218 psi ) More than 1.5 MPa ( 218 psi ) 4.9 L/min ( 1.3 gal./min ) 4.9 L/min ( 1.3 gal./min )
High pressure relief valve pressure setting
14.4 MPa (
2,088 psi )
Case pressure Drainage
0.5 MPa ( 2.8 L/min (
72.5 psi ) or less 0.7 gal./min )
13.5 MPa (
1,958 psi )
Steering oil pressure
Motor Motor
Remarks
2-024
SPECIFICATIONS
SW504
6-4. 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
6-5. Brakes Clearance between brake pedal and floorboard (as released)
Note 1: 119 mm (4.7 in.)
Clearance between brake pedal and floorboard (when pressed down)
Note 2: 79 mm (3.1 in.)
Remarks
Note 1
Standard value
Note 2
Item
SW354-02002
Brake lock condition
L1
Replacement standard brake stroke length
More than 3.5 mm (0.14 in.) (L2-L1)
Bolt Brake releasing condition
L2
SW300-1-02001
6-6. Capacities Item Engine oil pan Fuel tank Coolant Hydraulic oil tank Vibrator case Water spray tank
2-025
Standard value 7.0 L ( 1.8 gal. ) 50 L ( 13.2 gal. ) 6.5 L ( 1.7 gal. ) 43 L ( 11.4 gal. ) 6.0 L × 2 ( 1.6 gal. × 2) 310 L ( 81.9 gal. )
Remarks
SW504
SPECIFICATIONS
7. FUEL AND LUBRICANTS SPECIFICATION (SW504) 7-1. 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
SAE10W-30
SAE30
SAE40
MIL-L-2104D
Gear oil
API grade GL5
SAE75W-90
SAE75W-90
SAE140
MIL-L-2105
Hydraulic oil
Wear resisting
ISO-VG32 over VI 140
ISO-VG46 over VI 140
ISO-VG68 over VI 110
ISO-3448
Lubricant
Grease
Lithium type extreme pressure grease
Fuel
Ambient temp. -15 to -10°C
Ambient temp. -10 to 55°C
Diesel fuel ASTM D975 NO.1-D S15 or S500*1
Diesel fuel ASTM D975 NO.2-D S15 or S500*2
NLGI-2
*1: For EPA regulation:Diesel fuel ASTM D975 NO.1-D S15 only. *2: For EPA regulation:Diesel fuel ASTM D975 NO.2-D S15 only.
7-2. Recommended Lubricants Lubricant Engine oil API-CJ-4
Gear oil API GL 5
Hydraulic oil VG 46
Grease NLGI-2
Chevron
DELO 400 LE
RPM UNIVERSAL GEAR LUBRICANTS
RANDO HDZ
MULTIFAK EP
BP
—
Energear HYPO-U
Bartran HV
Energrease LS-EP
CASTROL
Tection Extra
EPX GEAR OILS
Castrol Hyspin AWH
Castrol Spheerol EPL
Shell
Shell Rimura R4L
Shell Spirax S2 A 90
Shell Tellus S2 V
Shell Alvania Grease EP
ExxonMobil
Mobil Delvac 1 ESP
Mobilude HD
Mobil DTE 10 Excel
Mobilux EP
Oil company
2-026
ENGINE AND CONTROLS
ENGINE AND CONTROLS
1. ENGINE 1-1. Engine Mount 1 2 3
12 11 10
13
A
4
B 9
5 6
8
14
5
7
15 6
17
16
21
18
8
20
7
19
16
19
VIEW B VIEW A 0446-01805-0-10913-0
(1) (2) (3) (4) (5) (6) (7)
Bolt : M12×30 Bracket Nut : M12 Rubber isolator Bolt : M12×30 P=1.25 Bracket Bracket
(8) Bolt (9) Spacer (10) Bolt (11) Bracket (12) Bolt (13) Engine (14) Bolt
: M12×30 P=1.25 : M10×20 : M12×30 : M12×35 P=1.25
(15) Bolt : M10×30 P=1.25 (16) Bracket (17) Nut : M12 (18) Bolt : M10×20 (19) Bracket (20) Rubber isolator (21) Bolt : M12×35 P=1.25
N•m
(3) Nut M12 : 88 N·m ( (14) Bolt M12×35 P=1.25 : 118 N·m ( (15) Bolt M10×30 : 69 N·m (
65 lbf·ft ) 87 lbf·ft ) 51 lbf·ft )
(17) Nut M12 : 88 N·m ( 65 lbf·ft ) (21) Bolt M12×35 P=1.25 : 118 N·m ( 87 lbf·ft )
3-001
ENGINE AND CONTROLS
2. CONTROL SYSTEM 2-1. Throttle Control IDLE 2
FULL
A
C
1
B
3
11 15
10 9 8 7 6 5
B
4
DETAIL A
14
16
13 12
SECTION B-B
VIEW C 0446-12806-0-10917-B
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Control cable Throttle lever ECO lamp switch 2 (Apply grease) ECO lamp switch 1 (Apply grease) Lock nut : M8 Stopper bolt (IDLE) : M8×35 Lock nut : M6 Rod end (Apply grease*) Lock nut : M8
* : Lithium-based grease
3-002
(10) Stopper bolt (FULL) : M8×35 (11) Washer (Apply grease*) (12) Nut : M14 (13) Disc spring (14) Bush (15) Washer (Apply grease*) (16) Lock nut : M6 (17) Rod end (Apply grease*)
17
ENGINE AND CONTROLS
2-2. Forward-reverse Control F
3
2
N R
A
D
A
C
1
16
B 6 15
7
DETAIL C
8
14
B
17
18
19
13
9 4
5
VIEW A-A
12 11
10
SECTION B-B
VIEW D 0446-12807-0-10939-B
(1) (2) (3) (4) (5) (6) (7)
Control cable F-R lever (L) F-R lever (R) Backup buzzer switch F-R lever switch Spring (Fill grease*) Steel ball (Apply grease)
(8) Friction plate (9) Bush (10) Holder (Apply grease) (11) Disc spring (Apply grease*) (12) Lock nut : M12 (13) Set screw : M12×22
(14) Lock nut : M12 (15) Set screw : M12×22 (16) Rod end (17) Lock nut : M6 (18) Rod end (19) Lock nut : M6
* : Lithium-based grease
3-003
ENGINE AND CONTROLS
3. PUMP MOUNT 3-1. Pump Mount 1
2
A
7
1
6
4
5
3
2 Weep hole
VIEW A (1) Cover (2) Bolt : M10×35 P=1.25 (3) Pin (4) Bolt : M 8×20 N•m
(4) Bolt M 8×20 : 23 N·m ( 17 lbf·ft ) (6) Bolt M12×40 : 108 N·m ( 80 lbf·ft ) 3-004
0446-36804-0-20215-B
(5) Coupling (6) Bolt : M12×40 (7) Pump
ENGINE AND CONTROLS
3-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (7) and coupling (5) splines. ② Secure coupling (5) to engine flywheel with six bolts (4), spring washers and washers. N•m
(4) Bolt M8×20 : 23 N·m (17 lbf·ft)
③ Install pins (3) to flywheel housing. ④ Position cover (1) as shown in the figure, and secure to flywheel housing with seven bolts (2) and washers. ⑤ Engage spline of pump (7) with coupling (5). ⑥ Secure pump (7) to cover (1) with two bolts (6) and washers. N•m
(6) Bolt M12×40 : 108 N·m (80 lbf·ft)
(NOTICE) • Bolts (4) is treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
3-005
SW504
ENGINE AND CONTROLS
4. ENGINE (SW504) 4-1. Engine Mount 1 12
2
11 10 9
3
A
4
B
5 6
8 7
13
5
14 6
15,16
17
26
18
8
25 19,20
15,16
7
21
24 (1) (2) (3) (4) (5) (6) (7) (8) (9)
23
VIEW A
Bolt : M12×30 Bracket Nut : M12 P=1.25 Rubber isolator Bolt : M14×30 P=1.25 Bracket Bracket Bolt : M14×30 P=1.25 Bolt : M10×20
VIEW B
22
19,20
0448-01806-0-10620-A
(10) Bracket (11) Bolt (12) Engine (13) Bolt (14) Bolt (15) Base (16) Bracket (17) Nut (18) Bolt
: M12×30 : M12×35 P=1.25 : M10×30 P=1.25
: M12 P=1.25 : M10×20
(19) Base (20) Bracket (21) Bolt : M10×25 (22) Stopper (23) Bracket (24) Bolt : M12×25 (25) Rubber isolator (26) Bolt : M12×35 P=1.25
N•m
(3) Nut M12 P=1.25 : 88 N·m ( (13) Bolt M12×35 P=1.25 : 118 N·m ( (14) Bolt M10×30 P=1.25 : 69 N·m (
65 lbf·ft ) 87 lbf·ft ) 51 lbf·ft )
(17) Nut M12 P=1.25 : 88 N·m ( 65 lbf·ft ) (26) Bolt M12×35 P=1.25 : 118 N·m ( 87 lbf·ft ) 3-006
ENGINE AND CONTROLS
SW504
5. FUEL SYSTEM (SW504) 1 24 8
16
7
17
2 3 4 5
6
23 18 19
22 21 13
14
20
12
A
DETAIL A 13
9 3 3 10
B
11 14 12
C
15
11
0448-02806-0-10621-A
3-007
SW504
ENGINE AND CONTROLS 25
26
8
Engine Engine (return)
Engine (suction)
Fuel cooler Main filter
3 27
Tee
VIEW B 29 15
28
Fuel pump
Check valve
Sedimenter
Fuel tank (suction)
33
8
Fuel tank
Fuel tank (return)
Fuel system diagram
32 31
30
VIEW C 0448-02806-0-10621-A
(1) Fuel gauge unit (2) Cap (3) Hose ( 9 → 27) (4) Fuel tank (5) Return (fuel tank) (6) Hose ( 7 → 22) (7) Suction (fuel tank) (8) Hose (25 → 29) (9) Return (engine) (10) Suction (engine) (11) Hose (13 → 10) (12) Main filter (13) OUT (main filter) (14) IN (main filter) (15) Hose (29 → 14) (16) Hose (17 → 5) (17) OUT (check valve)
(18) Check valve (19) IN (check valve) (20) Hose (21 → 19) (21) VENT (main filter) (22) IN (sedimenter) (23) Sedimenter (24) OUT (sedimenter) (25) OUT (fuel cooler) (26) Fuel cooler (27) IN (fuel cooler) (28) Hose (33 → 29) (29) Tee (30) Hose (24 → 31) (31) IN (fuel pump) (32) Fuel pump (33) OUT (fuel pump)
3-008
ENGINE AND CONTROLS
SW504
6. CONTROL SYSTEM (SW504) 6-1. Throttle Control 1 IDLE
FULL
B A
2
B
6
7
8
3
9
10
4
5
VIEW A
15
14 13
12 11
SECTION B-B (1) (2) (3) (4) (5) (6) (7) (8)
Throttle lever Lock nut : M8 Stopper bolt (FULL) : M8×35 Potentiometer Screw : M4×20 Wire Washer (Apply grease*) Washer (Apply grease*)
* : Lithium-based grease
3-009
0448-12803-0-10627-0
(9) Key (10) Nut : M14 (11) Disc spring (12) Bush (Apply grease*) (13) Shaft (14) Base (15) Bush (Apply grease*)
SW504
ENGINE AND CONTROLS
6-2. Forward-reverse Control F
3
2
N R
D
A A
1
C
16
B 6 15
7
17
DETAIL C
8
14
B
13 18 9 19
5
4
SECTION A-A
12 11
10
SECTION B-B
VIEW D 0448-12804-0-10628-A
(1) (2) (3) (4) (5) (6) (7)
Control cable F-R lever (L) F-R lever (R) Backup buzzer switch F-R lever switch Spring (Fill grease*) Steel ball (Apply grease)
(8) Friction plate (9) Bush (10) Holder (Apply grease) (11) Disc spring (Apply grease*) (12) Lock nut : M12 (13) Set screw : M12×22
(14) Lock nut : M12 (15) Set screw : M12×22 (16) Rod end (17) Lock nut : M6 (18) Lock nut : M6 (19) Rod end
* : Lithium-based grease 3-010
ENGINE AND CONTROLS
SW504
7. PUMP MOUNT (SW504) 7-1. Pump Mount B
2
1
A
B 8 Engine flywheel
6
7
5
4
3 1
1
4
5
2 Weep hole
VIEW A (1) Bolt (2) Bolt (3) Pin (4) Bolt
: M 8×16 : M10×35 : M 8×20
N•m
(1) Bolt M 8×16 : 23 N·m ( 17 lbf·ft ) (4) Bolt M 8×20 : 23 N·m ( 17 lbf·ft ) (7) Bolt M12×35 : 108 N·m ( 80 lbf·ft ) 3-011
4
1
1
SECTION B-B (5) Cover (6) Coupling (7) Bolt : M12×35 (8) Pump
0448-36814-0-20631-0
SW504
ENGINE AND CONTROLS
7-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (8) and coupling (6) splines. ② Secure coupling (6) to engine flywheel with four bolts (1), two bolts (4), spring washers and washers.
N•m
(1) Bolt M8×16 : 23 N·m (17 lbf·ft) (4) Bolt M8×20 : 23 N·m (17 lbf·ft)
③ Install pins (3) to flywheel housing. ④ Position weep hole of cover (5) with bottom, and secure to flywheel housing with eight bolts (2) and washers. ⑤ Engage spline of pump (8) with coupling (6). ⑥ Secure pump (8) to cover (5) with two bolts (7) and washers. N•m
(7) Bolt M12×35 : 108 N·m (80 lbf·ft)
(NOTICE) • Bolts (1) and (4) are treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
3-012
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")
1-2-1. Hydraulic circuit diagram (SW354)
(1/2")
(1/2")
VFB
RVB Vibrator motor (R)
VBR VAR
29.0kN/4000min
FVB
(1/2")
29.0kN/4000min-1
VPF
VFP -1
RVD
FVD
VTF
(1/2")
Vibrator solenoid valve (R)
0.4MPa
Check valve
(1/2")
CMS
(1/2") T8
(3/8")
Check valve
VRA TT8
50X 25X220ST
(3/8")
(1/2")
0.7MPa
TCS VFA
Steering cylinder
SBR
(1/2")
(1/2") T2
Vibrator solenoid valve (F)
T6
SRL
FVA
(3/8")
RVA
(3/8")
VTR
8.4 cm3/rev
12.7MPa
8.4 cm3/rev
12.7MPa
Vibrator motor (F)
Cooling fan
14.4 cm3/rev 5.0MPa
Cooling fan drive motor
CMD T
R
TOS (1/2")
(1/2")
13.5MPa
(1/2")
Hydraulic oil filter Orbitrol
(3/8")
T5
FD 100cm3/rev
(1/2")
CO
X
Oil cooler
FS 10μ
(1/4")
TO8 CS
Propulsion motor (F)
FM3
FMA
1200
T8 0.6MPa
(1/2")
1.67to 1.86MPa
1.5MPa
232 cm3/rev
(3/8") TF4 TR4
0.6MPa
(1/2") P5
Vibrator pump (R) VPD
0.7
0.7
0.7
0.7
Drum (F)
FMB
(3/8")
P4
FM4 PC
FMD (1/2")
(1/4")
T9 (1/4")
X
13.9 cm3/rev
VPS Forward
PTO i=1.17
PFB PRA
PA VD
SD
16.2 cm3/rev
12.5 cm3/rev
(3/8")
28.0 cm3/rev
MAX min-1 :2400min-1 SET min-1 :2200min-1
Reverse
Propulsion pump
PD
Propulsion motor (R)
RMA 1200
BV1
Bypass valve
VSS PB
ENGINE
TRA TV1
1.5MPa 465 cm3/rev
BV2
1.9MPa
34.5MPa
TPA
RM3
(3/8")
34.5MPa
18.5kW/2200min-1 (25.2PS) KUBOTA D1703M-DI
232 cm3/rev
675
P
675
L
(3/8") PFA PRB
Vibrator (F) + steering charge pump
(3/8")
TV2 TPB TRB
RMB
Drum (R) RMD (3/8")
(3/4")
(1 1/4")
(1")
T6
TRS TVS
105μ
T7
Suction filter
0446-99022-0-10965-0
4-003
HYDRAULIC SYSTEMS
1-2-2. Hydraulic circuit diagram (TW354)
(1/2") FVB (1/2")
VFP
20.6kN/3120min-1
VPF
10.8 cm3/rev
12.75MPa
FVD
FVA (1/2")
(3/8") (1/2")
VTF
T2
Vibrator solenoid valve
Steering cylinder 50X 25X220
Oil cooler
SBR
(1/2") (3/8")
(3/8")
CS CO
T5
P
T
(1/4")
(3/8")
(1/2")
Propulsion motor (F)
FM3
FMA
Cooling fan drive motor
1200
0.6MPa
T8
(1/2") L
(1/2")
CMS
14.4 cm3/rev
TO8
Check valve
X
SRL
CMD
TOS (1/2")
0.7MPa
VFA TCS
Cooling fan
ST
Vibrator motor
1.67to 1.86MPa
5.0MPa
1.5MPa 232 cm3/rev
R
675
VFB
232 cm3/rev
(1/2") 0.6MPa
13.5MPa
Drum
FS 10μ
FMB
(3/8")
Hydraulic oil filter FD 100cm3/rev
Orbitrol
FM4
(1/2") AFD ADC
(1/2") PFB PRA
(3/8")
FMD
(3/8")
PFA PRB
(3/8")
T9 PR RM3 LM3
(1/4")
TF4 TR4
(1/4")
X
RLP
PC
X
P5
P4
(1/4")
(1/4")
(1/2")
(3/8")
RLA 0.7
0.7
0.7
RRP
RRB
TV2 TRB
(3/8") TDA (3/8") TV1 BV1
BV2
Bypass valve
1.5MPa 224 cm3/rev
1.5MPa 224 cm3/rev
671
0.7
FPB (3/8") TLA
PA VD
SD
16.2 cm3/rev
12.5 cm3/rev
34.5MPa
18.5kW/2200min-1 (25.2PS) KUBOTA D1703M-DI
28.0 cm3/rev
MAX min-1 :2400min-1 SET min-1 :2200min-1
ENGINE
Wheel (R,L)
RRA
RLD 1.9MPa
34.5MPa
VSS PB
PD
Propulsion pump
(3/8")
Vibrator (F) + steering charge pump
T6 (1/4")
Propulsion motor (R,L)
(3/8")
(1 1/4")
105μ
T7
(3/8") DA
DC
Propulsion motor (R,R)
RRD (3/8")
T6
0.034MPa 0.034MPa 1.0
B2 (3/4")
Wheel (R,R)
RLB
B1
Differential lock valve
Suction filter 0447-99019-0-10191-A
4-004
HYDRAULIC SYSTEMS
1-2-3. Hydraulic circuit diagram (TW504) (1/2")
(1/2")
(1/2")
FVA VP
VT
Cooling fan drive motor
Steering cylinder 63X 30X250
ST
VB
VA
Vibrator motor
LOW :26.5kN/3120min-1 HIGH:34.3kN/3120min-1
10.8 cm3/rev
FVB
14.0MPa
(1/2")
HIGH
FVD
LOW
(3/8")
5.0MPa
T2
(3/8")
(3/8")
L
P
T
(1/4")
Vibrator solenoid valve 14.4 cm3/rev
CMS
R
TOS
CMD
(1/2")
Oil cooler
13.5MPa
(1/2")
Cooling fan
Propulsion motor (F)
FMA
(1/2")
(1/2") TO8
1300 0.6MPa
CS
1.67to 1.86MPa
CO
T5
FM3
1.5MPa 372 cm3/rev
T8
372 cm3/rev
800
SBR
X
SRL
0.6MPa
(1/2")
160cm3/rev
FS
Orbitrol
Drum
FMB
(1/2")
10μ
X
Hydraulic oil filter
FM4 FD (1/2")
PFA PRB
AFD ADC
(3/8")
(1/2")
(1/2") PFB PRA
FMD
T9
(1/2")
TF4 TR4
PR RM3 LM3
(1/4") (1/4")
(1/4")
0.7
0.7
0.7
X
0.7
(1/4")
X
P5
P4
RLP
FPB TLA
(3/8") RLA
PC
Forward
PA VD
SD
16.2 cm3/rev
12.5 cm3/rev
MAX min-1 :2400min-1 SET min-1 :2200min-1
ENGINE
1.9MPa
34.5MPa
Reverse
Propulsion pump
PD
(3/4")
(1 1/4")
105μ
RLD (3/8")
Vibrator (F) + steering charge pump
1.5MPa 280 cm3/rev
Wheel (R,R) RLB
VSS PB
BV2
Wheel (R,L)
34.5MPa 28.0 cm3/rev
RRB
Bypass valve
1.5MPa
RRP
(3/8")
TDA (3/8") TV1 BV1 280 cm3/rev
18.5kW/2200min-1 (25.2PS) KUBOTA D1703M-DI
(3/8") TV2 TRB
815
(1/2")
Propulsion motor (R,L)
RRA (3/8")
(3/8") DA
RRD (3/8") T6
T6 (1/4")
Propulsion motor (R,R)
DC
0.034MPa 0.034MPa 1.0
B2
B1
Differential lock valve
Suction filter
T7
0449-99018-0-10258-A
4-005
HYDRAULIC SYSTEMS
2. PROPULSION HYDRAULIC SYSTEM
A
2-1. Propulsion Hydraulic Piping
T9
Hydraulic oil tank
Oil cooler
2-1-1. Propulsion hydraulic piping (F) (SW/TW354) Speed change solenoid valve
T7 PB
PA PFB
PD
Parking brake solenoid valve
AFD
PFA
TF4
SECTION D-D
SECTION C-C
E P4 P5 T7 PC
Propulsion pump
SECTION B-B T9
Hose (FMD
T9)
Hydraulic oil tank
Hose (PD T7) Hose (P5 FM4)
Hose (PFA
FD T5
Hose (CO T5)
Cooling fan drive motor
FMA)
F
FMA
D
FMD FMB
T10
Hydraulic oil filter
Hose (TF4 FM3)
B
B
VIEW E
Hose (FD AFD)
C Hose (PFB
C
CMD
D TOS
FMB)
VIEW F
FM3 Drain hose CO
FM4
VIEW A
Propulsion motor (F)
CS
Hose (TOS
CS)
The letters and numbers in the figure such as “PFA” and “FMA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0446-36809-0-10919-B
4-006
HYDRAULIC SYSTEMS
2-1-2. Propulsion hydraulic piping (F) (TW504)
A T9
Hydraulic oil tank
Oil cooler Speed change solenoid valve
Parking brake solenoid valve
AFD TF4
T3 PB
PA PFB
T5
PD
D
PFA
SECTION C-C
SECTION B-B
T9
Hose (FMD
T9)
P4 P5
Hose (PD T3)
Hydraulic oil tank
PC
Propulsion pump Hose (P5 FM4)
FD Hydraulic oil filter
VIEW D
Hose (FD AFD) Hose (CO T5)
Cooling fan drive motor
Hose (TF4 FM3)
TOS
CMD FMA FMD FMB
T10
C
Hose (PFA
FMA)
Hose (PFB
FMB)
B
B
C
VIEW E
FM3
E
FM4 Drain hose Propulsion motor (F)
VIEW A
CO
CS
Hose (TOS
CS)
The letters and numbers in the figure such as “PFA” and “FMA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0449-36806-0-10252-B
4-007
HYDRAULIC SYSTEMS
2-1-3. Propulsion hydraulic piping (R) (SW354) Hydraulic oil tank
Bypass valve PB
PA BV2
BV1
Hose (TV1
PRA
PRB
SECTION B-B
SECTION A-A
BV1)
TT6
C TT6
AD1 AD3
TPB
E
AD4
TPB TV1 AD2
TPA
DETAIL C
TV2 AP4 Hose (TR4 Hose (PRB Hose (PRA
Propulsion pump
TPB)
T6
Hose (TT6
AP4)
Hose (TT6
T6)
Hose (TR4
AP4)
T6) Hose (PRA
TPA)
TPA)
Hose (PRB
AD1)
SECTION D-D Hose (AD2
B
A
A
Hose (AD4
D
B
RM3)
Hose (RMD Hose (AD1
D
Hose (TV2
BV2)
RMA
RMD
RM3
RMB
Propulsion motor (R)
TR4
RMA) AD3) RMB)
VIEW E
The letters and numbers in the figure such as “PRA” and “TPA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0446-36810-0-10962-0
4-008
HYDRAULIC SYSTEMS
2-1-4. Propulsion hydraulic piping (R) (TW354) TV2
TLA
Differential lock valve
LDR PB
PA Hose (ADC
D
C
PRB
PRA
SECTION B-B
SECTION A-A
DC)
LM3
F
BV2 Hose (TV2
OTK
RDR RM3
Bypass valve
F
FPB
TRB
DA
BV1 Hose (TV1
BV2)
PR
B2 B1
DC
BV1)
TDA
TV1
DETAIL D
DETAIL C Hose (TR4
Differential lock valve
PR) Hose (OTK
Propulsion pump
Hydraulic oil tank Hose (PRB Hose (PRA
T6
Hose (OTK
FPB)
TR4
T6)
Hose (PRA
T6)
TDA)
Hose (ADC
Hose (TR4 Hose (PRB
DC)
PR) ADC
FPB)
SECTION E-E
B
A
A
B E
RRP)
Hose (B1
RRA)
Hose (RRD
RDR)
Hose (TRB
RRB)
VIEW G
SECTION F-F
TDA)
E
Hose (RM3
Hose (LM3
RLP)
Hose (B2
RLB)
Hose (RLD
LDR)
RLP RLB
G Propulsion motor (R,L)
Hose (TLA
RLA)
RRP RRA
Propulsion motor (R,R)
RLD
RRD
RLA
RRB
The letters and numbers in the figure such as “TLA” and “RLA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0447-36802-0-10064-E
4-009
HYDRAULIC SYSTEMS
2-1-5. Propulsion hydraulic piping (R) (TW504) TV2
TLA Hydraulic oil tank
Hose (OTK
Hose (ADC
T6)
DC)
PB
PA
D
PRA
PRB
SECTION B-B
SECTION A-A
C
FPB
TRB LM3
T6
OTK
RDR RM3
PR
B2 B1
Bypass valve BV2 Hose (TR4
F
PR)
Differential lock valve
LDR
Hose (TV2
F
DA
BV1 Hose (TV1
BV2)
DC BV1) TDA
TV1
DETAIL C Propulsion pump
Differential lock valve Hose (OTK
Hose (PRB
Hose (PRA FPB)
T6)
TDA)
Hose (ADC
DETAIL D Hose (RM3
TR4
DC)
Hose (TR4 Hose (PRB
RRP)
Hose (B1
RRA)
Hose (RRD
RDR)
PR) FPB)
Hose (TRB
ADC
SECTION E-E
RRB)
VIEW G
SECTION F-F E B Hose (PRA
A
A
B E
Hose (LM3
RLP)
Hose (B2
RLB)
Hose (RLD
LDR)
RLP RLB
G Propulsion motor (R,L)
TDA) Hose (TLA
RLA)
RRP RRA
Propulsion motor (R,R)
RLD
RRD
RLA
RRB
The letters and numbers in the figure such as “TLA” and “RLA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0449-36807-0-10261-0
4-010
HYDRAULIC SYSTEMS
2-2. Hydraulic Component Specifications 2-2-1. Propulsion hydraulic pump 2
1
3
A
B
4
5
6
7
8
11
12
10
13 9
16
VIEW A 3 11
7
8
12
VIEW B
15
14
5
6
1 16
4
2
Hydraulic circuit diagram SW354-04001
4-011
HYDRAULIC SYSTEMS (1) Port B (Reverse) (2) High pressure gauge port (For port B) (3) Servo pressure gauge port (4) Drain port (5) High pressure gauge port (For port A) (6) Port A (Forward) (7) Parking brake release pressure port (8) Speed change pressure port (9) Speed change solenoid valve (10) Parking brake solenoid valve (11) Servo pressure gauge port (12) Charge pressure suction port (13) High pressure relief valve (For port B) (14) High pressure relief valve (For port A) (15) Charge relief valve (16) Drain port Specifications • Displacement • High pressure relief valve pressure setting • Charge relief valve pressure setting • Allowable pump case pressure • Pump weight
[PB] : 1 1/16-12UN : 9/16-18UNF : 9/16-18UNF [PD] : 1 1/16-12UN : 9/16-18UNF [PA] : 1 1/16-12UN [P4] : 9/16-18UNF [P5] : 9/16-18UNF : [PC] :
9/16-18UNF 3/ 4-16UNF
: 1 1/16-12UN
: 28.0 cm3/rev ( : 34.5 MPa ( : 1.9 MPa ( : 0.25 MPa ( : 34.5 kg (
1.7 cu.in./rev 5,003 psi 276 psi 36.3 psi 76.1 lbs.
) ) ) ) or less )
4-012
HYDRAULIC SYSTEMS
2-2-2. Propulsion hydraulic motor (F) (SW/TW354)
B
2
1
3 4
A
6
5
7 8
5 2 X
4
VIEW B
7 1 6
3
Motor circuit diagram
Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4 1
1 Clockwise rotation 4 Counterclockwise rotation SW354-04002
(1) Port B (2) Parking brake pilot port (3) Drain port (4) Port A
[FMB] : G1/2 : G1/4 [FMD] : G3/8 [FMA] : G1/2
(5) Parking brake pilot port [FM3] (6) Speed change port [FM4] (7) Manual brake release port (8) Charge relief valve
Specifications • Displacement : 465 cm3/rev ( 28 cu.in./rev ) • Maximum working pressure : 34.3 MPa ( 4,974 psi ) • Charge relief valve pressure setting : 1.67 to 1.86 MPa ( 242 to 270 psi ) • Allowable motor case pressure : 0.3 MPa ( 43.5 psi ) • Brake release pressure : 1.5 MPa ( 218 psi ) • Weight : 42 kg ( 93 lbs. )
4-013
: G1/4 : G1/4 : M10
HYDRAULIC SYSTEMS
2-2-3. Propulsion hydraulic motor (F) (TW504) 2
1
8
3 4 5
A
7
6
9
X
2 6
5
8 3 X
Flow of oil (Rotation direction is when viewed in direction of arrow A.)
7
9
4
Motor circuit diagram
5 3
3 Clockwise rotation 5 Counterclockwise rotation
TW504-04001
(1) Charge relief valve (2) Parking brake pilot port (3) Port B (4) Drain port (5) Port A
: G1/4 [FMB] : G1/2 [FMD] : G1/2 [FMA] : G1/2
(6) Parking brake pilot port [FM3] (7) Speed change port [FM4] (8) Manual brake release port (9) Drain port
: G1/4 : G1/4 : M12 : G1/2
Specifications • Displacement : 745 cm3/rev ( 45 cu.in./rev ) • Maximum working pressure : 34.3 MPa ( 4,974 psi ) • Charge relief valve pressure setting : 1.67 to 1.86 MPa ( 242 to 270 psi ) • Allowable motor case pressure : 0.3 MPa ( 43.5 psi ) • Brake release pressure : 1.5 MPa ( 218 psi ) • Weight : 77 kg ( 170 lbs. )
4-014
HYDRAULIC SYSTEMS
2-2-4. Propulsion hydraulic motor (R) (SW354) 1
2
3 4
A
6
5
X
5 2
4
6
Flow of oil (Rotation direction is when viewed in direction of arrow A.)
1
3
Motor circuit diagram
4 1
1 Clockwise rotation 4 Counterclockwise rotation
SW354-04003
(1) Port B (2) Parking brake pilot port (3) Drain port
[RMB] : G1/2 : G1/4 [RMD] : G3/8
(4) Port A [RMA] : G1/2 (5) Parking brake pilot port [RM3] : G1/4 (6) Manual brake release port : M10
Specifications • Displacement : 465 cm3/rev ( 28 cu.in./rev ) • Maximum working pressure : 34.3 MPa ( 4,974 psi ) • Allowable motor case pressure : 0.3 MPa ( 43.5 psi ) • Brake release pressure : 1.5 MPa ( 218 psi ) • Weight : 42 kg ( 93 lbs. )
4-015
HYDRAULIC SYSTEMS
2-2-5. Propulsion hydraulic motor (R) (TW354,504) 2
1
3 4
A
5
6
X
2 5
4
6
1
Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4
Motor circuit diagram
4 1
1 Clockwise rotation 4 Counterclockwise rotation
TW504-04002
(1) Port B (2) Parking brake pilot port (3) Drain port
[RLB] [RRB] : G1/2 [RLP] : G1/4 [RLD] [RRD] : G3/8
(4) Port A [RLA] [RRA] : G1/2 (5) Parking brake pilot port [RRP] : G1/4 (6) Manual brake release port : M10
Specifications • Displacement (TW354) : 224 cm3/rev ( 13.7 cu.in./rev ) (TW504) : 280 cm3/rev ( 17.0 cu.in./rev ) • Maximum working pressure : 41.2 MPa ( 5,974 psi ) • Allowable motor case pressure : 0.3 MPa ( 43.5 psi ) • Brake release pressure : 1.5 MPa ( 218 psi ) • Weight : 77 kg ( 170 lbs. )
4-016
HYDRAULIC SYSTEMS
2-2-6. Differential lock valve (TW354,504) 1
5
6
A
2 4
7
3
9
8
VIEW A 7
8 4 5
6 2 9 3
Hydraulic diagram (1) Body (2) Port C [DC] (3) Port A [DA] (4) Orifice (5) Check valve
: 9/16-18UNF : 3/ 4-16UNF
Specifications • Maximum control flow (interflow) • Rated pressure • Check valve cracking pressure • Flow division ratio [B1 : B2] • Weight
4-017
(6) (7) (8) (9)
Check valve Port B1 [B1] Port B2 [B2] Flow control valve
: 45 L/min ( 12 gal./min ) : 20.6 MPa ( 2,987 psi ) : 0.034 MPa ( ) 5 psi : 1:1 : 4.6 kg ( 10 lbs. )
SW300-1-04004
: 3/4-16UNF : 3/4-16UNF
HYDRAULIC SYSTEMS
3. VIBRATOR HYDRAULIC SYSTEM
F
3-1. Vibrator Hydraulic Piping 3-1-1. Vibrator hydraulic piping (SW354)
VAR)
Hose (TT8
TVR)
Vibrator solenoid valve (R)
Vibrator solenoid valve (F)
T8
VBR
SECTION A-A
VAR
Vibrator (F) + steering charge pump
TVD
C
C
B
T2 TT8
Hose (VFP
Hose (VPD
VTR
TRA
DETAIL B
Check valve
VTF
TCC
CMS
Hose (TO8
TCC)
D
TO8
VPF) VFB VFP
Hydraulic oil tank
VD
VTF
VPF
TCS
T1 VPD
TRS
Vibrator pump (R)
Check valve
TFA
VIEW D Hose (VPD
VAR)
E
TCS
CMD
TRS Hose (TCS
Cooling fan drive motor
TVT) TVR
A
T8
VIEW E
TVT
VIEW C-C
Hose (VFB
FVB)
Hose (RVA TRA)
Hose (FVD
T2)
Hose (RVD
TVD)
Hose (FVA
TFA)
Hose (VBR
RVB)
A
Hose (TRS FVA
FVD
VPS)
VPS
Hose (TT8
TVR)
FVB Vibrator motor (F)
RVA The letters and numbers in the figure such as “FVA” and “TFA” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the oil.
RVD
RVB Vibrator motor (R)
VIEW F
0446-49806-0-10963-A
4-018
HYDRAULIC SYSTEMS
3-1-2. Vibrator hydraulic piping (TW354)
Vibrator solenoid valve
Hydraulic oil tank
VTF
T2 TCS Check valve
TFA
VIEW A
Vibrator (F) + steering charge pump
Hose (VFP
VPF) VFB
VD
VTF
VPF Hose (TO8
VFP
T8)
A
TO8
B
CMD Cooling fan drive motor
Hose (VFB
FVB)
Hose (FVD
T2)
Hose (FVA
TFA)
VIEW B
FVA
FVD
FVB Vibrator motor
Hose (TCS
TVT)
T8
TVT The letters and numbers in the figure such as “FVA” and “TFA” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the oil.
0447-49808-0-10190-B
4-019
HYDRAULIC SYSTEMS
3-1-3. Vibrator hydraulic piping (TW504)
Hydraulic oil tank
Vibrator (F) + steering charge pump
VP T2
VT
VA
Hose (VT TVT)
VB
DETAIL A
A Vibrator solenoid valve
Hose (VD VP)
VD
T8
TVT
CMS
Cooling fan drive motor TO8 Hose (VB
FVB)
Hose (FVD
T2)
Hose (VA
FVA)
CMD
B VIEW B
FVA
FVD
FVB Vibrator motor
Hose (TO8
T8) The letters and numbers in the figure such as “VA” and “FVA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0449-49805-0-10255-A
4-020
HYDRAULIC SYSTEMS
3-2. Hydraulic Component Specifications 3-2-1. Hydraulic pump assembly (vibrator (F) + steering • charge)
1
A
3
VIEW A 2
3
1 Hydraulic circuit diagram (1) Suction port (2) Discharge port (steering) (3) Discharge port (vibration)
2
SW354-04004
[VVS] : G1 [SD] : G1/2 [VD] : G1/2
Specifications • Displacement (vibration) : 16.2 cm3/rev (steering) : 12.5 cm3/rev • Rated pressure (vibration) : 20.6 MPa (steering) : 20.6 MPa • Weight : 7.2 kg
( 0.99 cu.in./rev ) ( 0.76 cu.in./rev ) ( 2,987 psi ) ( 2,987 psi ) ( 15.9 lbs )
4-021
HYDRAULIC SYSTEMS
3-2-2. Vibrator hydraulic pump (R) (SW354)
A
1
2
1
2
1
Hydraulic circuit diagram
VIEW A SW354-04005
(1) Suction port (2) Discharge port
[RVS] : G3/4 [RVD] : G1/2
Specifications • Displacement : 13.9 cm3/rev ( 0.85 cu.in./rev ) • Rated pressure : 17.2 MPa ( 2,494 psi ) • Weight : 2.3 kg ( 5.1 lbs )
4-022
HYDRAULIC SYSTEMS
3-2-3. Vibrator hydraulic motor
2
B
A
1
3
3
1
2
Motor circuit diagram
VIEW A
Flow of oil (Rotation direction is when viewed in direction of arrow B.) 2 3
3 Clockwise rotation 2 Counterclockwise rotation SW354-04006
(1) Drain port (2) Port B (3) Port A
[FVD] [RVD]* : 9/16-18UNF [FVB] [RVB]* : 7/ 8-14UNF [FVA] [RVA]* : 7/ 8-14UNF
Specifications • Displacement (SW354) : 8.4 cm3/rev ( 0.51 cu.in./rev ) (TW354,504) : 10.8 cm3/rev ( 0.66 cu.in./rev ) • Rated pressure : 25 MPa ( 3,625 psi ) • Allowable motor case pressure : 0.5 MPa ( 72.5 psi ) • Weight (SW354) : 2.5 kg ( 5.5 lbs. ) (TW354,504) : 2.7 kg ( 6.0 lbs. ) * [RVD], [RVA], [RVB] : SW354 only
4-023
HYDRAULIC SYSTEMS
3-2-4. Cooling fan drive hydraulic motor
1
A
2
3
1
2
Motor circuit diagram
VIEW A SW354-04007
(1) Suction port [CMS] : 7/ 8-14UNF (2) Discharge port [CMD] : 1 1/16-12UN (3) Relief valve Specifications • Displacement : • Rated pressure : • Relief valve pressure setting : • Allowable motor case pressure : • Weight :
4-024
14.4 cm3/rev ( 5.0 MPa ( 5.0 MPa ( 0.5 MPa ( 3.14 kg (
0.88 cu.in./rev ) 725 psi ) 725 psi ) ) 72.5 psi 6.9 lbs. )
HYDRAULIC SYSTEMS
3-2-5. Vibrator solenoid valve (F), (R) (SW/TW354)
4
3 1 5 Hydraulic circuit diagram 2
4
5
1
3
SW654-04003
(F) (1) (2) (3) (4) (5)
Port B Solenoid valve Port A Port T [VTF] Port P [VPF]
: G3/4 : G3/4 : G3/4 : G3/4
(R)* (1) Port B [VBR] : G3/4 (2) Solenoid valve (3) Port A [VAR] : G3/4 (4) Port T [VTR] : G3/4 (5) Port P : G3/4
Specifications • Maximum flow : 75 L/min ( 19.8 gal./min • Maximum pressure : 21.0 MPa ( 3,045 psi • Relief valve pressure setting : 12.7 MPa ( 1,842 psi • Weight : 1.30 kg ( 2.9 lbs.
) ) ) )
* (R) : SW354 only
4-025
HYDRAULIC SYSTEMS
3-2-6. Vibrator solenoid valve (TW504) 1
2
5
4
3
6
8
7
4
5
2
1
6
Hydraulic circuit diagram TW504-04003
(1) Port B [VB] : 3/4-16UNF (2) Port A [VA] : 3/4-16UNF (3) Relief valve (4) Port T [VT] : 3/4-16UNF
Specifications • Rated flow • Rated pressure • Relief valve pressure setting • Weight 4-026
(5) Port P [VP] : 3/ 4-16UNF (6) Port M : 7/16-20UNF (7) Solenoid valve a (8) Solenoid valve b
: : : :
50 L/min ( 13.2 gal./min 25 MPa ( 3,625 psi 14 MPa ( 2,030 psi 2.9 kg ( 6.4 lbs.
) ) ) )
HYDRAULIC SYSTEMS
4. STEERING SYSTEM
Suction filter
4-1. Steering Hydraulic Piping 4-1-1. Steering hydraulic piping (SW/TW354)
Hose (SSP
Hydraulic oil tank
P)
Hose (SD SSP)
Hose (T STF) Hose (STF FS)
T
VSS
L
P
R
Steering cylinder
Vibrator (F) + steering charge pump
Orbitrol
DETAIL A
Hose (TVS
Hose (SD SSP)
VSS) Hydraulic oil filter
Coupling : Charge pressure gauge port
TVS
SBR
SRL Hose (T STF)
SD
Hose (STF
A
FS)
SECTION B-B
B
Hose (T STF)
Hose (SSP
STF
SSP
FS)
Hose (SD SSP)
P)
FS
B
C Hose (STF
VIEW C Hose (SD SSP)
Hose (STF
FS)
Hose Hose (R SBR) (L SRL) The letters and numbers in the figure such as “R” and “SBR” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the oil.
0446-32804-0-10951-A
4-027
HYDRAULIC SYSTEMS
4-1-2. Steering hydraulic piping (TW504)
Suction filter
Hydraulic oil tank
Hose (SSP
VSS
Hose (SD SSP)
P)
Hose (T STF) Hose (STF FS) T
L
P
Vibrator (F) + steering charge pump
R
Steering cylinder
DETAIL A
Hose (T1 VSS)
Hydraulic oil filter
T1
Coupling : Charge pressure gauge port SD
Hose (SD SSP)
SBR
SRL Hose (T STF)
Orbitrol
A
Hose (STF
FS)
SECTION B-B
B
Hose (T STF)
Hose (SSP
STF
SSP
P)
FS
B
C Hose (STF
Hose (SD SSP)
FS)
VIEW C Hose (SD SSP)
Hose (STF
FS)
Hose Hose (R SBR) (L SRL) The letters and numbers in the figure such as “R” and “SBR” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the oil.
0449-32802-0-10251-0
4-028
HYDRAULIC SYSTEMS
4-2. Steering Wheel
1
2
3
4
5
0446-32803-0-20620-A
(1) Nut (2) Steering wheel (3) Column shaft (4) Bolt (5) Orbitrol
: M12 P=1.25
: M10×35
N•m
(1) Nut M12 P=1.25 (4) Bolt M10×35
: :
64 N·m ( 39.2 N·m (
47 lbf·ft ) 29 lbf·ft )
4-029
HYDRAULIC SYSTEMS
4-3. Hydraulic Component Specifications 4-3-1. Orbitrol
5
1
3
1
2
4
3
2
4
Hydraulic circuit diagram ORB-SD-04140
(1) Port L (2) Port R (3) Port P (4) Port T (5) Relief valve
[L] : 3/4-16UNF [R] : 3/4-16UNF [P] : 3/4-16UNF [T] : 3/4-16UNF
Specifications • Displacement (SW/TW354) : 100 cm3/rev ( 6.1 cu.in./rev ) (TW504) : 160 cm3/rev ( 9.8 cu.in./rev ) • Maximum pressure : 17.5 MPa ( 2,538 psi ) • Relief valve pressure setting : 13.5 MPa ( 1,958 psi ) • Weight : 5.2 kg ( 11.5 lbs. ) 4-030
HYDRAULIC SYSTEMS
SW504
5. HYDRAULIC CIRCUIT DIAGRAM (SW504) 5-1. Hydraulic Circuit Diagram Vibrator solenoid valve (F) Vibrator solenoid valve (R) VPR
VPF VAR
(1/2")
Vibrator motor LOW :26.5kN/3300min (R) RVA
14.4MPa
(1/2")
VAF
Vibrator motor LOW :26.5kN/3300min (F) FVA
14.4MPa
-1
HIGH:34.3kN/3300min-1
8.4 cm3/rev HIGH
8.4 cm3/rev HIGH
RVB VBR (1/2")
(1/2")
FVB
LOW
RVD
T6
(1/2") TO4
Steering cylinder
(3/8")
VTF
(1/2")
LOW
FVD
(1/2")
VBF
(1/2")
VTR
-1
HIGH:34.3kN/3300min-1
T2
TVT (1/2")
1.3
CMS
63X 30X250ST
SBR (3/8")
5.0MPa
CMD
(1/2") L
P
T
TOS
R
13.5MPa
(1/2")
(1/2")
Orbitrol
(1/2")
CO
T5
T4
(1/4")
CS
Oil cooler
X
Hydraulic oil filter
TO8
(1/2")
FS 10μ
FD
159cm3/rev
Cooling fan drive motor
(1/2")
FM3
FMA
1300 0.6MPa
T8
1.67~ 1.86MPa
(1/2")
1.5MPa 372 cm3/rev
(3/8") (1/2")
0.7
0.7
FM4
T9 (1/4")
VFD
SD
VRD
34.5MPa
ENGINE
11.2 cm3/rev
31.5 cm3/rev
Propulsion pump
T3
1300
Pump assembly (vibrator + steering charge)
BV1
Bypass valve
1.5MPa 745 cm3/rev
SPS
(3/8") PRB
TV2 TPB AD1
(1/2")
RMB
Drum (R) RMD
AVS ASS
105μ
RMA
(3/8") ( 32)
(3/4")
11.2 cm3/rev
Propulsion motor (R)
(3/8")
PFA
VPS
前進 PB
PD
11.2 cm3/rev
AD4 TV1
BV2
1.8MPa
34.5MPa
TPA
(1/2")
X
RM5 PRA
PA
32.8kW/2400min-1 KUBOTA D1803-CR-TE4B
FMD
(1/2")
(1/4")
後進
ENGINE SET (NO LOAD) MAX min-1 :2550min-1 MIN min-1 :1000min-1
Drum (F)
FMB
PC
PFB
0.7
(1/2")
X
P5
P4
372 cm3/rev
0.6MPa
TF6 TR5
0.7
Propulsion motor (F)
800
SRL (3/8")
10.8 cm3/rev
800
T8
Cooling fan
T6 (1")
Suction filter 0448-99028-0-10637-0
4-031
HYDRAULIC SYSTEMS
SW504
6. PROPULSION HYDRAULIC SYSTEM (SW504)
A
6-1. Propulsion Hydraulic Piping
T9
6-1-1. Propulsion hydraulic piping (F)
PB
PA PFB
Hydraulic oil tank
Oil cooler
Speed change solenoid valve
PD
Parking brake solenoid valve
PFA
TF6
SECTION D-D
SECTION C-C
Hose (FD PC)
E
B
T3
B
P4 P5
PC
T5
SECTION B-B T9
Hose (FMD
VIEW E
FD T9)
Hydraulic oil tank
Hydraulic oil filter
Hose (PD T3)
Propulsion pump
(P.4-034)
Hose (TF6 FM3)
Hose (PFA
Hose (CO T5)
FMB)
Cooling fan drive motor
Hose (P5 FM4)
(P.4-039)
TOS
CMD FMA
D
FMD FMB
T10
C
C
D
VIEW F
FM3
F
FM4 Propulsion motor (F) (P.4-014)
VIEW A
Hose (PFB
FMA)
Drain hose (T10 )
CO
CS
Hose (TOS
CS)
The letters and numbers in the figure such as “PFB” and “FMA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
0448-36817-0-10712-A
4-032
HYDRAULIC SYSTEMS
SW504
6-1-2. Propulsion hydraulic piping (R)
Bypass valve
Hydraulic oil tank
PB
PA PRA
BV2
BV1
Hose (TV1
BV1)
PRB
SECTION C-C
SECTION B-B
T6
VIEW A D
E
A
TT6 TT6
AD3
TPB
AD4
G
E
AD1
TPB TV1 Hose (TT6
AD2
TPA
T6)
D 詳細
TV2 AP4 Hose (TR5 Hose (PRB
Hose (TT6
AP4)
Propulsion pump
TPA)
Hose (PRB
(P.4-034)
TPA)
Hose (PRA
SECTION E-E Hose (AD2
C
Hose (AD4
C
Hose (RMD
F B Hose (PRA
Hose (AD1
B F
TPB)
Hose (TV2
BV2)
RMA
RMD
RM5
RMB
Hose (TR5
T6)
AP4)
TPB) Hose (PRB
Hose (PRA
TPA)
TPB)
SECTION F-F
RM5) RMA)
TR5
AD3) RMB)
Propulsion motor (R) (P.4-036)
The letters and numbers in the figure such as “PRA” and “TPA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
VIEW G 0448-36818-0-10735-A
4-033
HYDRAULIC SYSTEMS
SW504
6-2. Hydraulic Component Specifications 6-2-1. Propulsion hydraulic pump 2
1
3
A
B
4
5
6
7
8
11
12
10
13 9
16
VIEW A 3 11
7
8
12
VIEW B
15
14
5
6
1 16
4
2
Hydraulic circuit diagram SW354-04001
4-034
SW504 (1) Port B (Forward) (2) High pressure gauge port (For port B) (3) Servo pressure gauge port (4) Drain port (5) High pressure gauge port (For port A) (6) Port A (Reverse) (7) Parking brake release pressure port (8) Speed change pressure port (9) Speed change solenoid valve (10) Parking brake solenoid valve (11) Servo pressure gauge port (12) Charge pressure suction port (13) High pressure relief valve (For port B) (14) High pressure relief valve (For port A) (15) Charge relief valve (16) Drain port Specifications • Displacement • High pressure relief valve pressure setting • Charge relief valve pressure setting • Allowable pump case pressure • Weight
HYDRAULIC SYSTEMS [PB] : 1 1/16-12UN : 9/16-18UNF : 9/16-18UNF [PD] : 1 1/16-12UN : 9/16-18UNF [PA] : 1 1/16-12UN [P4] : 9/16-18UNF [P5] : 9/16-18UNF : [PC] :
9/16-18UNF 3/ 4-16UNF
: 1 1/16-12UN
: 31.5 cm3/rev ( : 34.5 MPa ( : 1.8 MPa ( : 0.25 MPa ( : 34.5 kg (
1.9 cu.in./rev 5,003 psi 261 psi 36.3 psi 76.1 lbs.
) ) ) ) or less )
4-035
HYDRAULIC SYSTEMS
SW504
6-2-2. Propulsion hydraulic motor (R) 1
6
2 3 4
A
5
7
X
5 1
4
Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4 2
2 7
Motor circuit diagram
2 Clockwise rotation 4 Counterclockwise rotation
3
SW504-04001
(1) Parking brake pilot port (2) Port B (3) Drain port
: G1/4 [RMB] : G1/2 [RMD] : G1/2
Specifications • Displacement • Maximum working pressure • Allowable motor case pressure • Brake release pressure • Weight
4-036
: : : : :
(4) Port A [RMA] : G1/2 (5) Parking brake pilot port [RM5] : G1/4 (6) Manual brake release port : M12
745 cm3/rev ( 34.3 MPa ( 0.3 MPa ( 1.5 MPa ( 77 kg (
45 cu.in./rev ) 4,974 psi ) 43.5 psi ) 218 psi ) 170 lbs. )
HYDRAULIC SYSTEMS
SW504
7. VIBRATOR HYDRAULIC SYSTEM (SW504)
F
7-1. Vibrator Hydraulic Piping
T4
T1 T8
T8 Hose (VTF
VBR
TCC
VAR
TVT )
T2
Vibrator solenoid valve (R)
B
Pump assembly (vibrator + steering charge)
Hose (VTF
A
VTF
E T1 Hose (AVS
Vibrator solenoid valve (F) (P.4-040)
VAF Hydraulic oil tank
Hose (VFD
VBF T4
VPF)
VPF Hose (TO4
Hose (FVD Hose (VAF
Hose (VRD
VPR)
Hose (VRD
VPR)
TO4 CMS
VTR
VPR
SECTION B-B
Hose (VTR
VPS)
VPS
Cooling fan drive motor
CMD
(P.4-039)
T4)
TVR)
SECTION C-C
TVD
TO8
D
Hose (VBF
TVT
TVT )
TVR
VIEW A
(P.4-040)
B
(P.4-038)
T2
Hose (VRD
DETAIL D VPR)
DETAIL E Hose (VAR
C FVB)
Hose (RVD Hose (VBR
T2)
C
FVA)
VFD FVA
FVD
FVB
VRD
Vibrator motor (F)
(P.4-023)
AVS
Hose (VTR Hose (TO8
TVR)
RVA
RVD
RVA) TVD) RVB)
RVB Vibrator motor (R)
TCC) The letters and numbers in the figure such as “VBR” and “RVB” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
VIEW F
(P.4-023)
0448-49808-0-10742-A
4-037
HYDRAULIC SYSTEMS
SW504
7-2. Hydraulic Component Specifications 7-2-1. Hydraulic pump assembly (vibrator + steering • charge) 1
2
3
A
4 6
7
5 8
VIEW A 8
7
6
4
5
Hydraulic circuit diagram SW504-04002
(1) Vibrator pump (F) (2) Vibrator pump (R) (3) Steering • charge pump (4) Suction port (vibrator)
[VPS] : G1
Specifications • Displacement (vibrator (F)) (vibrator (R)) (steering) • Rated pressure (vibrator (F)) (vibrator (R)) (steering) • Pump assembly weight
: : : : : : :
11.23 cm3/rev 11.23 cm3/rev 11.23 cm3/rev 25 MPa 25 MPa 25 MPa 7.64 kg
(5) Suction port (steering) (6) Discharge port (steering) (7) Discharge port (vibrator (R)) (8) Discharge port (vibrator (F))
( ( ( ( ( ( (
[SPS] : G3/4 [SD] : G1/2 [VRD] : G1/2 [VFD] : G1/2
0.69 cu.in./rev ) 0.69 cu.in./rev ) 0.69 cu.in./rev ) 3,626 psi ) 3,626 psi ) 3,626 psi ) 16.84 lbs. ) 4-038
HYDRAULIC SYSTEMS
SW504
7-2-2. Cooling fan drive hydraulic motor
1
A
2
3
1
2
Motor circuit diagram
VIEW A SW354-04007
(1) Suction port [CMS] : 7/ 8-14UNF (2) Discharge port [CMD] : 1 1/16-12UN (3) Relief valve Specifications • Displacement : • Rated pressure : • Relief valve pressure setting : • Allowable motor case pressure : • Weight :
4-039
10.8 cm3/rev ( 5.0 MPa ( 5.0 MPa ( 0.5 MPa ( 3.14 kg (
0.66 cu.in./rev ) 725 psi ) 725 psi ) ) 72.5 psi 6.9 lbs. )
HYDRAULIC SYSTEMS
SW504
7-2-3. Vibrator solenoid valve assembly
1
A 2
3
5
7
4
6
VIEW A 5
4
sol.a
sol.b
7
6
Hydraulic circuit diagram
(1) Solenoid valve b (2) Solenoid valve a (3) Relief valve (4) Port B [VBF] [VBR]
: G3/4 : G1/2
(5) Port A (6) Port T (7) Port P
Specifications • Maximum flow : 35 L/min ( 9.2 gal./min • Maximum pressure : 17.9 MPa ( 2,595 psi • Relief valve pressure setting : 14.4 MPa ( 2,088 psi • Valve assembly weight : 3.5 kg ( 7.7 lbs.
SW504-04003
[VAF] [VAR] [VTF] [VTR] [VPF] [VPR]
: G1/2 : G1/2 : G1/2
) ) ) )
4-040
HYDRAULIC SYSTEMS
SW504
8. STEERING SYSTEM (SW504)
Suction filter
T
8-1. Steering Hydraulic Piping
L
P
Hydraulic oil tank
Hose (SSP
SPS
Hose (SD SSP)
P)
R
Hose (T STF) Hose (STF FS)
Orbitrol
DETAIL A
Pump assembly (vibrator + steering charge) (P.4-038)
(P.4-042)
Steering cylinder Hose (SD SSP)
Hose (ASS
Hose (STF
FS)
SECTION B-B
SPS)
Hydraulic oil filter
Coupling : Charge pressure gauge port ASS
SBR
SRL
T1
Hose (SD SSP)
Hose (T STF)
A
Hose (STF
FS)
SECTION C-C B C
FS
Hose (T STF)
Hose (SSP
STF
SSP
P)
B SD
D
C
Hose (STF
Hose (SD SSP)
The letters and numbers in the figure such as “R” and “SBR ” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
Hose (STF
FS)
Hose (L SRL)
FS)
Hose (SD SSP)
VIEW D
Hose (R SBR) 0448-32804-0-10630-A
4-041
HYDRAULIC SYSTEMS
SW504
8-2. Hydraulic Component Specifications 8-2-1. Orbitrol 1
5
2
4
1
3
2
4
3
Hydraulic circuit diagram ORB-ET-04140
(1) Port L (2) Port R (3) Port P (4) Port T (5) Relief valve
[L] : 3/4-16UNF [R] : 3/4-16UNF [P] : 3/4-16UNF [T] : 3/4-16UNF
Specifications • Displacement : 159 cm3/rev ( 9.7 cu.in./rev ) • Maximum pressure : 17.2 MPa ( 2,494 psi ) • Relief valve pressure setting : 13.5 MPa ( 1,958 psi ) • Weight : 6.2 kg ( 13.7 lbs. )
4-042
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
1. Precautions for work 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses • Codes used in electrical circuit diagrams give the following information. • The wire size is AVS 0.85 unless otherwise specified. 26 Lg
7 5G
24 1.25 BR R2
26 Lg
B BR
4 5BY
Wire color AVS wire size Wire number
24 1.25BR
ACC
28 LgW
R1
C
STARTER SWITCH
Fuel sensor (BrR),(GL)
Wire color Reference page
J
(P.5-005)
Mark S
Starter relay harness
Type of terminal
(P.5-017)
58X-2F
3LY Marking "C"
C
* * 9 Brw
38 LY
38
63 GB
* * 63 9 GB Brw
SWP-4㧲
SWP-4M
LY
120
Marking
770
50
2BrW
AVS Size
70
Wire color (Indicated inconnectors in case of wires)
Length between
200
38
Reference page
Corrugate Ǟ70
58X-2M 9
9 38 2BrW 3LY
Wire number
Marking
C Corrugate Ǟ13
CB104
GB,100
Corrugate Ǟ10
63
Wire number Protection between
Type of terminal
• The pin or socket layout of mating connectors are symmetrical, either vertically or horizontally. When the connector valves are connected, the pin and socket that have the same number are connected. Wire number Terminal type
Wire number
BR,70
2Lg,70
1.25LgW,70
4
LA305
(B)
24
LA105
(BR)
26
LA205
(C)
28
LA105
(ACC)
BW,150
Starter switch
5BY,70
Switch terminal number
WG,150
RY,150
RW,150
94
(1)
93
(3)
30
(4)
97
(5)
Throttle switch
Switch terminal number
5-001
ELECTRICAL SYSTEM • Wire color code chart B
Black
W White R
Red
G
Green
Y
Yellow
Br Brown L
Blue
Lg Light green
O Orange (Or)
Gy Gray (Gr)
Sb Sky blue P
Pink
Pu Purple
5-002
Black/ White stripe White/ WR Red stripe Red RW /White stripe Green/ GW White stripe Yellow/ YR Red stripe Brown/ BrW White stripe Blue/ LW White stripe Light green/ LgR Red stripe BW
Black/ Yellow stripe White/ WB Black stripe Red/ RB Black stripe Green/ GR Red stripe Yellow/ YB Black stripe Brown/ BrR Red stripe Blue/ LR Red stripe Light green/ LgY Yellow stripe BY
Yellow/ Orange/ OW Orange stripe White stripe Blue/ Orange/ LO OB Orange stripe Black stripe Green/ Orange/ GO OG Orange stripe Green stripe Gray/ Gray/ GyR GrW Red stripe White stripe Gray/ Gray/ GyL GrY Blue stripe Yellow stripe Gray/ GrB Black stripe Pink/ Pink/ PB PG Black stripe Green stripe Pink/ PL Blue stripe YO
Black/ Black/ BG Red stripe Green stripe White/ White/ WL WY Blue stripe Yellow stripe Red/ Red/ RY RG Yellow stripe Green stripe Green/ Green/ GY GB Yellow stripe Black stripe Yellow/ Yellow/ YG YL Green stripe Blue stripe Brown/ Brown/ BrY BrB Yellow stripe Black stripe Blue/ Blue/ LY LB Yellow stripe Black stripe Light green/ Light green/ LgB LgW Black stripe White stripe BR
Black/ Blue stripe White/ WG Green stripe Red/ RL Blue stripe Green/ GL Blue stripe Yellow/ YW White stripe Brown/ BrG Green stripe Blue/ LG Green stripe Light green/ LgL Blue stripe BL
BrL
Brown/ Blue stripe
ELECTRICAL SYSTEM
2. SYSTEM CIRCUIT DIAGRAM
37 GB
2-1. Electrical Circuit Diagram (SW354)
35 G 36 GR 38 Or
38 Or 46 BrR
37 2GB
42 3LB
39 LW 33 LgW
37 2GB
40 WB
R
R 37 2GB 3 2
GY
35 G
41 RW
4
B
B 24 RY
NC NO
R
5
3
302 LgR
PARKING BRAKE SWITCH
6 5
1
23 RL
47 LgR
4
23 RL
B
3
B
39 LW
NC NO COM
2 6
39 LW
5
21W
STOP LAMP 21W
5W
TAIL LAMP 5W
B
B
COMBINATION LAMP (L)
SOL
1
18 LY
49 LgB
4
27 GY
B
46 BrR
B
SOL
WATER SPRAY MODE SELECT SWITCH
FULL
46 BrR
VIBRATOR SOLENOID (F)
309 G W
ECO LAMP
VIBRATOR SOLENOID (R)
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
B
10A
18 LY
24 RY
NO COM
COM
NC
ECO LAMP SWITCH 1
BACKUP BUZZER SWITCH
NC NO COM
W
B 309 G
308 Br
1
2
2
TURN SIGNAL LAMP (R) 21W
24 RY
33 LgW
3 43 RW
21W
IDLE
F-R LEVER SWITCH
W
1
R
F
B
2 6
307 GW
YG
LIGHTING 1650 to1850min-1
308 Br
21 RG
3
15 YL
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
B
B
40 WB 301 Y
B
G
ECO LAMP SWITCH 2
TURN SIGNAL SWITCH NC NO COM
COMBINATION METER
NO
44 BrY
B
24 RY
L
R
35 G
BACKUP BUZZER
W
G
TURN SIGNAL LAMP (L) 21W
C Br
37 GB
VIBRATION MODE SELECT SWITCH
G GR
36 GR
SPEED CHANGE SWITCH 24 RY
61 RG
24 RY
c
e
60 BrY
B
B
3 LgR
B
54 YB
59 Sb
53 LR
55 YG
57 L
45 Br
B
44 BrY
2 B
300 3BW B
VIBRATOR LAMP RELAY
25 3W 5
3
2
1
300 3BW
VIBRATOR RELAY G E
FUEL GAUGE UNIT
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
42 3LB D
ALTERNATOR
B B
1
2
3
4
5
1.25Br
21 RG
19 3R
22 RB
6
23 RL
32 3BY
e
B
e
g
6 3G
8 5R
F.L.
5 3GW AV60
b
INTERLOCK RELAY
39 LW
7 5WR
AV60
B a
18 3LY G
SOL
26 3BR
B
S
WATER SPRAY RELAY
NO
AV60
COM
+ BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
f
c
B
B
E
301 Y
ENGINE STOP SOLENOID
302 LgR
HYDRAULIC OIL FILTER SWITCH
28 8WY
PARKING INTERLOCK RELAY
B
B
7
FUEL PUMP
23 RL
B
45A
3 1
1
TACHO METER SENSOR
13 2Y
F.L.
5 2
27 GY Y
IG
L
5 3GW
46 BrR
43 RW
R
17 WR
23 RL
W
46 BrR
SUB POWER (12V/120W)
7 5WR
51 Br 53 LR
6 3G 8 5R
65A
GLOW PLUGS
57 L 55 YG
FUSE BOX
22 RB
13 2Y
10 WG
12 Y
3
STARTER SWITCH
10 5WG
21 RG
11 BrB
22 RB
R1
BR 10 5WG
34 GY
R2
B
1.25B
16 3W
11
FLASHER UNIT
ACC
C
32 3BY
12
FUSE
2B
6 2G
E
2 5WR 14 WL
Lg
B
L
B
2 WR
5A
4
51 Br 54 YB
12 Y
305 2Br
FUSE
11 BrB
21 RG
HORN RELAY
HORN SWITCH
15 YL
17 WR
39 LW
38 Or
37 GB
52 YW
1
13
39 LW
2
24 RY
31 LgW G
3
8
21 RG 5
25 3W
30 Lg
36 GR
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
35 G
9
a
b
BRAKE LAMP RELAY
10
W GY RB GB OG LgY WB OW
14
L
f
16 3W
LB
Br
27 GY
G
26 5BR
LW
BrW GR GW
12 Y
YL
YR YW
25 3W
LR
Y
27 GY
WR GL
B
23 RL
O
302 LgR
P
22 RB
R
21 RG
G
R
36 GR
36 GR
B
B
FOOT BRAKE SWITCH
27 GY
HORN
STOP
34 GY
B
WATER SPRAY PUMP
R
W
30 Lg
B
61 RG
NC
SPEED CHANGE SOLENOID
LIGHTING SWITCH
60 BrY
TURN SIGNAL LAMP (R) 21W
19 3R
19 3R
COMBINATION LAMP (R) 35 G Or
G
F-R LEVER VIBRATION SWITCH (L)
R
SOL
PARKING BRAKE SOLENOID
B
4
5
37 GB
G 38 Or
G
6
38 Or
35 G
B
R
R
SOL
19 3R
1
45 Br
29 BY
37 2GB
NO
F-R LEVER VIBRATION SWITCH (R)
B
B
11 BrB
HEAD LAMP (L) 55W
NC
C Br
43 RW
18 3LY
45 Br
45 Br
18 3LY
44 BrY
42 3LB
R
28 8WY
HEAD LAMP (R) 55W
FLOOD LAMP 55W
R
18 3LY
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A
1 5W
F.L. GLOW LAMP TIMER
0446-99023-0-10966-0
5-003
ELECTRICAL SYSTEM
2-2. Electrical Circuit Diagram (SW354 ROPS)
37 GB 35 G 36 GR 38 Or
38 Or
HEAD LAMP (R) 55W
37 2GB R
FLOOD LAMP 55W
R
18 3LY 46 BrR 44 BrY 45 Br
45 Br 39 LW 33 LgW
TURN SIGNAL SWITCH
R 302 LgR
PARKING BRAKE SWITCH 24 RY
6 70 P
5
1
18 LY
4
27 GY
COM
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
B
WATER SPRAY MODE SELECT SWITCH 18 LY
ECO LAMP SWITCH 1
BACKUP BUZZER SWITCH
WATER SPRAY TIMER
NC NO COM
W
39 LW B 3 49 LgB
B
1
308 Br
2 6
4
2
47 LgR
47 LgR
SOL
VIBRATOR SOLENOID (F) 49 LgB
SPEED CHANGE SWITCH
G
f 61 RG
24 RY
c
e
60 BrY
B
GLOW PLUGS
57 L 51 Br
B
44 BrY
300 3BW
1
B
VIBRATOR LAMP RELAY
5
3
2
1
B
B
300 3BW
VIBRATOR RELAY G E
FUEL GAUGE UNIT
HYDRAULIC OIL FILTER SWITCH
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
42 3LB D
ALTERNATOR
32 3BY
e
B B
B
e
g
1.25Br
1.25B
18 3LY
19 3R
22 RB
21 RG
1
2
3
4
5
7
6
11
12
6 3G
5 3GW AV60 NO
B
S
WATER SPRAY RELAY
AV60
COM
+
b
INTERLOCK RELAY
39 LW
7 5WR
AV60
B a
18 3LY G
SOL
26 3BR
BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
f
c
B
B
E
ENGINE STOP SOLENOID
302 LgR
B
301 Y
28 8WY
PARKING INTERLOCK RELAY
1
TACHO METER SENSOR
25 3W
27 GY Y
8
FUEL PUMP
23 RL
B
W
54 YB
59 Sb
53 LR
55 YG
57 L
45 Br
2
3
3
5 2
43 RW
22 RB
46 BrR
13 2Y
Lg
46 BrR
53 LR
R IG
L
23 RL
4
55 YG
SUB POWER (12V/120W)
22 RB
13 2Y
17 WR
6 3G 8 5R
F.L.
11 BrB 12 Y
FUSE BOX
8 5R
21 RG
STARTER SWITCH
10 5WG
65A
34 GY
R1
BR 10 5WG
B
R2
B 3 LgR
13
FLASHER UNIT
16 3W
7 5WR
B
ACC
C
32 3BY
28 8WY
B
E
2 5WR 14 WL
FUSE
6 2G
L
2 WR
5A
10
12 Y
2B
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
21 RG
10 WG
B
1
305 2Br
FUSE
26 5BR
51 Br 54 YB
2
10A
11 BrB
HORN RELAY
HORN SWITCH
15 YL
17 WR
39 LW
38 Or
52 YW
3
14
31 LgW G 39 LW
5
23 RL
21 RG
16 3W
30 Lg
36 GR
25 3W
35 G
25 3W
BRAKE LAMP RELAY
24 RY
a
b
37 GB
VIBRATOR SOLENOID (R)
9
W GY RB GB OG LgY WB OW
27 GY
L
27 GY
YR YW
23 RL
LB
Br
Y
B
SOL
302 LgR
LW
B
BrW GR GW
22 RB
O YL
11 BrB
P LR
46 BrR
B
21 RG
R
B
B
24 RY
WR GL
46 BrR
5
VIBRATORY DRUM SELECT SWITCH
3 4
309 G
1
2
NC NO COM
TAIL LAMP 5W
45A
33 LgW
39 LW 2
STOP LAMP 21W
5W
COMBINATION LAMP (L)
24 RY
B
3
B
FULL
NC
W
4
5
NO COM
B
15 YL
NC NO
21 RG
2 6
ECO LAMP
3
21W
B
23 RL 1
F-R LEVER SWITCH
W
301 Y
23 RL
IDLE
41 RW
1
4
70 P
27 GY
40 WB
5
23 RL
70 P
5
HAZARD SWITCH 3
R
B
4
34 GY
W
LIGHTING 1650 to1850min-1
308 Br
24 RY
34 GY B
1
24 RY
36 GR
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
B
F
NC NO COM
2 6
6
1
309 G
ECO LAMP SWITCH 2
W
36 GR
35 G
L
3 35 GB
COMBINATION METER
BACKUP BUZZER
307 GW
YG
B
G GR
G
TURN SIGNAL LAMP (L) 21W
FOOT BRAKE SWITCH
R
36 GR
36 GR G
B
2
VIBRATION MODE SELECT SWITCH 29 BY
GY
35 G B
STOP
34 GY
HORN
44 BrY
R
R
30 Lg
LIGHTING SWITCH
60 BrY
TURN SIGNAL LAMP (R) 21W
19 3R
19 3R
3 43 RW
SPEED CHANGE SOLENOID
37 GB
WATER SPRAY PUMP
B
G
4
5
37 GB
G 38 Or
G
6
38 Or
35 G
B
PARKING BRAKE SOLENOID
NO
F-R LEVER VIBRATION SWITCH (L)
R
SOL
61 RG
B
5 3GW
2
R
R
SOL
19 3R
1
B
NC
C Br
21W
F.L.
3
45 Br
COMBINATION LAMP (R) TURN SIGNAL LAMP (R) 21W
35 G Or
G
F-R LEVER VIBRATION SWITCH (R)
B
B
R 37 2GB
37 2GB
B
18 3LY
40 WB
NO
46 BrR
37 2GB R
12 Y
HEAD LAMP (L) 55W
NC
C Br
43 RW
42 3LB
42 3LB
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A F.L.
GLOW LAMP TIMER
1 5W
0446-99023-0-10966-0 0446-09804-0-10645-0 0446-75805-0-20518-C
5-004
ELECTRICAL SYSTEM
2-3. Electrical Circuit Diagram (TW354)
37 GB 35 G 36 GR 38 Or
38 Or
HEAD LAMP (R) 55W
37 2GB
FLOOD LAMP 55W
R
18 3LY
R
46 BrR 42 3LB BrW
42 3LB
37 2GB
43 RW
R
33 LgW 40 WB
3
20 2BrR
B
B
1
9 BrW
9 2BrW
2
R 37 2GB 3 2
G
R
GY
B
34 GY
HORN
35 G
36 GR
GR
G
BACKUP BUZZER
308 Br L
TURN SIGNAL SWITCH
B
R
5
33 LgW
302 LgR
PARKING BRAKE SWITCH 3
LW
LB
Br
W
L
BACKUP BUZZER SWITCH
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
NC
C Br
NO
B
B G
F-R LEVER VIBRATION SWITCH (R) Br 45
ECO LAMP SWITCH 1
TAIL LAMP 5W
21W
NC
C Br
B
NO G
39 LW 2 6 39 LW 5
NC NO COM
W
B
18 LY
4
27 GY
18 LY
WATER SPRAY MODE SELECT SWITCH
309 G
308 Br
1
24 RY 27 GY
YR YW
BrW GR GW
B
5W
61 RG
f
G
61 RG
GY RB GB
OG LgY WB OW
24 RY
c
e
60 BrY
B b
a
54 YB
59 Sb
53 LR
55 YG
57 L
45 Br
B
44 BrY
2 B
300 3BW
1
B
VIBRATOR LAMP RELAY
25 3W 5
3
2
1
B
300 3BW
VIBRATOR RELAY G E
FUEL GAUGE UNIT
HYDRAULIC OIL FILTER SWITCH
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
42 3LB D
ALTERNATOR
32 3BY
e
B B
B
e
g
18 3LY
19 3R
20 2BrR
21 RG
22 RB
1
2
3
4
5
7
6
6 2G
11
12
6 3G
8 5R 5 3GW AV60
b
INTERLOCK RELAY
39 LW
7 5WR
AV60
B a
18 3LY G
SOL
26 3BR
B
S
WATER SPRAY RELAY
NO
AV60
COM
+ BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
f
c
B
B
E
301 Y
B
ENGINE STOP SOLENOID
302 LgR
B
28 8WY
PARKING INTERLOCK RELAY
1
TACHO METER SENSOR
13 2Y
FUEL PUMP
23 RL
27 GY Y
IG
L
F.L.
3
5 2
43 RW
3
46 BrR
R
17 WR
23 RL
W
46 BrR
53 LR
22 RB
13 2Y
Lg
55 YG
SUB POWER (12V/120W)
45A
51 Br
6 3G 8 5R
5 3GW
GLOW PLUGS
57 L
FUSE BOX
F.L.
12 Y
STARTER SWITCH
10 5WG
65A
21 RG
11 BrB
2B
FUSE
7 5WR
B
R1
BR
13
3 LgR 10 5WG
34 GY
R2
B
12 Y
25 3W
27 GY
302 LgR
11 BrB
23 RL
FLASHER UNIT
22 RB
B
4
B
E
26 5BR
B
22 RB
ACC
C
32 3BY
10 WG
54 YB
L
23 RL
14 WL
FUSE
16 3W
51 Br
305 2Br
2 5WR
2 WR
5A
24 RY
12 Y
8
11 BrB
21 RG
25 3W
1
HORN RELAY
HORN SWITCH
52 YW
2
21 RG
15 YL
17 WR
39 LW
38 Or
37 GB
39 LW
5
9
G
10A
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
31 LgW
9 BrW
14
36 GR
21 RG 3
16 3W
30 Lg
35 G
10
BRAKE LAMP RELAY
1.25B
LR YL
Y
37 GB
1.25Br
WR GL
B
O
B
VIBRATOR SOLENOID
FULL
24 RY
SPEED CHANGE SWITCH P
NO
TAIL LAMP 5W
1
2
R
COM
COM
5W
COMBINATION LAMP (L)
SOL
Br 45
STOP LAMP 21W
46 BrR
B
NC NO COM
21W
B
47 LgR
24 RY
NC NO
B
B
4
4
23 RL
LIGHTING 1650 to1850min-1
NC
W
15 YL
23 RL
309 G W
ECO LAMP
1
3
F-R LEVER SWITCH
41 RW
1
WATER SPRAY PUMP
B
IDLE
21 RG
2 6
37 GB
F-R LEVER VIBRATION SWITCH (L)
W
40 WB 301 Y
R
F
24 RY
R
60 BrY B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
COMBINATION METER
61 RG
B
LIQUID SPRAY PUMP
ECO LAMP SWITCH 2 NC NO COM
3
B
5
307 GW
YG
B
B
35 G
TURN SIGNAL LAMP (L) 21W
FOOT BRAKE SWITCH
G
36 GR 36 GR
G
R
W
B
2
44 BrY
LIGHTING SWITCH
24 RY
30 Lg
3 43 RW
6
27 GY
38 Or
TURN SIGNAL LAMP (R) 21W
SPEED CHANGE SOLENOID
4
5
21W
VIBRATION MODE SELECT SWITCH
SOL
PARKING BRAKE SOLENOID
19 3R
19 3R
6
38 Or 37 GB
G
R
29 BY
35 G
B
R
R
SOL
19 3R
1
STOP
37 2GB
M
R
LIQUID SPRAY SWITCH
COMBINATION LAMP (R) TURN SIGNAL LAMP (R) 21W
35 G Or B
39 LW
28 8WY
HEAD LAMP (L) 55W
9 BrW
45 Br
18 3LY
9
44 BrY
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A
1 5W
F.L. GLOW LAMP TIMER
0447-99020-0-10192-A
5-005
ELECTRICAL SYSTEM
2-4. Electrical Circuit Diagram (TW354 ROPS)
37 GB 35 G 36 GR 38 Or
38 Or
HEAD LAMP (R) 55W
37 2GB R
FLOOD LAMP 55W
R
18 3LY 46 BrR 42 3LB
37 2GB
9 BrW
45 Br 43 RW
R
39 LW 33 LgW 40 WB
B
20 2BrR
3
1
2
B
9 BrW
9 2BrW
3
43 RW
LIGHTING SWITCH
R
44 BrY
GY
B
34 GY
HORN
35 G
36 GR
GR
G
5
HAZARD SWITCH
F-R LEVER SWITCH
3
302 LgR
PARKING BRAKE SWITCH
33 LgW
24 RY
LW
LB
Br
W
L
VIBRATOR SOLENOID
B
TAIL LAMP 5W
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
NC NO COM
B
45 Br 3 39 LW 2 5
18 LY
1
18 LY
4
27 GY
45 Br
NO
NC
C Br
B
G
70 P
39 LW
70 P
B
309 G
308 Br
G
61 RG
GY RB GB
OG LgY WB OW
24 RY
c
e
60 BrY
B a
54 YB
59 Sb
53 LR
57 L
55 YG
43 RW 45 Br
B
44 BrY
2
46 BrR
5
3
2
1
B
300 3BW
25 3W
B
VIBRATOR LAMP RELAY
5
3
2
1
B
300 3BW
VIBRATOR RELAY
e
FUEL GAUGE UNIT
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
42 3LB D
ALTERNATOR
32 3BY
B B
B
e
g
18 3LY
19 3R
20 2BrR
23 RL
21 RG
24 RY
8
22 RB
25 3W
9
1
2
3
4
5
7
6
11
12
1.25Br 6 3G
5 3GW AV60
b
INTERLOCK RELAY
39 LW
7 5WR
AV60
B a
18 3LY G
SOL
26 3BR
B
S
WATER SPRAY RELAY
NO
AV60
COM
+ BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
Lg
G E
HYDRAULIC OIL FILTER SWITCH
B
B
E
f
c
B
ENGINE STOP SOLENOID
302 LgR
B
301 Y
28 8WY
PARKING INTERLOCK RELAY
1
TACHO METER SENSOR
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A FUEL PUMP
23 RL
27 GY Y
13 2Y
W
46 BrR
53 LR
R IG
L
26 5BR
55 YG
17 WR
23 RL
F.L.
51 Br
45A
GLOW PLUGS
57 L
22 RB
13 2Y
SUB POWER (12V/120W)
8 5R
5 3GW
12 Y
6 3G
FUSE BOX
8 5R
21 RG
11 BrB
STARTER SWITCH
65A
B
R1
BR 10 5WG
13
3 LgR 10 5WG
34 GY
R2
B
12 Y
25 3W
27 GY
23 RL
302 LgR
16 3W
7 5WR
B
2B
FUSE
6 2G
E
ACC
C
32 3BY
4
L
B
14 WL
FUSE
FLASHER UNIT
305 2Br
10A
2 5WR
2 WR
5A
10 WG
B
12 Y
22 RB
51 Br 54 YB
11 BrB
21 RG
HORN RELAY
HORN SWITCH
52 YW
1
11 BrB
15 YL
17 WR
39 LW
38 Or
37 GB
39 LW
2
14
G
16 3W
31 LgW
BrW
3
21 RG
36 GR
21 RG 5
10
30 Lg
35 G
3
WATER SPRAY TIMER
2
3 4
24 RY
f
b
22 RB
B
NO
BRAKE LAMP RELAY
9
B G
F-R LEVER VIBRATION SWITCH (L)
NC NO COM
W
NC
C Br
F-R LEVER VIBRATION SWITCH (R)
WATER SPRAY MODE SELECT SWITCH ECO LAMP SWITCH 1
BACKUP BUZZER SWITCH
5W
61 RG
27 GY
YR YW
BrW GR GW
37 GB
SOL
1.25B
LR YL
Y
B
B
FULL
NC
TAIL LAMP 5W
F.L.
WR GL
B
NO
STOP LAMP 21W
5W
COMBINATION LAMP (L)
1
SPEED CHANGE SWITCH O
COM
COM
21W
46 BrR
1
2
P
23 RL
TURN SIGNAL LAMP (R) 21W
24 RY
R
5
W
NC NO
B
B
4
21 RG
41 RW
1
4
21W
B
47 LgR
309 G W
ECO LAMP
23 RL
IDLE
W
15 YL
5
1
6
B
3 2 6
B
LIQUID SPRAY PUMP
70 P
24 RY
40 WB 301 Y
37 GB
WATER SPRAY PUMP
LIGHTING 1650 to1850min-1
R
F
27 GY
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
COMBINATION METER
B
35 G
36 GR
4 34 GY
24 RY
1 34 GY
2 6
B
ECO LAMP SWITCH 2 NC NO COM
3
R
B
308 Br
TURN SIGNAL SWITCH
35 GB
2
307 GW
YG
B
L
36 GR
G
BACKUP BUZZER
G
36 GR
TURN SIGNAL LAMP (L) 21W
FOOT BRAKE SWITCH
W
B
3 6
R
61 RG
18 3LY
5
R
30 Lg
SPEED CHANGE SOLENOID
4
60 BrY
38 Or
TURN SIGNAL LAMP (R) 21W
Or
VIBRATION MODE SELECT SWITCH
SOL
PARKING BRAKE SOLENOID
19 3R
19 3R
6
38 Or
R
29 BY
G 37 GB
G
19 3R
1
2
35 G
B
SOL
STOP
37 2GB
37 2GB
R
R
M
R
LIQUID SPRAY SWITCH R
35 G
B
28 8WY
HEAD LAMP (L) 55W
COMBINATION LAMP (R)
42 3LB
9 BrW 44 BrY
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A
1 5W
F.L. GLOW LAMP TIMER
0447-99020-0-10192-A 0446-75805-0-20518-C
5-006
ELECTRICAL SYSTEM
2-5. Electrical Circuit Diagram (TW504)
37 GB 35 G 36 GR 38 Or
38 Or
HEAD LAMP (R) 55W
37 2GB R
FLOOD LAMP 55W
R
18 3LY 46 BrR 42 3LB
43 RW 39 LW 33 LgW 40 WB
3
20 2BrR
B
B
1
9 BrW
9 2BrW
2
37 2GB 3
PARKING BRAKE
34 GY
NC NO COM
41 RW
R
35 G
W
47 LgR
2
48 LgY
45 Br
NC NO COM
SOL
HI 2
2
VIBRATOR SOLENOID
45 Br
302 LgR
3
LW
LB
Br
O
NO
B
B G
NC
B
NO G
W
L
W
B
2
39 LW
NC NO COM
5
B
18 LY
4
27 GY
WATER SPRAY MODE SELECT SWITCH
309 G
308 Br
18 LY
1
24 RY 27 GY
YR YW
BrW GR GW
TURN SIGNAL LAMP (L) 21W
f
G
61 RG
GY RB GB
OG LgY WB OW
24 RY
c
e
60 BrY
B b
a
51 Br
2
3
1
B
VIBRATOR LAMP RELAY
25 3W 5
3
2
1
B
B
300 3BW
VIBRATOR RELAY
1 B
42 3LB
G E
TACHO METER SENSOR
FUEL GAUGE UNIT
HYDRAULIC OIL FILTER SWITCH
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
D
ALTERNATOR
32 3BY
c
e
B B
B
e
g
18 3LY 1
2
19 3R
20 2BrR
3
4
21 RG 5
23 RL
22 RB
24 RY
8
7
25 3W
9
6
1.25Br
6 2G
11
12
3G 6
5 3GW AV60
AV60
b
INTERLOCK RELAY
39 LW
7 5WR
26 3BR B
a
18 3LY G
SOL ENGINE STOP SOLENOID
B
S
WATER SPRAY RELAY
NO
AV60
COM
+ BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
f
302 LgR
B B
B
E
301 Y
PARKING INTERLOCK RELAY
GY 27 Y
28 8WY
W
44 BrY
300 3BW
Lg
B
FUEL PUMP
23 RL
28 8WY
54 YB
59 Sb
53 LR
55 YG
57 L
22 RB
45 Br
13 2Y
23 RL 3
5
46 BrR
2
43 RW
R IG
L
26 5BR
46 BrR
53 LR
SUB POWER (12V/120W)
22 RB
13 2Y
17 WR
6 3G 8 5R
F.L.
GLOW PLUGS
57 L
FUSE BOX
45A
12 Y
STARTER SWITCH
2B
5 3GW
21 RG
11 BrB
55 YG
R1
BR 10 5WG
13
3 LgR
5R 8
B
R2
B
12 Y
25 3W
27 GY
23 RL
302 LgR
16 3W
10 5WG 34 GY
ACC
C
32 3BY
65A
B
FUSE
7 5WR
E
14 WL
4
L
B
FLASHER UNIT
2 5WR
2 WR
5A
10 WG
B
12 Y
22 RB
51 Br 54 YB
11 BrB
21 RG
HORN RELAY
HORN SWITCH
52 YW
1
11 BrB
15 YL
17 WR
39 LW
38 Or
37 GB
39 LW
2
305 2Br
10A FUSE
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
G
14
31 LgW
9 BrW
3
21 RG
36 GR
21 RG 5
16 3W
30 Lg
10
BRAKE LAMP RELAY 35 G
1.25B
P
LR YL
21W
F.L.
R WR GL
STOP LAMP 21W
36 GR NC
C Br
6 W
24 RY
SPEED CHANGE SWITCH Y
BACKUP BUZZER SWITCH
TAIL LAMP 5W
21W
1
2
B
NO
39 LW
24 RY
33 LgW
COM
COM
ECO LAMP SWITCH 1
5W
61 RG
F-R LEVER VIBRATION SWITCH (R)
FULL
NC
21 RG
R
5
PARKING BRAKE SWITCH
W
B
B
15 YL
4
NC NO
37 GB
46 BrR
C Br
3
F-R LEVER SWITCH
41 RW
1
24 RY
3 2 6
TAIL LAMP 5W
COMBINATION LAMP (L)
F-R LEVER VIBRATION SWITCH (L)
27 GY
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
40 WB 301 Y
STOP LAMP 21W
5W
LOW
IDLE
COMBINATION METER
21W
1
1
5
B
ECO LAMP SWITCH 2
R
3
VIBRATION Lo-Hi CHANGE SWITCH
309 G
307 GW
TURN SIGNAL LAMP (R) 21W
B
6
4
LIGHTING 1650 to1850min-1 B
F
23 RL
4
5
23 RL 1
23 RL
1
2
ECO LAMP
L
TURN SIGNAL SWITCH
YG
B
308 Br
B
GR
G
44 BrY
BACKUP BUZZER
G
36 GR
G
R
3
B
R
36 GR
TURN SIGNAL LAMP (L) 21W
FOOT BRAKE SWITCH
B
LIQUID SPRAY PUMP
24 RY
36 GR
B
GY
35 G
43 RW
6
LIGHTING SWITCH
HORN
SPEED CHANGE SOLENOID
29 BY
5
37 GB
WATER SPRAY PUMP
VIBRATION MODE SELECT SWITCH
4
STOP
30 Lg
37 GB
38 Or
TURN SIGNAL LAMP (R) 21W
R
SOL
19 3R SOLENOID
19 3R
6
38 Or
W
G
19 3R
1
2
35 G G
SOL
60 BrY
37 2GB
R
R
M
R
61 RG
B
B
LIQUID SPRAY SWITCH R
B
Or
21W
18 3LY
37 2GB R
35 G
9 BrW
45 Br
HEAD LAMP (L) 55W
COMBINATION LAMP (R)
42 3LB
9 BrW 44 BrY
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A
1 5W
F.L. GLOW LAMP TIMER
0449-99016-0-10244-A
5-007
ELECTRICAL SYSTEM
2-6. Electrical Circuit Diagram (TW504 ROPS)
37 GB 35 G 36 GR 38 Or
38 Or
HEAD LAMP (R) 55W
37 2GB
FLOOD LAMP 55W
R
18 3LY
R
46 BrR 42 3LB
37 2GB
43 RW
R
33 LgW 40 WB
3
20 2BrR
B
B
1
9 BrW
9 2BrW
2
R 3 2
LIGHTING SWITCH
35 G G
3 35 GB
1 34 GY
2 6
36 GR
4 34 GY
5
R
R
5
33 LgW
3
302 LgR
PARKING BRAKE SWITCH 24 RY
LW
LB
Br
W
L
VIBRATOR SOLENOID
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
B
3
5
1
18 LY
4
27 GY
45 Br
18 LY
45 Br
NC
C Br
B
G
70 P
39 LW
70 P
B
309 G
308 Br
G
61 RG
GY RB GB
OG LgY WB OW
24 RY
c
e
60 BrY
B a
46 BrR
53 LR
54 YB
59 Sb
53 LR
55 YG
57 L
45 Br
B
44 BrY
2
25 3W
300 3BW
1
B
VIBRATOR LAMP RELAY
5
3
2
1
B
e
THERMO UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
22 RB 39 LW 43 RW 45 Br 44 BrY 42 3LB 46 BrR 18 3LY
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
TEMP. 50-103
H
F
42 3LB D
ALTERNATOR
32 3BY
B B
B
e
g
18 3LY 1
20 2BrR
19 3R 2
3
4
21 RG
22 RB
23 RL
6
24 RY
8
7
25 3W
5
1.25Br
6 2G
11
12
6 3G
8 5R 5 3GW AV60
b
INTERLOCK RELAY
39 LW
7 5WR
AV60
B a
18 3LY G
SOL
26 3BR
B
S
WATER SPRAY RELAY
NO
AV60
COM
+ BR
B
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
STARTER MOTOR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
Lg
G E
HYDRAULIC OIL FILTER SWITCH
B
ENGINE STOP SOLENOID
302 LgR
FUEL GAUGE UNIT
B
B
E
f
300 3BW c
VIBRATOR RELAY
B
301 Y
28 8WY
PARKING INTERLOCK RELAY
1
TACHO METER SENSOR
9
FUEL PUMP
23 RL
27 GY B
13 2Y
45A
3
5
46 BrR
2
43 RW
R IG
L
W
55 YG
17 WR
23 RL
5 3GW
51 Br
22 RB
13 2Y
F.L.
GLOW PLUGS
57 L
SUB POWER (12V/120W)
8 5R
65A
12 Y
6 3G
FUSE BOX
2B
FUSE
7 5WR
21 RG
11 BrB
STARTER SWITCH
10 5WG
4
B
R1
BR
13
3 LgR 10 5WG
34 GY
R2
B
12 Y
25 3W
16 3W 27 GY
FLASHER UNIT
23 RL
B
ACC
C
32 3BY
26 5BR
B
E
14 WL
FUSE 302 LgR
L
2 5WR
2 WR
5A
10
12 Y
10 WG
B
11 BrB
21 RG
11 BrB
51 Br 54 YB
1
HORN RELAY
HORN SWITCH
52 YW
2
22 RB
15 YL
17 WR
39 LW
38 Or
37 GB
39 LW
5
305 2Br
10A
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
G
14
31 LgW
9 BrW
21 RG
36 GR
21 RG 3
16 3W
30 Lg
35 G
Y
WATER SPRAY TIMER
2
3 4
24 RY
f
b
3
B
NO
BRAKE LAMP RELAY
22 RB
B G
F-R LEVER VIBRATION SWITCH (L)
NC NO COM
W
NO
F-R LEVER VIBRATION SWITCH (R)
WATER SPRAY MODE SELECT SWITCH ECO LAMP SWITCH 1
NC
C Br
27 GY
YR YW
BrW GR GW
37 GB
46 BrR
1.25B
LR YL
Y
COMBINATION LAMP (L)
2
NC NO COM
39 LW 2
BACKUP BUZZER SWITCH
TAIL LAMP 5W
LOW
B
FULL
NC
5W
F.L.
WR GL
B
O
NO
SOL
HI 2
1
SPEED CHANGE SWITCH P
COM
COM
STOP LAMP 21W
1
1
1
2
R
W
NC NO
TURN SIGNAL LAMP (R) 21W
21W
24 RY
B
B
4
F-R LEVER SWITCH
W
41 RW
21 RG
1
48 LgY
5
6
B
15 YL
W
47 LgR
2 6
4
309 G
307 GW
3
VIBRATION Lo-Hi CHANGE SWITCH
39 P
24 RY
3 2 6
4
23 RL
23 RL 1
IDLE
27 GY
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
40 WB 301 Y
23 RL
ECO LAMP SWITCH 2
HAZARD SWITCH
COMBINATION METER
1
21W
B
LIGHTING 1650 to1850min-1 B
F
5
ECO LAMP
308 Br
NC NO COM
R
35 G
TURN SIGNAL SWITCH
YG
B
L
W
GR
G 36 GR
G
BACKUP BUZZER
R
36 GR
TURN SIGNAL LAMP (L) 21W
B
B
36 GR
B
GY
FOOT BRAKE SWITCH
LIQUID SPRAY PUMP
24 RY
HORN
2
44 BrY
R STOP
34 GY
3 43 RW
6
41 RW
30 Lg
37 GB
38 Or
TURN SIGNAL LAMP (R) 21W
SPEED CHANGE SOLENOID
4
5
WATER SPRAY PUMP
B
VIBRATION MODE SELECT SWITCH
SOL
PARKING BRAKE SOLENOID
19 3R
19 3R
6
38 Or
60 BrY
G
R
37 GB
18 3LY
35 G G
SOL
19 3R
1
R
R
29 BY
37 2GB
37 2GB
M
R
61 RG
B
B
LIQUID SPRAY SWITCH
B
35 G Or
39 LW
28 8WY
HEAD LAMP (L) 55W
9 BrW
45 Br
COMBINATION LAMP (R)
42 3LB
9 BrW 44 BrY
52 YW
10 WG 14 WL
6
5
3
4
3 LgR
15A
4 LgW
FUSE 2 5WR
65A
1 5W
F.L. GLOW LAMP TIMER
0449-99016-0-10244-A 0446-75805-0-20518-C
5-008
SW354
ELECTRICAL SYSTEM
3. ELECTRICAL COMPONENTS
Battery relay
3-1. Wiring Harness Layout (SW354) 3-1-1. Wiring harness layout (1)
Cap to Drum edge lamp (F,R) (option) Vibrator solenoid (F) Engine oil pressure switch
Turn signal lamp (R) (B),(G)
Head lamp (R)
(GB)
D
E
Alternator Thermo unit
C
W(COM)
B
LgW
VIEW A
Cap to Mihaalu (option) K : Not in use
Fuel gauge unit
(B),(YG)
GW(NO) WR(NO)
Engine harness (P.5-015)
Combination lamp (R)
(Sb)
WB B LgW B
Battery Frame (F) harness (P.5-019)
Mihaalu harness
Parking brake solenoid (upper position)
(P.5-036)
Cap to Backup lamp (option) Cap to Drum edge lamp (R,R) (option)
Ground
(B)
Speed change solenoid (lower position)
DETAIL B
Flood lamp
(Or)
Cap to Drum edge lamp (R,L) (option)
Horn
(Lg)
(LR)
Cap to Drum edge lamp (F,L) (option)
Turn signal lamp (L) (B),(GR)
to Glow plugs (WG)
Engine stop solenoid
Water spray pump
Vibrator solenoid (R)
H : to Vibrator solenoid (R) harness
Frame (R) harness
(P.5-032)
(P.5-023)
Frame (F) harness
H
(P.5-019)
(P.5-010)
Parking interlock relay
H
Vibrator lamp relay Ground
VIEW C
CB104 BrR LgR
G GW
(GB)
(P.5-015)
Hydraulic oil filter switch
WR W
A
Head lamp (L)
Combination lamp (L)
F
Engine harness
(red)
(black)
R RW
B
Fusible link 45A
Fusible link 65A
B,250
Water spray relay
Vibrator solenoid (F)
G (P.5-010)
Backup buzzer
LW(g) LB(G) B(e) LY(B)
B,250 CA104
(BY)
DETAIL E
DETAIL D Vibrator solenoid (R) harness (P.5-032)
CB104 B,250 B,250 CA104
Vibrator solenoid (R) Starter motor
(BR),(WY)
Tachometer sensor
Fuel pump
Vibrator relay
BrR LgB LgW Insulation protection
DETAIL F 0446-09822-0-11080-0
5-009
SW354
ELECTRICAL SYSTEM
3-1-2. Wiring harness layout (2) Dashboard harness (P.5-017)
to Turn signal switch
to Horn switch
(G),(GR),(GY)
(LgW)
(LgW)
to Combination meter
J : to Working switch harness
(P.5-046)
E : to Parking brake switch harness
D : Cap
(Not in use)
(P.5-029)
L : Short harness
(P.5-034)
J
to ECO lamp
Ground
Fuse box Interlock relay Brake lamp relay
(P.5-043)
OUT1 : to Mihaalu OUT 1 (option)
Interlock relay
Dashboard harness
Brake lamp relay
Insulation protection
M
(P.5-017)
VIEW G
(P.5-029)
E
F
Control switch harness
(P.5-026)
BrY(5) RL(4) RW(2) RL(1) LW(2) LY(1) LW(5) GY(4)
R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
(P.5-029)
E
J
G
(P.5-035)
F
(SW354)
OUT1 : to Mihaalu OUT 1 (option)
RY
B(COM)
Insulation protection
Control switch harness
(P.5-026)
RW(1) Y(2) WB(3) B(4) YL(5) GY(4) GR(5) GY(1) GB(2) R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
(P.5-017)
Dashboard harness (P.5-017)
DETAIL M
Starter switch harness
DETAIL L Starter switch
J
Vibratory drum select switch harness
(SW354 ROPS)
W(NO) B(COM) R(NC)
Insulation protection
(P.5-025) LgR(BR) Y(BR) BrB(ACC) W(C) WL(C) BY(C) WR(B) WG(R1)
H
DETAIL N D
F-R lever vibration switch (L) harness
(Starter switch)
(P.5-041)
Dashboard harness (P.5-017)
VIEW H-H
BrY RY RW
ECO lamp switch 1
BrY(5) RL(4) RW(2) RL(1) P(5) LY(4) LW(2) LY(1) RL(1) LgR(6) RL(4) LgB(3) LgY LgW
(P.5-040)
Foot brake switch
R(NC)
Dashboard harness
(P.5-028)
Hazard switch harness
VIEW H-H
W(NO)
Working switch harness
Parking brake switch harness
(P.5-027)
RW(1) Y(2) WB(3) B(4) YL(5)
G
(SW354 ROPS)
Working switch harness
B(COM)
GND : to Mihaalu ground (option)
VIEW G
(SW354)
Parking brake switch harness
M
G
SECTION J-J
DETAIL K
Insulation protection
J
W(NO)
Insulation protection
L
Fuse box
GND : to Mihaalu ground (option)
GW
R(NC)
Fuse (5A,10A,15A)
(B)
Insulation protection
J
K R
Ground
L
(P.5-043)
H : to Starter switch harness
(P.5-025)
P
Fuse (5A,10A,15A)
(B)
Starter switch : N
J
Sub power (12V/120W)
K R
P
ECO lamp switch 2
(B),(GW)
(P.5-025)
Grow lamp relay
(P.5-035)
(P.5-039)
H : to Starter switch harness
W(NO) B(COM) R(NC)
Flasher unit
G : to Hazard switch harness
L : Short harness
Starter switch : N
Br RG
Horn relay
(P.5-029)
(B),(GW)
Sub power (12V/120W)
W(NO) B(COM) R(NC)
E : to Parking brake switch Insulation protection harness
D : Cap
(Not in use)
to ECO lamp
GY RY LgR
(P.5-026)
(P.5-040)
G : Cap
(P.5-039)
F : to Control switch harness
D : to Vibratory drum select switch harness
(P.5-026)
(P.5-030)
to Combination meter
(P.5-028)
F : to Control switch harness
D : Short harness
(G),(GR),(GY)
J : to Working switch harness
(P.5-046)
(P.5-027)
to Turn signal switch
to Horn switch
Backup buzzer switch
F-R lever switch
CA104 Br B CA104
Br G W
Insulation protection
DETAIL P
F-R lever vibration switch (R) harness (P.5-042)
Dashboard harness (P.5-017)
CA104 Br B CA104
Br G W
Insulation protection
DETAIL R
0446-09812-0-10956-B 0446-09810-0-20880-0 0446-09804-0-10645-0 0446-75805-0-20518-C
5-010
TW354
ELECTRICAL SYSTEM
3-2. Wiring Harness Layout (TW354)
Battery relay
3-2-1. Wiring harness layout (1) Cap to Drum edge lamp (F,R) (option) Vibrator solenoid Engine oil pressure switch Fuel gauge unit
Turn signal lamp (R)
(B),(G)
Head lamp (R)
(GB)
(B),(YG)
D
LgW
VIEW A Engine harness
(P.5-038)
Thermo unit
C
W(COM)
B
Cap to Mihaalu (option) K : to Liquid spray pump harness
E
Alternator
GW(NO) WR(NO)
(P.5-015)
Combination lamp (R)
(Sb)
WB B LgW B
Battery Frame (F) harness
Mihaalu harness
(P.5-019)
Parking brake solenoid (upper position)
(P.5-036)
Cap to Backup lamp (option) Cap to Drum edge lamp (R,R) (option) Flood lamp
Ground
(B)
Speed change solenoid (lower position)
DETAIL B
(Or)
Cap to Drum edge lamp (R,L) (option) Combination lamp (L)
Horn
A
Head lamp (L) Turn signal lamp (L)
Engine harness (P.5-015)
Hydraulic oil filter switch
Water spray pump
(LR)
Cap to Drum edge lamp (F,L) (option)
(B),(GR)
to Glow plugs (WG)
Frame (R) harness (P.5-023)
R RW
(GB)
H
Engine stop solenoid (P.5-012)
VIEW C
Parking interlock relay
H
H
Vibrator lamp relay Ground
Frame (F) harness (P.5-019)
G (P.5-012)
CB104 BrR LgR
B,250 B,250 CA104
Vibrator solenoid
DETAIL D
Starter motor
(BR),(WY)
Tachometer sensor
(red)
(black)
Fuel pump
G GW
B
Fusible link 45A
Fusible link 65A
WR W
(Lg)
Water spray relay LW(g) LB(G) B(e) LY(B)
Backup buzzer
(BY)
DETAIL E
Vibrator relay 0447-09812-0-10211-0
5-011
TW354
ELECTRICAL SYSTEM
3-2-2. Wiring harness layout (2) Dashboard harness (P.5-017)
to Turn signal switch
to Horn switch
(G),(GR),(GY)
(LgW)
(LgW)
to Combination meter
J : to Working switch harness
(P.5-046)
F : to Control switch harness
D : Short harness
(P.5-026)
(P.5-030)
to Combination meter
(P.5-028)
F : to Control switch harness
D : Short harness
(G),(GR),(GY)
J : to Working switch harness
(P.5-046)
(P.5-027)
to Turn signal switch
to Horn switch
(P.5-029)
(P.5-037)
(P.5-039)
to ECO lamp
J
H : to Starter switch harness
(P.5-025)
Ground
Fuse box
(P.5-044)
J
OUT1 : to Mihaalu OUT 1 (option)
Interlock relay
Brake lamp relay
M
Dashboard harness
Brake lamp relay
Insulation protection (P.5-017)
VIEW G
VIEW G
(TW354)
E
F
(P.5-026)
BrY(5) RL(4) RW(2) RL(1) LW(5) GY(4) LW(2) LY(1) BrW(2) BrR(1)
RW(1) Y(2) WB(3) B(4) YL(5)
R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
Control switch harness
Parking brake switch harness
Working switch harness
(P.5-029)
(P.5-027)
J
E Hazzard switch harness
(P.5-035)
D G Control switch harness
(P.5-026)
Liquid spray switch harness (P.5-037)
VIEW H-H (TW354)
F
RW(1) Y(2) WB(3) B(4) YL(5) GY(4) GR(5) GY(1) GB(2) R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
B(COM)
GND : to Mihaalu ground (option)
G
W(NO)
OUT1 : to Mihaalu OUT 1 (option)
RY
B(COM)
Insulation protection
Foot brake switch BrY RY RW
Dashboard harness (P.5-017)
(P.5-017)
DETAIL M
Insulation protection
ECO lamp switch 1 Starter switch harness
DETAIL L
Working switch harness
Starter switch
(P.5-028) BrY(5) RL(4) RW(2) RL(1) LW(5) GY(4) LW(2) LY(1) BrW(2) BrR(1)
J
(P.5-025) LgR(BR) Y(BR) BrB(ACC) W(C) WL(C) BY(C) WR(B) WG(R1)
H
DETAIL N
D F-R lever vibration switch (L) harness
(Starter switch)
(P.5-041)
Liquid spray switch harness (P.5-037)
VIEW H-H (TW354 ROPS)
W(NO) B(COM) R(NC)
Dashboard harness
R(NC)
(TW354 ROPS)
Parking brake switch harness
(P.5-029)
M
G
SECTION J-J
DETAIL K
Insulation protection
J
W(NO)
Insulation protection
L
Fuse box
GND : to Mihaalu ground (option)
GW
R(NC)
Fuse (5A,10A,15A)
(B)
Insulation protection
Interlock relay
K R
Ground
L
(P.5-044)
H : to Starter switch harness
(P.5-025)
P
Fuse (5A,10A,15A)
(B)
Starter switch : N
J
Sub power (12V/120W)
K R
P
ECO lamp switch 2
(B),(GW)
Starter switch : N
Grow lamp relay
G : to Hazard switch harness
(B),(GW)
Sub power (12V/120W)
W(NO) B(COM) R(NC)
Flasher unit
(P.5-035)
(P.5-039)
to ECO lamp
Br RG
Horn relay
(P.5-029)
L : Short harness
(P.5-034)
W(NO) B(COM) R(NC)
E : to Parking brake switch Insulation protection harness
D : to Liquid spray switch harness
(P.5-037)
G : Cap
L : Short harness
GY RY LgR
(P.5-026)
(P.5-030)
E : to Parking brake switch harness
D : to Liquid spray switch harness
Backup buzzer switch
F-R lever switch
Dashboard harness (P.5-017)
CA104 Br B CA104
Br G W
Insulation protection
DETAIL P
F-R lever vibration switch (R) harness
(P.5-042)
Dashboard harness (P.5-017)
CA104 Br B CA104
Br G W
Insulation protection
DETAIL R
0447-09808-0-10187-B 0446-09810-0-20880-0 0446-75805-0-20518-C
5-012
ELECTRICAL SYSTEM
TW504
3-3. Wiring Harness Layout (TW504)
Battery relay
3-3-1. Wiring harness layout (1)
Cap to Drum edge lamp (F,R) (option) Fuel gauge unit Engine oil pressure switch
Turn signal lamp (R)
(B),(YG)
(B),(G)
Head lamp (R)
LgW
VIEW A Engine harness
(P.5-038)
Thermo unit
(P.5-015)
Combination lamp (R)
(Sb)
C
W(COM)
B
Cap to Mihaalu (option) K : to Liquid spray pump harness
E
Alternator
(GB)
GW(NO) WR(NO)
WB B LgW B
Battery Frame (F) harness
Mihaalu harness
(P.5-021)
(P.5-036)
Cap to Backup lamp (option) Cap to Drum edge lamp (R,R) (option)
Solenoid b (Lo)
Flood lamp
DETAIL B
Cap to Drum edge lamp (R,L) (option)
Horn
(Lg)
B A
Head lamp (L) Turn signal lamp (L)
Combination lamp (L)
Engine harness (P.5-015)
Fusible link 45A
Fusible link 65A
(red)
(black)
Hydraulic oil filter switch
Water spray pump
(LR)
Frame (R) harness (P.5-023)
Solenoid a (Hi)
(B),(GR)
to Glow plugs (WG)
Engine stop solenoid
H
(P.5-014)
Parking interlock relay
H
G GW
WR W
Cap to Drum edge lamp (F,L) (option) R RW
(GB)
Speed change solenoid (lower position)
(Or)
Ground
(B)
Parking brake solenoid (upper position)
VIEW C
Vibrator lamp relay Ground
G (P.5-014)
a Hi
Vibrator solenoid
Lo b
BrR,LgY BrR,LgR
DETAIL D Starter motor (BR),(WY)
Tachometer sensor
Fuel pump
Water spray relay
Frame (F) harness (P.5-021)
LW(g) LB(G) B(e) LY(B)
Backup buzzer
(BY)
DETAIL E
Vibrator relay 0449-09813-0-10320-0
5-013
ELECTRICAL SYSTEM
TW504
3-3-2. Wiring harness layout (2) Dashboard harness
F-R lever switch
(P.5-017)
to Turn signal switch
to Horn switch
(G),(GR),(GY)
(LgW)
(LgW)
to Combination meter
J : to Working switch harness
(P.5-046)
E : to Parking brake switch harness
D : to Liquid spray switch harness
to ECO lamp
(P.5-025)
K R
Ground
Fuse box
H : to Starter switch harness
(P.5-025)
K R
P
Ground
W(NO)
G
B(COM)
GND : to Mihaalu ground (option)
(P.5-045)
GND : to Mihaalu ground (option)
G
W(NO)
Interlock relay
OUT1 : to Mihaalu OUT 1 (option)
Interlock relay
OUT1 : to Mihaalu OUT 1 (option)
RY
B(COM)
Dashboard harness
Brake lamp relay
J
Brake lamp relay
M
VIEW G
Insulation protection (P.5-017)
Insulation protection
E
F
BrY(5) RL(4) RW(2) RL(1) LW(5) GY(4) LW(2) LY(1) BrW(2) BrR(1) LgY(2) RL(1) LgB(6) LgW(5) RL(4) LgR(3)
RW(1) Y(2) WB(3) B(4) YL(5)
R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
VIEW H-H (TW504)
Dashboard harness (P.5-017)
J
Hazzard switch harness
(P.5-035)
D
Liquid spray switch harness
G
(P.5-037)
D
Vibration Lo-Hi change switch harness (P.5-031)
E
F Control switch harness
(P.5-026)
BrY(5) RL(4) RW(2) RL(1) LW(5) GY(4) LW(2) LY(1) BrW(2) BrR(1) LgY(2) RL(1) LgB(6) LgW(5) RL(4) LgR(3)
RW(1) Y(2) WB(3) B(4) YL(5) GY(4) GR(5) GY(1) GB(2) R(4) Or(5) R(1) GB(3) RY(1) LgW(2)
VIEW H-H (TW504 ROPS)
Dashboard harness (P.5-017)
DETAIL M
ECO lamp switch 1
Starter switch
J
(P.5-025) LgR(BR) Y(BR) BrB(ACC) W(C) WL(C) BY(C) WR(B) WG(R1)
Liquid spray switch harness (P.5-037)
F-R lever vibration switch (L) harness D
H
DETAIL N
D
Vibration Lo-Hi change switch harness (P.5-031)
Starter switch harness
DETAIL L
(P.5-028)
(P.5-029)
W(NO) B(COM) R(NC)
Insulation protection
Working switch harness
Parking brake switch harness
(P.5-027)
Control switch harness
(P.5-026)
M
BrY RY RW
R(NC)
(TW504 ROPS)
Working switch harness
Parking brake switch harness
Insulation protection
VIEW G
(TW504)
(P.5-029)
J
Foot brake switch
DETAIL K
(P.5-045)
Insulation protection
SECTION J-J
Insulation protection
L
Fuse box
GW
R(NC)
Fuse (5A,10A,15A)
(B)
L
ECO lamp switch 2
Starter switch : N
J
Sub power (12V/120W)
Fuse (5A,10A,15A)
(B)
to ECO lamp
(B),(GW)
(P.5-039)
H : to Starter switch harness
P
Grow lamp relay
G : to Hazard switch harness
L : Short harness
Starter switch : N
J
Sub power (12V/120W)
W(NO) B(COM) R(NC)
Flasher unit
(P.5-035)
(B),(GW)
(P.5-039)
Br RG
Horn relay
(P.5-029)
(P.5-034)
L : Short harness
W(NO) B(COM) R(NC)
E : to Parking brake switch Insulation protection harness
D : to Liquid spray switch harness
(P.5-037)
G : Cap
GY RY LgR
(P.5-026)
(P.5-031)
(P.5-029)
(P.5-037)
F : to Control switch harness
D : to Vibration Lo-Hi chang switch harness
(P.5-026)
(P.5-031)
to Combination meter
(P.5-028)
F : to Control switch harness
D : to Vibration Lo-Hi chang switch harness
(G),(GR),(GY)
J : to Working switch harness
(P.5-046)
(P.5-027)
to Turn signal switch
to Horn switch
Backup buzzer switch
(Starter switch)
(P.5-041)
Dashboard harness (P.5-017)
CA104 Br B CA104
Br G W
Insulation protection
DETAIL P
F-R lever vibration switch (R) harness (P.5-042)
Dashboard harness (P.5-017)
CA104 Br B CA104
Br G W
Insulation protection
DETAIL R
0449-09813-0-10320-0 0446-09810-0-20880-0 0446-75805-0-20518-C
5-014
ELECTRICAL SYSTEM
4. WIRING HARNESSES 4-1. Engine Harness
12015792
Speed change solenoid
50
40 X WB B
12015792
Parking brake solenoid Terminal cover
Terminal cover 5WG,50
50 Thermo unit
LE104
300 Corrugate 10 (HCOT-FR)
(3BR,50) (VB5.5) (5BR,50)
10
100
* *
Terminal cover Sb,100
59
5BR,80
17 13 WR 2Y
Terminal cover 28
26 3BR
300 Corrugate 7 (HCOT-FR)
50
50
22 32 RB 2BY
22 57 X RB L B
7283-1528-10
Engine stop solenoid
7283-8732-40
Tachometer sensor
28
RB1B-SL (S)
50
8WY,50
0 10 e 7 ) at ug T-FR r r Co CO H (
180 Corrugate 7 (HCOT-FR)
00
26
Glow plugs LE304
100 Corrugate 13 (HCOT-FR)
1 Y, 8W
LCT RL-1A
32 2BY
15
Ground
0
58X-3M
13 2Y
180 Corrugate
LA108
0
10
* 54 53 * YB LR 59 X 57 Sb B L
B
X
B,10
100 Corrugate 7 (HCOT-FR)
SWP-6M
50
Hydraulic oil filter switch
150 7 te ) uga Corr OT-FR (HC
TW504 : Frame (F) harness (P.5-021)
22 17 RB WR 40 33 WB LgW
LE104
13 Co 0 r (H ruga CO te T-F 7 R) 630 Corrugate 10 (HCOT-FR)
7 150 Corrugate
7
SW/TW354 : Frame (F) harness (P.5-019)
SWP-4M
53
100 Corrugate 10 (HCOT-FR)
00 LR,1
150 gate
5WG,80
10
Corru
LCR RL-1B
54
7
PB104
33 X LgW B
210 Corrugate
Engine oil pressure switch
YB,50
50
LA308 (B)
Starter motor * *
6189-0443
LA306 (B) Alternator
1446-09085-0-20943-0
5-015
ELECTRICAL SYSTEM
NO.
SIZE, COLOR
CONTACT POINTS
B
5
B × 3, Ground, Tachometer sensor
5GW
2
B , Glow plugs
2Y
2
B , Alternator
WR
2
B , Alternator
RB
3
B , Engine stop solenoid, Tachometer sensor
3BR,5BR
2
B , Starter motor-S
8WY
2
Alternator-B, Starter motor-B
CONNECTION
NO.
SIZE, COLOR
CONTACT POINTS
2BY
2
B , Engine stop solenoid
LgW
2
B ×2
WB
2
B ×2
LR
2
B , Hydraulic oil filter switch
YB
2
B ×2
L
2
B , Tachometer sensor
Sb
2
B , Thermo unit
CONNECTION
5-016
ELECTRICAL SYSTEM
4-2. Dashboard Harness Combination meter (P.5-046)
150
6
7
LgW,40
150 Corrugate
22
13
6
RB6B-SL
50 50
150 Tape
41 X 301 RW B Y 40 15 * WB YL *
SWP-6M
24 33 RY LgW
SWP-2F
50
200 Tape
F
50
L
19 3R
150 Tape
150 e Tap
200 Tape H
37 2GB 38 Or
13 11 3 2Y BrB LgR 32 16 14 3BY 3W WL
80
0
13
CB104
50 Corrugate
13
F-R lever vibration switch (L) harness (P.5-041)
300 Tape
60 24 61 BrY RY RG 100 X B
Br,50
RG,50
GY,50
F-R lever switch
Flasher unit
Parking interlock relay
RB3B-SL
6110-4643
308
150 Tape
13
21
GW,50
GW,50 G,50
B,50 Br,50
LgW,50 GY,50 G,50 GR,50
150 Corrugate
27
CA104
24
CB104
302 300 26 LgR 3BW 3BR 100 X B
302
CA104
X B 100 52 14 10 YW WL WG
350 Tape
B,50
X
CA104
307
CB104
307
CA104
309
CB104
X
CB104
45
CB104
31
CB104
34
CB104
35
CB104
36
CB104
Backup buzzer switch 34 GY X 21 B RG
100
X 300 B 3BW 100 301 25 Y 3W
5WG,80 ECO lamp
ECO lamp switch 2 F-R lever vibration switch (R) harness (P.5-042)
200 Tape
150 Tape
50
G
J
50 50
Horn switch
100
46 51 BrR Br 6110-4643 23 23 RL RL 31 30 100 LgW Lg 6110-4643 21 21 RG RG
Vibrator lamp relay
Horn relay
Control switch harness (P.5-026) 58X-3F
RB6A-SL
2
LCT RL-1A
10
LCR RL-1B
34 35 GY G 34 36 GY GR
SWP-4M
18 39 27 LY LW GY
SWP-3M
44 43 23 BrY RW RL
SWP-3F
Stater switch harness (P.5-025)
Except ROPS : Cap (P.5-034) ROPS : Hazard switch harness (P.5-035) Except ROPS : Working switch harness (P.5-027) ROPS : Working switch harness (P.5-028)
SW/TW354 (except SW354 ROPS) : Short harness (P.5-030)
Turn signal switch
150 Tape
Parking brake switch harness (P.5-029)
48 47 23 LgY LgR RL 50 49 23 LgW LgB RL
SWP-6F
9 20 2BrW 2BrR
58X-2F
D
SW354 ROPS : Vibratory drum select switch harness (P.5-040) TW504 : Vibration Lo-Hi change switch harness (P.5-031)
50
Brake lamp relay
RB6B-SL
B,100
10 24
Foot brake switch
RB6B-SL
50
50
Interlock relay
E
22
350 Tape
CB104
RY,50
60
100
Glow lamp timer
7124-9681
200 Tape
29 308 BY Br
2G,40
LA208 Ground
X 350 Corrugate
X
CB104
41
CB104 CA104 CA104 CA104 CB104 ECO lamp switch 1
Fuse
7124-9681
10A Fuse
45
LgR,50
309
305 X 2Br 2B
7124-9681
WR,40
305 2Br,40
22
Br, (5BR,100)
24
Short harness (P.5-039) Sub power (12V/120W) SWP-2M DT04-2P-E005
5WR,80
(VB5.5)
C
100 22 Corrugate
RY,50
22
250 Corrugate
BrY,50
A
360 Corrugate
0
1 3LY,100
4
10
LCT RL-1A
100
0
LCT RL-1A
3
0 20 ate g rru Co
50 Tape
* 11 * 12 * BrB * Y * 36 35 37 * GR G GB 51 9 39 38 Br BrW LW Or
5A
100
100
LgR,40
12 Y,40
50
50
* *
3
2
2B,100 100
* *
59 55 57 X Sb YG L B 54 53 15 17 YB LR YL WR X X 52 17 B B YW WR * * * * * * * *
15
LCT RL-1A
4
3R,100
8
LCT RL-1A
10
2BrR,150
11
3W,100
3G,100
10 0
LCR RL-1B
9
LCR RL-1B
12 5R,100
3W,100
14
50
100 Tape
B,50
* *
21 RG
SWP-16M
15A Fuse
CA104
SWP-2M
18
5R,80
X 29 35 36 B BY G GR * 37 38 61 * GB Or RG
308 304 Br G
19
150 Corrugate
58X-2M
20
5WR,80
4 30 35 36 LgW Lg G GR 46 47 48 * BrR LgR LgY *
9 18 2BrW 3LY
25
* *
22 RB
(3BR,50)
SWP-4M
6
23 RL
5BR,80
6 37 3G 2GB
39 46 LW BrR 49 50 LgB LgW
8
7 0 10 te ga rru
SWP-8M
50
16
24 RY
SWP-12F
Co
SWP-8F
8
GND
RW,50
2
OUT1
27 44 GY BrY 46 X 43 45 BrR B RW Br
35 Ta 0 pe
LCT RL-1A
X
G,50
26
58X-2F
13 2Y * *
LCT RL-1A
LCR RL-1B
Frame (R) harness (P.5-023)
32 3BY
100
304
RB8B-SL
RY,50
TW504 : Frame (F) harness (P.5-021)
58X-3F
53 54 55 LR YB YG 57 X 59 L B Sb
CA104
SWP-2M SWP-2M SWP-2M
200 Tape
SW/TW354 : Frame (F) harness (P.5-019)
50
CB104
SWP-2M
70
SWP-6F
17 22 WR RB 33 40 LgW WB
Mihaalu Vibrator relay ground (option)
50 Tape
SWP-4F
10
Mihaalu OUT1 (option)
G,50
LCR RL-1B
5WG,80
LCR RL-1B
Fuse box
SW354 : Not in use TW354,504 : Liquid spray switch harness (P.5-037) 1446-09086-0-10944-0
5-017
ELECTRICAL SYSTEM
No.
SIZE, COLOR
B,2B
CONTACT POINTS
18
CONNECTION A (6F), C , E , Brake lamp relay, Combination meter (16M) × 3, ECO lamp, Flasher unit, F-R lever vibration switch (L) harness, F-R lever vibration switch (R) harness, Glow lamp timer, Ground, Interlock relay, Parking interlock relay, Sub power, Vibrator relay, GND (option)
WR,5WR
3
A , H , Fuse 5A
LgR
2
H , Fuse 15A
LgW
2
A (8F), Fuse 15A
2G,3G
3
11 , A (2F), Fuse 10A
5R
2
12 , A
BrW,2BrW
3
C , D , Combination meter (12F)
WG,5WG
3
A , H , Glow lamp timer
BrB
2
H , Combination meter (12F)
Y
2
Combination meter (12F), Fuse 5A
2Y
2
A (3F), H
WL
2
H , Glow lamp timer
YL
2
E , Combination meter (16M)
3W
2
14 , H
WR
3
A (4F), Combination meter (16M) × 2
LY,3LY
3
1 , C, J
3R
2
3, F
2BrR
2
4, D
RG
5
6 , Backup buzzer switch, Flasher unit, Horn relay × 2
RB
2
7 , A (4F)
RL
6
8 , D × 2, J , Vibrator lamp relay × 2
RY
6
9 , F , Brake lamp relay, ECO lamp switch 1, Foot brake switch, F-R lever switch
3W
2
10 , Parking interlock relay
3BR,5BR
2
A , Interlock relay
GY
3
J , F-R lever switch, Vibrator relay
BY
2
C, L
Lg
2
A (8F), Horn relay
LgW
2
Horn relay, Horn switch
3BY
2
A (3F), H
LgW
2
A (4F), F
No.
SIZE, COLOR
CONTACT POINTS
GY
4
G × 2, Flasher unit, Turn signal switch
G
5
A (8F), C , G , Combination meter (12F), Turn signal switch
GR
5
A (8F), C , G , Combination meter (12F), Turn signal switch
GB,2GB
4
A (2F), C , F , Combination meter (12F)
Or
3
C , F , Combination meter (12F)
LW
3
C , J , Combination meter (12F)
WB
2
A (4F), E
RW
2
E , Foot brake switch
RW
2
J , Vibrator relay
BrY
2
J , Vibrator relay
Br
3
F-R lever vibration switch (L) harness, F-R lever vibration switch (R) harness, Vibrator relay
BrR
4
A (8F), C , Vibrator lamp relay, Vibrator relay
LgR
2
A (8F), D
LgY
2
A (8F), D
LgB
2
C, D
LgW
2
C, D
Br
2
Combination meter (12F), Vibrator lamp relay
YW
2
Combination meter (16M), Glow lamp timer
LR
2
A (6F), Combination meter (16M)
YB
2
A (6F), Combination meter (16M)
YG
2
A (6F), Combination meter (16M)
L
2
A (6F), Combination meter (16M)
Sb
2
A (6F), Combination meter (16M)
BrY
2
Brake lamp relay, Foot brake switch
RG
2
C , Brake lamp relay
3BW
2
Interlock relay, Parking interlock relay
Y
2
E , Parking interlock relay
302
LgR
2
F-R lever switch, Interlock relay
G
2
C , OUT1 (option)
2Br
2
Fuse 10A, Sub power
GW
2
ECO lamp, ECO lamp switch 2
Br
3
C , L , Backup buzzer switch
G
2
ECO lamp switch 1,2
CONNECTION
5-018
ELECTRICAL SYSTEM
4-3. Frame (F) Harness 4-3-1. Frame (F) harness (SW/TW354)
Fuel gauge unit
Fuel pump
Vibrator solenoid (F)
Turn signal lamp (R)
CA104
CB104
CA104
CB104
CA104
CB104
X
55
46
47
X
35
G,90
B,50
BrR,50
YG,50
50
X B
150 Tape
2G
38 Or
2B,250
Lg,320
0
7 470 Corrugate
10
7 1100 Corrugate
B,
7 350 Corrugate
Drum edge lamp (F,L) (option)
1070 Corrugate
22 15
M
700 Corrugate
5BR,80
5R,80
50
36 35 30 4 GR G Lg LgW 100 * * 47 46 * * LgR BrR
38 Or
38 Or
X B
SWP-2F
* *
Drum edge lamp (F,R) (option)
B
SWP-2F Frame (R) harness (P.5-023)
270 Corrugate
10
300 Corrugate
7
2GB,100
LgW,150 B,150 5W,140
10 LCT RL-1A
17 22 WR RB 33 40 LgW WB
53 54 * LR YB * 57 X 59 L B Sb
32 13 3BY 2Y
SWP-4F
SWP-6F
58X-3F
Engine harness (P.5-015)
* *
37
7
CB104
100 Corrugate
26 LCR RL-1B
B,50
GR,90
130 Corrugate
7
80
5WR,80
600 Corrugate
10
10
250 Corrugate
320 Corrugate
22
10
150 Corrugate
Head lamp (L)
3GW,140
7
5WR,140
4
LE104 (BR)
X
LE104 (X)
1
LA308 (COM)
5
LA208 (NO)
7
LA308 (NO)
X
CA104
Turn signal lamp (L) 36
CB104
Battery relay
130 Corrugate
22
150 Tape
1000 Corrugate
22
80
37 6 2GB 3G
X
80
8
30
SWP-2F
5BR,80
2
100
A Corrugate
100
SWP-8M
100
50
58X-2M
50
* * 26
LA210
0 7 50 te ga
LCT RL-1A
32 3BY
Ground
rru
LCR RL-1B
13 2Y
Horn PB104
Co
LCR RL-1B
55 54 53 YG YB LR 59 X 57 Sb B L
100
58X-3M
CB104
100
5WG,80
Dashboard harness (P.5-017)
22 17 RB WR 40 33 WB LgW
7
SWP-6M
Head lamp (R)
37
600 Corrugate
SWP-4M
5WG,80
10
350 Tape
LCT RL-1A
B,50
22 RB X B
LgR,50
RB2B-SL
1 5W 2 5WR
5 3GW 6 3G
7 5RW 8 5R
7322-4123-30
7322-4125-50
7322-4123-30
65A (black)
45A (red)
65A (black)
Fusible link
1446-09050-1-10649-A
5-019
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
B,2B
10
A (6M), B , Battery relay-X, Fuel gauge unit, Fuel pump, Ground, Turn signal lamp (L), (R), Drum edge lamp (F,L) (option), (F,R) (option)
5W
2
Battery relay-COM, Fusible link 65A
5WR
2
A , Fusible link 65A
LgW
2
A (8M), Battery relay-BR
3GW
2
Battery relay-NO, Fusible link 45A
3G
2
A (2M), Fusible link 45A
5WR
2
Battery relay-NO, Fusible link 65A
5R
2
A , Fusible link 65A
5WG
2
A, B
2Y
2
A (3M), B
WR
2
A (4M), B
RB
3
A (4M), B , Fuel pump
5BR
2
A, B
Lg
2
A (8M), Horn
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
3BY
2
A (3M), B
LgW
2
A (4M), B
G
2
A (8M), Turn signal lamp (R)
GR
2
A (8M), Turn signal lamp (L)
2GB
3
A (2M), Head lamp (L), (R)
Or
3
M , Drum edge lamp (F,L) (option), (F,R) (option)
WB
2
A (4M), B
BrR
2
A (8M), Vibrator solenoid (F)
LgR
2
A (8M), Vibrator solenoid (F)
LR
2
A (6M), B
YB
2
A (6M), B
YG
2
A (6M), Fuel gauge unit
L
2
A (6M), B
Sb
2
A (6M), B
CONNECTION
5-020
ELECTRICAL SYSTEM
4-3-2. Frame (F) harness (TW504)
Fuel gauge unit
Turn signal lamp (R)
CA104
CB104
CA104
CB104
X
55
X
35
Fuel pump
Vibrator solenoid Lo DT06-2S
Hi DT06-2S
47 46 LgR BrR
48 46 LgY BrR
RB2B-SL
G,90
B,50
YG,50
B,50
5WG,80
LA210
30
X
100
600 Corrugate
2B,250
Lg,270
2G
B,
10
0
470 Corrugate
7 350 Corrugate
1070 Corrugate 10
440 Corrugate
10
160 Corrugate
7
rru 630 ga te
15
* *
SWP-2F
7
LgW,150 B,150
10 LCT RL-1A
53 54 * LR YB * 57 X 59 L B Sb
32 13 3BY 2Y
SWP-4F
SWP-6F
58X-3F
* *
5W,140
100 Corrugate
130 Corrugate
7
10
17 22 WR RB 33 40 LgW WB
X B
SWP-2F
GR,90
50
36 35 30 4 GR G Lg LgW 100 * 48 47 46 * LgY LgR BrR
38 Or
10
SWP-2F
26 LCR RL-1B
3GW,140
7
5WR,140
Head lamp (L)
0
B,50
Drum edge lamp (F,R) (option)
B
Frame (R) harness (P.5-023)
X B
CB104
37
15
320 Corrugate
700 Corrugate
38 Or
2GB,130 7
Co
150
22
5BR,80
37 6 2GB 3G
250 Corrugate
4
LE104 (BR)
X
LE104 (X)
1
LA308 (COM)
5
LA208 (NO)
7
LA308 (NO)
Drum edge lamp (F,L) (option)
X
CA104
Turn signal lamp (L) 36
CB104
Battery relay
130 Corrugate
SWP-8M
8
22
M 38 Or
5R,80
150 Corrugate
100
58X-2M
2
5WR,80
1050 Corrugate 22
22
50
LCT RL-1A
26
5BR,80
100
A Corrugate
100
LCR RL-1B
100
* *
5WG,80
LCR RL-1B
32 3BY
600 Corrugate
7 13 2Y
58X-3M
350
Dashboard harness (P.5-017)
50
250 Corrugate
55 54 53 YG YB LR 59 X 57 Sb B L
Ground 7
SWP-6M
Horn PB104
7
37
7
SWP-4M
22 17 RB WR 40 33 WB LgW
50
CB104
360 Corrugate
10
Head lamp (R)
50
LCT RL-1A
50
22 RB X B
80
80
80
Engine harness (P.5-015)
1 5W 2 5WR
5 3GW 6 3G
7 5RW 8 5R
7322-4123-30
7322-4125-50
7322-4123-30
65A (black)
45A (red)
65A (black)
Fusible link 1449-09004-1-10274-A
5-021
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
B,2B
10
A (6M), B , Battery relay-X, Fuel gauge unit, Fuel pump, Ground, Turn signal lamp (L), (R), Drum edge lamp (F,L) (option), (F,R) (option)
5W
2
Battery relay-COM, Fusible link 65A
5WR
2
A , Fusible link 65A
LgW
2
A (8M), Battery relay-BR
3GW
2
Battery relay-NO, Fusible link 45A
3G
2
A (2M), Fusible link 45A
5WR
2
Battery relay-NO, Fusible link 65A
5R
2
A , Fusible link 65A
5WG
2
A, B
2Y
2
A (3M), B
WR
2
A (4M), B
RB
3
A (4M), B , Fuel pump
5BR
2
A, B
Lg
2
A (8M), Horn
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
3BY
2
A (3M), B
LgW
2
A (4M), B
G
2
A (8M), Turn signal lamp (R)
GR
2
A (8M), Turn signal lamp (L)
2GB
3
A (2M), Head lamp (L), (R)
Or
3
M , Drum edge lamp (F,L) (option), (F,R) (option)
WB
2
A (4M), B
BrR
3
A (8M), Vibrator solenoid-Hi, Lo
LgR
2
A (8M), Vibrator solenoid-Lo
LgY
2
A (8M), Vibrator solenoid-Hi
LR
2
A (6M), B
YB
2
A (6M), B
YG
2
A (6M), Fuel gauge unit
L
2
A (6M), B
Sb
2
A (6M), B
CONNECTION
5-022
ELECTRICAL SYSTEM
4-4. Frame (R) Harness
SW/TW354 : Frame (F) harness (P.5-019)
Water spray pump
SWP-2M
58X-2F
RB6B-SL
Or 38
X 42 3B 3LB
37 * 61 GB * RG * 36 X * GR B
50
SWP-2F
37 * 61 GB * RG * 35 X * G B
38 Or
13
20
200 Corrugate
10
10
470 Corrugate
50
100
3LY,100
50 49 46 LgW LgB BrR
X
3LB,100
J
3B,100
29
X
39
42
18
CB104
PB104
PB104
LE206
LE206
Backup buzzer
(e)
(g)
(G)
(B)
LA208 Ground
38 Or
X B
SWP-2F Drum edge lamp (R,L) (option)
X B
130 Tape
130 Tape
1500 Corrugate
Or,50
10
20
38
600 Corrugate
10
100 Corrugate 100 Tape
SWP-2F
304 308 G Br
13
RB6B-SL
100 Tape
50
360 Corrugate
150
58X-2F
18 9 3LY 2BrW
Dashboard harness (P.5-017)
13
870 Corrugate
3B,100
SWP-4F
M
Combination lamp (R) Flood lamp CB104
10
C
46 39 BrR LW 50 49 LgW LgB
100 Corrugate
600 Corrugate
50
LW,70
29 X BY B 37 * GB *
B,70
36 35 GR G 61 38 RG Or
BY,80
SWP-8F
150 Tape
50
* *
Combination lamp (L)
Drum edge lamp (R,R) (option)
400 Tape
TW504 : Frame (F) harness (P.5-021)
38 X Or B 304 308 G Br
308 X Br B
SWP-4F Mihaalu harness (P.5-036)
SWP-2M Backup lamp (option)
7
K
2BrW,50
9
SW354 : Not in use LCR RL-1B TW354,504 : Liquid spray pump
SWP-3F SW354 : Vibrator solenoid (R) harness H (P.5-032) TW354,504 : Cap (P.5-033)
X
LA208 Ground
Water spray relay
1446-09087-1-20946-B
5-023
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
B,3B
11
C , Backup buzzer, Combination lamp (L), (R), Ground, Mihaalu harness, Water spray pump, Water spray relay-e, Backup lamp (option), Drum edge lamp (R,L) (option), (R,R) (option)
LW
2
C , Water spray relay-g
3LB
2
Water spray pump, Water spray relay-G
2BrW
2
C, K
BrR
2
C, J
3LY
2
C , Water spray relay-B
LgB
2
C, J
BY
2
C , Backup buzzer
LgW
2
C, J
G
2
C , Combination lamp (R)
RG
3
C , Combination lamp (L), (R)
GR
2
C , Combination lamp (L)
G
2
C , Mihaalu harness
GB
3
C , Combination lamp (L), (R)
Br
3
C , Mihaalu harness, Backup lamp (option)
Or
6
C , M , Flood lamp, Drum edge lamp (R,L) (option), (R,R) (option)
CONNECTION
5-024
ELECTRICAL SYSTEM
4-5. Stater Switch Harness
5WR,100 5WG,100 3 11 13 LgR BrB 2Y 14 16 32 WL 3W 3BY
RB6B-SL Dashboard harness (P.5-017)
LCR RL-1B
LCT RL-1A
2
10
BrB,100 50
2Y,100 LgR,100
5WR,50
H
50 Tape
WL,100 3W,100 3BY,100
5WG,50
2
LE305
(B)
10
LE305
(R1)
11
LE105
(ACC)
13
LE205
(ACC)
3
LE105
(BR)
14
LE105
(C)
16
LE205
(C)
32
LE205
(C)
Starter switch
1446-09027-0-30316-0
No.
SIZE, COLOR
CONTACT POINTS
5WR
2
H , Starter swich-B
LgR
2
H , Starter swich-BR
5WG
2
H , Starter swich-R1
BrB
2
H , Starter swich-ACC
2Y
2
H , Starter swich-ACC
WL
2
H , Starter swich-C
3W
2
H , Starter swich-C
3BY
2
H , Starter swich-C
CONNECTION
5-025
ELECTRICAL SYSTEM
4-6. Control Switch Harness
RY,80 33 24 LgW RY
SWP-2M Dashboard harness (P.5-017) 58X-3M
37 19 2GB 3R 38 2Or
LgW,80
50 50
3R,80
F
50 Tape
3R,80 2GB,80 2Or,80
24
(1)
33
(2)
19
(1)
19
(4)
37
(3)
38
(5)
Speed change switch
Lighting switch
1446-09028-0-30317-A
No.
SIZE, COLOR
CONTACT POINTS
2R,3R
3
F , Lighting swich-1, 4
RY
2
F , Speed change swich-1
LgW
2
F , Speed change swich-2
2GB
2
F , Lighting swich-3
2Or
2
F , Lighting swich-5
5-026
CONNECTION
ELECTRICAL SYSTEM
4-7. Working Switch Harness 4-7-1. Working switch harness (except ROPS)
LY,80 LW,80 SWP-3F
27 39 18 GY LW LY
Dashboard harness (P.5-017) SWP-3M
23 43 44 RL RW BrY
GY,80 50 50
J
50 Tape
LW,80 RL,80 RL,80 RW,80 BrY,80
18
(1)
39
(2)
27
(4)
39
(5)
23
(1)
23
(4)
43
(2)
44
(5)
Water spray mode select switch
Vibration mode select switch
1446-09063-0-30837-0
No.
SIZE, COLOR
CONTACT POINTS
LY
2
J , Water spray mode select switch-1
RL
3
J , Vibration mode select switch-1, 4
GY
2
J , Water spray mode select switch-4
LW
3
J , Water spray mode select switch-2, 5
RW
2
J , Vibration mode select switch-2
BrY
2
J , Vibration mode select switch-5
CONNECTION
5-027
ELECTRICAL SYSTEM
4-7-2. Working switch harness (ROPS)
SWP-3M
23 43 44 RL RW BrY
3 Ta 50 pe
* *
50
Ground
39 18 LW LY
SWP-3F Dashboard harness (P.5-017)
50
LA108
X
50
J
50 Tape
X 70 B P 39 70 LW P
LY,80 LY,80 LW,80 P,80
B,350
RL,80 RL,80 RW,80 BrY,80
RB4B-SL
18
(1)
18
(4)
39
(2)
70
(5)
23
(1)
23
(4)
43
(2)
44
(5)
Water spray timer
Water spray mode select switch
Vibration mode select switch
1446-75052-0-30851-0
No.
SIZE, COLOR
CONTACT POINTS
B
2
J , Water spray timer
LY
3
J , Water spray mode select switch-1, 4
RL
3
J , Vibration mode select switch-1, 4
LW
3
J , Water spray mode select switch-2, Water spray timer
RW
2
J , Vibration mode select switch-2
BrY
2
J , Vibration mode select switch-5
P
3
Water spray mode select switch-5, Water spray timer × 2
5-028
CONNECTION
ELECTRICAL SYSTEM
4-8. Parking Brake Switch Harness
RW,100 WB,100 Dashboard harness (P.5-017)
SWP-6F
301 X 41 Y B RW * 15 40 * YL WB
50
E
50 Tape
YL,100 B,100 Y,100
41
(1)
40
(3)
15
(5)
X
(4)
301
(2)
Parking brake switch
1446-09062-0-30834-0
No.
SIZE, COLOR
CONTACT POINTS
B
2
E , Parking brake switch-4
YL
2
E , Parking brake switch-5
WB
2
E , Parking brake switch-3
RW
2
E , Parking brake switch-1
Y
2
E , Parking brake switch-2
CONNECTION
5-029
ELECTRICAL SYSTEM
4-9. Vibration Lo-Hi Change Switch Harness 4-9-1. Short harness (SW/TW354 : except SW354 ROPS)
Dashboard harness (P.5-017)
SWP-6M
47 47 LgR LgR 49 49 LgB LgB
* * * *
1446-09015-0-40121-0
No.
SIZE, COLOR
CONTACT POINTS
LgR
2
Dashboard harness × 2
LgB
2
Dashboard harness × 2
5-030
CONNECTION
ELECTRICAL SYSTEM
4-9-2. Vibration Lo-Hi change switch harness (TW504)
RL,80 RL,80 Dashboard harness (P.5-017)
SWP-6M
23 47 48 RL LgR LgY 23 49 50 RL LgB LgW
50
D
50 Tape
LgR,80 LgY,80 LgB,80 LgW,80
23
(1)
23
(4)
47
(3)
48
(2)
49
(6)
50
(5)
Vibration Lo-Hi change switch
1448-09005-0-30064-A
No.
SIZE, COLOR
CONTACT POINTS
RL
3
D , Vibration Lo-Hi change switch-1, 4
LgR
2
D , Vibration Lo-Hi change switch-3
LgY
2
D , Vibration Lo-Hi change switch-2
LgB
2
D , Vibration Lo-Hi change switch-6
LgW
2
D , Vibration Lo-Hi change switch-5
CONNECTION
5-031
ELECTRICAL SYSTEM
4-10. Vibrator Solenoid (R) Harness 4-10-1. Vibrator solenoid (R) harness (SW354)
BrR,50 Frame (R) harness (P.5-023)
SWP-3M
46 49 50 BrR LgB LgW
50
H
50 Tape
46
CA104
49
CB104
50
CB104
Vibrator solenoid (R)
LgB,50 LgW,50
Not in use
1446-09012-0-30118-0
No.
SIZE, COLOR
CONTACT POINTS
BrR
2
H , Vibrator solenoid (R)
LgB
2
H , Vibrator solenoid (R)
LgW
2
H , CB104 (not in use)
5-032
CONNECTION
ELECTRICAL SYSTEM
4-10-2. Cap (TW354,504)
Frame (R) harness (P.5-023)
SWP-3M
* *
* *
* *
1447-09002-0-40043-0
5-033
ELECTRICAL SYSTEM
4-11. Hazard Switch Harness 4-11-1. Cap (except ROPS)
Dashboard harness SWP-4F (P.5-017)
* * * *
* * * *
1418-09044-0-40589-0
5-034
ELECTRICAL SYSTEM
4-11-2. Hazard switch harness (ROPS)
GY,100 Dashboard harness (P.5-017)
SWP-4F
40 6 GB GY 26 6 GR GY
50
G
100 Corrugate
GB,100 GY,100
7
GR,100
6
(1)
40
(2)
6
(4)
26
(5)
Hazard switch
1634-09078-0-31116-0
No.
SIZE, COLOR
CONTACT POINTS
GY
4
G × 2, Hazard switch-1, 4
GR
2
G , Hazard switch-5
GB
2
G , Hazard switch-2
CONNECTION
5-035
ELECTRICAL SYSTEM
4-12. Mihaalu Harness
Super flex vinyl cabtyre cord S-VCTF 0.75mm 2 ×4C Mihaalu (option)
X 38 B R 308 304 W G
38 X 304 R B G * * 308 * * W
SWP-6F
SWP-4M
Frame (R) harness (P.5-023)
750
1446-70015-0-30858-0
No.
SIZE, COLOR
CONTACT POINTS
B
2
Frame (R) harness, Mihaalu (option)
R
2
Frame (R) harness, Mihaalu (option)
G
2
Frame (R) harness, Mihaalu (option)
W
2
Frame (R) harness, Mihaalu (option)
5-036
CONNECTION
ELECTRICAL SYSTEM
4-13. Liquid Spray Switch Harness (TW354,504)
2BrR,130 Dashboard harness (P.5-017)
58X-2M
9 20 2BrR 2BrW
D
170 Tape
20
(1) Liquid spray switch
2BrW,130
9
(2)
1442-09001-0-30054-0
No.
SIZE, COLOR
CONTACT POINTS
2BrW
2
D , Liquid spray switch-2
2BrR
2
D , Liquid spray switch-2
CONNECTION
5-037
ELECTRICAL SYSTEM
4-14. Liquid Spray Pump Harness (TW354,504)
Frame (R) harness LCT RL-1A (P.5-023)
9
2BrW,30
K
1350 Corrugate
7
2BrW,30
9
CB104 Liquid spray pump
1447-09003-1-30081-A
No.
SIZE, COLOR
CONTACT POINTS
2BrW
2
5-038
CONNECTION K , Liquid spray pump
ELECTRICAL SYSTEM
4-15. Short Harness
Dashboard harness (P.5-017)
SWP-2F
29 29 BY BY
1446-09080-0-40879-0
No.
SIZE, COLOR
CONTACT POINTS
BY
2
CONNECTION Dashboard harness × 2
5-039
ELECTRICAL SYSTEM
4-16. Vibratory Drum Select Switch Harness (SW354 ROPS)
RL,80 RL,80 Dashboard harness (P.5-017)
SWP-6M
23 47 48 RL LgR LgY 23 49 50 RL LgB LgW
50
D
50 Tape
LgR,80 LgB,80 LgY,80 LgW,80
23
(1)
23
(4)
47
(6)
49
(3)
48
(6)
50
(5)
Vibratory drum select switch
Not in use
1448-09005-0-30064-A
No.
SIZE, COLOR
CONTACT POINTS
RL
3
D , Vibratory drum select switch-1, 4
LgR
2
D , Vibratory drum select switch-6
LgY
2
D , Vibratory drum select switch-6 (not in use)
LgB
2
D , Vibratory drum select switch-3
LgW
2
D , Vibratory drum select switch-5 (not in use)
5-040
CONNECTION
ELECTRICAL SYSTEM
4-17. F-R Lever Vibration Switch (L) Harness
Br,55 Dashboard harness (P.5-017)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (L)
See “Wiring Harness Layout (2), DETAIL P”. (P.5-010),(P.5-012),(P.5-014)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Dashboard harness, F-R lever vibration switch (L)-1
–
G
2
Dashboard harness, F-R lever vibration switch (L)-2
–
W
2
Dashboard harness, F-R lever vibration switch (L)-3
CONNECTION
5-041
ELECTRICAL SYSTEM
4-18. F-R Lever Vibration Switch (R) Harness
Br,55 Dashboard harness (P.5-017)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (R)
See “Wiring Harness Layout (2), DETAIL R”. (P.5-010),(P.5-012),(P.5-014)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Dashboard harness, F-R lever vibration switch (R)-1
–
G
2
Dashboard harness, F-R lever vibration switch (R)-2
–
W
2
Dashboard harness, F-R lever vibration switch (R)-3
5-042
CONNECTION
ELECTRICAL SYSTEM
5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Fuse Box (SW354)
(RB) Fuel pump Engine stop solenoid Tachometer sensor
Vibrator lamp relay (RL) Vibration mode select switch Vibrator solenoid (F) Vibrator solenoid (R) Vibratory drum select switch (ROPS)
(RG) Backup buzzer switch Horn relay Flasher unit
ECO lamp switch 1 (RY) Brake lamp relay F-R lever switch Speed change switch Foot brake switch
(R) Lighting switch (LY) Water spray mode select switch
Parking interlock relay (W)
Water spray relay
10
9
8
7
6
5
4
3
2
1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
(G) Battery relay Sub power (12V/120W)
(W) Starter switch
(R) Battery relay
SW354-05001
Harness color codes W : White R : Red RB : Red/Black stripe RY : Red/Yellow stripe
RG RL G LY
: Red/Green stripe : Red/Blue stripe : Green : Blue/Yellow stripe
5-043
ELECTRICAL SYSTEM
5-2. Fuse Box (TW354)
(RB) Fuel pump Engine stop solenoid Tachometer sensor
Vibrator lamp relay (RL) Vibration mode select switch Vibrator solenoid
(RG) Backup buzzer switch Horn relay Flasher unit ECO lamp switch 1 (RY) Brake lamp relay F-R lever switch Speed change switch Foot brake switch
(BrR) Liquid spray switch
(R) Lighting switch (LY) Water spray mode select switch
Parking interlock relay (W)
Water spray relay
10
9
8
7
6
5
4
3
2
1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
(W) Starter switch
(G) Battery relay Sub power (12V/120W) (R) Battery relay
TW354-05001
Harness color codes W : White R : Red RB : Red/Black stripe RY : Red/Yellow stripe RG : Red/Green stripe
5-044
RL : Red/Blue stripe G : Green BrR : Brown/Red stripe LY : Blue/Yellow stripe
ELECTRICAL SYSTEM
5-3. Fuse Box (TW504)
(RB) Fuel pump Engine stop solenoid Tachometer sensor
Vibrator lamp relay (RL) Vibration mode select switch Vibration Lo-Hi change switch
(RG) Backup buzzer switch Horn relay Flasher unit ECO lamp switch 1 (RY) Brake lamp relay F-R lever switch Speed change switch Foot brake switch
(BrR) Liquid spray switch
(R) Lighting switch (LY) Water spray mode select switch
Parking interlock relay (W)
Water spray relay
10
9
8
7
6
5
4
3
2
1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
(W) Starter switch
(G) Battery relay Sub power (12V/120W) (R) Battery relay
TW504-05001
Harness color codes W : White R : Red RB : Red/Black stripe RY : Red/Yellow stripe RG : Red/Green stripe
RL : Red/Blue stripe G : Green BrR : Brown/Red stripe LY : Blue/Yellow stripe
5-045
ELECTRICAL SYSTEM
5-4. Combination Meter
X GB, REV. ratio SEL.2
54 G, Engine oil pressure warning
SWP-16F
OW, Coolant temp. SEL.2
59 YW, Coolant temp. meter
X RB, REV. ratio SEL.1
53 GW, Hydraulic oil filter warning
SWP-12M
55 YR, Fuel meter
WB, Coolant temp. SEL.1
57 Y, REV. pulse input.2 (square wave) 15 GR, Parking brake
LgY, REV. ratio SEL.4 52 GY, Preheating OG, REV. ratio SEL.3
X B, Ground 17 BrW, Lamp check
SWP-16F
17 W, Charge warning
Harness side 12V BATT (12V)
KEY SW
Engine speed 2 Engine speed 3 Engine speed 4
12V
LCD
Hour meter
YL, Side maker lamp
O, REV. pulse input.1 (pickup)
51 L, Vibrator 9 LB, Liquid spray 39 Br, Water spray
Illumination LED
Frequency divider selector
Output interface
Vibration
Input interface
Engine charge warning Engine oil pressure Hydraulic filter
37 WR, Combination meter illumination
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Liquid spray
35 GL, Turn signal (R)
12 R, Battery12V (+)
Turn signal (L)
Parking brake
Temperature meter
Not in use
Turn signal (R)
Glow plug
Movement
SWP-16M
* * * * * * * *
11 P, Starter switch (ACC)
Backlight
Flood lamp
Fuel meter
17 WR 52 YW X B X B
36 LR, Turn signal (L)
Position lamp
Water spray
Movement
EEPROM
Output interface
Engine speed 1
Tachometer
CPU
Fuel sensor Temperature sensor
AD input interface TA input interface
TA pulse (square wave)
Input interface
TA pulse (pickup)
Movement
Input interface
CAN interface
12V
5V power supply
Power excitation circuit
17 WR 15 YL 53 LR 54 YB
X B 57 L 55 YG 59 Sb
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
SWP-12M
38 LW, Flood lamp
Harness side 12 Y
* *
11 BrB
* *
37 GB 35 G 36 GR
* *
38 Or 39 LW 9 BrW 51 Br
SWP-12F
Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram Note:
5-046
The circuit in the dashed box is not mounted.
SW354-05002
SW504
ELECTRICAL SYSTEM
6. SYSTEM CIRCUIT DIAGRAM (SW504) 6-1. Electrical Circuit Diagram (ROPS) HEAD LAMP (R) 55W
R
38 Or
DPF_TEMP.SEN._T2_2 C01 DPF_TEMP.SEN._T2_1 C02 DPF_TEMP.SEN._T1_2 C03 DPF_TEMP.SEN._T1_1 C04 DPF_TEMP.SEN._T0_2 C05 DPF_TEMP.SEN._T0_1 C06 DPF_PRE.SENSOR_3 C09 DPF_PRE.SENSOR_2 C10 DPF_PRE.SENSOR_1 C11
139 2LW 136 2BrR 137 2BrW 145 BrY 142 P 144 LB 142 P 143 GB 142 P 146 LgW 142 P
TEMP.SENSOR(-) (5) OUTPUT SIG. VO (3) GRAUND G (2) BATTERY VO. VB (1)
AIR FLOW SENSOR
109 0.5Gr 110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
V_V_BAT3(+BP) 253 ENG.RPM(SIG) 145
104 G_R_GND5(GND)
I_S_BRKPS(SW) 219
106 I_A_TOXCPOST(SIG TEMP)
G_R_GND1(GND) 209
107 I_A_TOXCPRE(SIG TEMP)
V_V_5VAPP1(5V) 201
130 I_A_PFDP(SIG)
G_R_GND1(GND) 240
I_S_TRO_N(SW) 217 I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227 B_D_CANL1(CAN1-L) 243 B_D_CANH1(CAN1-H) 231 203 G_R_AMS(GND)
POWER GND 251
204 I_A_IATS(SIG temp)
POWER GND 252
205 I_A_MAS(SIG)
POWER GND 254
238 O_V_12V
D1803 ECU
D1803 ECU
NC NO COM
82 1.25WL
21 RG
B
W
160 1.25B
I_S_T15(IG-SW) 226 I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241
+V2
O_S_STRTL(ST-REL) 136
OUT2 GND2 +V1 OUT1 GND1
POTENTIOMETER CAN (SERVICE TOOL) 107 G 106 Y
CAN-L
GND
CAN-H
12V
108 B
O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250 O_S_WELP(LAMP) 245 O_T_ESL(LAMP) 224
O_V_RH01(POW.) 249 O_T_IMPHL(LAMP) 246
CAP
80 WG 84 WY
80 WG 84 WY 85 LY
90 GW
90 GW
89 G
89 G
93 L
61 RG
18 3LY
B
ALTERNATOR
82 3WL 84 WY
313 5WB 5
3
2
1
1.25Br
1.25B
18 3LY
2B
1 11
6 2G
6 3G 3G
AV60
SUB POWER (12V/120W)
AV60
F.L.
45A
+
313 WB
-
12V BATTERY
B
COM
4 LgW B
15A
4 LgW
FUSE
2 5WR
25A
2 3WR
FUSE
AV60
W
NO
BR
STARTER MOTOR
ECU MAIN RELAY
85 LY
F.L.
65A E 26 5BR
R
86
STARTER RELAY
305 2Br
FUSE
28 8WY 5W
85
10A
5
30
2
3
4
19 3R
21 RG 5
6
23 RL 7
FUSE BOX
7
87
300 BW
92 W
39 LW B
IG
L
3 LgR
O_T_MREGL(LAMP) 233 O_T_PFREGLP(LAMP) 236
162 1.25B
106 Y
R1
82 3WL
314 BY
70 P 70 P
BATTERY RELAY
B
DIODE 2 8WR
75A
1 8W
F.L. 312 5BY
65A
311 5BW
F.L.
GLOW PLUGS
O_S_OHTL(LAMP) 244
161 1.25B
107 G
STARTER SWITCH
S
82 3WL
99 LY
106 Y
13 2Y
BR
12
301 Y
52 YW
98 LR
107 G
R2
28 8WY
b
314 BY
105 Br
B
8 5R
16 3W
26 5BR
92 W
301 Y
104 Y
ACC
C
2 5WR
93 L
DIAGNOSTIC SWITCH
WATER SPRAY TIMER
2
3 4
24 RY
14 WL
5A
301 Y
103 W
1
3 LgR
85 LY
B
53 LR
2
1
82 1.25WL
102 B
18 LY
8
B 300 BW
87 LR
12 Y
25 3W
302 LgR
314 BY
314 BY
12 Y
39 LW
17 WR
17 WR
92 W
315 GW
B
82 1.25WL
101 G
18 LY
13
1
22
25
15
10
35 18
32 24
31
29 21
315 GW
52 YW
28
13
149 YB
11
ޓ7 12
2
86 L
INTERLOCK RELAY
100 L
18 LY
4
25 3W
STOP
316 GR ޓ9 30
19
20 23
ޓ8
ޓ3 V_V_BAT2(+BP) 255
B
B
9
51 Br
98 LR
27 GY
35 G
36 GR
37 GB
38 Or
149 YB
82 WL
150 GB
V_V_BAT1(+BP) 256
139 I_A_TPFPOST(SIG TEMP)
D1803 ECU
1
98 LR
155 O_P_SVL12(TWV2)
132 RY
ENGINE CONNECTOR
TEMP.SENSOR(+) (4)
154 O_P_SVH12(TWV2)
2
a
82 WL
151 O_P_SVH21(TWV3) 150 O_P_SVL21(TWV3)
3
302 LgR
82 3WL
156 O_P_SVL11(TWV1)
80 WG
5
99 LY 55 YG
TURN SIGNAL LAMP (L) 21W
G
2 5WR
87 LR
c
STOP LAMP 21W
36 GR
25 3W
149 YB
153 O_P_SVH11(TWV1)
G
1 8W
138 2LR
5A
80 WG
141 2LgW
FUSE
2 WR
17 WR
f
TAIL LAMP 5W
61 RG
B
25 3W
17 WR
e
37 GB
VIBRATOR SOLENOID (R)
11 BrB
5A
36 GR
87 LR
COMBINATION LAMP (L)
24 RY
301 Y
140 2LgR
1
311 5BW
INJECTOR#2_1 B11
132 RY
1
50 LgW
39 LW
16 3W
38 Or
101 V_V_5VRAILPS(5V)
49 LgB
5
B
LOW
308 Br
PARKING INTERLOCK 39 LW RELAY
150 GB
142 I_F_CRSPOS(SIG)
6
SOL
21 RG
82 3WL
INJECTOR#2_2 B05
133 RG
115 V_V_5V_G5(5V)
5
1
82 WL
INJECTOR#3_1 B10
134 W
119 I_A_CTS(SIG temp)
HI
WATER SPRAY MODE SELECT SWITCH
314 BY
37 GB
132 I_A_BPS(SIG)
6
23 RL
55 YG
INJECTOR#3_2 B04
132 RY
2
70 P
NO
19 3R
55 YG
INJECTOR#1_1 B08
135 BrB
120 I_A_TVA(SIG)
300 BW
INJECTOR#1_2 B02
129 LY
39 LW
BACKUP BUZZER SWITCH
35 G
128 I_A_RAILPS(SIG)
48 LgY
46 BrR
2
NC
C
39 LW
B
2
2
F-R LEVER VIBRATION SWITCH (L)
23 RL
FUSE
53 LR
BOST_SEN._3 A42
106 Y
108 G_R_GND4(GND)
47 LgR
TAIL LAMP 5W
61 RG
300 BW
53 LR
RAIL_PRE.SEN._3 A41
130 BrY
Br
STOP LAMP 21W
37 GB
F-R LEVER VIBRATION SWITCH (R)
R
FUSE
93 L
CRANK_ANG.SEN.(NE)_2 A40
131 LgB
NO
Br
302 LgR
COMBINATION METER
3
NC
19 3R
12 Y
144 G_R_GND6(GND)
4
C
25 3W
131 I_A_BTS(SIG temp)
63 BrW
5
61 RG
2
VIBRATOR SOLENOID (F)
VIBRATORY DRUM SELECT SWITCH
308 Br
314 BY
92 W
BOST_SEN._4 A37 COLANT_TMP.SEN._2 A38 INTAKE_THRO.VAL._3 A39
127 Gr
102 V_V_5V_G8(5V)
6
45 Br
301 Y
52 YW
EGR VALVE_1 A36
107 G
103 V_V_5V_G6(5V)
301 Y
B
143 I_F_CRSNEG(GND) 213 I_S_OPS(SW)
4
61 RG
21 RG
21 RG
314 BY
RAIL_PRE.SEN._2 A33 INTAKE_THRO.VAL._2 A34
128 GY
1
27 GY
150 GB
EGR VALVE_2 A31 BOST_SEN._1 A32
124 LgY
3
2
23 RL
37 GB
INTAKE_THRO.VAL._1 A28
125 R
5
21 RG
ޓ4
BOST_SEN._2 A27
126 R
21 RG
62 BrB 1
2
23 RL
a
27 GY
36 GR
CAM_ANG.SEN.(G)_3 A24
121 GR
b
23 RL
27
OIL SW A21 CRANK_ANG.SEN.(NE)_3 A23
122 B
141 I_F_CASPOS(SIG)
24 RY 60 BrY
15 YL
137 G_R_GND3(GND) 140 G_R_GND8(GND)
c
99 LY
14
CRANK_ANG.SEN.(NE)_1 A19
119 B 123 W
23 RL 1
3
27 GY
15 YL
CAM_ANG.SEN.(G)_2 A18
23 RL
F-R LEVER SWITCH
HORN RELAY
HORN SWITCH
4
3
24 RY
129 G_R_RAILPS(GND)
99 LY
CAM_ANG.SEN.(G)_1 A15
120 YB
123 O_T_DCNEG(MOTOR-)
51 Br
COLANT_TMP.SEN._1 A14
118 BrW
111 O_V_MEU(SCV-)
98 LR
RAIL_PRE.SEN._1 A09
115 Sb
82 WL
INTAKE_THRO.VAL._5 A08
BUZZER
23 RL
F
BRAKE LAMP RELAY
31 LgW G
83 WR 116 LW
82 WL
MPROP._1 A07
117 X
B
124 O_T_DCPOS(MOTOR+)
B
f
SPEED CHANGE SWITCH 30 Lg
316 GR
B
112 O_V_MEU(SCV+)
83 WR
EGR VALVE_4 A06
112 YR
5A
SHIELD_DOREN A05
113 RW
FUSE
MPROP._2 A03 INTAKE_THRO.VAL._6 A04
24 RY 1
2
X B
82 3WL
EGR VALVE_3 A02
33 LgW
a
NEUTRAL RELAY
242 B_D_CANL2(CAN2-L)
82 3WL
SHIELD_DOREN A01
114 X
b
230 B_D_CANH2(CAN2-H)
3
34
150 GB
27 GY
B
4
e B
16
149 YB
239 I_S_REGINH(SW)
61 RG
HAZARD SWITCH
99 LY
c
55 YG
DPF SWITCH
f e
228 I_S_MRGESW(SW)
33
82 WL
98 LR
225 O_V_SWITCH(12V)
1
LOW
SOL
46 BrR
WATER SPRAY PUMP VIBRATION Lo-Hi CHANGE SWITCH
45 Br
4 34 GY
5
2
148 LgY
41 RW
HI 2
B
PARKING BRAKE SWITCH
1 34 GY
2 36 GR 6 5
21 RG
53 LR
148 LgY
107 G
3
3
35 G
Or B
NC NO M CO
82 WL 1
36 GR
34 GY
82 WL
1
5
B
149 YB
39 LW
10
15 YL
27 GY 150 GB
2 6
B
FLASHER UNIT
B
3
R
E
40 WB 301 Y
W
L
L
B
BACKUP BUZZER
24 RY
B
44 BrY
17
TERMINATING RESISTOR (120Ω)
G GR
g
R
R
34 GY
B
e
VIBRATION MODE SELECT SWITCH
27 GY
45 Br
36 GR
TURN SIGNAL SWITCH
GY
302 LgR
43 RW
36 GR
93 L
B
35 G
23 RL
D
35 G
33 LgW
F
34 GY
301 Y
H
23 RL
30 Lg
E
36 GR
G
1
6 44 BrY 5
19 3R
46 BrR
VIBRATOR RELAY
2
VIBRATOR LAMP RELAY
43 RW 2
NC NO COM
46 BrR
G
3
15 YL
G
TURN SIGNAL LAMP (L) 21W
5
3
FOOT BRAKE SWITCH
R
36 GR
B
LIGHTING SWITCH
23 RL
35 G
30
106 Y
24 25 26 27 28
4
5 51 Br
45 Br
SPEED CHANGE SOLENOID
19 3R
G
WATER SPRAY RELAY
R SOL
PARKING BRAKE SOLENOID
19 3R
6
10 11 12
ޓ6
9
26
8
38 Or
5
35 G
4
13 14 15 16 17 18 19 20 21 22 23
19 3R
1
2
HORN
R
R SOL
W
3
60 BrY
37 2GB
30 Lg
46 BrR
TURN SIGNAL LAMP (R) 21W
37 GB
G
B
COMBINATION LAMP (R) TURN SIGNAL LAMP (R) 21W
35 G
1
1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
R
35 G G
38 Or
B
B
29 BY
40 WB
24 RY
R
18 3LY
42 3LB
B
14
33 LgW
16 3W
37 2GB
51 Br
3
42 3LB
43 RW 37 2GB
HEAD LAMP (L) 55W
43 RW
32 33 34 35
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
45 Br
25 26 27 28 29 30 31
15 YL
2
R
46 BrR
45 Br
38 Or 1
FLOOD LAMP 55W
38 Or
44 BrY
44 BrY
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
36 GR
38 Or 46 BrR
36 GR
13 14 15 16 17 18 19 20 21 22 23 24
35 G
36 GR
18 3LY
35 G
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
37 GB
35 G
37 2GB
COMBINATION METER 1 2 3 4 5 6 7 8 9 10 11 12
37 GB
O_S_WOL(LAMP) 248
D1803 ECU
Y
B
312 5BY B
90 GW 82 WL
52 YW
HYDRAULIC FUEL GAUGE OIL FILTER UNIT SWITCH
P
FUEL PUMP
10 5WG B
G
e
9
GLOW RELAY 89 G
89 G
0448-99029-0-10638-A 0448-09805-0-10368-0 0446-09810-0-20880-0 0446-75805-0-20518-C
5-047
SW504
ELECTRICAL SYSTEM
6-2. Electrical Circuit Diagram (except ROPS) HEAD LAMP (R) 55W
38 Or
DPF_TEMP.SEN._T2_2 C01 DPF_TEMP.SEN._T2_1 C02 DPF_TEMP.SEN._T1_2 C03 DPF_TEMP.SEN._T1_1 C04 DPF_TEMP.SEN._T0_2 C05 DPF_TEMP.SEN._T0_1 C06 DPF_PRE.SENSOR_3 C09 DPF_PRE.SENSOR_2 C10 DPF_PRE.SENSOR_1 C11
139 2LW 136 2BrR 137 2BrW 145 BrY 142 P 144 LB 142 P 143 GB 142 P 146 LgW 142 P
TEMP.SENSOR(-) (5) TEMP.SENSOR(+) (4) OUTPUT SIG. VO (3) GRAUND G (2) BATTERY VO. VB (1)
AIR FLOW SENSOR
154 O_P_SVH12(TWV2)
109 0.5Gr 110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
V_V_BAT2(+BP) 255 V_V_BAT3(+BP) 253 ENG.RPM(SIG) 145
104 G_R_GND5(GND)
I_S_BRKPS(SW) 219
106 I_A_TOXCPOST(SIG TEMP)
G_R_GND1(GND) 209
107 I_A_TOXCPRE(SIG TEMP)
V_V_5VAPP1(5V) 201
130 I_A_PFDP(SIG)
G_R_GND1(GND) 240
I_S_TRO_N(SW) 217
STOP
B
NC NO COM
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227 B_D_CANL1(CAN1-L) 243 B_D_CANH1(CAN1-H) 231 203 G_R_AMS(GND)
POWER GND 251
204 I_A_IATS(SIG temp)
POWER GND 252
205 I_A_MAS(SIG)
POWER GND 254
D1803 ECU
B
W
21 RG
R
D1803 ECU
82 1.25WL
93 L
DIAGNOSTIC SWITCH
92 W
98 LR
I_S_T15(IG-SW) 226
99 LY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241
+V2
O_S_STRTL(ST-REL) 136
OUT2 +V1 OUT1 GND1
POTENTIOMETER CAN (SERVICE TOOL) 107 G 106 Y
CAN-L
GND
CAN-H
12V
108 B
O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250 O_S_WELP(LAMP) 245 O_T_ESL(LAMP) 224
O_V_RH01(POW.) 249 O_T_IMPHL(LAMP) 246
CAP
84 WY
80 WG 84 WY
82 3WL 84 WY
300 BW 85 LY
90 GW
90 GW
89 G
89 G
92 W 93 L
313 5WB 5
3
2
1
313 WB
ECU MAIN RELAY
85 LY
O_T_MREGL(LAMP) 233 O_T_PFREGLP(LAMP) 236
162 1.25B
106 Y
80 WG
1.25Br
1.25B
18 3LY 1 11 6 3G
6 2G
19 3R 2
3
4
5
6
23 RL 7
21 RG
12
F.L.
45A
F.L.
+
AV60
-
12V
W
BATTERY
NO
B
COM
4 LgW B
15A
4 LgW
FUSE
2 5WR
25A
2 3WR
FUSE
AV60
BR
BATTERY RELAY
B
DIODE 2 8WR
75A
1 8W
F.L. 312 5BY
65A
311 5BW
F.L.
GLOW PLUGS
O_S_OHTL(LAMP) 244
161 1.25B
107 G
24 RY
65A 3 LgR
314 BY
3G
STARTER MOTOR
82 3WL
82 3WL
314 BY
160 1.25B
8
S
52 YW
301 Y
106 Y
25 3W
ALTERNATOR
301 Y
GND2
B
R
E 26 5BR
5W
86
SUB POWER (12V/120W)
AV60
5
85
STARTER RELAY
2B
FUSE
28 8WY
7
30
26 5BR
53 LR
2
1
82 1.25WL
107 G
FUSE BOX
305 2Br
IG
L
2 5WR
315 GW
B
b
87
85 LY
B
55 YG
82 1.25WL
105 Br
8 5R
300 BW
87 LR
12 Y
25 3W
302 LgR
314 BY
314 BY
12 Y
39 LW
17 WR
17 WR
92 W
302 LgR
INTERLOCK RELAY
104 Y
R1
28 8WY
86 L
98 LR
103 W
STARTER SWITCH
13
1
22
25
15
10
35 18
32 24
31
29 21
315 GW
52 YW
28
ޓ6
13 11
149 YB
2
c
e a
102 B
13 2Y
25 3W f 87 LR
99 LY
101 G
9
316 GR ޓ9 26
30
19
20 23
ޓ8
17 WR
100 L
R2
BR
10
51 Br
98 LR
27 GY
35 G
36 GR
37 GB
38 Or
149 YB
82 WL
150 GB
V_V_BAT1(+BP) 256
301 Y
17 WR
82 WL
139 I_A_TPFPOST(SIG TEMP)
238 O_V_12V
1
36 GR
155 O_P_SVL12(TWV2)
D1803 ECU
2
B 3 LgR
16 3W
82 3WL
151 O_P_SVH21(TWV3) 150 O_P_SVL21(TWV3)
3
PARKING INTERLOCK 39 LW RELAY
149 YB
156 O_P_SVL11(TWV1)
16 3W
35 G
38 Or
153 O_P_SVH11(TWV1)
132 RY
ENGINE CONNECTOR
B
5
ACC
C
10A
1 8W
138 2LR
14 WL
5A FUSE
80 WG
141 2LgW
2 5WR
87 LR
301 Y
140 2LgR
80 WG
300 BW
150 GB
101 V_V_5VRAILPS(5V)
18 LY
11 BrB
5A FUSE
2 WR
5A
37 GB
142 I_F_CRSPOS(SIG)
B G
311 5BW
INJECTOR#2_1 B11
132 RY
115 V_V_5V_G5(5V)
B
25 3W
82 3WL
INJECTOR#2_2 B05
133 RG
119 I_A_CTS(SIG temp)
TURN SIGNAL LAMP (L) 21W
24 RY
FUSE
128 I_A_RAILPS(SIG)
132 I_A_BPS(SIG)
STOP LAMP 21W
36 GR
B
G
TAIL LAMP 5W
61 RG
WATER SPRAY MODE SELECT SWITCH
82 WL
INJECTOR#3_1 B10
134 W
108 G_R_GND4(GND)
37 GB
39 LW 314 BY
55 YG
INJECTOR#3_2 B04
132 RY
27 GY
61 RG
55 YG
INJECTOR#1_1 B08
135 BrB
144 G_R_GND6(GND)
120 I_A_TVA(SIG)
4
19 3R
COMBINATION METER
300 BW
INJECTOR#1_2 B02
129 LY
5
18 LY
19 3R
12 Y
53 LR
BOST_SEN._3 A42
106 Y
39 LW
1
61 RG
314 BY
53 LR
RAIL_PRE.SEN._3 A41
130 BrY
6
308 Br
301 Y
93 L
CRANK_ANG.SEN.(NE)_2 A40
131 LgB
301 Y
92 W
BOST_SEN._4 A37 COLANT_TMP.SEN._2 A38 INTAKE_THRO.VAL._3 A39
127 Gr
2
21 RG
131 I_A_BTS(SIG temp)
COMBINATION LAMP (L)
1
302 LgR
52 YW
EGR VALVE_1 A36
107 G
102 V_V_5V_G8(5V)
3 39 LW
27 GY
314 BY
RAIL_PRE.SEN._2 A33 INTAKE_THRO.VAL._2 A34
128 GY
103 V_V_5V_G6(5V)
BACKUP BUZZER SWITCH
NO
23 RL
38 Or
EGR VALVE_2 A31 BOST_SEN._1 A32
124 LgY
213 I_S_OPS(SW)
Br
25 3W
143 I_F_CRSNEG(GND)
LOW
F-R LEVER VIBRATION SWITCH (L)
21 RG
B
SOL
NC
27 GY
37 GB
INTAKE_THRO.VAL._1 A28
125 R
141 I_F_CASPOS(SIG)
46 BrR
2
VIBRATOR SOLENOID (R)
C
23 RL
15 YL
137 G_R_GND3(GND) 140 G_R_GND8(GND)
R
24 RY
129 G_R_RAILPS(GND)
2
NC
21 RG
ޓ4
BOST_SEN._2 A27
126 R
21 RG
1
50 LgW
99 LY
36 GR
CAM_ANG.SEN.(G)_3 A24
121 GR
1
49 LgB
5
27 GY
ޓ3
OIL SW A21 CRANK_ANG.SEN.(NE)_3 A23
122 B
2
6
23 RL
27
CRANK_ANG.SEN.(NE)_1 A19
119 B 123 W
3
HI
45 Br
a
21 RG 5
48 LgY
NO
TAIL LAMP 5W
F-R LEVER VIBRATION SWITCH (R)
F-R LEVER SWITCH
24 RY
2
C
STOP LAMP 21W
37 GB
B
47 LgR
45 Br
61 RG
VIBRATOR SOLENOID (F)
VIBRATION Lo-Hi CHANGE SWITCH
23 RL
HORN RELAY
HORN SWITCH
14
CAM_ANG.SEN.(G)_2 A18
120 YB
123 O_T_DCNEG(MOTOR-)
23 RL 4
308 Br
LOW 2
3
27 GY
15 YL
CAM_ANG.SEN.(G)_1 A15
118 BrW
111 O_V_MEU(SCV-)
99 LY
COLANT_TMP.SEN._1 A14
115 Sb
51 Br
RAIL_PRE.SEN._1 A09
116 LW
98 LR
INTAKE_THRO.VAL._5 A08
BUZZER
83 WR
23 RL
F
BRAKE LAMP RELAY
31 LgW G
82 WL
MPROP._1 A07
117 X
82 WL
EGR VALVE_4 A06
B
124 O_T_DCPOS(MOTOR+)
83 WR
SHIELD_DOREN A05
112 YR
5A
INTAKE_THRO.VAL._6 A04
c
b
SPEED CHANGE SWITCH 30 Lg
316 GR
B
112 O_V_MEU(SCV+)
24 RY 1
2
X B 113 RW
FUSE
MPROP._2 A03
114 X
82 3WL
EGR VALVE_3 A02
33 LgW
a
NEUTRAL RELAY
242 B_D_CANL2(CAN2-L)
82 3WL
SHIELD_DOREN A01
b
230 B_D_CANH2(CAN2-H)
3
34
150 GB
B
60 BrY
B
27 GY
B
16
149 YB
239 I_S_REGINH(SW)
99 LY
c
e
228 I_S_MRGESW(SW)
f e
55 YG
82 WL
f
33
148 LgY
4
21 RG
5
148 LgY
2
DPF SWITCH
98 LR
225 O_V_SWITCH(12V)
4
23 RL 1
PARKING BRAKE SWITCH
61 RG
107 G
3
23 RL
NC NO M CO
82 WL 1
15 YL
34 GY
82 WL
1
SOL
46 BrR
WATER SPRAY PUMP
41 RW
1
5
B
149 YB
HI 2
B
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
15 YL
27 GY 150 GB
2 6
Or B
14
FLASHER UNIT
B
3
39 LW
Br
B
E
40 WB 301 Y
W
L
L
B
BACKUP BUZZER
24 RY
B
44 BrY
G GR
53 LR
TERMINATING RESISTOR (120Ω)
R
34 GY
g
R
27 GY
45 Br
36 GR
B
e
VIBRATION MODE SELECT SWITCH
302 LgR
43 RW
36 GR
17
B
35 G
93 L
D
35 G
TURN SIGNAL SWITCH
GY
23 RL
F
34 GY
33 LgW
H
23 RL
301 Y
E
36 GR
G
1
6 44 BrY 5
19 3R
46 BrR
VIBRATOR RELAY
2
VIBRATOR LAMP RELAY
43 RW 2
NC NO COM
46 BrR
G
3
30 Lg
G
TURN SIGNAL LAMP (L) 21W
5
3
FOOT BRAKE SWITCH
R
36 GR
B
LIGHTING SWITCH
23 RL
35 G
30
106 Y
24 25 26 27 28
4
5 51 Br
45 Br
SPEED CHANGE SOLENOID
19 3R
G
WATER SPRAY RELAY
R SOL
PARKING BRAKE SOLENOID
19 3R
6
10 11 12
ޓ7
9
12
8
150 GB
5
35 G
4
13 14 15 16 17 18 19 20 21 22 23
19 3R
1
2
HORN
R
R SOL
W
3
60 BrY
37 2GB
30 Lg
46 BrR
TURN SIGNAL LAMP (R) 21W
37 GB
G
B
COMBINATION LAMP (R) TURN SIGNAL LAMP (R) 21W
35 G 1
1
16 3W
R
35 G G
38 Or
B
B
29 BY
40 WB
24 RY
R
18 3LY
42 3LB
B
61 RG
33 LgW
18 3LY
37 2GB
51 Br
3
42 3LB
43 RW 37 2GB
HEAD LAMP (L) 55W
43 RW
32 33 34 35
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
45 Br
25 26 27 28 29 30 31
15 YL
2
FLOOD LAMP 55W
R
46 BrR
45 Br
38 Or 1
38 Or
44 BrY
44 BrY
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
36 GR
38 Or 46 BrR
36 GR
13 14 15 16 17 18 19 20 21 22 23 24
35 G
36 GR
18 3LY
R
35 G
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
37 GB
35 G
37 2GB
COMBINATION METER 1 2 3 4 5 6 7 8 9 10 11 12
37 GB
O_S_WOL(LAMP) 248
D1803 ECU
Y
B
312 5BY B
90 GW 82 WL
52 YW
HYDRAULIC FUEL GAUGE OIL FILTER UNIT SWITCH
P
FUEL PUMP
10 5WG B
G
e
9
89 G
GLOW RELAY 89 G
0448-99029-0-10638-A 0446-09810-0-20880-0
5-048
SW504
ELECTRICAL SYSTEM
7. ELECTRICAL COMPONENTS (SW504)
Battery relay
7-1. Wiring Harness Layout (1) Turn signal lamp (R)
K : Not in use Insulation protection
Cap to Drum edge lamp (F,R) (option)
(B),(G)
Fuel gauge unit
(B),(YG)
Head lamp (R)
(GB)
LgW
(P.5-051)
LgW B WB B
Speed change solenoid (lower position)
E
Parking brake solenoid (upper position)
DETAIL A
Combination lamp (R)
S
Battery
W(COM)
B
Cap to Mihaalu (option)
Alternator
C
GW(NO) WR(NO)
Engine Harness
DETAIL B
(P.5-050)
Frame (F) harness (P.5-061)
A
Mihaalu harness
Fusible link 65A (black)
(P.5-082)
Cap to Backup lamp (option)
Ground
(B)
Fusible link 45A (red) Fusible link 75A (gray)
Cap to Drum edge lamp (R,R) (option)
(GB)
D
Turn signal lamp (L)
Engine Harness
Cap to Drum edge lamp (F,L) (option)
(B),(GR)
(P.5-051)
Water spray pump
F
Frame (R) harness (P.5-063)
W WR
GW G
Combination lamp (L)
B
Head lamp (L)
WR R
(Lg)
BW BY
Flood lamp
(Or)
Horn
VIEW C
Cap to Drum edge lamp (R,L) (option)
Vibrator solenoid (F) harness (1) (P.5-071) B
Vibrator solenoid (F)
Hydraulic oil filter switch (LR)
Diode
Air flow sensor
to Glow plugs (WG)
Starter motor
H
(P.5-050)
1
a W HI 2
1
W LOW 2 b B
B W
LgY BrR
W B
BrR LgR
Water spray relay Frame (F) harness (P.5-061)
H
Vibrator lamp relay
(BY)
VIEW E
Vibrator solenoid (F) harness (2) Parking interlock relay
Backup buzzer
LW(g) LB(G) B(e) LY(B)
(P.5-072)
VIEW D
Glow relay
Vibrator solenoid (R) harness (1) (P.5-073)
G
B
(P.5-050)
a 1 W HI 2
Ground Vibrator solenoid (R)
1
W LOW 2 b B
B W
Vibrator solenoid (R) harness (3) (P.5-075)
LgW BrR
(P.5-064)
BrR W B
BrR LgB
Frame (R) harness J
Vibrator solenoid (R) harness (4) (P.5-076)
Vibrator solenoid (R) harness (2) (P.5-074)
VIEW F ECU harness (engine) (P.5-059)
Engine Harness
(P.5-051)
Fuel pump
Vibrator relay
ECU harness (vehicle) (P.5-057)
0448-09816-0-10613-B
5-049
SW504
ELECTRICAL SYSTEM
7-2. Wiring Harness Layout (2) to Horn switch (LgW)
Dashboard harness (2)
to Turn signal switch
(G),(GR),(GY)
to Combination meter
(P.5-089)
J : to Working switch harness
F : to Control switch harness
ROPS: (P.5-067) Except ROPS: (P.5-068)
(P.5-066)
E : to Parking brake switch harness
D : to Vibration switch harness (ROPS) / Vibration Lo-Hi change switch harness (except ROPS) ROPS: (P.5-069) Except ROPS: (P.5-070)
(P.5-081)
R Ground
K J
Brake lamp relay
1
DETAIL L
OUT1 : to Mihaalu OUT 1 (option) (P.5-053),(P.5-055)
Dashboard harness (2)
F-R lever vibration switch (L) harness
(P.5-055)
Br B CA104
E Hazard switch harness (P.5-077)
G Q
Or(5) R(1) GB(3) R(4) RY(1) LgW(2) RW(1) Y(2) WB(3) B(4) YL(5) GY(4) GR(5) GY(1) GB(2) WL(1) LgY(2)
DPF switch harness
(P.5-079)
Water spray timer
VIEW H-H (ROPS)
Br G W
RL(4) BrW(3) RL(1) BrB(6) LgY(2) BrB(1) LgB(6) LgW(5) BrW(4) LgR(3)
J
CA104
Ground
ECU
F
E
Or(5) R(1) GB(3) R(4) RY(1) LgW(2) RW(1) Y(2) WB(3) B(4) YL(5)
Vibration switch harness (P.5-069)
Q DPF switch harness
ECU harness (vehicle) (P.5-057)
DETAIL R
(P.5-066)
Parking brake switch harness
Br G W
Insulation protection
(P.5-081)
D
(P.5-087)
Stater switch harness
(P.5-066)
(P.5-085)
Br B
Control switch harness Working switch harness
F-R lever vibration switch (R) harness
(Starter switch)
Cord
H
CA104
DETAIL P
(P.5-067)
DETAIL N
(P.5-053)
Insulation protection
BrY(5) RL(4) RW(2) RL(1) LY(4) LW(2) LY(1) P(5)
Neutral relay
LgR(BR) Y(BR) BrB(ACC) W(C) WL(C) BY(C) WR(B) WG(R1)
W(NO) B(COM) R(NC)
Dashboard harness (1)
(P.5-084)
CA104
CAN (service tool)
Starter switch
DETAIL M
GND : to Mihaalu ground (option)
Dashboard harness (1),(2)
VIEW G
BrY RY RW
2
Insulation protection
(P.5-080)
SECTION K-K
(P.5-053)
3
GW(2)
Insulation protection
L Diagnostic switch harness
Dashboard harness (1)
(P.5-080)
M
Fuse box
(P.5-081)
(P.5-083)
Foot brake switch
Diagnostic switch
B(1)
Parking interlock relay
F
Stater relay harness
ECU main relay
Glow relay
Diagnostic switch harness
Vibrator lamp relay
Parking brake switch harness
Buzzer
SECTION J-J
(P.5-065)
(B)
(P.5-088)
Flasher unit
Horn relay
Starter switch: N
K
Fuse (5A,10A,15A,25A)
(P.5-066)
W(NO) B(COM) R(NC)
Potentiometer
Starter relay
Backup buzzer switch
Except ROPS: (P.5-078)
J
P
Control switch harness
Br RG
G : to Hazard switch harness (ROPS) / Cap (except ROPS) ROPS: (P.5-077) Insulation protection
H : to Stater switch harness
Interlock relay
W(NO) B(COM) R(NC)
(P.5-079)
L : Short harness Sub power (12V/120W)
GY RY LgR
Q : to DPF switch harness
D : Cap
(P.5-086)
F-R lever switch
(P.5-055)
WL(1) LgY(2)
VIEW S
BrY(5) RL(4) RW(2) RL(1) GY(4) LW(2) LY(1) LW(5) RL(1) LgB(6) LgW(5) RL(4) LgR(3) LgY(2)
Working switch harness
(P.5-068)
J
D
Vibration Lo-Hi change switch harness
(P.5-070)
(P.5-079)
VIEW H-H (except ROPS)
0448-09816-0-10739-B 0448-09816-0-10613-B 0446-09805-0-10368-0 0446-09809-0-20817-0 0446-09810-0-20880-0 0446-75805-0-20518-C
5-050
ELECTRICAL SYSTEM
SW504
8. WIRING HARNESSES (SW504) 8-1. Engine Harness
Starter motor 250 Corrugate 7 (H-COT)
5WG, 50
10 LE304 Glow plugs
(B) LA308
(S) RB1B-SL
28
50 100 Corrugate 10 (H-COT)
82 109 111 110 109 6189-1046 Air flow sensor 0.5WL 0.5Gr 0.5L 0.5G 0.5Gr
8WY, 50
250
AEX 0.85 50
33 X LgW B
12015792
(20)
80
100 Tape
Tape
8WY, 50
250 Corrugate 20 (H-COT)
250 Corrugate 15 (H-COT)
400 Corrugate 10 (H-COT)
50
50
50
28
RB2B-SL
LA306 (B)
12015792
10 26 5WG 5BR
58Y-2M
Parking brake solenoid
AEX 0.85
100 Corrugate 15 (H-COT)
B
50 Tape
50 e p Ta
Alternator
40 X WB B
50 Ta pe
13 2Y 17 WR
Speed change solenoid
AEX 0.85
#
Marking tape (Color:yellow)
50
Corrugate 15 (H-COT)
750 Corrugate 10 (H-COT)
# # (5BR, 50) (VB5.5) (3BR, 50)
26 3BR
50
82 40 33 17 WL WB LgW WR X 111 110 109 B L G Gr
SWP-8M
Frame (F) harness (P.5-061)
AEX 0.85 50
13 2Y
58X-1M
・"#" indicates connection of the sleeve (3BR, 5BR) in the corrugate tube. ・Harness wires to be AVX 0.85 unless otherwise specified. ・Where the numbers differ, wires of the same color must not be united. 1448-09033-0-20725-0
5-051
ELECTRICAL SYSTEM
SW504
NO.
SIZE, COLOR
CONTACT POINTS
X
B
3
10
5WG
13
NO.
SIZE, COLOR
CONTACT POINTS
B , Parking brake solenoid, Speed change solenoid
33
LgW
2
B , Speed change solenoid
2
B , Glow plugs
40
WB
2
B , Parking brake solenoid
2Y
2
B , Alternator
82
0.5WL, WL
2
B , Air flow sensor
17
WR
2
B , Alternator
109
0.5Gr, Gr
3
B , Air flow sensor × 2
26
3BR,5BR
2
B , Starter motor -S
110
0.5G, G
2
B , Air flow sensor
28
8WY
2
Alternator -B, Starter motor -B
111
0.5L, L
2
B , Air flow sensor
CONNECTION
CONNECTION
5-052
50
P
B, 50
Br, 50
5 Ta 0 pe
100 ugat e
Corr
50 Tape
50 Tape
A
430 Corrugate
32
200 e gat
SWP-8M Frame (R) harness (P.5-063)
X B * *
29 BY 37 GB
35 G 38 Or
36 GR 100 61 RG
C
50 Tape
100 Tape
50 Tape
250 Tape
50
COMB
DIA
X 316 B GR MTL-2PL-F Buzzer
50
ECU-VD 308 304 Br G
100 Tape
50
19 to Dashboard harness (2) (P.5-055)
28
SWP-2F Diagnostic switch harness
41
60
24
CAN
314 106 BY Y 108 107 B G 174257-2 CAN (service tool)
Foot brake switch 100 Tape
* * * * * * * * 174259-2 (Cap)
Twist cable
・Where the numbers differ, wires of the same color must not be united.
SWP-8M
SWP-12F
SWP-8F
ECU harness (vehicle) (P.5-057)
CAN (service tool) Combination meter
107 G 106 Y 107 G 149 YB 150 GB
Terminating resistor (120Ω)
SWP-12F
100 99 98 93 L LY LR W 104 103 102 101 Y W B G
106 Y ECU harness (vehicle)
84 82 80 52 WY 1.25WL WG YW 92 90 89 85 W GW G LY
150 149 107 106 GB YB G Y 162 161 160 105 1.25B 1.25B 1.25B Br 314 301 300 148 BY Y BW LgY
Frame (F) harness
SWP-8F
Twist cable 100
Twist cable 50
100
50 Tape
SWP-2M
X 315 B GW
(P.5-080)
1 Ta 00 pe
SWP-4M
39 46 LW BrR 49 50 LgB LgW
7
250 e ugat o C rr 10
ru Cor
100 Tape
9 18 2BrW 3LY
58X-2M
180 Corrugate
105 104 103 Br Y W 102 101 100 B G L
200 Tape
50 Tape
250 Corrugate
Potentiometer 6189-0319
50
50
150 Tape
10
5 Ta 0 pe
SWP-4F
50
20 Ta 0 pe
RY, 50
SWP-6F
4 53 30 LgW LR Lg 46 47 48 BrR LgR LgY
5 Ta 0 pe
CB104
30
50 Tape
58X-2F
13 37 2Y 2GB
15
80
150 Corrugate
8 5R
Terminating resistor (DT04-3P-P006) DT06-3S
100 Corrugate 7
6 3G
BrY, 50
58Y-2M
CA104
30
CB104 CB104 45
RW, 50
2 312 8WR 5BY
150 149 GB YB 100 Tape * *
X
CA104
58Y-2F
50 Tape
80
F-R lever vibration switch (R) harness (P.5-085)
50 pe Ta
10 26 5WG 5BR
35 55 G YG 36 X GR B
Twist pair cable (AVS 0.85 mm2 x 2C)
50 pe Ta
Frame (F) harness (P.5-061)
12 150149 17 316 X * * 93 35 X 314 12 1 GB YB WR GR B * * L G B BY Y 23 36 314 315 X X 55 92 53 17 15 37 13 GR BY GW B B YG W LR WR YL GB 35 * * * * * 37 * 9 51 38 39 52 24 * * * * * GB * BrW Br Or LW YW
50 pe Ta
Twist cable 58Y-2F
GND
27 99 * GY LY * X * 98 B * LR
50
50
SWP-8F
17 33 40 82 WR LgW WB WL 106 107 83 X Y G WR 1.25B
OUT1
10 90 5WG GW 312 89 5BY G
Combination meter (P.5-089) 776164-1
Twist pair cable (AVS 0.85 mm2 x 2C)
50
25 26 3W 5BR
X
Neutral relay RB6B-SL
70 Tape
85 86 LY L
304
Glow relay 7123-9246
120 Corrugate 19
58Y-2M
50
SWP-2M
Mihaalu ground (option) CA104
450 Corrugate 19
Stater relay harness (P.5-083)
Mihaalu OUT 1 (option) CB104
50
8-2. Dashboard Harness (1)
B, 50
SW504
G, 50
ELECTRICAL SYSTEM
Twist cable
Twist cable processing diagram 1448-09032-1-10724-B
5-053
ELECTRICAL SYSTEM
SW504
No.
X
SIZE, COLOR
B, 1.25B, 2B
CONNECTION
CONTACT POINTS
21
Dashboard Harness (1)
(2)
A (4F), (8F), C (8M), COMB , DIA , Combination meter -3, 12 8, 19, 20, F-R lever vibration switch (R) harness, Neutral relay, GND (option)
9
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
39
LW
3
C (4M), Combination meter -25
2
1
40
WB
2
A (8F)
1
41
RW
2
Foot brake switch
SIZE, COLOR
CONTACT POINTS
98
LR
2
ECU-VD (8F), Neutral relay
2
99
LY
2
ECU-VD (8F), Neutral relay
2
1
100
L
2
ECU-VD (8F), Potentiometer
2
1
1
101
G
2
ECU-VD (8F), Potentiometer
2
102
B
2
ECU-VD (8F), Potentiometer
2
103
W
2
ECU-VD (8F), Potentiometer
2
104
Y
2
ECU-VD (8F), Potentiometer
2
105
Br
2
ECU-VD (12F), Potentiometer
2
106
Y
3
A (8F), CAN , ECU-VD (12F)
3
107
G
3
A (8F), CAN , ECU-VD (12F)
3
108
B
2
CAN
1
1
148
LgY
2
ECU-VD (12F)
1
1
149
YB
3
ECU-VD (12F), Combination meter -11, Terminating resistor
3
150
GB
3
ECU-VD (12F), Combination meter -12, Terminating resistor
3
Dashboard Harness (1)
(2)
2
3WR, 5WR, 8WR
4
A (2F)
1
3
45
Br
3
F-R lever vibration switch (R) harness
1
2
4
LgW
2
A (6F)
1
1
46
BrR
4
A (6F), C (4M)
2
2
6
2G, 3G
3
A (2M)
1
2
47
LgR
2
A (6F)
1
1
8
5R
2
A (2M)
1
1
48
LgY
2
A (6F)
1
1
9
BrW, 2BrW
3
C (2M), Combination meter -28
2
1
49
LgB
2
C (4M)
1
1
50
LgW
2
C (4M)
1
1
10
5WG
2
A (2F), Glow relay
2
51
Br
2
Combination meter -27
1
1
12
Y
2
Combination meter -1
1
1
13
2Y
2
A (2F)
1
1
2
15
YL
2
Combination meter -14
1
1
17
WR
3
A (8F), Combination meter -10, 15
2
3
52
YW
2
ECU-VD (8M), Combination meter -24
53
LR
2
A (6F), Combination meter -16
2
55
YG
2
A (4F), Combination meter -18
CONNECTION
No.
Dashboard Harness (1)
(2)
18
LY, 3LY
3
C (2M)
1
2
24
RY
5
Foot brake switch
1
4
60
BrY
2
Foot brake switch
1
1
25
3W
2
P
1
1
61
RG
2
C (8M)
1
1
26
5BR
2
A (2F), P
2
80
WG
2
ECU-VD (8M)
1
1
160
1.25B
2
ECU-VD (12F)
1
1
27
GY
4
Neutral relay
1
3
82
5
A (8F), ECU-VD (8M)
2
3
161
1.25B
2
ECU-VD (12F)
1
1
29
BY
2
C (8M)
1
1
WL, 1.25WL, 3WL
1
1
1
1
1
1
ECU-VD (12F)
A (6F)
A (8F)
2
2
2
1.25B
Lg
WR
162
30
83
1
1
1
1
1
1
ECU-VD (12F)
A (8F)
ECU-VD (8M)
2
2
2
BW
LgW
WY
300
33
84
LY
2
P , ECU-VD (8M)
2
301
Y
3
ECU-VD (12F)
1
2
35
G
5
A (4F), C (8M), Combination meter -4
85
3
2
86
L
2
P
1
304
G
2
C , OUT1
2
89
G
2
ECU-VD (8M), Glow relay
2
308
Br
3
C (2M)
1
90
GW
2
ECU-VD (8M), Glow relay
2
312
5BY
2
A (2F), Glow relay
2
2
ECU-VD (8M), Combination meter -17
2
314
BY
5
CAN , ECU-VD (12F), Combination meter -2, 22
4
315
GW
2
DIA , Combination meter -21
2
2
ECU-VD (8F), Combination meter -5
2
316
GR
2
COMB , Combination meter -9
2
36 37 38
GR GB, 2GB Or
5
A (4F), C (8M), Combination meter -23
5
A (2F), C (8M), Combination meter -13, 30
3
C (8M), Combination meter -26
3 4 2
2 1 1
92 93
W W, L
1
2
1
5-054
ELECTRICAL SYSTEM
SW504
8-3. Dashboard Harness (2) 3 LgR, 40 15A Fuse 4 LgW, 40 7124-9681 2 3WR, 40 12 Y, 40
3W
25A Fuse 313 3WB, 40 7124-9681
15
B, 50
108 LA108
2B, 50
X
25 Ta 0 pe
161 1.25B, 50
LA208
SWP-2M
Short harness (P.5-086)
E
50
41 X 301 RW B Y 40 15 * WB YL *
SWP-6M
Parking brake switch harness (P.5-081)
24 33 RY LgW
SWP-2F
50
F
50
19 3R
LA308 200 Tape
25
H
34
CB104
CB104
CB104
34 GY X 21 B RG
X 300 B BW 301 87 Y LR
31 30 LgW Lg 21 21 RG RG
46 51 BrR Br 23 23 RL RL
RB6B-SL
6110-4643
RB6B-SL
RB3B-SL
6110-4643
6110-4643
6110-4643
Brake lamp relay
ECU main relay
Interlock relay
Horn relay
Vibrator lamp relay
Turn signal switch
G
50
LgW, 50
Br, 50
35
CA104
36
CB104
RG, 50
302 87 86 LgR LR L X B
Flasher unit Parking interlock relay
21 308
Backup buzzer switch
84 82 WY 3WL 313 313 WB 3WB
2
15 Ta 0 pe
7 50 Corrugate CA104
RY, 50
GY, 50
15
0
F-R lever 100 switch
200 Tape
31
150 Tape
J
37 2GB 38 Or
13 11 3 2Y BrB LgR 16 14 3W WL
80
0 #
# (VB5.5) # 0
10
27
60 24 61 BrY RY RG X B
・"#" indicates connection of the sleeve (3WB, 5WB) (1.25WL, 3WL) in the corrugate tube. ・Where the numbers differ, wires of the same color must not be united.
29 308 BY Br
Ground
10 10
100
100
302 24 CB104
15 150 Corrugate
F-R lever vibration switch (L) harness (P.5-084)
100
200 Tape
B,
X
CB104 CB104
LgR, 50
45
50
5WR, 80
CA104
Marking tape (Color:yellow)
L
162 1.25B, 50
28
,1 Br
200 Tape
2 3WR, 40
350 Corrugate
00
150 Tape
5A Fuse 83 WR, 40 7124-9681
82 (3-1.25WL, 120)
32
100 Corrugate
DT04-2P-E005 Sub power (12V/120W)
50 50
CB104
3LY, 100
3R, 100
L,
) 30
150 Corrugate
150 Corrugate
28
100
3 3(
( # .5) 82 B5 V ( 0 ) # 0) 25 te 70 1 a 17 , g , B L rru W W o 5 5 C .2 3( -1 31 (3 82
20
305 X 2Br 2B
82 3WL, 40
)
30
B,
160 1.25B, 50
10 Ta 0 pe
50
150 Tape
Fuse
5A Fuse 80 WG, 40 7124-9681
W
31
5A
7124-9681
14 WL, 40
#
313 (5WB, 120)
180 Corrugate
1
6
313 (3WB, 30)
to Dashboard harness (1) (P.5-053)
3
8
82 (3WL, 30)
50
27 44 GY BrY 46 X 43 45 BrR B RW Br
2BrR, 150
3W, 100
3G, 100
Vibrator relay RB8B-SL
5R, 100
3W, 100
14 12 11 10 4
9
314 BY, 40
GY, 50
18
11 BrB, 40
* *
G, 50
LCT RL-1A
19
21 RG
* *
10A Fuse 305 2Br, 40 7124-9681
GR, 50
LCT RL-1A
20
23 RL
* *
0
LCT RL-1A
25
24 RY
15
LCT RL-1A
6
SWP-2M SWP-2M
0
LCR RL-1B
8
SWP-2M
15
LCR RL-1B
16
Fuse
6 2G, 40
100
LCR RL-1B
Fuse box
5A
7124-9681
58X-3F
RB6A-SL
LCT RL-1A
150 Tape
150 Tape
D
Q
34 35 GY G 34 36 GY GR
SWP-4M
18 39 27 LY LW GY
SWP-3M
44 43 23 BrY RW RL
SWP-3F
48 47 23 LgY LgR RL 50 49 23 LgW LgB RL
SWP-6F
9 20 2BrW 2BrR
58X-2F
* *
* *
58X-2M Cap
148 82 LgY WL
SWP-2M
50
50
Stater switch harness (P.5-065)
ROPS : Hazard switch harness (P.5-077)
Horn switch
50
Control switch harness (P.5-066)
Except ROPS : Cap (P.5-078) ROPS : Working switch harness (P.5-067) Except ROPS : Working switch harness (P.5-068)
ROPS : Vibration switch harness (P.5-069) Except ROPS : Vibration Lo-Hi change switch harness (P.5-070) Not in use
DPF switch harness (P.5-079)
1448-09032-1-10724-B
5-055
ELECTRICAL SYSTEM
SW504
No.
X
SIZE, COLOR
B, 1.25B, 2B
CONTACT POINTS
21
2
3WR, 5WR, 8WR
4
3
LgR
2
4
LgW
2
6
2G, 3G
8
CONNECTION (1)
Dashboard Harness (2)
12
E , Brake lamp relay, F-R lever vibration switch (L) harness, Flasher unit, Ground, Interlock 9 relay, Parking interlock relay, Sub power, Vibrator relay
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
(1)
25
3W
2
1
10
1
27
GY
4
1
J , F-R lever switch, Vibrator relay
3
29
BY
2
1
L
1
30
Lg
2
1
Horn relay
1
31
LgW
2
Horn relay, Horn switch
2
33
LgW
2
F
1
34
GY
4
G × 2, Flasher unit, Turn signal switch
4
Dashboard Harness (2)
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
(1)
51
Br
2
1
Vibrator lamp relay
1
60
BrY
2
1
Brake lamp relay
1
61
RG
2
1
Brake lamp relay
1
80
WG
2
1
Fuse 5A
1
82
WL, 1.25WL, 3WL
5
2
Q , ECU main relay, Fuse 5A
3
83
WR
2
1
Fuse 5A
1
84
WY
2
1
ECU main relay
1
86
L
2
1
Interlock relay
1
87
LR
2
Interlock relay, Parking interlock relay
2
Dashboard Harness (2)
H , Fuse 5A, 25A
3
H , Fuse 15A
2
1
Fuse 15A
1
3
1
11 , Fuse 10A
2
5R
2
1
12
1
35
G
5
3
G , Turn signal switch
2
9
BrW, 2BrW
3
2
D
1
36
GR
5
3
G , Turn signal switch
2
11
BrB
2
H , Fuse 5A
2
37
GB, 2GB
5
4
F
1
108
B
2
1
Ground
1
12
Y
2
1
Fuse 5A
1
38
Or
3
2
F
1
148
LgY
2
1
Q
1
13
2Y
2
1
H
1
39
LW
3
2
J
1
160
1.25B
2
1
Ground
1
14
WL
2
H , Fuse 5A
2
40
WB
2
1
E
1
161
1.25B
2
1
Ground
1
15
YL
2
E
1
41
RW
2
1
E
1
162
1.25B
2
1
Ground
1
16
3W
2
14 , H
2
43
RW
2
J , Vibrator relay
2
300
BW
2
1
Parking interlock relay
1
18
LY, 3LY
3
1, J
2
44
BrY
2
J , Vibrator relay
2
301
Y
3
1
E , Parking interlock relay
2
19
3R
2
3, F
2
20
2BrR
2
4, D
2
45
Br
3
1
F-R lever vibration switch (L) harness, Vibrator relay
2
302
LgR
2
F-R lever switch, Interlock relay
2
21
RG
5
6 , Backup buzzer switch, Flasher unit, Horn relay × 2
5
46
BrR
4
2
Vibrator lamp relay, Vibrator relay
2
305
2Br
2
Fuse 10A, Sub power
2
308
Br
3
L , Backup buzzer switch
2
47
LgR
2
1
D
1
313
WB, 3WB
3
ECU main relay × 2, Fuse 25A
3
48
LgY
2
1
D
1
314
BY
5
Fuse 5A
1
49
LgB
2
1
D
1
50
LgW
2
1
D
1
23
RL
6
24
RY
5
1
1 1
1
8 , D × 2, J , Vibrator lamp relay × 2
6
9 , F , Brake lamp relay, F-R lever switch
4
1
1 4
5-056
ELECTRICAL SYSTEM
SW504
8-4. ECU Harness (Vihicle)
Twist shield cable Shield drain(117)
Twist shield cable (122,126,134)
Twist shield cable Shield drain(114)
100 Tape
ECU-VF
100 Tape
1000 Corrugate
28
120 Corrugate
80
Twist cable
52 80 82 84 YW WG 1.25WL WY 85 89 90 92 LY G GW W SWP-8F
80
100 Twist cable
50
100
106 107 149 150 Y G YB GB 105 160 161 162 Br 1.25B 1.25B 1.25B 148 300 301 314 LgY BW Y BY SWP-12M
19
C2
30 Tape
* *
* * 93 L
* * 212
93 98 99 100 L LR LY L 101 102 103 104 G B W Y
* * * *
* *
* *
* *
* *
52 YW * *
* *
92 W
98 LR
* *
Shield drain
SWP-8M
Dashboard harness (1) (P.5-053)
SWP-16M
138 139 2LR 2LW 140 141 2LgR 2LgW
156
155
141 137 LgW BrW 136 140 BrR LgR 138 * LR * 139 * LW * 150 149
Engine side connector 1 928 404 881
Twist cable
Twist cable
58X-4M
Frame (F) Harness (P.5-061)
SWP-12M CAN COM.
* *
ECU
256 255 82 82 1.25WL 1.25WL 162 82 1.25B 1.25WL 161 160 1.25B 1.25B 89 * G * 250 249
Vihicle side connector 1 928 405 730
Twist shield cable
114 X 122 B 126 R 134 W 117 X 119 B 123 W 125 R
143 103 142 140 141 102
136 2BrR 137 2BrW
154 155
138 2LR 139 2LW 140 2LgR 141 2LgW
Twist cable
Dashboard harness (1) (P.5-053)
* *
237 107 150 84 102 82 * * G GB WY B WL * * 106 149 101 148 105 314 * Y YB G LgY Br BY * 301 99 80 104 121 * * * Y LY WG * Y GR * * 111 110 109 103 100 * * L G Gr W L * * 201 * *
Engine side connector
248
58X-2M
58X-4M
136 137 2BrW 2BrW
* *
151 150 153 156
ECU
Twist cable
149 YB 150 GB
230 242
106 Y 107 G
231 243
Vihicle side connector
100
Twist cable 58X-2M
30 Tape
* *
Twist cable
100 Tape
109 110 111 Gr G L
C1
* *
ECU-VD
120 Corrugate SWP-3F
19
100 Tape
50
Twist cable
137
128 122 134 123 119 145 120 * GY B W W B BrY YB * 300 90 129 124 146 118 131 * * * * * BW GW * LY LgY LgW BrW LgB * * * * 112 115 85 130 135 132 * * * * * * YR Sb LY BrY BrB RY * * * * * * 113 116 127 143 144 142 126 125 133 * * * RW LW Gr GB LB P R R RG * * * 112 101 * *
100 Tape
Frame (F) Harness (P.5-061)
148
100
SWP-16F
120 121 124 127 YB GR LgY Gr 128 129 130 131 GY LY BrY LgB 132 133 135 142 RY RG BrB P 143 144 145 146 GB LB BrY LgW
Twist cable
10 Ta 0 pe
SWP-16M
114 122 117 119 X B X B 134 126 123 125 W R W R 112 113 115 116 YR RW Sb LW 118 * * * BrW * * *
Twist shield cable (119,123,125)
Twist cable and shield cable processing diagram ・Where the numbers differ, wires of the same color must not be united.
1448-09036-0-10731-B
5-057
ELECTRICAL SYSTEM
SW504
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
52
YW
2
C2 -246, ECU-VD (8F)
123
W
2
C1 -141, ECU-VF (16M)
80
WG
2
C2 -216, ECU-VD (8F)
124
LgY
2
C1 -131, ECU-VF (16F)
82
WL, 1.25WL
5
C2 -239, 253, 255, 256, ECU-VD (8F)
125
R
2
C1 -102, ECU-VF (16M)
84
WY
2
C2 -241, ECU-VD (8F)
126
R
2
C1 -103, ECU-VF (16M)
85
LY
2
C1 -121, ECU-VD (8F)
127
Gr
2
C1 -108, ECU-VF (16F)
89
G
2
C2 -250, ECU-VD (8F)
128
GY
2
C1 -144, ECU-VF (16F)
90
GW
2
C1 -135, ECU-VD (8F)
129
LY
2
C1 -132, ECU-VF (16F)
92
W
2
C2 -245, ECU-VD (8F)
130
BrY
2
C1 -120, ECU-VF (16F)
93
L
2
C2 -224, ECU-VD (8M)
131
LgB
2
C1 -128, ECU-VF (16F)
98
LR
2
C2 -209, ECU-VD (8M)
132
RY
2
C1 -115, ECU-VF (16F)
99
LY
2
C2 -217, ECU-VD (8M)
133
RG
2
C1 -101, ECU-VF (16F)
100
L
2
C2 -201, ECU-VD (8M)
134
W
2
C1 -142, ECU-VF (16M)
101
G
2
C2 -229, ECU-VD (8M)
135
BrB
2
C1 -119, ECU-VF (16F)
102
B
2
C2 -240, ECU-VD (8M)
136
BrR, 2BrW
2
C1 -154, ECU-VF (2M)
103
W
2
C2 -202, ECU-VD (8M)
137
BrW, 2BrW
2
C1 -155, ECU-VF (2M)
104
Y
2
C2 -214, ECU-VD (8M)
138
LR, 2LR
2
C1 -151, ECU-VF (4M)
105
Br
2
C2 -227, ECU-VD (12M)
139
LW, 2LW
2
C1 -150, ECU-VF (4M)
106
Y
2
C2 -231, ECU-VD (12M)
140
LgR, 2LgR
2
C1 -153, ECU-VF (4M)
107
G
2
C2 -243, ECU-VD (12M)
141
LgW, 2LgW
2
C1 -156, ECU-VF (4M)
109
Gr
2
C2 -203, ECU-VF (3F)
142
P
2
C1 -104, ECU-VF (16F)
110
G
2
C2 -204, ECU-VF (3F)
143
GB
2
C1 -107, ECU-VF (16F)
111
L
2
C2 -205, ECU-VF (3F)
144
LB
2
C1 -106, ECU-VF (16F)
112
YR
2
C1 -124, ECU-VF (16M)
145
BrY
2
C1 -139, ECU-VF (16F)
113
RW
2
C1 -112, ECU-VF (16M)
146
LgW
2
C1 -130, ECU-VF (16M)
114
(X)
1
ECU-VF (16M)
148
LgY
2
C2 -228, ECU-VD (12M)
115
Sb
2
C1 -123, ECU-VF (16M)
149
YB
2
C2 -230, ECU-VD (12M)
116
LW
2
C1 -111, ECU-VF (16M)
150
GB
2
C2 -242, ECU-VD (12M)
117
(X)
1
ECU-VF (16M)
160
1.25B
2
C2 -251, ECU-VD (12M)
118
BrW
2
C1 -129, ECU-VF (16M)
161
1.25B
2
C2 -252, ECU-VD (12M)
119
B
2
C1 -140, ECU-VF (16M)
162
1.25B
2
C2 -254, ECU-VD (12M)
120
YB
2
C1 -137, ECU-VF (16F)
300
BW
2
C1 -136, ECU-VD (12M)
121
GR
2
C2 -213, ECU-VF (16F)
301
Y
2
C2 -219, ECU-VD (12M)
122
B
2
C1 -143, ECU-VF (16M)
314
BY
2
C2 -226, ECU-VD (12M)
CONNECTION
CONNECTION
5-058
ELECTRICAL SYSTEM
SW504
8-5. ECU Harness (Engine)
1
Shield drain
5 9
80
13
ECA
18
23 28 33
0
1 0 10 te ) a OT g rru -C Co (H
Twist cable
4 8 12 17 22
TYCO: 0-936421-2 Engine connector A
27 32 37 42 Twist cable
Twist cable
50
100 Tape
1000 Corrugate 20 (H-COT)
ECU-E
130 Tape Corrugate 7 (H-COT)
50
6
ECB
12
KUBOTA engine harness * 136 138 * BrR LR * 137 139 * BrW LW
Twist cable
* 140 * LgR * 141 * LgW
* * * *
1 7
MOLEX: 33472-1206 Engine connector B
Twist cable
10
0
SWP-16F
113 112 107 106 RW YR G Y 120 118 116 115 YB BrW LW Sb 128 127 124 121 GY Gr LgY GR 132 131 130 129 RY LgB BrY LY
38
114 X 113 112 X B RW YR 117 83 116 115 X WR LW Sb 118 * * * BrW * * * * 120 119 * * * YB B * * 123 122 * 121 * W B * GR * 126 125 * * 124 R R * * LgY 128 * * 107 127 GY * * G Gr 131 130 * 106 129 LgB BrY * Y LY 135 132 134 133 132 BrB RY W RG RY
10 Tap 0 e
50
Twist shield cable Shield drain(114) 119 117 122 114 B X B X 125 123 126 134 R W R W
16
Shield drain
137 136 2BrW 2BrR
SWP-8F
Twist shield cable Shield drain(117) 58X-2F
80 Twist cable
* 142 143 142 144 142 145 1 * P GB P LB P BrY * * * * 132 142 146 * * * * RY P LgW 9
MOLEX: 33472-1606 Engine connector C
Twist shield cable
114 X 122 B 126 R 134 W 117 X 119 B 123 W 125 R
A-01 A-19 A-23 A-40 A-05 A-15 A-18 A-24
106 Y 107 G Twist cable
58X-2F
Twist cable
58X-4F
58X-4F
80
Frame (F) Harness (P.5-061)
SWP-16F
Twist cable 139 138 2LW 2LR 141 140 2LgW 2LgR
* * * *
50
136 2BrR 137 2BrW 138 2LR 139 2LW 140 2LgR 141 2LgW
A-36 A-31
Engine connector A
SWP-8F
8
ECC
Twist cable B-05 B-11 B-04 B-10 B-02 B-08
KUBOTA engine harness
Engine connector B
Frame (F) Harness (P.5-061)
80 rru Tap e g (H at -C e OT ) 10
Co
100 Tape
SWP-12M
143 142 135 133 GB P BrB RG 83 146 145 144 WR LgW BrY LB * * * X * * * 1.25B
Twist cable and shield cable processing diagram
・Harness wires to be AESSX 0.75 unless otherwise specified. ・Where the numbers differ, wires of the same color must not be united.
1448-09035-0-10730-A
5-059
ELECTRICAL SYSTEM
SW504
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
X
B, 1.25B
2
ECA -2, ECU-E (12M)
128
GY
2
ECA -28, ECU-E (16F)
83
WR
2
ECA -6, ECU-E (12M)
129
LY
2
ECA -37, ECU-E (16F)
106
Y
2
ECA -36, ECU-E (16F)
130
BrY
2
ECA -34, ECU-E (16F)
107
G
2
ECA -31, ECU-E (16F)
131
LgB
2
ECA -33, ECU-E (16F)
112
YR
2
ECA -4, ECU-E (16F)
132
RY
4
ECA -39, 42, ECC -11, ECU-E (16F)
113
RW
2
ECA -3, ECU-E (16F)
133
RG
2
ECA -41, ECU-E (12M)
114
(X)
2
ECA -1, ECU-E (8F)
134
W
2
ECA -40, ECU-E (8F)
115
Sb
2
ECA -8, ECU-E (16F)
135
BrB
2
ECA -38, ECU-E (12M)
116
LW
2
ECA -7, ECU-E (16F)
136
BrR, 2BrR
2
ECB -5, ECU-E (2F)
117
(X)
2
ECA -5, ECU-E (8F)
137
BrW, 2BrW
2
ECB -11, ECU-E (2F)
118
BrW
2
ECA -9, ECU-E (16F)
138
LR, 2LR
2
ECB -4, ECU-E (4F)
119
B
2
ECA -15, ECU-E (8F)
139
LW, 2LW
2
ECB -10, ECU-E (4F)
120
YB
2
ECA -14, ECU-E (16F)
140
LgR, 2LgR
2
ECB -2, ECU-E (4F)
121
GR
2
ECA -21, ECU-E (16F)
141
LgW, 2LgW
2
ECB -8, ECU-E (4F)
122
B
2
ECA -19, ECU-E (8F)
142
P
5
ECC -2, 4, 6, 10, ECU-E (12M)
123
W
2
ECA -18, ECU-E (8F)
143
GB
2
ECC -5, ECU-E (12M)
124
LgY
2
ECA -27, ECU-E (16F)
144
LB
2
ECC -3, ECU-E (12M)
125
R
2
ECA -24, ECU-E (8F)
145
BrY
2
ECC -1, ECU-E (12M)
126
R
2
ECA -23, ECU-E (8F)
146
LgW
2
ECC -9, ECU-E (12M)
127
Gr
2
ECA -32, ECU-E (16F)
CONNECTION
CONNECTION
5-060
ELECTRICAL SYSTEM
SW504
CB104
CA104
CB104
CA104
47
46
48
46
Twist cable
Shield drain
Hydraulic oil filter switch LE104
X
35
37
50 Tape
A
BrR, 100
LgY, 100
BrR, 100
LgR, 100
LR, 100
55
Horn PB104
Ground LA210
30
X
5-061
139 138 2LW 2LR 141 140 2LgW 2LgR
600 Corrugate
19
80 Twist cable
10
300 Corrugate
320 Corrugate
Cap
Twist cable
37 CB104
150
38 Or
X B
SWP-2F
* *
* *
SWP-2M Cap
B, 50
Head lamp (L) Drum edge lamp (F,L) (option)
X CA104 Turn signal lamp (L)
GR, 90
36 CB104
15
50 Tape
LgW, 150 50 Tap e
4 LE104 (BR)
B, 150
X LE104 (X)
8W, 140 50
100 Corrugate
26 10 5BR 5WG
58X-1F
SWP-8F
58Y-2F
130 Corrugate
1 LA308 (COM)
5BW, 140 13
15
13 2Y
17 33 40 82 WR LgW WB WL 109 110 111 X Gr G L B
13
311 LA308 (COM)
3GW, 140
130 Corrugate
Battery relay
5 LA208 (NO)
5WR, 140
80
Twist cable
138 139 2LR 2LW 140 141 2LgR 2LgW
58X-4M ECU harness (engine) (P.5-059)
80
80
Marking tape (Color:yellow)
80
136 137 2BrR 2BrW
Drum edge lamp (F,R) (option)
50 100
Twist cable
7 LA308 (NO)
Engine Harness (P.5-051)
80 58X-2M
SWP-2M
50 pe Ta
50
106 Y 107 G
00
15
B
Twist shield cable Shield drain(117)
114 122 117 119 X B X B 134 126 123 125 W R W R
SWP-2F
700 Corrugate
100
* *
15
80
SWP-8M
ECU-E
* *
50
133 135 142 143 RG BrB P GB 144 145 146 83 LB BrY LgW WR X * * * 1.25B * * *
Twist shield cable Shield drain(114)
100
100 Tape
106 107 112 113 Y G YR RW 115 116 118 120 Sb LW BrW YB 121 124 127 128 GR LgY Gr GY 129 130 131 132 LY BrY LgB RY
X B
300 Corrugate
80
SWP-12F
SWP-2F Frame (R) harness (P.5-063)
* *
10 Ta 0 pe
50
38 Or
100 Tape
150 Tape
350 Corrugate
M
38 Or
2B, 250
270 Corrugate
20
150
19
Lg, 320
7 470 Corrugate
350 Corrugate
7
600 Corrugate
100 Tape
5 Ta 0 pe
10 Ta 0 pe
SWP-16M
ECU harness (engine) (P.5-059)
Marking tape (Color:yellow)
Twist cable
100
100 Tape
58X-4F
30
1070 Corrugate
B 2G
7
111 110 109 L G Gr
ECU-VF
Twist cable 58X-2F
450 30 Corrugate
138 2LR 139 2LW 140 2LgR 141 2LgW
ECU harness (engine) (P.5-059)
Twist cable and shield cable processing diagram
500 ate rug
119 117 122 114 B X B X 125 123 126 134 R W R W 116 115 113 112 LW Sb RW YR * * * 118 * * * BrW
137 136 2BrW 2BrR
150 30 Corrugate
136 2BrR 137 2BrW
,1
7
22
900 Corrugate 30 20
00
,1
B 2G
Dashboard harness (1) (P.5-053)
Cor
Twist shield cable Shield drain(114)
127 124 121 120 Gr LgY GR YB 131 130 129 128 LgB BrY LY GY SWP-16M 142 135 133 132 P BrB RG RY 146 145 144 143 LgW BrY LB GB
SWP-3M
50 Corrugate
50
Twist shield cable Shield drain(117)
ECU harness (vehicle) (P.5-057)
7
55 35 YG G X 36 B GR
SWP-4M
SWP-16F
100
58X-2F
SWP-6M
30 53 4 Lg LR LgW 48 47 46 LgY LgR BrR
X
58X-4F
80
82 WL X B
5 Ta 0 pe
Twist cable
SWP-8M
13 2Y
CB104
ECU harness (vehicle) (P.5-057)
7
58X-2M
37 2GB
CB104
G, 90
80
CA104
B, 50
6 3G
CB104
B, 50
8 5R
CA104
7
58Y-2F
RB2B-SL
YG, 50
80
Turn signal lamp (R) Head lamp (R)
Fuel gauge unit
0 30 te ga rru Co
Dashboard harness (1) (P.5-053)
50 e Tap
312 2 5BY 8WR
58Y-2M BLACK
Fuel pump
50
58Y-2M
80
SWP-16F
53 26 10 5BR 5WG
Twist shield cable
114 X 122 B 126 R 134 W 117 X 119 B 123 W 125 R
SWP-8M
100
58X-2M
82 40 33 17 WL WB LgW WR X 83 107 106 1.25B WR G Y
58X-4M
SWP-8M
Vibrator solenoid (F) Vibrator solenoid (F) harness (2) harness (1) (P.5-072) (P.5-071)
SWP-16M
8-6. Frame (F) Harness
1 8W 2 8WR
5 3GW 6 3G
311 5BW 312 5BY
7 5WR 8 5R
100 Corrugate
7
X
4
B
LgW
DT06-2S
Diode DT04-2P-RT01
7322-4127-40 7322-4125-50 7322-4123-30 7322-4123-30 75A(gray) 45A(red) 65A(black) 65A(black) Fusible link
・Harness wires to be AVX 0.85 unless otherwise specified. ・Where the numbers differ, wires of the same color must not be united. 1448-09034-1-10728-B
ELECTRICAL SYSTEM
SW504
No.
SIZE, COLOR
CONTACT POINTS
X
B, 1.25B, 2B
13
A (4M), (8M), B (8F), ECU-E (12F), Battery relay, Diode, Fuel gauge unit, Fuel pump, Ground, Turn signal lamp (L), (R), Drum edge lamp (F, L)(option), (F, R)(option)
1
8W
2
Battery relay -COM, Fusible link 75A
2
8WR
2
A (Y-2M(B)), Fusible link 75A
4
LgW
3
A (6M), Battery relay -BR, Diode
5
3GW
2
Battery relay -NO, Fusible link 45A
6
3G
2
A (2F), Fusible link 45A
7
5WR
2
Battery relay -NO, Fusible link 65A
8
5R
2
A (2F), Fusible link 65A
10
5WG
2
A (Y-2M), B (2F)
13
2Y
2
A (X-2M), B (1F)
17
WR
2
A (8M), B (8F)
26
5BR
2
A (Y-2M), B (2F)
30
Lg
2
A (6M), Horn
33
LgW
2
A (8M), B (8F)
35
G
2
A (4M), Turn signal lamp (R)
36
GR
2
A (4M), Turn signal lamp (L)
37
2GB
3
A (X-2M), Head lamp (L), (R)
38
Or
3
M , Drum edge lamp (F, L)(option), (F, R)(option)
40
WB
2
A (8M), B (8F)
46
BrR
3
A (6M), Vibrator solenoid (F) harness (1), (2)
47
LgR
2
A (6M), Vibrator solenoid (F) harness (2)
48
LgY
2
A (6M), Vibrator solenoid (F) harness (1)
53
LR
2
A (6M), Hydraulic oil filter switch
55
YG
2
A (4M), Fuel gauge unit
82
WL
3
A (8M), B (8F), Fuel pump
83
WR
2
A (8M), ECU-E (12F)
106
Y
2
A (8M), ECU-E (16M)
107
G
2
A (8M), ECU-E (16M)
109
Gr
2
ECU-VF (3M), B (8F)
110
G
2
ECU-VF (3M), B (8F)
111
L
2
ECU-VF (3M), B (8F)
112
YR
2
ECU-E (16M), ECU-VF (16F)
113
RW
2
ECU-E (16M), ECU-VF (16F)
114
X
2
ECU-E (8M), ECU-VF (16F)
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
115
Sb
2
ECU-E (16M), ECU-VF (16F)
116
LW
2
ECU-E (16M), ECU-VF (16F)
117
X
2
ECU-E (8M), ECU-VF (16F)
118
BrW
2
ECU-E (16M), ECU-VF (16F)
119
B
2
ECU-E (8M), ECU-VF (16F)
120
YB
2
ECU-E (16M), ECU-VF (16M)
121
GR
2
ECU-E (16M), ECU-VF (16M)
122
B
2
ECU-E (8M), ECU-VF (16F)
123
W
2
ECU-E (8M), ECU-VF (16F)
124
LgY
2
ECU-E (16M), ECU-VF (16M)
125
R
2
ECU-E (8M), ECU-VF (16F)
126
R
2
ECU-E (8M), ECU-VF (16F)
127
Gr
2
ECU-E (16M), ECU-VF (16M)
128
GY
2
ECU-E (16M), ECU-VF (16M)
129
LY
2
ECU-E (16M), ECU-VF (16M)
130
BrY
2
ECU-E (16M), ECU-VF (16M)
131
LgB
2
ECU-E (16M), ECU-VF (16M)
132
RY
2
ECU-E (16M), ECU-VF (16M)
133
RG
2
ECU-E (12F), ECU-VF (16M)
134
W
2
ECU-E (8M), ECU-VF (16F)
135
BrB
2
ECU-E (12F), ECU-VF (16M)
136
2BrR
2
ECU-E (2M), ECU-VF (2F)
137
2BrW
2
ECU-E (2M), ECU-VF (2F)
138
2LR
2
ECU-E (4M), ECU-VF (4F)
139
2LW
2
ECU-E (4M), ECU-VF (4F)
140
2LgR
2
ECU-E (4M), ECU-VF (4F)
141
2LgW
2
ECU-E (4M), ECU-VF (4F)
142
P
2
ECU-E (12F), ECU-VF (16M)
143
GB
2
ECU-E (12F), ECU-VF (16M)
144
LB
2
ECU-E (12F), ECU-VF (16M)
145
BrY
2
ECU-E (12F), ECU-VF (16M)
146
LgW
2
ECU-E (12F), ECU-VF (16M)
311
5BW
2
Battery relay -COM, Fusible link 65A
312
5BY
2
A (Y-2M(B)), Fusible link 65A
CONNECTION
5-062
ELECTRICAL SYSTEM
SW504
8-7. Frame (R) Harness
Cap SWP-2M * *
100 Corrugate
360 Corrugate
13
37 * 61 GB * RG * 35 X * G B
38 Or
1500 Corrugate
13
200 Corrugate
10
10
X B
400 Tape
38
130 Tape
Or,50
10
870 Corrugate
13
130 Tape
M
SWP-2F
20
50
C
600 Corrugate
Marking tape (Color:yellow)
50
RB6B-SL
Flood lamp CB104
20
37 * 61 GB * RG * 36 X * GR B
600 Corrugate
10
100 Corrugate
SWP-3F Vibrator solenoid (R) harness (3) (P.5-075)
X 29
X
39
42
18
CB104
PB104
PB104
LE206
LE206
Backup buzzer
(e)
(g)
(G)
(B)
LA208 Ground
100 Tape
LA208 Ground
100 Tape
X
150
B,70
50 49 46 LgW LgB BrR
BY,80
J
3B,100
3B,100
100
50
3LY,100
50
3LB,100
SWP-2F
304 308 G Br
X 42 3B 3LB
Combination lamp (R)
Drum edge lamp (R,R) (option)
7
K
2BrW,50
9
LCR RL-1B Not in use
10
SWP-4F
Or 38
* *
50
29 X BY B 37 * GB *
46 39 BrR LW 50 49 LgW LgB
RB6B-SL
470 Corrugate
Dashboard harness (1) (P.5-053)
36 35 GR G 61 38 RG Or
Combination lamp (L)
58X-2F
LW,70
SWP-8F
18 9 3LY 2BrW
Water spray pump
SWP-2M
150 Tape
58X-2F
Frame (F) Harness (P.5-061)
* *
38 Or
38 X Or B 304 308 G Br
308 X Br B
SWP-4F Mihaalu harness (P.5-082)
SWP-2M Backup lamp (option)
X B
SWP-2F Drum edge lamp (R,L) (option) * *
* *
* *
* *
SWP-2M
SWP-2F
Cap
Cap
Water spray relay
1446-09087-1-20946-B
5-063
ELECTRICAL SYSTEM
SW504
No.
SIZE, COLOR
CONTACT POINTS
CONNECTION
X
B, 3B
11
C (8F), Combination lamp (L), (R), Ground × 2, Mihaalu harness, Water spray pump, Water spray relay -e, Backup lamp (option), Drum edge lamp (R, L)(option), (R, R)(option)
9
2BrW
2
C (X-2F), K (not in use)
18
3LY
2
C (X-2F), Water spray relay -B
29
BY
2
C (8F), Backup buzzer
35
G
2
C (8F), Combination lamp (R)
36
GR
2
C (8F), Combination lamp (L)
37
GB
3
C (8F), Combination lamp (L), (R)
38
Or
6
C (8F), M , Flood lamp, Mihaalu harness, Drum edge lamp (R, L)(option), (R, R)(option)
39
LW
2
C (4F), Water spray relay -g
42
3LB
2
Water spray pump, Water spray relay -G
46
BrR
2
C (4F), J
49
LgB
2
C (4F), J
50
LgW
2
C (4F), J
61
RG
3
C (8F), Combination lamp (L), (R)
304
G
2
C (2F), Mihaalu harness
308
Br
3
C (2F), Mihaalu harness, Backup lamp (option)
5-064
ELECTRICAL SYSTEM
SW504
8-8. Stater Switch Harness
5WR,100 5WG,100
Dashboard harness (2) (P.5-055)
H
Not in use Insulation protection
3 11 13 LgR BrB 2Y 14 16 32 WL 3W 3BY
RB6B-SL
LCR RL-1B
LCT RL-1A
BrB,100
2
10
2Y,100
50
LgR,100
5WR,50
H
50 Tape
WL,100 3W,100 3BY,100
5WG,50
2
LE305 (B)
10
LE305 (R1)
11
LE105 (ACC)
13
LE205 (BR)
3
LE105 (BR)
14
LE105 (C)
16
LE205 (C)
32
LE205 (C)
Starter switch
1446-09027-0-30316-A
No.
SIZE, COLOR
CONTACT POINTS
2
5WR
2
H , Starter swich -B
3
LgR
2
H , Starter swich -BR
10
5WG
2
Starter swich -R1, H (not in use)
11
BrB
2
H , Starter swich -ACC
13
2Y
2
H , Starter swich -BR
14
WL
2
H , Starter swich -C
16
3W
2
H , Starter swich -C
32
3BY
2
H , Starter swich -C
5-065
CONNECTION
ELECTRICAL SYSTEM
SW504
8-9. Control Switch Harness
RY,80 33 24 LgW RY
SWP-2M Dashboard harness (2) (P.5-055)
F 58X-3M
37 19 2GB 3R 38 2Or
LgW,80
50 50
3R,80
F
50 Tape
3R,80 2GB,80 2Or,80
24
(1)
33
(2)
19
(1)
19
(4)
37
(3)
38
(5)
Speed change switch
Lighting switch
1446-09028-0-30317-B
No.
SIZE, COLOR
CONTACT POINTS
19
3R
3
F , Lighting swich -1, 4
24
RY
2
F , Speed change swich -1
33
LgW
2
F , Speed change swich -2
37
2GB
2
F , Lighting swich -3
38
2Or
2
F , Lighting swich -5
CONNECTION
5-066
ELECTRICAL SYSTEM
SW504
8-10. Working Switch Harness 8-10-1. Working switch harness (ROPS)
* *
SWP-3M
23 43 44 RL RW BrY
J
3 Ta 50 pe
39 18 LW LY
SWP-3F
50
Dashboard harness (2) (P.5-055)
50
Ground
LA108
X
50
J
50 Tape
X 70 B P 39 70 LW P
LY,80 LY,80 LW,80 P,80
B,350
RL,80 RL,80 RW,80 BrY,80
RB4B-SL
18
(1)
18
(4)
39
(2)
70
(5)
23
(1)
23
(4)
43
(2)
44
(5)
Water spray timer
Water spray mode select switch
Vibration mode select switch
1446-75052-0-30851-0
No.
SIZE, COLOR
CONTACT POINTS
X
B
2
J , Water spray timer
18
LY
3
J , Water spray mode select switch -1, 4
23
RL
3
J , Vibration mode select switch -1, 4
39
LW
3
J , Water spray mode select switch -2, Water spray timer
43
RW
2
J , Vibration mode select switch -2
44
BrY
2
J , Vibration mode select switch -5
70
P
3
Water spray mode select switch -5, Water spray timer × 2
5-067
CONNECTION
ELECTRICAL SYSTEM
SW504
8-10-2. Working switch harness (except ROPS)
LY,80 LW,80 SWP-3F Dashboard harness (2) (P.5-055)
27 39 18 GY LW LY
J SWP-3M
23 43 44 RL RW BrY
GY,80 50 50
J
50 Tape
LW,80 RL,80 RL,80 RW,80 BrY,80
18
(1)
39
(2)
27
(4)
39
(5)
23
(1)
23
(4)
43
(2)
44
(5)
Water spray mode select switch
Vibration mode select switch
1446-09063-0-30837-0
No.
SIZE, COLOR
CONTACT POINTS
18
LY
2
J , Water spray mode select switch -1
23
RL
3
J , Vibration mode select switch -1, 4
27
GY
2
J , Water spray mode select switch -4
39
LW
3
J , Water spray mode select switch -2, 5
43
RW
2
J , Vibration mode select switch -2
44
BrY
2
J , Vibration mode select switch -5
CONNECTION
5-068
ELECTRICAL SYSTEM
SW504
8-11. Vibration Switch Harness 8-11-1. Vibration switch harness (ROPS)
Vibratory drum select switch
Dashboard harness (2) (P.5-055)
D
SWP-6M
23 47 48 RL LgR LgY 23 49 50 RL LgB LgW
50
D
50 Tape
63
62
BrB,90
23
RL,90
RL,90
23
(3) (6)
BrW,90
(1) (4)
BrB,80 BrW,80 LgR,80 LgY,80 LgB,80 LgW,80
62
(1)
63
(4)
47
(3)
48
(2)
49
(6)
50
(5)
Vibration Lo-Hi change switch
1448-09015-0-30369-A
No.
SIZE, COLOR
CONTACT POINTS
23
RL
4
D × 2, Vibratory drum select switch -1, 4
47
LgR
2
D , Vibration Lo-Hi change switch -3
48
LgY
2
D , Vibration Lo-Hi change switch -2
49
LgB
2
D , Vibration Lo-Hi change switch -6
50
LgW
2
D , Vibration Lo-Hi change switch -5
62
BrB
2
Vibratory drum select switch -6, Vibration Lo-Hi change switch -1
63
BrW
2
Vibratory drum select switch -3, Vibration Lo-Hi change switch -4
5-069
CONNECTION
ELECTRICAL SYSTEM
SW504
8-11-2. Vibration Lo-Hi change switch harness (except ROPS)
RL,80 RL,80 Dashboard harness (2) (P.5-055)
D
SWP-6M
23 47 48 RL LgR LgY 23 49 50 RL LgB LgW
50
D
50 Tape
LgR,80 LgY,80 LgB,80 LgW,80
23
(1)
23
(4)
47
(3)
48
(2)
49
(6)
50
(5)
Vibration Lo-Hi change switch
1448-09005-0-30064-B
No.
SIZE, COLOR
CONTACT POINTS
23
RL
4
D × 2, Vibration Lo-Hi change switch -1, 4
47
LgR
2
D , Vibration Lo-Hi change switch -3
48
LgY
2
D , Vibration Lo-Hi change switch -2
49
LgB
2
D , Vibration Lo-Hi change switch -6
50
LgW
2
D , Vibration Lo-Hi change switch -5
CONNECTION
5-070
ELECTRICAL SYSTEM
SW504
8-12. Vibrator Solenoid (F) Harness (1)
(1) Vibrator solenoid (F) Hi
B,2
0
5
125 VCTF 0.75mm2 × 2C
5 W,2
(2)
CA104 (LgY)
B,5
Frame (F) harness (P.5-061)
W,5 0
CB104 (BrR)
・(LgY), (BrR) indicate the connection line color. 1448-09003-0-40062-0
No.
SIZE, COLOR
CONTACT POINTS
-
B
2
Vibrator solenoid (F) Hi -1, Frame (F) harness -(LgY)
-
W
2
Vibrator solenoid (F) Hi -2, Frame (F) harness -(BrR)
5-071
CONNECTION
ELECTRICAL SYSTEM
SW504
8-13. Vibrator Solenoid (F) Harness (2)
(1) Vibrator solenoid (F) Lo
B,2
0
5
125 VCTF 0.75mm2 × 2C
5 W,2
(2)
CA104 (LgR)
B,5
Frame (F) harness (P.5-061)
W,5 0
CB104 (BrR)
・(LgR), (BrR) indicate the connection line color. 1448-09003-0-40062-0
No.
SIZE, COLOR
CONTACT POINTS
-
B
2
Vibrator solenoid (F) Lo -1, Frame (F) harness -(LgR)
-
W
2
Vibrator solenoid (F) Lo -2, Frame (F) harness -(BrR)
CONNECTION
5-072
ELECTRICAL SYSTEM
SW504
8-14. Vibrator Solenoid (R) Harness (1)
(1) Vibrator solenoid (R) Hi
B,2
0
5
125 VCTF 0.75mm2 × 2C
5 W,2
(2)
CA104 (LgW)
Vibrator solenoid (R) harness (3) (P.5-075)
CB104 (BrR)
Vibrator solenoid (R) harness (4) (P.5-076)
B,5
W,5 0
・(LgW), (BrR) indicate the connection line color. 1448-09003-0-40062-0
No.
SIZE, COLOR
CONTACT POINTS
-
B
2
Vibrator solenoid (R) Hi -1, Vibrator solenoid (R) harness (3) -(LgW)
-
W
2
Vibrator solenoid (R) Hi -2, Vibrator solenoid (R) harness (4) -(BrR)
5-073
CONNECTION
ELECTRICAL SYSTEM
SW504
8-15. Vibrator Solenoid (R) Harness (2)
(1) Vibrator solenoid (R) Lo
B,2
0
5
125 VCTF 0.75mm2 × 2C
5 W,2
(2)
CA104 (LgB)
Vibrator solenoid (R) harness (3) (P.5-075)
CB104 (BrR)
Vibrator solenoid (R) harness (4) (P.5-076)
B,5
W,5 0
・(LgB), (BrR) indicate the connection line color. 1448-09003-0-40062-0
No.
SIZE, COLOR
CONTACT POINTS
-
B
2
Vibrator solenoid (R) Lo -1, Vibrator solenoid (R) harness (3) -(LgB)
-
W
2
Vibrator solenoid (R) Lo -2, Vibrator solenoid (R) harness (4) -(BrR)
CONNECTION
5-074
ELECTRICAL SYSTEM
SW504
8-16. Vibrator Solenoid (R) Harness (3)
BrR,50
Frame (R) harness (P.5-063)
J
SWP-3M
46 49 50 BrR LgB LgW
50
H
50 Tape
LgB,50
LgW,50
46
CA104 (BrR)
Vibrator solenoid (R) harness (4) (P.5-076)
49
CB104
(B)
Vibrator solenoid (R) harness (2) (P.5-074)
50
CB104
(B)
Vibrator solenoid (R) harness (1) (P.5-073)
・(BrR), (B) indicate the connection line color. 1446-09012-0-30118-0
No.
SIZE, COLOR
CONTACT POINTS
46
BrR
2
H , Vibrator solenoid (R) harness (4) -(BrR)
49
LgB
2
H , Vibrator solenoid (R) harness (2) -(B)
50
LgW
2
H , Vibrator solenoid (R) harness(1) -(B)
5-075
CONNECTION
ELECTRICAL SYSTEM
SW504
8-17. Vibrator Solenoid (R) Harness (4)
Vibrator solenoid (R) harness (3) (P.5-075)
BrR,50
(BrR) CB104 46
50 Tape
BrR,50
BrR,50
46 CA104 (W)
Vibrator solenoid (R) harness (1) (P.5-073)
46 CA104 (W)
Vibrator solenoid (R) harness (2) (P.5-074)
・(BrR), (W) indicate the connection line color. 1448-09004-0-40063-0
No. 46
SIZE, COLOR BrR
CONTACT POINTS 3
CONNECTION Vibrator solenoid (R) harness (1) -(W), Vibrator solenoid (R) harness (2) -(W), Vibrator solenoid (R) harness (3) -(BrR)
5-076
ELECTRICAL SYSTEM
SW504
8-18. Hazard Switch Harness 8-18-1. Hazard switch harness (ROPS)
GY,100 Dashboard harness (2) (P.5-055)
G
SWP-4F
40 6 GB GY 26 6 GR GY
50
G
100 Corrugate
GB,100 GY,100
7
GR,100
6
(1)
40
(2)
6
(4)
26
(5)
Hazard switch
1634-09078-0-31116-A
No.
SIZE, COLOR
CONTACT POINTS
6
GY
4
G × 2, Hazard switch -1, 4
26
GR
2
G , Hazard switch -5
40
GB
2
G , Hazard switch -2
5-077
CONNECTION
ELECTRICAL SYSTEM
SW504
8-18-2. Cap (except ROPS)
Dashboard harness (2) (P.5-055)
G
SWP-4F
* * * *
* * * *
1418-09044-0-40589-0
5-078
ELECTRICAL SYSTEM
SW504
8-19. DPF Switch Harness
WL,100 Dashboard harness (2) (P.5-055)
Q
SWP-2F
82 148 WL LgY
50
Q
50 Tape
82
(1) DPF switch
LgY,100
148
(2)
1448-09021-0-30554-A
No.
SIZE, COLOR
CONTACT POINTS
82
WL
2
Q , DPF switch -1
148
LgY
2
Q , DPF switch -2
5-079
CONNECTION
ELECTRICAL SYSTEM
SW504
8-20. Diagnostic Switch Harness
B,50 Dashbord harness (1) (P.5-053)
DIA
SWP-2M
315 X GW B
50
DIA
100 Tape
X
LA104 (1) Diagnostic switch
GW,50
315 LA104 (2)
1448-09040-0-30777-0
No.
SIZE, COLOR
CONTACT POINTS
X
B
2
DIA , Diagnostic switch -1
315
GW
2
DIA , Diagnostic switch -2
CONNECTION
5-080
ELECTRICAL SYSTEM
SW504
8-21. Parking Brake Switch Harness
RW,100 WB,100 Dashboard harness (2) (P.5-055)
E
SWP-6F
301 X 41 Y B RW * 15 40 * YL WB
50
E
50 Tape
YL,100 B,100 Y,100
41
(1)
40
(3)
15
(5)
X
(4)
301
(2)
Parking brake switch
1446-09062-0-30834-A
No.
SIZE, COLOR
CONTACT POINTS
X
B
2
E , Parking brake switch -4
15
YL
2
E , Parking brake switch -5
40
WB
2
E , Parking brake switch -3
41
RW
2
E , Parking brake switch -1
301
Y
2
E , Parking brake switch -2
5-081
CONNECTION
ELECTRICAL SYSTEM
SW504
8-22. Mihaalu Harness
Super flex vinyl cabtyre cord S-VCTF 0.75mm 2 ×4C Mihaalu (option)
38 X 304 R B G * * 308 * * W
SWP-6F
50
50
X 38 B R 308 304 W G
SWP-4M
Frame (R) harness (P.5-063)
750
1446-70015-0-30858-0
No.
SIZE, COLOR
CONTACT POINTS
X
B
2
Frame (R) harness, Mihaalu (option)
38
R
2
Frame (R) harness, Mihaalu (option)
304
G
2
Frame (R) harness, Mihaalu (option)
308
W
2
Frame (R) harness, Mihaalu (option)
CONNECTION
5-082
ELECTRICAL SYSTEM
SW504
8-23. Starter Relay Harness
86 L Dashboard harness (1) (P.5-053)
58Y-2F
26 25 5BR 3W
SWP-2F
86 L
P
85 LY
50
P
100 Tape
30
26 5BR
25 3W
VCF4-1002
Starter relay
85 LY
30
1448-09022-0-30555-A
No.
SIZE, COLOR
CONTACT POINTS
25
3W
2
P , Starter relay
26
5BR
2
P , Starter relay
85
LY
2
P , Starter relay
86
L
2
P , Starter relay
5-083
CONNECTION
ELECTRICAL SYSTEM
SW504
8-24. F-R Lever Vibration Switch (L) Harness
Br,55 Dashboard harness (2) (P.5-055)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (L)
See “Wiring Harness Layout (2), DETAIL P”. (P.5-050)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Dashboard harness (2), F-R lever vibration switch (L) -1
–
G
2
Dashboard harness (2), F-R lever vibration switch (L) -2
–
W
2
Dashboard harness (2), F-R lever vibration switch (L) -3
CONNECTION
5-084
ELECTRICAL SYSTEM
SW504
8-25. F-R Lever Vibration Switch (R) Harness
Br,55 Dashboard harness (1) (P.5-053)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (R)
See “Wiring Harness Layout (2), DETAIL R”. (P.5-050)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Dashboard harness (1), F-R lever vibration switch (R) -1
–
G
2
Dashboard harness (1), F-R lever vibration switch (R) -2
–
W
2
Dashboard harness (1), F-R lever vibration switch (R) -3
5-085
CONNECTION
ELECTRICAL SYSTEM
SW504
8-26. Short Harness
Dashboard harness (2) (P.5-055)
SWP-2F
29 29 BY BY
1446-09080-0-40879-0
No.
SIZE, COLOR
CONTACT POINTS
29
BY
2
CONNECTION
Dashboard harness (2) × 2
5-086
ELECTRICAL SYSTEM
SW504
8-27. Cord
150 AV3,B
ECU LA208
LA208 Ground
1745-33006-0-40486-0
No.
SIZE, COLOR
CONTACT POINTS
–
B
2
5-087
CONNECTION ECU, Ground
ELECTRICAL SYSTEM
SW504
9. ELECTRICAL COMPONENT SPECIFICATIONS (SW504) 9-1. Fuse Box
(RG) Backup buzzer switch Horn relay Flasher unit
Vibrator lamp relay (RL) Vibration mode select switch Vibratory drum select switch (ROPS) Vibration Lo-Hi change switch (except ROPS) Brake lamp relay (RY) F-R lever switch Speed change switch Foot brake switch
(R) Lighting switch (LY) Water spray mode select switch Water spray relay
Starter relay (W)
10
9
8
7
6
5
4
3
2
1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
(W) Starter switch
(G) Battery relay Sub power (12V/120W) (R) Battery relay
SW504-05001
Harness color codes W : White R : Red G : Green RY : Red/Yellow stripe
RG : Red/Green stripe RL : Red/Blue stripe LY : Blue/Yellow stripe
5-088
ELECTRICAL SYSTEM
SW504
9-2. Combination Meter
A 1
150 149 17 316 X * * 93 35 X 314 12 1 GB YB WR GR B * * L G B BY Y 36 314 315 X X 55 92 53 17 15 37 23 13 GR BY GW B B YG W LR WR YL GB 37 * 9 51 38 39 52 35 * * * * * 24 * * * * * GB * BrW Br Or LW YW
12
12 23 35
13 24
Harness side
DETAIL A PIN DESCRIPTION
System configuration diagram
Battery 24V (+)
12
2
Starter switch (ACC)
314
3
Ground
X
4
Turn signal (R)
35
5
Engine stop
93
6
Over heat
7
REV. ratio SEL.1
8
REV. ratio SEL.3
X
9
Buzzer
316
10
Lamp check
17
11
CAN(+)
149
Illumination LED
12
CAN(-)
150
Engine oil pressure indicator
13
Head lamp
37
14
Parking brake
15
15
Charge warning
17
16
HYD. oil filter warning
53
17
Engine warning
92
18
Fuel meter
55
DEF low level
19
REV. ratio SEL.2
X
Engine warning
20
REV. ratio SEL.4
X
Water splay
21
DTC display
315
Liquid spray
22
Hour meter
314
Vibrator
23
Turn signal (L)
36
24
Preheating
52
25
Water splay
39
26
Flood lamp
38
27
Vibrator
51
28
Liquid spray
9
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
+BAT Battery 24V (+)
+ -
DC/DC Converter
5V LDO
TACHO
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
REV. ratio SEL.1
FUEL
TEMP
CAN Transceiver
Fuel meter 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
+BAT
Engine stop HYD. oil filter warning Parking brake
Flood lamp
+BAT
NO.
1
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
37
SW504-05002
5-089
VIBRATORY DRUM • REAR WHEEL
VIBRATORY DRUM • REAR WHEEL
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 • REAR WHEEL
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 • REAR WHEEL
2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 2-1-1. Removal of vibratory drum • Use same procedure to remove drum assembly from SW/TW354 front drum assembly and SW354 rear drum assembly. 1) Securing machine • Hold drum with chocks. • Lock front and rear frames with lock pin (1).
1
SW354-06075
DANGER When lifting the machine body, use an appropriate hoist of sufficient strength. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. Also, to firmly secure the machine body, use a support stand of sufficient strength. 2) Supporting frame • Lift frame with a crane. • Place support stands under frame when drum is slightly off ground to support machine body.
Lift with crane.
Front axle Rear axle SW354 : 1,470 kg (3,240 lbs.) 1,430 kg (3,155 lbs.) TW354 : 1,470 kg (3,240 lbs.) TW504 : 3,510 kg (7,740 lbs.)
Support stand TW5025023
6-003
VIBRATORY DRUM • REAR WHEEL
WARNING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work. 3) Disconnecting piping 3-1) Disconnecting propulsion motor piping • Remove bolts (3). • Remove cover (2). • Disconnect hydraulic hoses (4), (5), (6), (7) and (8) connecting to propulsion motor. (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter.
2
8
3 4 5
7
6
TW5025020
3-2) Disconnecting vibrator motor piping • Remove bolts (10). • Remove cover (9). • Disconnect hydraulic hoses (11), (12), and (13) connecting to vibrator motor.
9 10 13
11 12
TW5025021
6-004
VIBRATORY DRUM • REAR WHEEL 4) Removal of drum assembly • Flip up scraper blade (14). • Lift left plate (15), right plate (16) and hold them. • Remove bolts (17) (left and right sides). • Remove drum assembly together with plates (15), (16) from frame. • Remove rear drum assembly in same way. (SW354)
17 14
(NOTICE) • Damper mounting bolts and nuts must not be stressed during the removal.
15,16
Front drum assembly Rear drum assembly SW354 : 710 kg (1,565 lbs.) 710 kg (1,565 lbs.) TW354 : 710 kg (1,565 lbs.) TW504 : 1,060 kg (2,337 lbs.) 5) Removal of plates (TW504) • Hold drum (18) with chocks. • Remove nuts (20) and bolts (19) (left and right sides). • Remove plate (15), (16). (15) Front left plate : 80 kg (176 lbs.) (16) Front right plate : 85 kg (187 lbs.)
TW5025022
TW504: Lift with crane. 15,16 19,20
18
Chock TW504-06001
6) Removal of plates (SW/TW354) • Hold drum (23) with chocks. • Remove nuts (24) (left and right sides). • Remove plate (21), (22). (21) Front left plate : 60 kg (132 lbs.) (22) Front right plate : 65 kg (143 lbs.)
SW/TW354: Lift with crane. 21,22 24
• Remove rear drum assembly in same way. (SW354) (22) Rear left plate : 65 kg (143 lbs.) (21) Rear right plate : 60 kg (132 lbs.)
23
Chock SW354-06001
6-005
VIBRATORY DRUM • REAR WHEEL
2-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. N•m
(17) Bolt M16×50 : 265 N·m (195 lbf·ft) (19) Bolt M12×50 : 108 N·m ( 80 lbf·ft) (24) Nut M16 : 196 N·m (145 lbf·ft)
2) Upon installing vibratory drum, pay particular attention to items mentioned below. • Fill hydraulic oil tank to specified level to make up for any oil leakage. • Start engine and circulate oil through piping. Then check oil level again, ensuring that oil is at specified level. (NOTICE) • If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed, the piston packing or other items may be damaged by air entering into the cylinder.
6-006
VIBRATORY DRUM • REAR WHEEL
3. VIBRATORY DRUM ASSEMBLY
(1) O-ring (2) Holder (3) O-ring (4) Vibrator bearing (5) Eccentric shaft (6) Drum (7) Vibrator bearing (8) Boss (9) O-ring (10) Bolt (11) Plug (12) Bolt (13) Plug (14) Plate (15) Roller bearing (16) Breather (17) Bolt (18) O-ring (19) Nut (20) Damper (21) Sleeve (22) Spring pin (23) Bolt (24) Cover (25) Bolt (26) Cover (27) O-ring (28) Shim (29) Disc (30) Oil seal (31) Bolt (32) Snap ring (33) Bolt (34) Disc (35) Bolt (36) Damper (37) Nut (38) Bolt (39) Propulsion motor (40) Plate (41) Bolt (42) Plug (43) Vibrator motor (44) Bolt
3-1. Vibratory Drum Assembly (SW/TW354)
1
41,42
2
3
4
5
6
7
8
9
10
11
12,13
14
40
15 16 17 18 19
20
39
21, 22 23 44 24
38
43
37 36
35
34
33 32 31
30 29
28
27
26
25
11-1 (Oil filter plug)
11-2 (Level plug)
: M16×40 : M16×50
: M16×40 : M16
: M10×35 : M10×25
: M16×40 : M16×45 : M16×40 : M16 : M16×40
: M16×50
: M10×35
11-3 (Drain plug)
Vibrator motor side 0446-43804-0-10957-B
6-007
VIBRATORY DRUM • REAR WHEEL
3-2. Vibratory Drum Assembly (TW504)
1
2
3
4
5
6
7
8
9
10
11
(1) O-ring (2) Holder (3) O-ring (4) Vibrator bearing (5) Eccentric shaft (6) Drum (7) Vibrator bearing (8) Boss (9) O-ring (10) Bolt (11) Plug (12) Bolt (13) Plug (14) Plate (15) Roller bearing (16) Breather (17) Bolt (18) O-ring (19) Bolt (20) Damper (21) Sleeve (22) Spring pin (23) Bolt (24) Cover (25) Bolt (26) Cover (27) O-ring (28) Shim (29) Disc (30) Oil seal (31) Bolt (32) Snap ring (33) Bolt (34) Disc (35) Bolt (36) Damper (37) Bolt (38) Bolt (39) Propulsion motor (40) Plate (41) Bolt (42) Plug (43) Vibrator motor (44) Bolt
12,13
41,42
14
40
15 16 17 18 19
A 20 21, 22
A
39
23 44
38
24
37
43
36 35
34 33 32 31
30 29
28
27
26
25
11-1 (Oil filter plug)
11-2 (Level plug) 11-3 (Drain plug)
Vibration mode: High Counterclockwise rotation
: M16×40 : M16×50
: M12×30 : M12×50
: M10×35 : M10×25
: M16×40 : M18×50 : M12×30 : M12×50 : M18×40
: M16×50
: M10×35
Vibration mode: Low Clockwise rotation
SECTION A-A Vibrator motor side 0449-43802-0-10253-A
6-008
VIBRATORY DRUM • REAR WHEEL
3-3. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures are constant with part numbers of vibratory drum assembly shown on page 6-007 (SW/TW354), page 6-008 (TW504).
Drum assembly
11-1
3-3-1. Disassembly of vibratory drum 1) Lay drum assembly with plugs (11-1), (11-2), and (11-3) positioned as shown on the right. • Hold with chocks. Drum assembly SW/TW354 : 590 kg (1,301 lbs.) TW504 : 890 kg (1,962 lbs.)
11-2
11-3
Chock 2) Remove plugs (11-1) and (11-3). • Drain gear oil.
SW354-06045
11-1
Supply port
• Quantity of gear oil SW/TW354 : 5.0 L (1.3 gal.) TW504 : 6.0 L (1.6 gal.)
11-3
WARNING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like.
Drain port
SW354-06046
43 Drum assembly
3) Stand drum assembly with its vibrator motor (43) side facing up. Drum assembly SW/TW354 : 585 kg (1,290 lbs.) TW504 : 885 kg (1,951 lbs.)
Wooden block SW300-1-06015
6-009
VIBRATORY DRUM • REAR WHEEL 4) Remove adapters. Adapter
SW300-1-06016
5) Remove bolts (44). • Remove vibrator motor (43). • Remove breather (16). (43) Vibrator motor : 5 kg (11 lbs.)
43 44
16 SW300-1-06017
6) Remove sleeve (21).
21
SW354-06040
6-010
VIBRATORY DRUM • REAR WHEEL 7) Remove bolts (25). 25
SW354-06047
8) Lift cover (26) using two pulling bolts (M10×40). • Remove cover.
26
Pulling bolt
SW354-06048
9) Remove bolts (17). (17) Bolts SW/TW354 (four bolts) TW504 (eight bolts)
20
17
• Remove dampers (20).
SW354-06076
6-011
VIBRATORY DRUM • REAR WHEEL 10) Remove bolts (23). • Remove cover (24). • Remove shim (28).
23 24 28
SW354-06035
11) Put a piece of wooden board on end of boss (8). • Set a puller on disc (29). • Remove disc subassembly with roller bearing from boss subassembly.
8
Puller
Wooden board
29
SW300-1-06023
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
12) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to disc subassembly.
SW354-06049
6-012
VIBRATORY DRUM • REAR WHEEL 13) Lift disc subassembly with roller bearing from boss subassembly. Disc subassembly SW/TW354 : 35 kg (77 lbs.) TW504 : 45 kg (99 lbs.)
Disc subassembly
Boss subassembly
SW354-06050
14) Remove bolts (10).
10
SW354-06028
15) Lift boss subassembly using two pulling bolts (M16×40). Pulling bolt
SW354-06051
6-013
VIBRATORY DRUM • REAR WHEEL 16) Install lifting bolts (M16) to boss subassembly.
Lifting bolt
SW354-06052
17) Remove boss subassembly. Boss subassembly : 35 kg (77 lbs.)
Boss subassembly
SW354-06077
WARNING
Drum subassembly
Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
18) Reverse drum subassembly. Drum subassembly SW/TW354 : 500 kg (1,102 lbs.) TW504 : 790 kg (1,742 lbs.) Wooden block
6-014
SW354-06059
VIBRATORY DRUM • REAR WHEEL 19) Remove dampers (36) and bolts (35).
35
36
(35) Bolts SW/TW354 (six bolts) TW504 (twelve bolts)
SW354-06019
20) Remove adapters.
Adapter SW354-06018
21) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to disc (34).
34
Lifting bolt
SW354-06078
6-015
VIBRATORY DRUM • REAR WHEEL 22) Lift disc (34). • Remove bolts (38).
38
34
SW354-06054
23) Remove disc (34). (34) Disc SW/TW354 : 15 kg (33 lbs.) TW504 : 20 kg (44 lbs.)
34
SW354-06015
24) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to propulsion motor (39). • Remove bolts (33).
33
Lifting bolt
39
SW300-1-06036
6-016
VIBRATORY DRUM • REAR WHEEL 25) Remove propulsion motor (39). (39) Propulsion motor SW/TW354 : 45 kg ( 99 lbs.) TW504 : 85 kg (187 lbs.)
39
SW354-06011
26) Remove bolts (31).
31
SW354-06008
27) Lift holder subassembly using two pulling bolts (M16×40). Pulling bolt
Holder subassembly
SW354-06055
6-017
VIBRATORY DRUM • REAR WHEEL 28) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to holder subassembly.
Lifting bolt
Holder subassembly
SW354-06056
29) Remove holder subassembly. Holder subassembly SW/TW354 : 50 kg (110 lbs.) TW504 : 60 kg (132 lbs.)
Holder subassembly
SW354-06007
30) Remove snap ring (32) while supporting eccentric shaft (5).
32
5 SW354-06079
6-018
VIBRATORY DRUM • REAR WHEEL 31) Remove holder subassembly. Holder subassembly : 30 kg (66 lbs.)
Holder subassembly
5
SW354-06003
32) Put holder subassembly on wooden blocks. Wooden block
Holder subassembly SW354-06057
33) Remove vibrator bearing (4). Holder subassembly
4
SW354-06058
6-019
VIBRATORY DRUM • REAR WHEEL
3-3-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality.
WARNING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like.
(6) Drum SW/TW354 : 380 kg ( 838 lbs.) TW504 : 605 kg (1,334 lbs.)
a
1) Stand drum (6) with its propulsion motor side facing up.
6
(NOTICE) • Propulsion motor side dimension “a” SW/TW354 : 363.5 mm (14.3 in.) TW504 : 379.5 mm (14.9 in.)
SW354-06006
2) Reassembly of holder subassembly • Apply a coat of gear oil to holder (2) at where bearing will be press-fitted. • Drive in vibrator bearing (4)
2
4
(NOTICE) • Take care not to damage the bearing when installing it.
SW300-1-06043
6-020
VIBRATORY DRUM • REAR WHEEL 3) Reverse holder subassembly. Holder subassembly : 30 kg (66 lbs.)
Holder subassembly
SW354-06061
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
4) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to holder subassembly.
Holder subassembly SW354-06080
5) Lift holder subassembly. Holder subassembly : 30 kg (66 lbs.)
Holder subassembly
SW354-06002
6-021
VIBRATORY DRUM • REAR WHEEL 6) Install eccentric shaft (5) to holder subassembly. Holder subassembly
5
SW354-06063
7) Hold eccentric shaft (5) with snap ring (32). (NOTICE) • Make sure that the snap ring is fitted completely in its groove.
32
5
SW354-06081
8) Apply grease to O-ring (3). • Install O-ring to holder (2).
2 3
SW354-06005
6-022
VIBRATORY DRUM • REAR WHEEL 9) Lower holder subassembly on mounting surface of drum (6).
Holder subassembly
Holder subassembly SW/TW354 : 50 kg (110 lbs.) TW504 : 60 kg (132 lbs.)
6
SW354-06064
10) Secure holder subassembly with eight bolts (31) and washers. N•m
Holder subassembly
31
(31) Bolts M16×40 : 265 N·m (195 lbf·ft)
SW354-06065
11) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to propulsion motor (39).
Lifting bolt
39
SW300-1-06048
6-023
VIBRATORY DRUM • REAR WHEEL 12) Lift propulsion motor (39). (39) Propulsion motor SW/TW354 : 45 kg ( 99 lbs.) TW504 : 85 kg (187 lbs.) 39
• Apply grease to O-ring (1). • Install O-ring to propulsion motor.
1
SW300-1-06049
13) Lower propulsion motor (39) on mounting surface of holder subassembly. 39
SW354-06066
14) Secure propulsion motor (39) with six bolts (33) and washers. N•m
39
33
(33) Bolts SW/TW354 : M16×45 : 265 N·m (195 lbf·ft) TW504 : M18×50 : 343 N·m (253 lbf·ft)
SW300-1-06050
6-024
VIBRATORY DRUM • REAR WHEEL 15) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to disc (34).
Lifting bolt
34 SW354-06013
16) Lift disc (34). (34) Disc SW/TW354 : 15 kg (33 lbs.) TW504 : 20 kg (44 lbs.)
34 SW354-06014
17) Lower disc (34) on mounting surface of propulsion motor (39). 34
39 SW354-06067
6-025
VIBRATORY DRUM • REAR WHEEL (NOTICE) • The longer direction of the disc must face the same direction as the propulsion motor port A.
Longer direction of disc
Propulsion motor port A
SW354-06016
18) Secure disc (34) with six bolts (38) and washers. N•m
(38) Bolts
38
34
SW/TW354 : M16×40 : 265 N·m (195 lbf·ft) TW504 : M18×40 : 343 N·m (253 lbf·ft)
SW354-06017
19) Apply grease to O-rings for adapters. • Install adapters.
Adapter SW354-06018
6-026
VIBRATORY DRUM • REAR WHEEL 20) Secure three dampers (36) to disc subassembly with six / twelve bolts (35) and washers. N•m
35
36
(35) Bolts
SW/TW354 (six bolts) : M16×40 : 265 N·m (195 lbf·ft) TW504 (twelve bolts) : M12×30 : 108 N·m ( 80 lbf·ft)
SW354-06019
WARNING
Drum subassembly
Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 21) Reverse drum subassembly. Drum subassembly SW/TW354 : 500 kg (1,102 lbs.) TW504 : 790 kg (1,742 lbs.)
SW300-1-06054
22) Reassembly of boss subassembly 22-1) Apply a coat of gear oil to boss (8) at where bearing will be press-fitted. • Drive in vibrator bearing (7).
7
Wooden block
8
SW300-1-06057
6-027
VIBRATORY DRUM • REAR WHEEL 22-2) Reverse boss subassembly. Boss subassembly
Boss subassembly : 30 kg (66 lbs.)
SW354-06022
WARNING
15
Wear heat resistant gloves when handling heated parts to avoid burns.
8
22-3) H eat up roller bearing (15) inner race by using a ring heater or the like. • Apply a coat of gear oil to boss (8) at where bearing inner race will be press-fitted. • Drive in heated roller bearing inner race.
SW354-06023
22-4) Apply grease to O-rings for plugs (11). • Install plugs. • Apply sufficient amount of lithium-based grease to rollers of roller bearing (15) inner race.
11
15 SW354-06024
6-028
VIBRATORY DRUM • REAR WHEEL 23) Install lifting bolts (M16) to boss subassembly. Lifting bolt
SW354-06025
24) Lift boss subassembly. Boss subassembly : 35 kg (77 lbs.) • Apply grease to O-ring (9). • Install O-ring to boss (8).
8
9 SW300-1-06062
25) Lower boss subassembly on mounting surface of drum subassembly slowly.
5
Pipe
(NOTICE) • Support the eccentric shaft (5) with a pipe or the like, to prevents tilting of vibrator bearing inner race during installation.
SW354-06027
6-029
VIBRATORY DRUM • REAR WHEEL 26) Secure boss subassembly with eight bolts (10) and washers. N•m
10
Boss subassembly
(10) Bolts M16×40 : 265 N·m (195 lbf·ft)
SW354-06068
27) Install lifting bolts (M5) to end of eccentric shaft (5).
Lifting bolt
SW354-06029
28) Slowly lift eccentric shaft (5) with a crane and check that there is an axial play of 2 to 4 mm (0.08 to 0.16 in.).
SW354-06030
6-030
VIBRATORY DRUM • REAR WHEEL 29) Apply a coat of gear oil to disc (29) at where bearing outer races will be press-fitted. • Drive in roller bearings (15) outer races into disc. • Apply liquid packing to periphery of oil seal (30). • Drive in oil seal. • Apply grease to lip of oil seal.
29
15
30
15 SW300-1-06067
30) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to disc subassembly.
Lifting bolt
Disc subassembly SW354-06032
31) Lower disc subassembly on mounting surface of boss subassembly.
Disc subassembly
Boss subassembly
Disc subassembly : 35 kg (77 lbs.)
SW354-06033
6-031
VIBRATORY DRUM • REAR WHEEL 32) Apply sufficient amount of lithium-based grease to rollers of roller bearing (15) inner race. • Drive in roller bearing inner race until rollers come in contact with outer race.
Outer race
15
SW354-06034
33) Preload adjustment of roller bearing ① Install a shim of about 1 mm (0.04 in.) and secure cover (24) to boss subassembly with four bolts (23) and washers.
23 24 Shim Boss subassembly
SW354-06069
(NOTICE) • Tighten the bolts alternately in diagonal directions.
Disc subassembly
23
24
Gap
② A gap will remain between end of boss subassembly and inside of cover (24). • Tighten bolts (23) to a torque of 12.7 N·m (9.4 lbf·ft). • Give disc subassembly two to three turns. • Tighten bolts to a torque of 12.7 N·m (9.4 lbf·ft) again. • Repeat this work several times until tightening torque of bolts no longer fluctuates.
Boss subassembly SW300-1-06072
6-032
VIBRATORY DRUM • REAR WHEEL (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 (23). • Remove cover (24). • Remove shim.
23 24
(NOTICE) • Do not turn the disc subassembly after the cover is removed.
Shim
SW354-06070
④ Without inserting shim, install cover (24) to boss subassembly with four bolts (23) and washers. 23 24 Boss subassembly
SW354-06036
6-033
VIBRATORY DRUM • REAR WHEEL ⑤ Using a thickness gauge, measure clearance “A”.
No gap
A
reload adjusting ★ P = A + 0.1 mm (0.004 in.) shim thickness
SW300-1-06075
⑥ Remove bolts (23). • Remove cover (24). 23 24
SW354-06071
⑦ Install shim (28) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (24) to boss subassembly with four bolts (23) and washers. N•m
(23) Bolts M10×35 : 59 N·m (44 lbf·ft)
23 24 28 Boss subassembly
SW354-06072
6-034
VIBRATORY DRUM • REAR WHEEL 34) Apply grease to O-ring (27). • Install O-ring to cover (26). 27
26
SW300-1-06077
35) Lower cover (26) on mounting surface of disc subassembly. 26
Disc subassembly
SW354-06037
(NOTICE) • The recess of the disc must face the same direction as the breather mounting hole in the cover.
Breather mounting hole
Recess of disc
SW354-06073
6-035
VIBRATORY DRUM • REAR WHEEL 36) Secure cover (26) to disc subassembly with six bolts (25) and washers
25
26
SW354-06038
37) Secure two dampers (20) to disc subassembly with four / eight bolts (17) and washers. N•m
20
(17) Bolts
17
SW/TW354 (four bolts) : M16×40 : 265 N·m (195 lbf·ft) TW504 (eight bolts) : M12×30 : 108 N·m ( 80 lbf·ft)
SW354-06039
38) Drive two spring pins (22) into sleeve (21). 21
22 SW300-1-06080
6-036
VIBRATORY DRUM • REAR WHEEL 39) Apply molybdenum-based grease to splined portion of sleeve (21). • Fit sleeve to splined portion on eccentric shaft end. 21
SW354-06074
40) Apply grease to O-ring (18). • Install O-ring to vibrator motor (43).
43
18 SW300-1-06082
41) Wind seal tape around threaded portion of breather (16). • Install breather. • Secure vibrator motor (43) to cover (26) with two bolts (44) and washers.
43 44
(43) Vibrator motor : 5 kg (11 lbs.) N•m
(44) Bolts M10×35 : 49 N·m (36 lbf·ft)
26
16 SW300-1-06083
6-037
VIBRATORY DRUM • REAR WHEEL 42) Apply grease to O-rings for adapters.
Adapter
• Install adapters.
SW300-1-06084
43) Lay drum assembly with plugs (11-1), (11-2) and (11-3) positioned as shown right. • Hold with chocks.
Drum assembly
11-1
Drum assembly SW/TW354 : 585 kg (1,290 lbs.) TW504 : 885 kg (1,951 lbs.)
11-2
11-3
Chock 44) Remove plugs (11-1) and (11-2). • Supply gear oil from oil supply port • Check that oil drips from gauge port.
SW354-06045
Supply port
11-1
• Quantity of gear oil SW/TW354 : 5.0 L (1.3 gal.) TW504 : 6.0 L (1.6 gal.) • Reinstall plugs.
Gauge port
6-038
11-2
SW354-06044
VIBRATORY DRUM • REAR WHEEL
4. REAR AXLE 4-1. Rear Axle Assembly (TW types) 1
2
3
4
5
6
7, 8
9
10 11
30
12
29
13 14
28
27
26 25
24
23
22
21
20
19
18
17
15,16 SW300-1-06097
(1) Adapter (2) Hose (3) Hose (4) Hose (5) Hose (6) Adapter (7) Hub bolt : M14×45 P=1.5 (8) Hub nut : M14 P=1.5 (9) Tire (10) Disc wheel
(11) Adapter (12) Bolt : M14×50 (13) Hose (14) Adapter (15) Hub bolt : M14×45 P=1.5 (16) Hub nut : M14 P=1.5 (17) Disc (18) Propulsion motor (R,R) (19) Bolt : M16×40 (20) Adapter
(21) Hose (22) Bolt : M20×80 (23) Hose (24) Adapter (25) Bracket (26) Bolt : M16×40 (27) Propulsion motor (R,L) (28) Adapter (29) Hose (30) Adapter
N•m
(8) Nut M14 P=1.5 (12) Bolt M14×50 (16) Nut M14 P=1.5
: 186 N·m ( 137 lbf·ft ) : 167 N·m ( 123 lbf·ft ) : 186 N·m ( 137 lbf·ft )
(19) Bolt M16×40 (22) Bolt M20×80 (26) Bolt M16×40
: 265 N·m ( 195 lbf·ft ) : 539 N·m ( 398 lbf·ft ) : 265 N·m ( 195 lbf·ft )
Specification • Tire inflation pressure : 294 kPa ( 42.6 psi )
6-039
VIBRATORY DRUM • REAR WHEEL
4-2. Removal and Installation of Rear Axle (TW types) 1) Hold drum with chocks.
Chock 2) Lock front and rear frames with lock pin (1).
TW354-06004
1
SW354-06075
6-040
VIBRATORY DRUM • REAR WHEEL
4-2-1. Removal of rear axle • Lead line numbers shown in the illustrations for the following rear axle removal and installation procedures are constant with part numbers of rear axle assembly (TW types) shown on page 6-039.
DANGER When lifting the machine body, use an appropriate hoist of sufficient strength. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. Also, to firmly secure the machine body, use a support stand of sufficient strength. 1) Supporting rear frame • Lift frame with a crane. • Place support stands under frame when tires are slightly off ground to support machine body. • Flip up scraper blade. •
Lift with crane.
Scraper blade
Rear axle TW354 : 1,130 kg (2,490 lbs.) TW354 ROPS : 1,190 kg (2,625 lbs.) TW504 : 1,460 kg (3,220 lbs.) TW504 ROPS : 1,530 kg (3,375 lbs.)
Support stand TW354-06001
2) Remove bolts (12).
12 TW354-06002
6-041
VIBRATORY DRUM • REAR WHEEL 3) Remove wheel subassembly with forklift. Wheel subassembly TW354 : 110 kg (243 lbs.) TW504 : 145 kg (320 lbs.) • Wheel subassembly of right side is also removed in the same procedure.
Wheel subassembly TW354-06003
WARNING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work. 4) Disconnecting piping 4-1) Disconnect hydraulic hoses (13), (21), (23) and (29) connecting to rear propulsion motor. (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter.
6-042
29
13 23
21
Propulsion motor subassembly SW300-1-06091
VIBRATORY DRUM • REAR WHEEL 4-2) Disconnect hydraulic hoses (2), (3), (4) and (5) connecting to rear propulsion motor. 2 3
5 4
SW300-1-06100
5) Hold up propulsion motor subassembly with forklift. • Remove bolts (22). • Remove propulsion motor subassembly. Propulsion motor subassembly : 130 kg (287 lbs.) 22
Propulsion motor subassembly
TW354-06005
6-043
VIBRATORY DRUM • REAR WHEEL
4-2-2. Installation of rear axle 1) Install rear axle in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing rear axle. N•m
(12) Bolt M14×50 : 167 N·m ( 123 lbf·ft) (22) Bolt M20×80 : 539 N·m ( 398 lbf·ft)
2) Upon installing rear axle, pay particular attention to items mentioned below. • Fill hydraulic oil tank to specified level to make up for any oil leakage. • Start engine and circulate oil through piping. Then check oil level again, ensuring that oil is at specified level. (NOTICE) • If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed, the piston packing or other items may be damaged by air entering into the cylinder.
6-044
SW504
VIBRATORY DRUM • REAR WHEEL
5. VIBRATORY DRUM (SW504) 5-1. Removal and Installation of Vibratory Drum • For removal and installation, refer to "2-1. Removal and Installation of Vibratory Drum" (P.6-003). • Each mass is same as TW 504 except for supporting frame.
Front axle : 2,000 kg (4,410 lbs.) Rear axle : 2,090 kg (4,605 lbs.)
5-2. Disassembly and Reassembly of Vibratory Drum • For disassembly and reassembly, refer to "3-3. Disassembly and Reassembly of Vibratory Drum" (P.6-009). • Each mass is same as TW 504.
6-045
BRAKE
BRAKE
1. BRAKE PEDAL
1 2 3 4
9
5
A
6 10
B A
7
8 11
15 14 13
12
SECTION A-A (1) (2) (3) (4) (5)
Washer Split pin Rod (Apply grease to hole*) Nut : M10 P=1.25 Nut : M10
VIEW B (6) Rod end : M10 (7) Rubber bolt : M10×25 P=1.25 (8) Foot brake switch (9) F-R lever (10) Shaft
0446-51802-0-10194-A
(11) Nut : M10 P=1.25 (12) Rubber bolt : M10×25 P=1.25 (13) Nut : M10 (14) Spring (15) Bush (Apply grease)
* : Lithium-based grease 7-001
BRAKE
2. BRAKE SYSTEM 2-1. Brake System (SW354)
3 2 6 5
To combination meter
1
Foot brake switch (Condition in which brake pedal pressed)
4
Parking brake switch (Brake OFF condition)
Brake Propulsion (Brake ON condition) motor (F)
Parking brake solenoid valve when brake is OFF. (with solenoid excited)
15A Fuse
Brake (Brake ON condition)
Propulsion motor (R)
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. SW354-07001
7-002
BRAKE
2-2. Brake System (TW354, 504)
3 2 6 5
To combination meter
1
Foot brake switch (Condition in which brake pedal pressed)
4
Parking brake switch (Brake OFF condition)
Brake Propulsion (Brake ON condition) motor (F)
Parking brake solenoid valve when brake is OFF. (with solenoid excited)
15A Fuse Brake (Brake ON condition)
Propulsion motor (R,R)
Brake (Brake ON condition)
Propulsion motor (R,L)
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. TW354-07001
7-003
WATER SPRAY SYSTEM
WATER SPRAY SYSTEM
1-1. Water Spray Piping (SW354)
Tee 4
Pipe (F) (Water spray pipe (F))
Hose (Tee 4
Pipe (F))
Hose (Tank
3 way valve
Filter IN)
From Filter OUT
Tee 1
Water spray tank
Tee 3
Filter
Tee 2
Tee 1
OUT
P
IN
OUT
Drain valve Check valve Drain valve
IN
Water spray pipe (R)
Water spray pump
Water spray pipe (F)
1. WATER SPRAY PIPING
3 way valve
Drain valve
Water spray diagram Pump (Water spray pump)
Check valve
Pump OUT
Drain valve
Hose (Pump OUT
To Tee 4
Tee 2)
Pump IN Hose (Tee 3
Tee 3
Tee 4)
Hose (Filter OUT
Tee 4
Tee 1)
Filter OUT
Hose (Tee 4
Tee 1
Tee 2
Drain valve Pipe (R))
Drain valve Hose (Tee 1
DETAIL OF WATER SPRAY PUMP Filler cap
Pump IN)
Level gauge
Tank (Water spray tank)
Filter IN
DETAIL A
Strainer
Pump (Water spray pump)
Drain cap Nozzle
A Filter
Pipe (R) (Water spray pipe (R)) The letters and figures such as “Filter IN” and “Pump OUT” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the water.
Drain valve
0446-75811-0-10924-A
8-001
WATER SPRAY SYSTEM
1-2. Water Spray Piping (TW354,504)
Water spray tank
Water spray pump
Hose (Tee 4
Pipe (F))
Hose (Tank
3 way valve
Filter IN)
From Filter OUT
Tee 1
Tee 3
Filter
Tee 2
Tee 1
P
OUT
IN
OUT
Drain valve Check valve Drain valve
IN
Water spray pipe (R)
Pipe (F) (Water spray pipe (F))
Water spray pipe (F)
Tee 4
3 way valve
Drain valve Ball valve Pump (Water spray pump)
Check valve
Water spray diagram
Pump OUT
Drain valve
Hose (Pump OUT
To Tee 4
Tee 2)
Pump IN Hose (Tee 3 Hose (Filter OUT
Tee 3
Tee 4) Tee 4 Tee 1) Filter OUT
Ball valve
Hose (Tee 4
Pipe (R))
Tee 1
Tee 2
Drain valve
Drain valve
DETAIL OF WATER SPRAY PUMP Filler cap
Hose (Tee 1
Pump IN)
Level gauge
Tank (Water spray tank) Filter IN
DETAIL A
Strainer
Pump (Water spray pump)
Drain cap Nozzle
A Filter
Drain valve
Pipe (R) (Water spray pipe (R))
The letters and figures such as “Filter IN” and “Pump OUT” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the water.
0447-75807-0-10178-B
8-002
WATER SPRAY SYSTEM
2. LIQUID SPRAY SYSTEM 2-1. Liquid Spray Piping (TW354,504)
Hose (Pump OUT
Hose (Liquid pipe
Liquid pipe)
Liquid tank)
Drain valve
Liquid pipe (Liquid spray pipe)
Ball valve
Liquid spray pump Tee
Pump OUT Pump (Liquid spray pump)
OUT
IN P OUT Drain valve
IN
Pump IN
Hose (Tee Pump IN)
Liquid spray tank
SECTION A-A Liquid tank (Liquid spray tank)
Tee
Drain valve
Ball valve Liquid spray pipe
Filter
Hose (Tee
Filter OUT
Hose (Pump OUT
Liquid spray diagram Liquid pipe)
Pump IN)
Tee Filter
Hose (Liquid tank
Filter IN)
Filter Filter IN
A
A Liquid pipe (Liquid spray pipe)
Pump (Liquid spray pump)
Drain valve
Nozzle
Drain cap
The letters and figures such as “Filter IN” and “Pump OUT” show each port. Arrow “ ” symbols show the hose connection and the direction of the flow of the liquid.
0447-75804-0-10055-G
8-003
INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment WARNING
Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time. • Make sure that no one can enter any hazardous area.
CAUTION
Do not work on the hydraulic system while the engine is running and the system is hot and under pressure. Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved. Before removing any plugs from the pressure measurement ports, always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure.
WARNING
Inadvertent starting the engine may cause a serious accident. When inspecting the engine, make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents.
CAUTION
Before inspecting inside of the engine compartment, always stop the engine. Contact with the fan, V-belt or exhaust system parts while the engine is running may cause serious injury.
1-2. Preparation for Inspection and Adjustment • Prepare the necessary measuring instruments. In addition, particularly when measuring pressure values, make sure to prepare the appropriate hoses, adapters and a plug removal tool for the pressure reading port. • Make sure that the instruments to be used operate normally. When handling the instruments, exercise sufficient caution not to drop or apply any impact to them. Doing so may adversely affect the calibration. Another important point is to inspect the instruments regularly. An instrument that does not start from the appropriate zero point may give an inaccurate reading.
1-3. Precautions for Inspection and Adjustment • When performing inspections and adjustments, pay special attention to safety. • For each inspection, always take three measurements for each measurement point. If the measurements significantly differ, the measurement method may be incorrect. In such a case, take measurements once again and calculate their average.
1-4. Warm-up • Machinery will not exhibit their true performance under the cold condition. Before taking measurements, always warm up the engine and make sure that the fluid and engine coolant are warmed to their specified normal operating temperatures.
1-5. Inspection and Adjustment of Engine Related Items • Refer to shop manual of engine manufacturer for inspection and adjustment of engine itself. 9-001
INSPECTION AND ADJUSTMENT
2. M EASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement
WARNING Confirm that the parking brake works properly before measurement. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from high pressure gauge port (2) and (5) of propulsion pump. Attach pressure gauge with adapter ⓗ. • Adapter ⓗ : 9/16-18UNF
2
• High pressure gauge port (Reverse) : (2) • High pressure gauge port (Forward) : (5) • 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 Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, slowly move F-R lever to the side to be measured.
5 SW354-09001
h
⑧ Read pressure indicated by pressure gauge. ⑨ After measuring, promptly return F-R lever to “N”. ★ Maximum circuit pressure (high pressure relief valve setting) : 34.5 MPa (5,003 psi)
PG001014
• The numbers “2” and “5” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-011).
9-002
INSPECTION AND ADJUSTMENT
2-2. Inspection • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an inspection in accordance with procedure described below. 13
① Remove plug and valve from high pressure check relief valve port (13) or (14) of propulsion pump. • *High pressure relief valve (Reverse) : (13) • *High pressure relief valve (Forward) : (14) ② Check removed high pressure relief valve for trapped dirt and other abnormalities. ③ If trapped dirt is present, disassemble and clean high pressure relief valve. ④ If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned, replace high pressure relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range. N•m
14 SW354-09002
Plug
Plug : 70 N·m (52 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
High pressure relief valve SV201-1-08003
* High pressure relief valve = S.C.R. (System Check Relief) valve for charge check and high pressure relief. • The numbers “13” and “14” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-011).
9-003
INSPECTION AND ADJUSTMENT
3. M EASUREMENT 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 are aligned.
3
3-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from servo pressure gauge port (3) and (11) of propulsion pump. Attach pressure gauge with adapter ⓗ. • Adapter ⓗ : 9/16-18UNF • 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 Start the engine and set throttle lever to “Full”. ⑤ Read pressure indicated by pressure gauge.
SW354-09027
11
★ Standard charge relief valve setting : 1.9 ± 0.7 MPa (276 ± 100 psi)
SW354-09028
h
PG001014
• The numbers “3” and “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.4-011).
9-004
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 (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 pressure 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 : 0.19 MPa/turn (27.6 psi/turn) ③ If there is no evidence of nut having loosened, remove charge relief valve.
15
SW354-09004
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.
1
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) Nut : 24 N·m (18 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
2
SV520-08004
• The number “15” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-011).
9-005
INSPECTION AND ADJUSTMENT
4. M EASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement.
4-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion motor (F). Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Read pressure indicated by pressure gauge.
1
★ Standard charge relief valve setting : 1.9 ± 0.7 MPa (276 ± 100 psi) SW354-09005
m
PG002002
9-006
INSPECTION AND ADJUSTMENT
5. MEASUREMENT 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 5-1-1. SW types: front and rear, TW types: front • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) and (2) from propulsion motor. Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Release parking brake by pressing parking brake switch button. ⑥ Read brake release pressure indicated by pressure gauge.
1
Front SW354-09006
★ Brake release pressure : 1.5 MPa (218 psi)
2
Rear SW354-09026
m
PG002002
9-007
INSPECTION AND ADJUSTMENT
5-1-2. TW types: rear • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (3) and (4) from propulsion motor. Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Release parking brake by pressing parking brake switch button. ⑥ Read brake release pressure indicated by pressure gauge.
3
★ Brake release pressure : 1.5 MPa (218 psi)
4
TW354-09001
m
PG002002
9-008
INSPECTION AND ADJUSTMENT
6. MEASUREMENT 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 Disconnect hose (1) from vibrator motor. Attach pressure gauge through adapter ⓟ . • Adapter ⓟ : G1/2 to 50 MPa (0 to 7,250 psi) • Pressure gauge : 0
1
② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ SW354 ROPS : Set vibratory drum select switch to “ ”. ⑤ Set vibration mode change switch to “ ⑥ Start the engine and set throttle lever to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ Slowly move F-R lever to forward or reverse side. ⑨ Read pressure gauge for maximum value of vibrator circuit pressure. ⑩ Turn F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished.
”.
SW354-09009
p
★ Maximum circuit pressure (relief valve setting) SW/TW354 : 12.7 MPa (1,842 psi) TW504 : 14.0 MPa (2,030 psi) PG002004
9-009
INSPECTION AND ADJUSTMENT
7. M EASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 7-1. 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 Remove plug from coupling (1). Attach pressure gauge with hose ⓢ and connector ⓤ . • Coupling : 9/16-18UNF×M16 • Adapter for hose ⓢ • Pressure gauge connector ⓤ • Pressure gauge
: M16 P=2.0 : M16×G3/8 :0 to 25 MPa (0 to 3,625 psi)
② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Turn steering wheel to operate relief valve. ⑥ Read pressure indicated by pressure gauge. ★ Standard maximum circuit pressure (orbitroll relief pressure) : 13.5 MPa (1,958 psi)
1
Hydraulic oil filter SW354-09003
s
u
PG003163
9-010
INSPECTION AND ADJUSTMENT
7-2. 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.
2
ORB-SD-09150
9-011
INSPECTION AND ADJUSTMENT
8. M EASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 8-1. Measurement of Propulsion Pump Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion pump. Attach pressure gauge through adapter ⓠ . • Adapter ⓠ : G3/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively.
1 SW354-09011
” and
★ Allowable pump case pressure : 0.25 MPa (36.3 psi) or less
q
PG002006
9-012
INSPECTION AND ADJUSTMENT
9. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 9-1. Measurement 9-1-1. SW types: front and rear, TW types: front • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) and (2) from propulsion motor. Attach pressure gauge with adapter ⓝ . • Adapter ⓝ : G3/8 • 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 propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively.
Front SW354-09012
” and
★ Allowable motor case pressure : 0.3 MPa (43.5 psi) or less
2
Rear SW354-09029
n
PG002003
9-013
INSPECTION AND ADJUSTMENT
9-1-2. TW types: rear • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (3) and (4) from propulsion motor. Attach pressure gauge with adapter ⓝ . • Adapter ⓝ : G3/8 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively. ★ Allowable motor case pressure : 0.3 MPa (43.5 psi) or less
3
4
TW354-09002
” and
n
PG002003
9-014
INSPECTION AND ADJUSTMENT
10. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (EXCEPT TW504) 10-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from vibrator motor. Attach pressure gauge with adapter ⓝ . • Adapter ⓝ : G3/8 • 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 SW354 ROPS : Set vibratory drum select switch to “ ”. ⑤ Set vibration mode change switch to “ ⑥ Start the engine and set throttle lever to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ Slowly move F-R lever to forward or reverse side.
”.
⑨ Read pressure indicated by pressure gauge. ⑩ Press F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished.
SW354-09015
n ★ Allowable motor case pressure : 0.5 MPa (72.5 psi) or less
PG002003
9-015
INSPECTION AND ADJUSTMENT
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (TW504) 11-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from vibrator motor. Attach pressure gauge with adapter ⓝ . • Adapter ⓝ : G3/8 • 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 vibration mode change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Press F-R lever vibration switch ON. ⑦ Slowly move F-R lever to forward or reverse side. ⑧ Measure pressure when vibration Lo-Hi change switch is “ ” and “ ”, respectively. ⑨ Press F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished. ★ Allowable motor case pressure : 0.5 MPa (72.5 psi) or less
TW504-09001
n
PG002003
9-016
INSPECTION AND ADJUSTMENT
12. ADJUSTMENT OF THROTTLE LEVER 12-1. Adjustment of Linkage • In cases such as maximum no-load rotational speed or minimum no-load rotational speed deviating from standard value, control cable is replaced, or throttle lever does not move smoothly, make an adjustment in accordance with procedure described below. • Make the adjustment after amply warming up engine. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Set throttle lever (1) to “IDLE”. ② Attach control cable (4) to throttle lever (1). ③ Attach control cable (4) to fuel injection pump’s control lever.
IDLE 1
④ Start the engine. ⑤ Loosen lock nut (3). ⑥ Using stopper bolt (2), adjust so that standard minimum no-load rotational speed is achieved. ★ Standard minimum no-load rotational speed : 1,050 ± 50 rpm ⑦ Using lock nut (3), firmly secure stopper bolt (2).
2 3 4 SW354-09016
⑧ Set throttle lever (1) to “FULL”. ⑨ Loosen lock nut (6). ⑩ Using stopper bolt (5), adjust so that standard maximum no-load rotational speed is achieved. ★ Standard maximum no-load rotational speed : 2,200 ± 50 rpm
1
FULL
5 6
⑪ Using lock nut (6), firmly secure stopper bolt (5).
SW354-09030
9-017
INSPECTION AND ADJUSTMENT
12-2. Adjustment of Operating Force ① Tighten nut (7) and set operating force at center of throttle lever (1) knob to standard operating force. Do not turn nut to the loosening direction. ★ Standard operating force : 44.1 ± 6.86 N (9.9 ± 1.5 lbf)
A
(NOTICE) • In case of loosen nut (7), replace it with a new one.
A SW354-09031
1
7
SECTION A-A SW354-09017
9-018
INSPECTION AND ADJUSTMENT
13. ADJUSTMENT OF F-R LEVER 13-1. Adjustment of Linkage • In cases such as propulsion pump is replaced, control cable is replaced, or F-R lever does not move smoothly, make an adjustment in accordance with procedure described below. • “N”, maximum “F”, and maximum “R” positions of F-R lever (1) are positioned by notches. ① Set F-R lever in “N”. ② Attach control cable (2) to F-R lever.
F
N
★ Specified dimension a: 208 mm (8.19 in.)
1 R
a
2 SW354-09018
③ Attach control cable to propulsion pump control lever (3).
2
★ Specified dimension b: 208 mm (8.19 in.)
c
④ Confirm the strokes of propulsion pump control lever (3).
b
★ Specified dimension d: 23 mm (0.91 in.)
d
★ Specified dimension c: 24 mm (0.94 in.)
3
SW354-09019
9-019
INSPECTION AND ADJUSTMENT
13-2. Adjustment of Operating Force ① Loosen lock nut (7), and set screw (6) so that operating force at center of F-R lever (1) knob matches standard operating force.
1
★ Standard operating force : 34.3 ± 4.9 N (7.7 ± 1.1 lbf) • After adjustment, fix set screw (6) with lock nut (7).
A
② Loosen lock nut (5), and set screw (4) to match operating force of lever to standard operating force +14.7 N, when getting over notch at center of F-R lever knob.
A
★ Operating force to move lever over notch : 49 ± 4.9 N (11 ± 1.1 lbf)
SW354-09020
• After adjustment, fix set screw (4) with lock nut (5).
B 4,5
6,7
B
VIEW A-A
SW354-09021
4
5 6
7
SECTION B-B
9-020
SW354-09022
INSPECTION AND ADJUSTMENT
14. PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) 14-1. Measurement ① Remove cap plug (1) from manual brake release port.
1
SW354-09023
② Attach bolt (3) for forced brake releaseing. Allow bolt to be out of contact with seating surface without tightening bolt completely. (3) Bolt
SW/TW354 : M10×25 TW504 : M12×30
2
③ Leave manual brake release port open to atmosphere (brake lock state). ④ Measure distance (L1) between brake cover (2) and bolt (3) head with depth calipers.
L1
3 SW354-09024
⑤ M easure distance (L2) up to bolt (3) head with depth calipers when complete release pressure is applied to manual brake release port. Quantity of brake stroke = L2 - L1 2 (NOTICE) • When brake stroke exceeds replacement standard shown below, replace all friction plates and separation plates. ★ Standard quantity of brake stroke for replacement : 3.5 mm (0.14 in.)
L2
3 SW354-09025
9-021
INSPECTION AND ADJUSTMENT
SW504
15. MEASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE (SW504) 15-1. Measurement
WARNING Confirm that the parking brake works properly before measurement. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from high pressure gauge port (2) and (5) of propulsion pump. Attach pressure gauge with adapter ⓗ. • Adapter ⓗ : 9/16-18UNF
2
• High pressure gauge port (Forward) : (2) • High pressure gauge port (Reverse) : (5) • 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 Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, slowly move F-R lever to the side to be measured.
5 SW354-09001
h
⑧ Read pressure indicated by pressure gauge. ⑨ After measuring, promptly return F-R lever to “N”. ★ Maximum circuit pressure (high pressure relief valve setting) : 34.5 MPa (5,003 psi)
PG001014
• The numbers “2” and “5” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “6-2. Hydraulic Component Specifications” (P.4-034).
9-022
INSPECTION AND ADJUSTMENT
SW504
15-2. Inspection • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an inspection in accordance with procedure described below. 13
① Remove plug and valve from high pressure check relief valve port (13) or (14) of propulsion pump. • *High pressure relief valve (Forward) : (13) • *High pressure relief valve (Reverse) : (14) ② Check removed high pressure relief valve for trapped dirt and other abnormalities. ③ If trapped dirt is present, disassemble and clean high pressure relief valve. ④ If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned, replace high pressure relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range. N•m
14 SW354-09002
Plug
Plug : 70 N·m (52 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
High pressure relief valve SV201-1-08003
* High pressure relief valve = S.C.R. (System Check Relief) valve for charge check and high pressure relief. • The numbers “13” and “14” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “6-2. Hydraulic Component Specifications” (P.4-034).
9-023
INSPECTION AND ADJUSTMENT
SW504
16. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE (SW504) • 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 are aligned.
3
16-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from servo pressure gauge port (3) and (11) of propulsion pump. Attach pressure gauge with adapter ⓗ. • Adapter ⓗ : 9/16-18UNF • 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 Start the engine and set throttle lever to “Full”. ⑤ Read pressure indicated by pressure gauge.
SW354-09027
11
★ Standard charge relief valve setting : 1.8 ± 0.7 MPa (261 ± 100 psi)
SW354-09028
h
PG001014
• The numbers “3” and “11” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “6-2. Hydraulic Component Specifications” (P.4-034).
9-024
INSPECTION AND ADJUSTMENT
SW504
16-2. 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 (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 pressure 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 : 0.19 MPa/turn (27.6 psi/turn) ③ If there is no evidence of nut having loosened, remove charge relief valve.
15
SW354-09004
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.
1
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) Nut : 24 N·m (18 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
2
SV520-08004
• The number “15” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “6-2. Hydraulic Component Specifications” (page 4-034).
9-025
INSPECTION AND ADJUSTMENT
SW504
17. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE (SW504) • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement.
17-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion motor (F). Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Read pressure indicated by pressure gauge.
1
★ Standard charge relief valve setting : 1.8 ± 0.7 MPa (261 ± 100 psi) SW354-09005
m
PG002002
9-026
INSPECTION AND ADJUSTMENT
SW504
18. MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE (SW504) 18-1. 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. 1
• Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from vibrator motor. Attach pressure gauge through adapter ⓟ . • Adapter ⓟ : G1/2 • 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 vibratory drum select switch to “ ”. ⑤ Set vibration mode change switch to “ ⑥ Start the engine and set throttle lever to “Full”. ⑦ Press F-R lever vibration switch ON. ⑧ Slowly move F-R lever to forward or reverse side. ⑨ Read pressure gauge for maximum value of vibrator circuit pressure.
SW354-09009
p
⑩ Turn F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished. ★ Maximum circuit pressure (relief valve setting) : 14.4 MPa (2,088 psi)
PG002004
9-027
INSPECTION AND ADJUSTMENT
SW504
19. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE (SW504) 19-1. 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 Remove plug from coupling (1). Attach pressure gauge with hose ⓢ and connector ⓤ . • Coupling : 9/16-18UNF×M16 • Adapter for hose ⓢ • Pressure gauge connector ⓤ • Pressure gauge
Hydraulic oil filter
: M16 P=2.0 : M16×G3/8 :0 to 25 MPa (0 to 3,625 psi)
② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Turn steering wheel to operate relief valve. ⑥ Read pressure indicated by pressure gauge. ★ Standard maximum circuit pressure (orbitroll relief pressure) : 13.5 MPa (1,958 psi)
1 SW504-09001
s
u
PG003163
9-028
SW504
INSPECTION AND ADJUSTMENT
19-2. 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.
2
ORB-ET-09140
9-029
INSPECTION AND ADJUSTMENT
SW504
20. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE (SW504) 20-1. Measurement of Propulsion Pump Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion pump. Attach pressure gauge through adapter ⓠ . • Adapter ⓠ : G3/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively.
1 SW504-09002
” and
★ Allowable pump case pressure : 0.25 MPa (36.3 psi) or less
q
PG002006
9-030
INSPECTION AND ADJUSTMENT
SW504
21. ADJUSTMENT OF THROTTLE LEVER (SW504) 21-1. Adjustment of Potentiometer • If potentiometer (1) is replaced, make following adjustments. • Make adjustments after amply warmed engine. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Insert potentiometer shaft in the groove on shaft (2), and fix it with two screws (4). (NOTICE) • When fixing potentiometer (1), position the potentiometer in the direction shown, mounting the potentiometer parallel to the base (5).
1
2
② Tighten screws (4) with wire (3).
4
5
3 SW504-09003
③ Set throttle lever (6) to “IDOL”. ④ Adjust engine rotational speed to standard value.
FULL
IDLE
6
★ Engine rotational speed : 1,000 - 50 min-1 ⑤ Set throttle lever to “FULL”. ⑥ Loosen lock nut (7), and adjust engine rotational speed to standard value with stopper bolt (8). ★ Engine rotational speed : 2,550 ± 50 min-1 • After adjustment, fix stopper bolt (8) with lock nut (7).
7 8 SW504-09005
9-031
INSPECTION AND ADJUSTMENT
SW504
21-2. Adjustment of Operating Force ① Tighten nut (9) and set operating force at center of throttle lever (6) knob to standard operating force. Do not turn nut to the loosening direction.
6
★ Standard operating force : 45 ± 10 N (10 ± 2 lbf) (NOTICE) • In case of loosen nut (9), replace it with a new one.
B
B SW504-09006
SECTION B-B
9 SW504-09007
9-032
INSPECTION AND ADJUSTMENT
SW504
22. ADJUSTMENT OF F-R LEVER (SW504) 22-1. Adjustment of Linkage • In cases such as propulsion pump is replaced, control cable is replaced, or F-R lever does not move smoothly, make an adjustment in accordance with procedure described below. • “N”, maximum “F”, and maximum “R” positions of F-R lever (1) are positioned by notches. ① Set F-R lever in “N”. ② Attach control cable (2) to F-R lever.
F
N
★ Specified dimension a: 210 mm (8.27 in.)
1 R
a
2 SW354-09018
③ Attach control cable (2) to propulsion pump control lever (3).
2
★ Specified dimension b: 198 mm (7.80 in.)
c c
★ Specified dimension c: 24 mm (0.94 in.)
b
④ Confirm the strokes of propulsion pump control lever (3).
3
SW504-09008
9-033
INSPECTION AND ADJUSTMENT
• MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE Refer to (P.9-007). • MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE Refer to (P.9-013). Refer to (P.9-016). • MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE • PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) Refer to (P.9-021).
9-034
SW504
TROUBLESHOOTING
TROUBLESHOOTING
1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time. • Make sure that no one can enter any hazardous area.
CAUTION Do not work on the hydraulic system while the engine is running and the system is hot and under pressure. Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved. Before removing any plugs from the pressure measurement ports, always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure.
WARNING Inadvertent starting the engine may cause a serious accident. When inspecting the engine, make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents.
CAUTION Before inspecting inside of the engine compartment, always stop the engine. Contact with the fan, V-belt or exhaust system parts while the engine is running may cause serious injury.
1-2. Important Information for Troubleshooting Before conducting troubleshooting, it is important to carefully read the operation manual and workshop manual and understand the electric circuits for each component as well as the structure and function of each system. Sufficient knowledge of the systems will enable you to identify a possible cause much faster. A fault or problem may seem to be related to many different factors. To identify the true cause, some experience is needed. To perform the appropriate troubleshooting, it is important to learn not only the normal operations of the systems but also the possible symptoms that may occur when an abnormal condition is present. This chapter explains the possible causes and remedies for likely incidents taken from past experience.
10-001
TROUBLESHOOTING
1-3. Before Starting The information in this section is provided to assist the troubleshooter in understanding the systems and quickly determine the causes when operating abnormalities occur. The following steps are recommended: 1. If not familiar with the machine, study the Operator’s Manual and this Shop Manual. 2. Check with the operator for full details of the trouble, ask questions. 3. Verify the trouble by warming up the machine and operating it. Check the problem yourself. 4. Identify the problem with either a mechanical, hydraulic or electrical system source. 5. Isolate the problem to a particular component or circuit. 6. Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components. 7. Following repair or replacement of any parts, perform operational tests to verify that the problem has been eliminated and the performance of all the systems is normal.
10-002
TROUBLESHOOTING
2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis WARNING Be very careful because equipment can return to normal during an inspection and suddenly operate properly when a failure occurs due to a faulty contact or other such cause.
2-1-1. Precautions to take during electrical circuit fault diagnosis • When disconnecting or connecting a connector, be sure to turn the power supply OFF. (Electronic control parts such as the engine control unit, in particular, could be damaged internally.) • Since connectors are not numbered, be sure to affix alignment marks so that you can restore them to their original condition. • Before making a diagnosis, check related connectors for faulty connections. (Check by disconnecting and reconnecting related connectors several times.) • Before proceeding to the next step, be sure to return the disconnected connectors to their original condition. • When diagnosing a circuit (measuring the voltage, resistance, continuity and current), move related wiring and connectors several times, and check whether the tester’s numerical values change. (If values change, faulty contact in the circuit is possible.) • Do not ground the circuit of the control unit or apply voltage to it unless otherwise specified. • For information of wire number, wire size, and wire color used in the sample circuit diagrams, refer to "1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses" (P.5-001).
10-003
TROUBLESHOOTING
2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below.
Equipment A
1
5
Main power source of equipment B
1
2
3
2
3
4
Ground of equipment A
Power to equipment A
Signal from equipment A
Battery Equipment B
TS-10001
1) Measuring resistance using tester 1-1) Measuring resistance of equipment A (measuring resistance between terminals 1 and 3)
Equipment A Connector
Harness 1
Equipment A
2
3
1
2
3
2
3
4
Ohmmeter (tester) 1
2
3 1
5
Main power source of equipment B
Ground of equipment A
Signal from Power to equipment A equipment A
Equipment B TS-10002
Inspection procedure ① Disconnect the connector of equipment A. ② Connect the test probe (+) to connector terminal 1 of equipment A and the test probe (-) to connector terminal 3 of equipment A and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement.
10-004
TROUBLESHOOTING 1-2) Measuring resistance of harness (measuring resistance between terminal 1 of equipment A and terminal 2 of equipment B) Connector A
Harness
Connector B
Equipment A
Equipment A
Equipment B
3
2
1
5
4
3
2
Ohmmeter (tester)
1
2
3
1
2
3
2
3
4
1
1
5
Main power source of equipment B
Ground of equipment A
Signal from Power to equipment A equipment A
Equipment B
TS-10003
Inspection procedure ① Disconnect the connectors of equipment A and equipment B. ② Connect the test probe (+) to connector terminal 1 of equipment A and the test probe (-) to connector terminal 2 of equipment B and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement. Criteria for harness defects When there is no abnormality in the harness: Less than 10 Ω (measured value) If there is any abnormality in the harness such as broken wire: 10 Ω or higher (measured value) 1-3) Measuring resistance of grounding wire (measuring resistance between terminal 5 of equipment B and ground) Connector A Harness Equipment B
5
4
3
2
1
1
Battery
5
Ohmmeter (tester)
Main power source of equipment B
Equipment B TS-10004
Inspection procedure ① Disconnect the connector of equipment B. ② Connect the test probe (+) to connector terminal 5 of equipment B and the test probe (-) to a machine ground point (the bolt fastening the ground terminal or an unpainted portion on the body) and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement. (NOTICE) • When measuring the resistance, connect the test probes to both ends of the portion to be measured. Make also sure that no voltage is applied to the portion to be measured. • When measuring the internal resistance of equipment, be sure first to disconnect all harnesses from the equipment. • When measuring the resistance of a harness, disconnect the equipment connected to both ends of the harness. 10-005
TROUBLESHOOTING 2) Measuring voltage and current flowing using tester 2-1) Measuring voltage of equipment A (measuring voltage between terminals 1 and 3)
Equipment A
Equipment A
Equipment B
1
2
Voltmeter (tester)
1
2
3
2
3
4
3 1
5
Main power source of equipment B
Ground of equipment A
Signal from equipment A
Power to equipment A
Equipment B TS-10005
Inspection procedure ① Connect the connectors of equipment A and that of equipment B. ② Connect the test probe (+) to connector terminal 3 of equipment A and the test probe (-) to connector terminal 1 of equipment A and measure the voltage. Note that reversing the connector terminals between the probes (+) and (-) changes the result of the measurement. Be sure to connect the probe (+) to the power source side and the probe (-) to the ground side.
10-006
TROUBLESHOOTING Measurement using a test harness Test harness
Equipment A
Equipment B
1
2
3
Measurement from the backside of connector
Measurement on a lead cable
Test probe Connector
Wire
Needle
Lead cable
TS-10006
Measurement method For measurement of voltage, connect the tester probes in parallel to the portion to be measured. Because the voltage can be measured only when the connector is connected in position, contact the tester probes to the terminals without disconnecting the connector. The following methods are available: • Measurement using a test harness Prepare the test harness for the measurement. • Measurement from the backside of connector Insert a wire from the backside of the connector. • Measurement on a lead cable Remove the bundling tape from the harness to separate each cable, and stick the needle into the relevant cable. (NOTICE) • Except for preparing the test harness, proper protection must be made after the measurement to prevent corrosion in the connector terminals or harnesses. 10-007
TROUBLESHOOTING 2-2) Measuring current flowing from equipment B to equipment A (measuring current between terminal 2 of equipment B and terminal 1 of equipment A)
Test harness Equipment A Equipment A
Equipment B 1
Ammeter (tester) 1
2
3
3
2
3
1
2
3
2
3
4
Harness (connecting terminals)
1
1
The test harness connects the corresponding terminals other than those to be measured.
2
5
Main power source of equipment B
Ground of Signal from Power to equipment A equipment A equipment A
Equipment B TS-10007
Inspection procedure ① Disconnect the connector of equipment A and connect the test harness. ② Connect the test probe (+) to connector terminal 1 (harness side) of equipment A and the test probe (-) to connector terminal 1 (equipment side) of equipment A and measure the current. Note that reversing the connector terminals between the probes (+) and (-) changes the result of the measurement. Be sure to connect the probe (+) to the power source side and the probe (-) to the ground side. Measurement method When measuring the current, connect the tester in series to the portion to be measured. Because the current cannot be measured when the connector is connected in position, disconnect the connector to allow the test probe to connect between the terminals.
10-008
TROUBLESHOOTING
2-1-3. Inspection of electrical system Operate the applicable switches and turn the relays ON and OFF. Ultimately, if the solenoid valve operates (makes a sound) and the pump runs, the electrical system is OK. If there is a failure (fault), narrow the range of the inspection to the six broad steps described below. 1) Ground inspection • Check for disconnected or loose ground. If rust or corrosion is present (which can cause faulty contact), remove the rust. 2) Fuse inspection 2-1) Check for blown fuses, disconnections and corrosion. (A fatigue open circuit cannot be identified visually. Use a tester for checking.) 2-2) If a fuse is blown Check whether a pump or valve (that is supposed to be protected by a blown fuse) burned, and whether there is a burning odor. Especially if the pump and valve are not burned, check the harness for signs of burning. If it is burned, replace it. If a fuse is blown and a relay along the pathway has failed, replace it. And if there is a timer, replace the timer, too. If a switch visually appears to be unsatisfactory (burned, melted, etc.) even though it operates, replace it. • Simply replacing a fuse may not eliminate the true cause of a problem, and over current may flow again. Also, if over current secondarily causes an electrical path to fail (such as a wiring meltdown inside a solenoid valve), current will not flow. Thus, a fuse may not be blown out, but it also will not operate. If you do not know the location of burning or of an odor, investigate as described follows. 2-3) How to find cause of failure when fuse blown is reproduced ① Turn the starter switch OFF, and remove the connector from the load (valve, pump). ② Referring to the circuit diagram, remove electrical parts that are connected to the circuit, such as relays, timers and diodes. ③ Turn the starter switch ON, and see whether the conditions can be reproduced (fuse is blown). ④ If a fuse is blown, a part such as a relay may have caused a short between the previous harness and ground (vehicle body). (Replace the harness.) If the conditions are not reproduced, check for signs of burning (odor) on the removed electrical parts. ⑤ If there is no problem, turn the starter switch OFF and reattach the parts. ⑥ Turn the starter switch ON and try again. ⑦ If a fuse is blown with this action, the problem was caused by a short between the harness and ground (vehicle body) that followed the attached electrical part. (Replace the harness.) ⑧ If the conditions are not reproduced, turn the starter switch OFF, and connect the loads (valve and pump) one at a time. Turn the starter switch ON and try again to see whether the fuse blown is reproduced. ⑨ If the fuse blown is reproduced, whatever was added at that time (including a harness added electrically) will be the cause of the failure. • Even if the fuse is not blown and the valve or pump is not burned, the valve or pump may be damaged electrically and may not operate. There may simply be a disconnection in the interior or an abnormal heat-up. • Even if the fuse is not blown, abnormal heat-up (hot enough to cause burns if touched) may occur if a relay, timer, diode or other semiconductor fails.
10-009
TROUBLESHOOTING 3) Connector inspection • Is a connector disconnected or loose? • Check that pins are not snapped or corroded. • If faulty contact is suspected Turn the starter switch OFF. Then disconnect and check the connectors (including relay and switch sockets). If the terminal has no luster, faulty contact due to oxidation can be suspected. Therefore, polish the terminal by inserting and removing the connector (relay, switch) repeatedly at least five times. (Luster will return.) 4) Relay inspection (Check ON/OFF operation by sound.) • Conduct without running the engine. (If you run the engine, you cannot hear the sound of operation.) Sound heard : A relay failure occurred. No sound heard : Using a tester, check the harness. Sound heard : A relay failure occurred. Still no sound : Using a tester, check the harness. Continuity : Turn the starter switch OFF temporarily, disconnect the relay and check for continuity between the harness-side grounding terminal (color: black) and vehicle body ground. (If there is none, replace the harness.) Voltage : With the relay disconnected, turn the starter switch ON and turn the operating switch ON. 24 V (or 12 V) (between vehicle body ground) should not reach the relay coil input terminal. Confirm this. Identify the location (section) to which 24 V (or 12 V) reaches. Then replace the harness or take other action. 5) Solenoid valve inspection (Check ON/OFF operation by sound.) • Conduct without running the engine. (If you run the engine, you cannot hear the sound of operation.) Sound heard : The electrical system is normal. No sound heard : Check with a tester. Continuity : ① Turn the starter switch OFF temporarily, disconnect the connector and check for continuity between the harness-side grounding terminal (color: black) and vehicle body ground. (If there is none, replace the harness.) : ② Is the solenoid valve coil burnt? (Turn the starter switch OFF, disconnect the connector and check the resistance between the solenoid valve terminals.) Voltage : With the connector disconnected, turn the starter switch ON and check whether 24 V (or 12 V) exists between the harness-side connector and vehicle body ground. If YES : Replace the valve. If NO : Investigate and identify the location (section) to which 24 V (or 12 V) reaches. Then replace the harness or take other action. 6) Harness check • If an incomplete disconnection inside the harness is suspected, wiggle (move) the harness during the relay inspection and solenoid valve inspection to see whether the relay (valve) operates incorrectly. • Check for burned areas of the harness. • Turn the starter switch OFF, disconnect the connector and check the continuity, referring to the circuit diagram and wiring coloring.
10-010
TROUBLESHOOTING
Fig.: 2-2-1
R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH NC
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
27 GY
1
NO COM
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH
TO WATER SPRAY MODE SELECT SWITCH, VIBRATOR RELAY
TO BRAKE LAMP RELAY
300 3BW
f
c
e
302 LgR a 300 3BW 5
3
2
1
b
INTERLOCK RELAY
25 3W
B
26 3BR B
301 Y
PARKING INTERLOCK RELAY
ON
1
2
3
4
5
ST 11 BrB 2 5WR 14 WL
ACC
C
32 3BY 16 3W
R2
B 3 LgR
R1 10 5WG
13 2Y
BR
STARTER SWITCH
TO TACHO METER SENSOR
F.L.
2 WR
8 5R
5A FUSE
65A
12 Y
7 5WR
TO COMBINATION METER
FUSE BOX
16 3W
OFF
GLOW LAMP TIMER
11
R 1 R 2 A CC B R C
12
B HEAT
8 5R
3
14
4
5
22 RB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
STARTER SWITCH 6
6
10 5WG
7
10 WG
13
GLOW PLUGS
14 WL
24 RY
10 WG
8
52 YW
25 3W
TO COMBINATION METER
9
B
10
10 5WG
22 RB
TO COMBINATION METER
17 WR
IG
L
R
13 2Y
FUEL PUMP
28 8WY
B B
B
E
ALTERNATOR 22 RB
SOL
32 3BY
3 LgR
15A
4 LgW
AV60 NO
AV60
COM
+ B
Lg
W
BR
4
S
AV60
28 8WY
26 5BR
7
5
WR
ENGINE STOP SOLENOID
STARTER MOTOR
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10001
10-011
TROUBLESHOOTING
2-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked.
2-2-1. Engine will not start (Starter motor does not run) 1/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-2-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. Starter Switch
• Check continuity between O-O according to starter switch Replace starter switch. connection table. Switch is OK if there is continuity between connection O-O. • If there is no continuity, starter switch is faulty.
3. Starter Motor
(1) W hen starter switch is ON, measure voltage between starter motor terminal B and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter motor terminal S and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and starter motor does not run, starter motor is faulty.
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 voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between battery relay coil terminal BR inlet wire LgW and coil ground terminal outlet wire B. 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.
Replace starter motor.
10-012
TROUBLESHOOTING
Fig.: 2-2-1
R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH NC
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
27 GY
1
NO COM
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH
TO WATER SPRAY MODE SELECT SWITCH, VIBRATOR RELAY
TO BRAKE LAMP RELAY
300 3BW
f
c
e
302 LgR a 300 3BW 5
3
2
1
b
INTERLOCK RELAY
25 3W
B
26 3BR B
301 Y
PARKING INTERLOCK RELAY
ON
1
2
3
4
5
ST 11 BrB 2 5WR 14 WL
ACC
C
32 3BY 16 3W
R2
B 3 LgR
R1 10 5WG
13 2Y
BR
STARTER SWITCH
TO TACHO METER SENSOR
F.L.
2 WR
8 5R
5A FUSE
65A
12 Y
7 5WR
TO COMBINATION METER
FUSE BOX
16 3W
OFF
GLOW LAMP TIMER
11
R 1 R 2 A CC B R C
12
B HEAT
8 5R
3
14
4
5
22 RB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
STARTER SWITCH 6
6
10 5WG
7
10 WG
13
GLOW PLUGS
14 WL
24 RY
10 WG
8
52 YW
25 3W
TO COMBINATION METER
9
B
10
10 5WG
22 RB
TO COMBINATION METER
17 WR
IG
L
R
13 2Y
FUEL PUMP
28 8WY
B B
B
E
ALTERNATOR 22 RB
SOL
32 3BY
3 LgR
15A
4 LgW
AV60 NO
AV60
COM
+ B
Lg
W
BR
4
S
AV60
28 8WY
26 5BR
7
R 5W
ENGINE STOP SOLENOID
STARTER MOTOR
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10001
10-013
TROUBLESHOOTING
2-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-2-1 Check point 5. Interlock Relay
Check/Cause
Action
(1) W hen starter switch is ON, measure voltage between interlock relay terminal a inlet wire LgR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between interlock relay terminal c inlet wire BW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between interlock relay terminal e 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, interlock relay is faulty.
Replace interlock relay.
6. Parking Interlock Relay (1) W hen starter switch is ON, measure voltage between parking interlock relay terminal 1 inlet wire Y 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 W 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 BW 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.
7. F-R Lever Switch
(1) W hen starter switch is ON, measure voltage between F-R lever switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal outlet wire LgR 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.
Replace F-R lever switch.
8. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire RW 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.
10-014
TROUBLESHOOTING
Fig.: 2-2-1
R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH NC
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
27 GY
1
NO COM
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH
TO WATER SPRAY MODE SELECT SWITCH, VIBRATOR RELAY
TO BRAKE LAMP RELAY
300 3BW
f
c
e
302 LgR a 300 3BW 5
3
2
1
b
INTERLOCK RELAY
25 3W
B
26 3BR B
301 Y
PARKING INTERLOCK RELAY
ON
1
2
3
4
5
ST 11 BrB 2 5WR 14 WL
ACC
C
32 3BY 16 3W
R2
B 3 LgR
R1 10 5WG
13 2Y
BR
STARTER SWITCH
TO TACHO METER SENSOR
F.L.
2 WR
8 5R
5A FUSE
65A
12 Y
7 5WR
TO COMBINATION METER
FUSE BOX
16 3W
OFF
GLOW LAMP TIMER
11
R 1 R 2 A CC B R C
12
B HEAT
8 5R
3
14
4
5
22 RB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
STARTER SWITCH 6
6
10 5WG
7
10 WG
13
GLOW PLUGS
14 WL
24 RY
10 WG
8
52 YW
25 3W
TO COMBINATION METER
9
B
10
10 5WG
22 RB
TO COMBINATION METER
17 WR
IG
L
R
13 2Y
FUEL PUMP
28 8WY
B B
B
E
ALTERNATOR 22 RB
SOL
32 3BY
3 LgR
15A
4 LgW
AV60 NO
AV60
COM
+ B
Lg
W
BR
4
S
AV60
28 8WY
26 5BR
7
R 5W
ENGINE STOP SOLENOID
STARTER MOTOR
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10001
10-015
TROUBLESHOOTING
2-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-2-1 Check point
Check/Cause
Action
9. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between parking brake switch terminal 1 inlet wire RW 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 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.
10. 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.
2-2-2. Engine will not start (But starter motor runs) • In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate. • Check that fuel is supplied to inlet of fuel pump. Reference Fig.: 2-2-1 Check point
Check/Cause
Action
1. Fuel Pump
• When starter switch is ON, measure voltage between fuel Repair or replace fuel pump terminal inlet wire RB and chassis ground. pump. Standard voltage : 12 V or more • If above item is OK and fuel pump does not operate, fuel pump is faulty.
2. Engine Stop Solenoid
Replace engine stop (1) W hen starter switch is ON, measure voltage between engine stop solenoid terminal inlet wire RB and chassis solenoid. ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between engine stop solenoid terminal inlet wire BY and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and engine does not start, engine stop solenoid is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-016
TROUBLESHOOTING
Fig.: 2-2-1
R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH NC
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
27 GY
1
NO COM
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH
TO WATER SPRAY MODE SELECT SWITCH, VIBRATOR RELAY
TO BRAKE LAMP RELAY
300 3BW
f
c
e
302 LgR a 300 3BW 5
3
2
1
b
INTERLOCK RELAY
25 3W
B
26 3BR B
301 Y
PARKING INTERLOCK RELAY
ON
1
2
3
4
5
ST 11 BrB 2 5WR 14 WL
ACC
C
32 3BY 16 3W
R2
B 3 LgR
R1 10 5WG
13 2Y
BR
STARTER SWITCH
TO TACHO METER SENSOR
F.L.
2 WR
8 5R
5A FUSE
65A
12 Y
7 5WR
TO COMBINATION METER
FUSE BOX
16 3W
OFF
GLOW LAMP TIMER
11
R 1 R 2 A CC B R C
12
B HEAT
8 5R
3
14
4
5
22 RB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
STARTER SWITCH 6
6
10 5WG
7
10 WG
13
GLOW PLUGS
14 WL
24 RY
10 WG
8
52 YW
25 3W
TO COMBINATION METER
9
B
10
10 5WG
22 RB
TO COMBINATION METER
17 WR
IG
L
R
13 2Y
FUEL PUMP
28 8WY
B B
B
E
ALTERNATOR 22 RB
SOL
32 3BY
3 LgR
15A
4 LgW
AV60 NO
AV60
COM
+ B
Lg
W
BR
4
S
AV60
28 8WY
26 5BR
7
R 5W
ENGINE STOP SOLENOID
STARTER MOTOR
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10001
10-017
TROUBLESHOOTING
2-2-3. Engine does not stop running Reference Fig. : 2-2-1 Check point
Check/Cause
Action
1. Engine Stop Solenoid
(1) W hen starter switch is OFF, measure voltage between Replace engine stop engine stop solenoid terminal inlet wire RB and chassis solenoid. ground. There is no electricity in normal condition (2) W hen starter switch is OFF, measure voltage between engine stop solenoid terminal inlet wire BY and chassis ground. There is no electricity in normal condition • If above items (1) and (2) are OK and engine does not stop after started, engine stop solenoid is faulty.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-2-4. No charging Reference Fig.: 2-2-1 Check point 1. Alternator
Check/Cause
Action
• After starting engine, measure voltage between alternator Replace alternator or terminal B wire WY 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.
2-2-5. Glow plugs is not heated (Engine starting performance is bad in cold weather) Reference Fig. : 2-2-1 Check point
Check/Cause
Action
1. Glow Plugs
• When starter switch is ON, measure voltage between glow plugs terminal inlet wire WG and chassis ground. Standard voltage : 12 V or more • If voltage is OK, glow plugs is faulty.
Replace glow plugs.
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. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-018
TROUBLESHOOTING
Fig.: 2-2-1
R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH NC
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
27 GY
1
NO COM
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH
TO WATER SPRAY MODE SELECT SWITCH, VIBRATOR RELAY
TO BRAKE LAMP RELAY
300 3BW
f
c
e
302 LgR a 300 3BW 5
3
2
1
b
INTERLOCK RELAY
25 3W
B
26 3BR B
301 Y
PARKING INTERLOCK RELAY
ON
1
2
3
4
5
ST 11 BrB 2 5WR 14 WL
ACC
C
32 3BY 16 3W
R2
B 3 LgR
R1 10 5WG
13 2Y
BR
STARTER SWITCH
TO TACHO METER SENSOR
F.L.
2 WR
8 5R
5A FUSE
65A
12 Y
7 5WR
TO COMBINATION METER
FUSE BOX
16 3W
OFF
GLOW LAMP TIMER
11
R 1 R 2 A CC B R C
12
B HEAT
8 5R
3
14
4
5
22 RB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
STARTER SWITCH 6
6
10 5WG
7
10 WG
13
GLOW PLUGS
14 WL
24 RY
10 WG
8
52 YW
25 3W
TO COMBINATION METER
9
B
10
10 5WG
22 RB
TO COMBINATION METER
17 WR
IG
L
R
13 2Y
FUEL PUMP
28 8WY
B B
B
E
ALTERNATOR 22 RB
SOL
32 3BY
3 LgR
15A
4 LgW
AV60 NO
AV60
COM
+ B
Lg
W
BR
4
S
AV60
28 8WY
26 5BR
7
R 5W
ENGINE STOP SOLENOID
STARTER MOTOR
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10001
10-019
TROUBLESHOOTING
2-2-6. Starter motor runs even when F-R lever is not at “N” Reference Fig. : 2-2-1 Check point 1. F-R Lever Switch
Check/Cause • When starter switch is OFF and F-R lever is “F” or “R”, check continuity between F-R lever switch terminal wire RY and terminal wire LgR. There is no continuity in normal condition. • If there is continuity, F-R lever switch is faulty.
Action Replace F-R lever switch.
10-020
TROUBLESHOOTING
Fig.: 2-3-1
33 LgW
STOP
40 WB
R
R
R
SOL
R
SOL
PARKING BRAKE SOLENOID
FOOT BRAKE SWITCH
B
B
SPEED CHANGE SOLENOID
TO COMBINATION METER
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
R
W
B
60 BrY
24 RY
TO PARKING INTERLOCK RELAY
41 RW
NC NO COM
TO BRAKE LAMP RELAY
5
PARKING BRAKE SWITCH 33 LgW
3
24 RY 1
2
SPEED CHANGE SWITCH SPEED CHANGE SWITCH CONNECTION
1
2
3
4
5
6
7
11
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-2
8
24 RY
1-3
9
SPEED
B C
ACC B
3 LgR BR
R2 R1
7 5WR
STARTER SWITCH
2 5WR
F.L.
65A
8 5R
FUSE BOX
R 1 R 2 A CC B R C
HEAT OFF ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10002
10-021
TROUBLESHOOTING
2-3. 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.10-006 to P.10-008). • Check any ground circuit which belongs to components to be checked.
2-3-1. Machine moves neither forward nor backward • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-3-1 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard resistance : 9.0 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 RW 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 WB 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. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire RW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
Replace foot brake switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-022
TROUBLESHOOTING
Fig.: 2-3-1
33 LgW
STOP
40 WB
R
R
R
SOL
R
SOL
PARKING BRAKE SOLENOID
FOOT BRAKE SWITCH
B
B
SPEED CHANGE SOLENOID
TO COMBINATION METER
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
R
W
B
60 BrY
24 RY
TO PARKING INTERLOCK RELAY
41 RW
NC NO COM
TO BRAKE LAMP RELAY
5
PARKING BRAKE SWITCH 33 LgW
3
24 RY 1
2
SPEED CHANGE SWITCH SPEED CHANGE SWITCH CONNECTION
1
2
3
4
5
6
7
11
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-2
8
24 RY
1-3
9
SPEED
B C
ACC B
3 LgR BR
R2 R1
7 5WR
STARTER SWITCH
2 5WR
F.L.
65A
8 5R
FUSE BOX
R 1 R 2 A CC B R C
HEAT OFF ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10002
10-023
TROUBLESHOOTING
2-3-2. Machine speed cannot be changed • Speed change switch must be “ Reference Fig.: 2-3-1 Check point
”. Check/Cause
Action
1. Speed Change Solenoid
• Disconnect harness and measure resistance of coil. Standard resistance : 9.0 Ω • If measured resistance is abnormal, speed change solenoid is faulty.
Replace speed change solenoid.
2. Speed Change Switch
(1) W hen starter switch is ON, measure voltage between speed change switch terminal 1 inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between speed change switch terminal 2 outlet wire LgW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and (2) is NG, speed change switch is faulty.
Replace speed change switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-024
TROUBLESHOOTING
Fig.: 2-3-1
33 LgW
STOP
40 WB
R
R
R
SOL
R
SOL
PARKING BRAKE SOLENOID
FOOT BRAKE SWITCH
B
B
SPEED CHANGE SOLENOID
TO COMBINATION METER
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
R
W
B
60 BrY
24 RY
TO PARKING INTERLOCK RELAY
41 RW
NC NO COM
TO BRAKE LAMP RELAY
5
PARKING BRAKE SWITCH 33 LgW
3
24 RY 1
2
SPEED CHANGE SWITCH SPEED CHANGE SWITCH CONNECTION
1
2
3
4
5
6
7
11
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-2
8
24 RY
1-3
9
SPEED
B C
ACC B
3 LgR BR
R2 R1
7 5WR
STARTER SWITCH
2 5WR
F.L.
65A
8 5R
FUSE BOX
R 1 R 2 A CC B R C
HEAT OFF ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10002
10-025
TROUBLESHOOTING
2-3-3. Brake cannot be released • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-3-1 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard resistance : 9.0 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 RW 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 WB 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. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire RW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
Replace foot brake switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-026
TROUBLESHOOTING
Fig.: 2-3-1
33 LgW
STOP
40 WB
R
R
R
SOL
R
SOL
PARKING BRAKE SOLENOID
FOOT BRAKE SWITCH
B
B
SPEED CHANGE SOLENOID
TO COMBINATION METER
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
R
W
B
60 BrY
24 RY
TO PARKING INTERLOCK RELAY
41 RW
NC NO COM
TO BRAKE LAMP RELAY
5
PARKING BRAKE SWITCH 33 LgW
3
24 RY 1
2
SPEED CHANGE SWITCH SPEED CHANGE SWITCH CONNECTION
1
2
3
4
5
6
7
11
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-2
8
24 RY
1-3
9
SPEED
B C
ACC B
3 LgR BR
R2 R1
7 5WR
STARTER SWITCH
2 5WR
F.L.
65A
8 5R
FUSE BOX
R 1 R 2 A CC B R C
HEAT OFF ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10002
10-027
TROUBLESHOOTING
2-3-4. Brake does not work • Parking brake switch must be applied. • Brake pedal is depressed. Reference Fig.: 2-3-1 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard resistance : 9.0 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 WB and chassis ground. There is no electricity in normal condition. • If there is electricity, parking brake switch is faulty.
Replace parking brake switch.
3. Foot Brake Switch
• When starter switch is ON, measure voltage between foot Replace foot brake brake switch terminal outlet wire RW and chassis ground. switch. There is no electricity in normal condition. • If there is electricity, foot brake switch is faulty.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-028
TROUBLESHOOTING
Fig.: 2-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
47 LgR
4
23 RL
B
VIBRATOR SOLENOID (F)
VIBRATION MODE SELECT SWITCH
49 LgB
CONNECTION 1-2,4-6
45 Br
VIBRATOR SOLENOID (R) SW354 (Except ROPS type)
NC NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
23 RL
NO
B
G
TO COMBINATION
51 Br
46 BrR METER
46 BrR
46 BrR
43 RW 45 Br
3
2
1
23 RL
47 LgR
47 LgR
6
VIBRATORY DRUM SELECT SWITCH
B
VIBRATORY DRUM SELECT SWITCH
VIBRATOR SOLENOID (F)
POSITION
49 LgB
CONNECTION
B
1-3,4-6 1-3,4-5
D
B
VIBRATOR SOLENOID (R)
SW354 (ROPS type)
R
F
G E F
46 BrR
SOL
27 GY
H
B
SOL
1-2,4-6
VIBRATOR RELAY
46 BrR
5
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
2
4
F-R LEVER VIBRATION SWITCH (L)
49 LgB
3
1
NC
C Br
B
SOL
1-3,4-5
C Br
46 BrR
B
1-3,4-6 AUTO
B
SOL
VIBRATION MODE SELECT SWITCH
VIBRATION
46 BrR
B
47 LgR
46 BrR
B
B
SOL VIBRATOR SOLENOID TW354
F-R LEVER SWITCH NC
NO COM
B 24 RY
3
47 LgR
2
48 LgY
1
1 HI
6
4 27 GY
302 LgR
R
W
23 RL 1
2
SOL
LOW 2 46 BrR
5
VIBRATION Lo-Hi CHANGE SWITCH
VIBRATOR SOLENOID
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
VIBRATION
CONNECTION
1
2
3
4
5
6
23 RL 8
TW504 7
24 RY 9
1-2
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-3
FUSE BOX STARTER SWITCH B
2 5WR
R 1 R 2 A CC B R C
HEAT C B
R2 R1
8 5R
65A F.L.
ON
3 LgR BR
7 5WR
OFF
ACC
ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10003
10-029
TROUBLESHOOTING
2-4. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle lever must be “FULL”. • Check any ground circuit which belongs to components to be checked.
2-4-1. No vibration occurs 1/2 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 2-4-1 Check point
Check/Cause
Action
1. Vibrator Solenoid
• Disconnect harness and measure resistance of coil. Standard resistance SW/TW354 : 8.6 to 8.8 Ω TW504 : 5.42 Ω • If measured resistance is abnormal, vibrator solenoid is faulty.
Replace vibrator solenoid.
2. Vibration Mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace vibration mode vibration mode select switch terminal 4 inlet wire RL select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration mode select switch terminal 5 outlet wire BrY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration mode select switch is faulty.
3. Vibratory Drum Select Switch (SW354 ROPS)
(1) W hen starter switch is ON, measure voltage between vibratory drum select switch terminal 1 inlet wire RL, terminal 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR, terminal 3 outlet wire LgB and chassis ground. There is no electricity in normal condition. (4) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 3 outlet wire LgB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibratory drum select switch is faulty.
Replace vibratory drum select switch.
10-030
TROUBLESHOOTING
Fig.: 2-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
47 LgR
4
23 RL
B
VIBRATOR SOLENOID (F)
VIBRATION MODE SELECT SWITCH
49 LgB
CONNECTION 1-2,4-6
45 Br
VIBRATOR SOLENOID (R) SW354 (Except ROPS type)
NC NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
23 RL
NO
B
G
TO COMBINATION
51 Br
46 BrR METER
46 BrR
46 BrR
43 RW 45 Br
3
2
1
23 RL
47 LgR
47 LgR
6
VIBRATORY DRUM SELECT SWITCH
B
VIBRATORY DRUM SELECT SWITCH
VIBRATOR SOLENOID (F)
POSITION
49 LgB
CONNECTION
B
1-3,4-6 1-3,4-5
D
B
VIBRATOR SOLENOID (R)
SW354 (ROPS type)
R
F
G E F
46 BrR
SOL
27 GY
H
B
SOL
1-2,4-6
VIBRATOR RELAY
46 BrR
5
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
2
4
F-R LEVER VIBRATION SWITCH (L)
49 LgB
3
1
NC
C Br
B
SOL
1-3,4-5
C Br
46 BrR
B
1-3,4-6 AUTO
B
SOL
VIBRATION MODE SELECT SWITCH
VIBRATION
46 BrR
B
47 LgR
46 BrR
B
B
SOL VIBRATOR SOLENOID TW354
F-R LEVER SWITCH NC
NO COM
B 24 RY
3
47 LgR
2
48 LgY
1
1 HI
6
4 27 GY
302 LgR
R
W
23 RL 1
2
SOL
LOW 2 46 BrR
5
VIBRATION Lo-Hi CHANGE SWITCH
VIBRATOR SOLENOID
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
VIBRATION
CONNECTION
1
2
3
4
5
6
23 RL 8
TW504 7
24 RY 9
1-2
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-3
FUSE BOX STARTER SWITCH B
2 5WR
R 1 R 2 A CC B R C
HEAT C B
R2 R1
8 5R
65A F.L.
ON
3 LgR BR
7 5WR
OFF
ACC
ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10003
10-031
TROUBLESHOOTING
2-4-1. No vibration occurs 2/2 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 2-4-1 Check point
Check/Cause
Action
hen starter switch is ON, measure voltage between Replace vibration Lo-Hi 4. Vibration Lo-Hi Change (1) W Switch change switch. vibration Lo-Hi change switch terminal 1 inlet wire RL (TW504) and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration Lo-Hi change switch is “ ”, measure voltage between vibration LoHi change switch terminal 3 outlet wire LgR and chassis ground. Standard voltage : 12 V or more. (3) W hen starter switch is ON and vibration Lo-Hi change ”, measure voltage between vibration Loswitch is “ Hi change switch terminal 2 outlet wire LgY and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2) or (3) is NG, vibration Lo-Hi change switch is faulty. 5. Vibrator Relay
(1) W hen starter switch is ON, measure voltage between vibrator relay terminal E inlet wire GY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibrator relay terminal G inlet wire BrY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, check continuity between vibrator relay terminal B inlet wire BrR and terminal D outlet wire B. There is continuity in normal condition. If above items (1) and (2) are OK and item (3) is NG, vibrator relay is faulty.
Replace vibrator relay.
6. F-R Lever Switch
(1) W hen starter switch is ON, measure voltage between F-R lever switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal outlet wire GY 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.
Replace F-R lever switch.
7. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-032
TROUBLESHOOTING
Fig.: 2-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
47 LgR
4
23 RL
B
VIBRATOR SOLENOID (F)
VIBRATION MODE SELECT SWITCH
49 LgB
CONNECTION 1-2,4-6
45 Br
VIBRATOR SOLENOID (R) SW354 (Except ROPS type)
NC NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
23 RL
NO
B
G
TO COMBINATION
51 Br
46 BrR METER
46 BrR
46 BrR
43 RW 45 Br
3
2
1
23 RL
47 LgR
47 LgR
6
VIBRATORY DRUM SELECT SWITCH
B
VIBRATORY DRUM SELECT SWITCH
VIBRATOR SOLENOID (F)
POSITION
49 LgB
CONNECTION
B
1-3,4-6 1-3,4-5
D
B
VIBRATOR SOLENOID (R)
SW354 (ROPS type)
R
F
G E F
46 BrR
SOL
27 GY
H
B
SOL
1-2,4-6
VIBRATOR RELAY
46 BrR
5
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
2
4
F-R LEVER VIBRATION SWITCH (L)
49 LgB
3
1
NC
C Br
B
SOL
1-3,4-5
C Br
46 BrR
B
1-3,4-6 AUTO
B
SOL
VIBRATION MODE SELECT SWITCH
VIBRATION
46 BrR
B
47 LgR
46 BrR
B
B
SOL VIBRATOR SOLENOID TW354
F-R LEVER SWITCH NC
NO COM
B 24 RY
3
47 LgR
2
48 LgY
1
1 HI
6
4 27 GY
302 LgR
R
W
23 RL 1
2
SOL
LOW 2 46 BrR
5
VIBRATION Lo-Hi CHANGE SWITCH
VIBRATOR SOLENOID
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
VIBRATION
CONNECTION
1
2
3
4
5
6
23 RL 8
TW504 7
24 RY 9
1-2
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-3
FUSE BOX STARTER SWITCH B
2 5WR
R 1 R 2 A CC B R C
HEAT C B
R2 R1
8 5R
65A F.L.
ON
3 LgR BR
7 5WR
OFF
ACC
ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10003
10-033
TROUBLESHOOTING
2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode select switch must be “ Reference Fig.: 2-4-1 Check point
” (manual mode). Check/Cause
Action
1. Vibration Mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace vibration mode vibration mode select switch terminal 1 inlet wire RL select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration mode select switch terminal 2 outlet wire RW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration mode select switch is faulty.
2. Vibrator Relay
(1) W hen starter switch is ON and F-R lever is “F” or “R”, measure voltage between vibrator relay terminal E inlet wire GY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibrator relay terminal F inlet wire RW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and F-R lever vibration switch pressed, check continuity between vibrator relay terminal H inlet wire Br and chassis ground. There is continuity in normal condition. (4) W hen starter switch is ON and F-R lever vibration switch pressed, check continuity between vibrator relay terminal B inlet wire BrR and terminal D outlet wire B. There is continuity in normal condition. If above items (1), (2) and (3) are OK and item (4) is NG, vibrator relay is faulty.
Replace vibrator relay.
3. F-R Lever Vibration Switch (L)
• Check continuity between F-R lever vibration switch (L) terminals. • Terminal NC and terminal C • Terminal NO and terminal C • If continuity is made and broken when switch is operated, it is normal. If not, switch is faulty.
Replace F-R lever vibration switch (L).
4. F-R Lever Vibration Switch (R)
• Check continuity between F-R lever vibration switch (R) terminals. • Terminal NC and terminal C • Terminal NO and terminal C • If continuity is made and broken when switch is operated, it is normal. If not, switch is faulty.
Replace F-R lever vibration switch (R).
5. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-034
TROUBLESHOOTING
Fig.: 2-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
47 LgR
4
23 RL
B
VIBRATOR SOLENOID (F)
VIBRATION MODE SELECT SWITCH
49 LgB
CONNECTION 1-2,4-6
45 Br
VIBRATOR SOLENOID (R) SW354 (Except ROPS type)
NC NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
23 RL
NO
B
G
TO COMBINATION
51 Br
46 BrR METER
46 BrR
46 BrR
43 RW 45 Br
3
2
1
23 RL
47 LgR
47 LgR
6
VIBRATORY DRUM SELECT SWITCH
B
VIBRATORY DRUM SELECT SWITCH
VIBRATOR SOLENOID (F)
POSITION
49 LgB
CONNECTION
B
1-3,4-6 1-3,4-5
D
B
VIBRATOR SOLENOID (R)
SW354 (ROPS type)
R
F
G E F
46 BrR
SOL
27 GY
H
B
SOL
1-2,4-6
VIBRATOR RELAY
46 BrR
5
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
2
4
F-R LEVER VIBRATION SWITCH (L)
49 LgB
3
1
NC
C Br
B
SOL
1-3,4-5
C Br
46 BrR
B
1-3,4-6 AUTO
B
SOL
VIBRATION MODE SELECT SWITCH
VIBRATION
46 BrR
B
47 LgR
46 BrR
B
B
SOL VIBRATOR SOLENOID TW354
F-R LEVER SWITCH NC
NO COM
B 24 RY
3
47 LgR
2
48 LgY
1
1 HI
6
4 27 GY
302 LgR
R
W
23 RL 1
2
SOL
LOW 2 46 BrR
5
VIBRATION Lo-Hi CHANGE SWITCH
VIBRATOR SOLENOID
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
VIBRATION
CONNECTION
1
2
3
4
5
6
23 RL 8
TW504 7
24 RY 9
1-2
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-3
FUSE BOX STARTER SWITCH B
2 5WR
R 1 R 2 A CC B R C
HEAT C B
R2 R1
8 5R
65A F.L.
ON
3 LgR BR
7 5WR
OFF
ACC
ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10003
10-035
TROUBLESHOOTING
2-4-3. Vibratory drum cannot be switched (SW354 ROPS) Reference Fig.: 2-4-1 Check point
Check/Cause
Action
1. Vibratory Drum Select Switch
(1) W hen starter switch is ON, measure voltage between vibratory drum select switch terminal 1 inlet wire RL, terminal 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR, terminal 3 outlet wire LgB and chassis ground. There is no electricity in normal condition. (4) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 3 outlet wire LgB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibratory drum select switch is faulty.
Replace vibratory drum select switch.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-036
TROUBLESHOOTING
Fig.: 2-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
47 LgR
4
23 RL
B
VIBRATOR SOLENOID (F)
VIBRATION MODE SELECT SWITCH
49 LgB
CONNECTION 1-2,4-6
45 Br
VIBRATOR SOLENOID (R) SW354 (Except ROPS type)
NC NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
23 RL
NO
B
G
TO COMBINATION
51 Br
46 BrR METER
46 BrR
46 BrR
43 RW 45 Br
3
2
1
23 RL
47 LgR
47 LgR
6
VIBRATORY DRUM SELECT SWITCH
B
VIBRATORY DRUM SELECT SWITCH
VIBRATOR SOLENOID (F)
POSITION
49 LgB
CONNECTION
B
1-3,4-6 1-3,4-5
D
B
VIBRATOR SOLENOID (R)
SW354 (ROPS type)
R
F
G E F
46 BrR
SOL
27 GY
H
B
SOL
1-2,4-6
VIBRATOR RELAY
46 BrR
5
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
2
4
F-R LEVER VIBRATION SWITCH (L)
49 LgB
3
1
NC
C Br
B
SOL
1-3,4-5
C Br
46 BrR
B
1-3,4-6 AUTO
B
SOL
VIBRATION MODE SELECT SWITCH
VIBRATION
46 BrR
B
47 LgR
46 BrR
B
B
SOL VIBRATOR SOLENOID TW354
F-R LEVER SWITCH NC
NO COM
B 24 RY
3
47 LgR
2
48 LgY
1
1 HI
6
4 27 GY
302 LgR
R
W
23 RL 1
2
SOL
LOW 2 46 BrR
5
VIBRATION Lo-Hi CHANGE SWITCH
VIBRATOR SOLENOID
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
VIBRATION
CONNECTION
1
2
3
4
5
6
23 RL 8
TW504 7
24 RY 9
1-2
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
1-3
FUSE BOX STARTER SWITCH B
2 5WR
R 1 R 2 A CC B R C
HEAT C B
R2 R1
8 5R
65A F.L.
ON
3 LgR BR
7 5WR
OFF
ACC
ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10003
10-037
TROUBLESHOOTING
2-4-4. Amplitude does not change (Remains either low or high) (TW504) • Vibration mode change switch must be “AUTO” (automatic mode). Reference Fig.: 2-4-1 Check point 1. Vibrator Solenoid
Check/Cause • Disconnect harness and measure resistance of coil. Standard resistance : 5.42 Ω • If measured resistance is abnormal, amplitude cylinder solenoid is faulty.
Action Replace amplitude cylinder solenoid.
2. Vibration Lo-Hi Change (1) W Replace vibration Lo-Hi hen starter switch is ON, measure voltage between Switch change switch. vibration Lo-Hi change switch terminal 1 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration Lo-Hi change switch is “ ”, measure voltage between vibration LoHi change switch terminal 3 outlet wire LgR and chassis ground. Standard voltage : 12 V or more. (3) W hen starter switch is ON and vibration Lo-Hi change ”, measure voltage between vibration Loswitch is “ Hi change switch terminal 2 outlet wire LgY and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2) or (3) is NG, vibration Lo-Hi change switch is faulty. 3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-038
TROUBLESHOOTING
Fig.: 2-5-1
42 3LB
Or B
B
WATER SPRAY PUMP
42 3LB
18 3LY
B
G
B
e
g
39 LW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY RELAY
VIBRATION
CONNECTION
CONT
1-2,4-6 1-3,4-6
AUTO
1-3,4-5
3 39 LW
2 6
39 LW
R
F
5
1
18 LY
4
27 GY
18 3LY
TO COMBINATION METER
18 LY
WATER SPRAY MODE SELECT SWITCH
Except ROPS type
70 P
F-R LEVER SWITCH
WATER SPRAY TIMER
R
W
B
27 GY
24 RY
NO COM
302 LgR
NC
2
1
3 4
70 P
39 LW
70 P
B
ROPS type
18 3LY 1
2
3
4
5
6
7
8
9
STARTER SWITCH 2 5WR
B C
3 LgR BR
R1
11
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
ACC
F.L.
65A
TW354,504
6 3G
B
F.L.
M
LIQUID SPRAY PUMP
45A
R
8 5R
9 BrW
FUSE BOX
5 3GW
1
12
20 2BrR
2
LIQUID SPRAY SWITCH
7 5WR
3
9 2BrW
13
9 BrW
14
TO COMBINATION METER
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
24 RY
20 2BrR
TO INTERLOCK RELAY
ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10004
10-039
TROUBLESHOOTING
2-5. Water Spray Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked.
2-5-1. Continuous water spray does not operate • Water spray mode select switch must be “CONT”. Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. W ater Spray Pump
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray pump terminal inlet wire LB and chassis pump. ground. Standard voltage : 12 V or more (2) C heck that no abnormality is found in water spray pump ground terminal. • If above items (1) and (2) are OK and water spray pump does not operate, water spray pump is faulty.
3. W ater Spray Relay
(1) W hen starter switch is ON, measure voltage between water spray relay terminal g inlet wire LW and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray relay terminal B inlet wire LY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between water spray relay terminal G outlet wire LB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray relay is faulty.
Replace water spray relay.
4. Water Spray Mode Select Switch
(1) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 1 inlet wire LY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 2 outlet wire LW 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.
5. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-040
TROUBLESHOOTING
Fig.: 2-5-1
42 3LB
Or B
B
WATER SPRAY PUMP
42 3LB
18 3LY
B
G
B
e
g
39 LW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY RELAY
VIBRATION
CONNECTION
CONT
1-2,4-6 1-3,4-6
AUTO
1-3,4-5
3 39 LW
2 6
39 LW
R
F
5
1
18 LY
4
27 GY
18 3LY
TO COMBINATION METER
18 LY
WATER SPRAY MODE SELECT SWITCH
Except ROPS type
70 P
F-R LEVER SWITCH
WATER SPRAY TIMER
R
W
B
27 GY
24 RY
NO COM
302 LgR
NC
2
1
3 4
70 P
39 LW
70 P
B
ROPS type
18 3LY 1
2
3
4
5
6
7
8
9
STARTER SWITCH 2 5WR
B C
3 LgR BR
R1
11
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
ACC
F.L.
65A
TW354,504
6 3G
B
F.L.
M
LIQUID SPRAY PUMP
45A
R
8 5R
9 BrW
FUSE BOX
5 3GW
1
12
20 2BrR
2
LIQUID SPRAY SWITCH
7 5WR
3
9 2BrW
13
9 BrW
14
TO COMBINATION METER
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
24 RY
20 2BrR
TO INTERLOCK RELAY
ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10004
10-041
TROUBLESHOOTING
2-5-2. Continuous water spray works, but auto water spray does not operate • Water spray mode select switch must be “AUTO”. • F-R lever must be “F” or “R”. Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Water Spray Mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray mode select switch terminal 4 inlet wire GY mode select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray mode select switch terminals and chassis ground. Except ROPS type : Terminal 5 outlet wire LW ROPS type : Terminal 5 outlet wire P If above item (1) is OK and item (2) is NG, water spray mode select switch is faulty.
2. Water Spray Timer (ROPS type)
Replace water spray (1) W hen starter switch is ON, measure voltage between water spray timer terminal 1 and 3 inlet wire P and timer. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray timer terminal 4 outlet wire LW and chassis ground. Standard voltage : 12 V or more (Electricity flows for a definite time.) • If above item (1) is OK and item (2) is NG, water spray timer is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-042
TROUBLESHOOTING
Fig.: 2-5-1
42 3LB
Or B
B
WATER SPRAY PUMP
42 3LB
18 3LY
B
G
B
e
g
39 LW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY RELAY
VIBRATION
CONNECTION
CONT
1-2,4-6 1-3,4-6
AUTO
1-3,4-5
3 39 LW
2 6
39 LW
R
F
5
1
18 LY
4
27 GY
18 3LY
TO COMBINATION METER
18 LY
WATER SPRAY MODE SELECT SWITCH
Except ROPS type
70 P
F-R LEVER SWITCH
WATER SPRAY TIMER
R
W
B
27 GY
24 RY
NO COM
302 LgR
NC
2
1
3 4
70 P
39 LW
70 P
B
ROPS type
18 3LY 1
2
3
4
5
6
7
8
9
STARTER SWITCH 2 5WR
B C
3 LgR BR
R1
11
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
ACC
F.L.
65A
TW354,504
6 3G
B
F.L.
M
LIQUID SPRAY PUMP
45A
R
8 5R
9 BrW
FUSE BOX
5 3GW
1
12
20 2BrR
2
LIQUID SPRAY SWITCH
7 5WR
3
9 2BrW
13
9 BrW
14
TO COMBINATION METER
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
24 RY
20 2BrR
TO INTERLOCK RELAY
ON ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10004
10-043
TROUBLESHOOTING
2-5-3. Liquid cannot be sprayed (TW354, 504) Reference Fig. : 2-5-1 Check point
Check/Cause
Action
1. L iquid Spray Pump
(1) W hen starter switch is ON and liquid spray switch Replace liquid spray pressed, measure voltage between liquid spray pump pump. terminal inlet wire BrW and chassis ground. Standard voltage : 12 V or more (2) C heck that no abnormality is found in liquid spray pump ground terminal. • If above items (1) and (2) are OK and liquid spray pump does not operate, liquid spray pump is faulty.
2. Liquid Spray Switch
(1) W hen starter switch is ON, measure voltage between Replace liquid spray liquid spray switch terminal 1 inlet wire BrR and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and liquid spray switch pressed, measure voltage between liquid spray switch terminal 2 outlet wire BrW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, liquid spray switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-044
TROUBLESHOOTING
Fig.: 2-6-1
HEAD LAMP (R) 55W
37 2GB
37 GB
R
35 G 36 GR 38 Or
38 Or
FLOOD LAMP 55W
R
HEAD LAMP (L) 55W
37 2GB
37 2GB 3
37 2GB
R 38 Or
35 G
19 3R
6
38 Or
19 3R
1
2
4
5
LIGHTING SWITCH 35 G
B
TURN SIGNAL LAMP (R) 21W
STOP LAMP 21W
5W
TAIL LAMP 5W
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
1-2,4-6
34 GY
GY
35 G 36 GR G
21W
LIGHTING SWITCH POSITION CONNECTION
G
B
TURN SIGNAL LAMP (R) 21W
37 GB
36 GR
G
1-3,4-5
GR
G
B
1-3,4-6
R L
TURN SIGNAL LAMP (L) 21W
TURN SIGNAL SWITCH
STOP
G
21W
61 RG
TURN SIGNAL SWITCH GY G GR
FOOT BRAKE SWITCH
L N R
B
W
B
24 RY
60 BrY
41 RW
34 GY
36 GR
35 G
37 GB
38 Or
R
NC NO COM
TO PARKING BRAKE SWITCH f 61 RG
c
e
24 RY 60 BrY
B a
b
B
1
19 3R 2
3
4
5
6
FLASHER UNIT
11
21 RG 7 5WR
34 GY
B
F.L.
E
65A
L
FUSE BOX
12
ROPS type
8 5R
TO COMBINATION METER
14
34 GY
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
HAZARD SWITCH
7
10
4 34 GY
5
8
24 RY
1 34 GY
2 6
36 GR
9
3 35 GB
21 RG
BRAKE LAMP RELAY
STARTER SWITCH
2 5WR
B C
ACC B
R2
3 LgR BR
R1
R 1 R 2 A CC B R C
HEAT OFF
AV60
ON
NO
ST
+
BR
STARTER SWITCH 3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10005
10-045
TROUBLESHOOTING
2-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses.
2-6-1. Head lamp and tail lamp do not light Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
3. Lighting Switch
Replace lighting switch. (1) W hen starter switch is ON, measure voltage between lighting switch terminal 1 inlet wire R 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 GB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, lighting switch is faulty.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-6-2. Flood lamp does not light Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
2. Lighting Switch
Replace lighting switch. (1) W hen starter switch is ON, measure voltage between lighting switch terminal 4 inlet wire R 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 5 outlet wire Or and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) 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.
10-046
TROUBLESHOOTING
Fig.: 2-6-1
HEAD LAMP (R) 55W
37 2GB
37 GB
R
35 G 36 GR 38 Or
38 Or
FLOOD LAMP 55W
R
HEAD LAMP (L) 55W
37 2GB
37 2GB 3
37 2GB
R 38 Or
35 G
19 3R
6
38 Or
19 3R
1
2
4
5
LIGHTING SWITCH 35 G
B
TURN SIGNAL LAMP (R) 21W
STOP LAMP 21W
5W
TAIL LAMP 5W
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
1-2,4-6
34 GY
GY
35 G 36 GR G
21W
LIGHTING SWITCH POSITION CONNECTION
G
B
TURN SIGNAL LAMP (R) 21W
37 GB
36 GR
G
1-3,4-5
GR
G
B
1-3,4-6
R L
TURN SIGNAL LAMP (L) 21W
TURN SIGNAL SWITCH
STOP
G
21W
61 RG
TURN SIGNAL SWITCH GY G GR
FOOT BRAKE SWITCH
L N R
B
W
B
24 RY
60 BrY
41 RW
34 GY
36 GR
35 G
37 GB
38 Or
R
NC NO COM
TO PARKING BRAKE SWITCH f 61 RG
c
e
24 RY 60 BrY
B a
b
B
1
19 3R 2
3
4
5
6
FLASHER UNIT
11
21 RG 7 5WR
34 GY
B
F.L.
E
65A
L
FUSE BOX
12
ROPS type
8 5R
TO COMBINATION METER
14
34 GY
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
HAZARD SWITCH
7
10
4 34 GY
5
8
24 RY
1 34 GY
2 6
36 GR
9
3 35 GB
21 RG
BRAKE LAMP RELAY
STARTER SWITCH
2 5WR
B C
ACC B
R2
3 LgR BR
R1
R 1 R 2 A CC B R C
HEAT OFF
AV60
ON
NO
ST
+
BR
STARTER SWITCH 3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10005
10-047
TROUBLESHOOTING
2-6-3. Turn signal lamp does not blink Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
2. Flasher Unit
(1) W hen starter switch is ON, measure voltage between flasher unit terminal B inlet wire RG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between flasher unit terminal L outlet wire GY and chassis ground. Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) is NG, flasher unit is faulty.
Replace flasher unit.
3. Turn Signal Switch
(1) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between turn signal switch terminal inlet wire GY and chassis ground. Standard voltage : 12 V or more with constant intervals (2) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between turn signal switch terminals and chassis ground. Turn signal (L) : Wire No.36 outlet wire GR Turn signal (R) : Wire No.35 outlet wire G Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) is NG, turn signal switch is faulty.
Replace turn signal switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-048
TROUBLESHOOTING
Fig.: 2-6-1
HEAD LAMP (R) 55W
37 2GB
37 GB
R
35 G 36 GR 38 Or
38 Or
FLOOD LAMP 55W
R
HEAD LAMP (L) 55W
37 2GB
37 2GB 3
37 2GB
R 38 Or
35 G
19 3R
6
38 Or
19 3R
1
2
4
5
LIGHTING SWITCH 35 G
B
TURN SIGNAL LAMP (R) 21W
STOP LAMP 21W
5W
TAIL LAMP 5W
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
1-2,4-6
34 GY
GY
35 G 36 GR G
21W
LIGHTING SWITCH POSITION CONNECTION
G
B
TURN SIGNAL LAMP (R) 21W
37 GB
36 GR
G
1-3,4-5
GR
G
B
1-3,4-6
R L
TURN SIGNAL LAMP (L) 21W
TURN SIGNAL SWITCH
STOP
G
21W
61 RG
TURN SIGNAL SWITCH GY G GR
FOOT BRAKE SWITCH
L N R
B
W
B
24 RY
60 BrY
41 RW
34 GY
36 GR
35 G
37 GB
38 Or
R
NC NO COM
TO PARKING BRAKE SWITCH f 61 RG
c
e
24 RY 60 BrY
B a
b
B
1
19 3R 2
3
4
5
6
FLASHER UNIT
11
21 RG 7 5WR
34 GY
B
F.L.
E
65A
L
FUSE BOX
12
ROPS type
8 5R
TO COMBINATION METER
14
34 GY
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
HAZARD SWITCH
7
10
4 34 GY
5
8
24 RY
1 34 GY
2 6
36 GR
9
3 35 GB
21 RG
BRAKE LAMP RELAY
STARTER SWITCH
2 5WR
B C
ACC B
R2
3 LgR BR
R1
R 1 R 2 A CC B R C
HEAT OFF
AV60
ON
NO
ST
+
BR
STARTER SWITCH 3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10005
10-049
TROUBLESHOOTING
2-6-4. Hazard lamp does not light (Turn signal blinks) (ROPS type) • Hazard switch must be ON. Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
2. Hazard Switch
(1) W hen starter switch is ON, measure voltage between hazard switch terminal 1 and 4 inlet wire GY and chassis ground. Standard voltage : 12 V or more with constant intervals (2) W hen starter switch is ON, measure voltage between hazard switch terminal 5 outlet wire GR and chassis ground. Standard voltage : 12 V or more with constant intervals (3) W hen starter switch is ON, measure voltage between hazard switch terminal 2 outlet wire GB and chassis ground. Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) or (3) is NG, hazard switch is faulty.
Replace hazard switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-050
TROUBLESHOOTING
Fig.: 2-6-1
HEAD LAMP (R) 55W
37 2GB
37 GB
R
35 G 36 GR 38 Or
38 Or
FLOOD LAMP 55W
R
HEAD LAMP (L) 55W
37 2GB
37 2GB 3
37 2GB
R 38 Or
35 G
19 3R
6
38 Or
19 3R
1
2
4
5
LIGHTING SWITCH 35 G
B
TURN SIGNAL LAMP (R) 21W
STOP LAMP 21W
5W
TAIL LAMP 5W
37 GB
5W
TAIL LAMP 5W
61 RG
21W
STOP LAMP 21W
36 GR
21W
TURN SIGNAL LAMP (L) 21W
1-2,4-6
34 GY
GY
35 G 36 GR G
21W
LIGHTING SWITCH POSITION CONNECTION
G
B
TURN SIGNAL LAMP (R) 21W
37 GB
36 GR
G
1-3,4-5
GR
G
B
1-3,4-6
R L
TURN SIGNAL LAMP (L) 21W
TURN SIGNAL SWITCH
STOP
G
21W
61 RG
TURN SIGNAL SWITCH GY G GR
FOOT BRAKE SWITCH
L N R
B
W
B
24 RY
60 BrY
41 RW
34 GY
36 GR
35 G
37 GB
38 Or
R
NC NO COM
TO PARKING BRAKE SWITCH f 61 RG
c
e
24 RY 60 BrY
B a
b
B
1
19 3R 2
3
4
5
6
FLASHER UNIT
11
21 RG 7 5WR
34 GY
B
F.L.
E
65A
L
FUSE BOX
12
ROPS type
8 5R
TO COMBINATION METER
14
34 GY
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
HAZARD SWITCH
7
10
4 34 GY
5
8
24 RY
1 34 GY
2 6
36 GR
9
3 35 GB
21 RG
BRAKE LAMP RELAY
STARTER SWITCH
2 5WR
B C
ACC B
R2
3 LgR BR
R1
R 1 R 2 A CC B R C
HEAT OFF
AV60
ON
NO
ST
+
BR
STARTER SWITCH 3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10005
10-051
TROUBLESHOOTING
2-6-5. Stop lamp does not light Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
2. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between Replace foot brake foot brake switch terminal inlet wire RY and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON while foot brake is depressed, measure voltage between foot brake switch terminal outlet wire BrY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
3. B rake Lamp Relay
(1) W hen starter switch is ON while foot brake is depressed, measure voltage between brake lamp relay terminal a inlet wire BrY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between brake lamp relay terminal c inlet wire RY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON while foot brake is depressed, measure voltage between brake lamp relay terminal e outlet wire RG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, brake lamp relay is faulty.
Replace brake lamp 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.
10-052
TROUBLESHOOTING
Fig.: 2-6-2 TO HEAD LAMP TAIL LAMP
37 2GB 3
37 2GB
12V BATT (12V)
Engine speed 2 Engine speed 3 Engine speed 4
12V
Movement
Temperature meter
LCD
Hour meter
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
Frequency divider selector
R
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Turn signal (L)
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
Input interface
Liquid spray
Parking brake
COMBINATION METER
Illumination LED
Backlight
Glow plug
CONNECTION 1-3,4-6
EEPROM
Turn signal (R)
Flood lamp
POSITION
1-3,4-5
Position lamp
Water spray
LIGHTING SWITCH
LIGHTING SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
P
O
WR GL
LR
YL
LW
LB
L
Br
B
Y
YR YW
BrW GR GW
G
W GY RB GB OG LgY WB OW
17 WR
Engine speed 1
Fuel meter
Output interface
Temperature sensor
Movement
CPU
Fuel sensor
AD input interface TA input interface
TA pulse (square wave)
Tachometer
4
1-2,4-6
Input interface
TA pulse (pickup)
Movement
19 3R
6 5
Input interface
37 GB
KEY SW
CAN interface
12V
38 Or
TO FLOOD LAMP
5V power supply
Power excitation circuit
19 3R
1
2
B
54 YB
B 12 Y 11 BrB 57 L 55 YG 53 LR
3
54 YB
59 Sb
2
System configuration diagram Note:
53 LR
22 RB
Coolant temperature 2
55 YG
Coolant temperature 1
57 L
Lamp check
Y
B
B
The circuit in the dashed box is not mounted.
1 B
TACHO METER SENSOR
THERMO UNIT
HYDRAULIC OIL FILTER SWITCH
FUEL GAUGE UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
TEMP. 50-103
1
19 3R 2
3
4
5
6
7
8
9
8 5R
ST
STARTER SWITCH
L
IG
E
B
7 5WR
13 2Y
R1
F.L.
ON
3 LgR BR
FUSE BOX
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
65A
C
11
B
ACC
12
STARTER SWITCH
2 5WR
13
11 BrB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
FUSE
10
12 Y
5A
14
2 WR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
17 WR
13 2Y
28 8WY
ALTERNATOR
TO STARTER MOTOR
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10006
10-053
TROUBLESHOOTING
2-6-6. Illumination of combination meter does not light Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 3 wire GB and combination meter connector terminal wire No.37 wire GB. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Combination meter illumination)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “ ”, measure voltage between combination meter illumination terminal wire No.37 inlet wire GB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and combination meter does not turn on, combination meter is faulty.
Replace combination meter.
2-6-7. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-6-2 Check point 1. Combination Meter (Lamp check)
Check/Cause (1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, check that parking brake indicator lamp, hydraulic oil filter warning lamp, engine oil pressure warning lamp and charge warning lamp illuminate and then go out after starting engine. • If above item (1) is OK and item (2) is NG, combination meter is faulty.
Action Replace combination meter.
(NOTICE) • Since engine cannot start unless parking brake switch is applied, parking brake indicator lamp does not go out even after starting engine.
10-054
TROUBLESHOOTING
Fig.: 2-6-2 TO HEAD LAMP TAIL LAMP
37 2GB 3
37 2GB
12V BATT (12V)
Engine speed 2 Engine speed 3 Engine speed 4
12V
Movement
Temperature meter
LCD
Hour meter
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
Frequency divider selector
R
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Turn signal (L)
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
Input interface
Liquid spray
Parking brake
COMBINATION METER
Illumination LED
Backlight
Glow plug
CONNECTION 1-3,4-6
EEPROM
Turn signal (R)
Flood lamp
POSITION
1-3,4-5
Position lamp
Water spray
LIGHTING SWITCH
LIGHTING SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
P
O
WR GL
LR
YL
LW
LB
L
Br
B
Y
YR YW
BrW GR GW
G
W GY RB GB OG LgY WB OW
17 WR
Engine speed 1
Fuel meter
Output interface
Temperature sensor
Movement
CPU
Fuel sensor
AD input interface TA input interface
TA pulse (square wave)
Tachometer
4
1-2,4-6
Input interface
TA pulse (pickup)
Movement
19 3R
6 5
Input interface
37 GB
KEY SW
CAN interface
12V
38 Or
TO FLOOD LAMP
5V power supply
Power excitation circuit
19 3R
1
2
B
54 YB
B 12 Y 11 BrB 57 L 55 YG 53 LR
3
54 YB
59 Sb
2
System configuration diagram Note:
53 LR
22 RB
Coolant temperature 2
55 YG
Coolant temperature 1
57 L
Lamp check
Y
B
B
The circuit in the dashed box is not mounted.
1 B
TACHO METER SENSOR
THERMO UNIT
HYDRAULIC OIL FILTER SWITCH
FUEL GAUGE UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
TEMP. 50-103
1
19 3R 2
3
4
5
6
7
8
9
8 5R
ST
STARTER SWITCH
L
IG
E
B
7 5WR
13 2Y
R1
F.L.
ON
3 LgR BR
FUSE BOX
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
65A
C
11
B
ACC
12
STARTER SWITCH
2 5WR
13
11 BrB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
FUSE
10
12 Y
5A
14
2 WR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
17 WR
13 2Y
28 8WY
ALTERNATOR
TO STARTER MOTOR
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10006
10-055
TROUBLESHOOTING
2-6-8. Tachometer reading is abnormal Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. C ombination Meter (Tachometer)
(1) W hen starter switch is ON, measure voltage between Replace tachometer combination meter terminal wires and ground terminal sensor or combination wire. meter. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) C heck that combination meter terminal wires B (rev. ratio sel. 1, 2) are grounded. (3) S tart engine and measure pulse between combination meter rev. pulse input. 2 terminal wire No.57 wire L and chassis ground. Standard pulse : 34 pulses/rotation of engine • If above items (1) and (2) are OK and pluse is NG in item (3), tachometer sensor is faulty. • If above items (1) and (2) are OK and tachometer reading is NG in item (3), combination meter is faulty.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-6-9. Hour meter is abnormal Reference Fig. : 2-6-2 Check point 1. C ombination Meter (Hour meter)
Check/Cause • When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Replace combination meter.
10-056
TROUBLESHOOTING
Fig.: 2-6-2 TO HEAD LAMP TAIL LAMP
37 2GB 3
37 2GB
12V BATT (12V)
Engine speed 2 Engine speed 3 Engine speed 4
12V
Movement
Temperature meter
LCD
Hour meter
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
Frequency divider selector
R
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Turn signal (L)
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
Input interface
Liquid spray
Parking brake
COMBINATION METER
Illumination LED
Backlight
Glow plug
CONNECTION 1-3,4-6
EEPROM
Turn signal (R)
Flood lamp
POSITION
1-3,4-5
Position lamp
Water spray
LIGHTING SWITCH
LIGHTING SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
P
O
WR GL
LR
YL
LW
LB
L
Br
B
Y
YR YW
BrW GR GW
G
W GY RB GB OG LgY WB OW
17 WR
Engine speed 1
Fuel meter
Output interface
Temperature sensor
Movement
CPU
Fuel sensor
AD input interface TA input interface
TA pulse (square wave)
Tachometer
4
1-2,4-6
Input interface
TA pulse (pickup)
Movement
19 3R
6 5
Input interface
37 GB
KEY SW
CAN interface
12V
38 Or
TO FLOOD LAMP
5V power supply
Power excitation circuit
19 3R
1
2
B
54 YB
B 12 Y 11 BrB 57 L 55 YG 53 LR
3
54 YB
59 Sb
2
System configuration diagram Note:
53 LR
22 RB
Coolant temperature 2
55 YG
Coolant temperature 1
57 L
Lamp check
Y
B
B
The circuit in the dashed box is not mounted.
1 B
TACHO METER SENSOR
THERMO UNIT
HYDRAULIC OIL FILTER SWITCH
FUEL GAUGE UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
TEMP. 50-103
1
19 3R 2
3
4
5
6
7
8
9
8 5R
ST
STARTER SWITCH
L
IG
E
B
7 5WR
13 2Y
R1
F.L.
ON
3 LgR BR
FUSE BOX
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
65A
C
11
B
ACC
12
STARTER SWITCH
2 5WR
13
11 BrB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
FUSE
10
12 Y
5A
14
2 WR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
17 WR
13 2Y
28 8WY
ALTERNATOR
TO STARTER MOTOR
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10006
10-057
TROUBLESHOOTING
2-6-10. Temperature meter is abnormal Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. Thermo Unit
• Disconnect harness and measure resistance of thermo unit. Standard resistance : 164.6 Ω (at unit temperature of 50℃) 26.44 Ω (at unit temperature of 103℃) • If resistance is abnormal, thermo unit is faulty.
Replace thermo unit.
2. Combination Meter (Temperature meter)
• When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Replace combination meter.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-6-11. Fuel meter is abnormal Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. Fuel Gauge Unit
• Disconnect harness and measure resistance of fuel gauge Replace fuel gauge unit. unit. Standard resistance : 13.5 Ω (with float in “F”) 80.0 Ω (with float in “E”) • If resistance is abnormal, fuel gauge unit is faulty.
2. Combination Meter (Fuel meter)
• When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Replace combination meter.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-058
TROUBLESHOOTING
Fig.: 2-6-2 TO HEAD LAMP TAIL LAMP
37 2GB 3
37 2GB
12V BATT (12V)
Engine speed 2 Engine speed 3 Engine speed 4
12V
Movement
Temperature meter
LCD
Hour meter
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
Frequency divider selector
R
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Turn signal (L)
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
Input interface
Liquid spray
Parking brake
COMBINATION METER
Illumination LED
Backlight
Glow plug
CONNECTION 1-3,4-6
EEPROM
Turn signal (R)
Flood lamp
POSITION
1-3,4-5
Position lamp
Water spray
LIGHTING SWITCH
LIGHTING SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
P
O
WR GL
LR
YL
LW
LB
L
Br
B
Y
YR YW
BrW GR GW
G
W GY RB GB OG LgY WB OW
17 WR
Engine speed 1
Fuel meter
Output interface
Temperature sensor
Movement
CPU
Fuel sensor
AD input interface TA input interface
TA pulse (square wave)
Tachometer
4
1-2,4-6
Input interface
TA pulse (pickup)
Movement
19 3R
6 5
Input interface
37 GB
KEY SW
CAN interface
12V
38 Or
TO FLOOD LAMP
5V power supply
Power excitation circuit
19 3R
1
2
B
54 YB
B 12 Y 11 BrB 57 L 55 YG 53 LR
3
54 YB
59 Sb
2
System configuration diagram Note:
53 LR
22 RB
Coolant temperature 2
55 YG
Coolant temperature 1
57 L
Lamp check
Y
B
B
The circuit in the dashed box is not mounted.
1 B
TACHO METER SENSOR
THERMO UNIT
HYDRAULIC OIL FILTER SWITCH
FUEL GAUGE UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
TEMP. 50-103
1
19 3R 2
3
4
5
6
7
8
9
8 5R
ST
STARTER SWITCH
L
IG
E
B
7 5WR
13 2Y
R1
F.L.
ON
3 LgR BR
FUSE BOX
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
65A
C
11
B
ACC
12
STARTER SWITCH
2 5WR
13
11 BrB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
FUSE
10
12 Y
5A
14
2 WR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
17 WR
13 2Y
28 8WY
ALTERNATOR
TO STARTER MOTOR
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10006
10-059
TROUBLESHOOTING
2-6-12. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between combination meter and Repair or replace hydraulic oil filter switch. harness. • Measure resistance between terminals and chassis ground. • Hydraulic oil filter switch terminal wire LR and chassis ground. • Combination meter connector terminal wire No.53 wire LR and chassis ground. Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
2. Hydraulic Oil Filter Switch
• When starter switch is OFF, check continuity between Replace hydraulic oil hydraulic oil filter switch inlet terminal wire LR and chassis filter switch. ground. There is no continuity in normal condition. • If there is continuity, hydraulic oil filter switch is faulty.
3. Combination Meter (Hydraulic oil filter warning)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter hydraulic oil filter warning terminal outlet wire No.53 wire LR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK but hydraulic oil filter warning lamp remains on after starting engine, combination meter is faulty.
Replace combination meter.
2-6-13. Charge warning lamp remains ON • Check with engine running. Reference Fig. : 2-6-2 Check point 1. Harness
Check/Cause • Disconnect connectors between combination meter and alternator terminal L. • Measure resistance between terminals and chassis ground. • Combination meter connector terminal wire No.17 wire WR and chassis ground. • Alternator terminal L wire WR and chassis ground Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
• Measure voltage between combination meter charge 2. Combination Meter (Charge warning lamp) warning terminal wire No.17 outlet wire WR and chassis ground. Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Repair or replace harness.
Replace combination meter.
10-060
TROUBLESHOOTING
Fig.: 2-6-2 TO HEAD LAMP TAIL LAMP
37 2GB 3
37 2GB
12V BATT (12V)
Engine speed 2 Engine speed 3 Engine speed 4
12V
Movement
Temperature meter
LCD
Hour meter
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
Frequency divider selector
R
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Turn signal (L)
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
Input interface
Liquid spray
Parking brake
COMBINATION METER
Illumination LED
Backlight
Glow plug
CONNECTION 1-3,4-6
EEPROM
Turn signal (R)
Flood lamp
POSITION
1-3,4-5
Position lamp
Water spray
LIGHTING SWITCH
LIGHTING SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
P
O
WR GL
LR
YL
LW
LB
L
Br
B
Y
YR YW
BrW GR GW
G
W GY RB GB OG LgY WB OW
17 WR
Engine speed 1
Fuel meter
Output interface
Temperature sensor
Movement
CPU
Fuel sensor
AD input interface TA input interface
TA pulse (square wave)
Tachometer
4
1-2,4-6
Input interface
TA pulse (pickup)
Movement
19 3R
6 5
Input interface
37 GB
KEY SW
CAN interface
12V
38 Or
TO FLOOD LAMP
5V power supply
Power excitation circuit
19 3R
1
2
B
54 YB
B 12 Y 11 BrB 57 L 55 YG 53 LR
3
54 YB
59 Sb
2
System configuration diagram Note:
53 LR
22 RB
Coolant temperature 2
55 YG
Coolant temperature 1
57 L
Lamp check
Y
B
B
The circuit in the dashed box is not mounted.
1 B
TACHO METER SENSOR
THERMO UNIT
HYDRAULIC OIL FILTER SWITCH
FUEL GAUGE UNIT
ENGINE OIL PRESSURE SWITCH
COMBINATION METER SET 34 PULSE/REV SET(NO.3)
TEMP. 50-103
1
19 3R 2
3
4
5
6
7
8
9
8 5R
ST
STARTER SWITCH
L
IG
E
B
7 5WR
13 2Y
R1
F.L.
ON
3 LgR BR
FUSE BOX
OFF
R2
B
R 1 R 2 A CC B R C
HEAT
65A
C
11
B
ACC
12
STARTER SWITCH
2 5WR
13
11 BrB
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
FUSE
10
12 Y
5A
14
2 WR
SET(NO.0)
COOLANT TEMP. SEL. 1 2 OPEN OPEN
22 RB
REV RATIO SEL. 1 2 3 4 GND GND OPEN OPEN
17 WR
13 2Y
28 8WY
ALTERNATOR
TO STARTER MOTOR
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10006
10-061
TROUBLESHOOTING
2-6-14. Engine oil pressure warning lamp remains ON Reference Fig. : 2-6-2 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between combination meter and engine oil pressure switch. • Measure resistance between terminals and chassis ground. • Engine oil pressure switch terminal wire YB and chassis ground. • Combination meter connector terminal wire No.54 wire YB and chassis ground. Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. E ngine oil pressure Switch
• After starting engine, check continuity between its terminals. There is no continuity in normal condition. • If there is continuity, engine oil pressure switch is faulty.
Replace engine oil pressure switch.
(1) W hen starter switch is ON, measure voltage between Replace combination 3. Combination Meter (Engine oil pressure combination meter terminal wires and ground terminal meter. warning indicator lamp) wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter engine oil pressure warning terminal outlet wire No.54 wire YB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK but engine oil pressure warning lamp remains on after starting engine, combination meter is faulty.
10-062
TROUBLESHOOTING
Fig.: 2-6-3 46 BrR
KEY SW
43 RW Movement
6
44 BrY
TA pulse (square wave)
Fuel sensor Temperature sensor
Engine speed 4
Movement
Temperature meter
LCD
Hour meter
VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH VIBRATION
Turn signal (R) Turn signal (L)
1-3,4-5
Illumination LED
51 Br
Input interface
46 BrR
Engine charge warning Engine oil pressure Hydraulic filter
46 BrR
46 BrR
43 RW 45 Br
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration Liquid spray
Glow plug
CONNECTION 1-3,4-6
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Parking brake
23 RL
TO F-R LEVER VIBRATION SWITCH (R), F-R LEVER VIBRATION SWITCH (L)
Backlight
Flood lamp
4
EEPROM
Position lamp
Water spray
23 RL
AUTO
Output interface
Engine speed 3
Fuel meter
CPU
Engine speed 2
Movement
5
1
1-2,4-6
Input interface
Engine speed 1
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup)
12V
2
Tachometer
Input interface
CAN interface
12V
3
5V power supply
Power excitation circuit
3
2
1
23 RL
VIBRATOR LAMP RELAY
B
44 BrY
23 RL 5
23 RL
BATT (12V)
23 RL
12V
TO VIBRATOR SOLENOID
27 GY
VIBRATOR RELAY G E H
F
D
B
Lamp check Coolant temperature 1 Coolant temperature 2
Note:
R
F
System configuration diagram The circuit in the dashed box is not mounted.
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
COMBINATION METER
F-R LEVER SWITCH
G
B
R
1
2
3
4
5
6
12
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A 14
11 BrB
12 Y
B
7
10
51 Br
23 RL
TO INTERLOCK RELAY
W GY RB GB OG LgY WB OW
8
L
YR YW
W
LB
Br
Y
24 RY
LW
B
BrW GR GW
24 RY
O YL
9
P LR
302 LgR
R WR GL
NO COM
27 GY
NC
FUSE BOX STARTER SWITCH
11 BrB 12 Y
5A
2 WR
B
2 5WR C
FUSE
R 1 R 2 A CC B R C
HEAT ACC B
R2 R1
65A
8 5R
F.L.
ON
3 LgR BR
7 5WR
OFF ST
AV60
STARTER SWITCH
NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10007
10-063
TROUBLESHOOTING
2-6-15. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-6-3 Check point
Check/Cause
Action
1. Harness
• Measure resistance between vibrator lamp relay terminal 5 wire Br and combination meter connector terminal wire No.51 wire Br. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Vibrator Lamp Relay
(1) W hen starter switch is ON, measure voltage between vibrator lamp relay terminal 1 and 3 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, check continuity between vibrator lamp relay terminal 2 outlet wire BrR and chassis ground. F-R lever : “F” or “R” Vibration mode select switch : “AUTO” There is continuity in normal condition. (3) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, measure voltage between vibrator lamp relay terminal 5 outlet wire Br and chassis ground. F-R lever : “F” or “R” Vibration mode select switch : “AUTO” Standard voltage : 12 V or more. If above items (1) and (2) are OK and item (3) is NG, vibrator lamp relay is faulty.
Replace vibrator lamp relay.
3. Combination Meter (Vibration indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, measure voltage between combination meter vibration terminal wire No. 51 inlet wire Br and chassis ground. F-R lever : “F” or “R” Vibration mode change switch : “AUTO” Standard voltage : 12 V or more • If above items (1) and (2) are OK and vibration indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-064
TROUBLESHOOTING
Fig.: 2-6-4 42 3LB
Or
12V Movement
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
WATER SPRAY PUMP
Input interface
KEY SW
42 3LB
AD input interface TA input interface
TA pulse (pickup)
Frequency divider selector
CAN interface
12V
5V power supply
Power excitation circuit
TA pulse (square wave)
Fuel sensor Temperature sensor
Engine speed 4
e
g
39 LW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY RELAY
1-3,4-6 AUTO
39 LW
Turn signal (R) Turn signal (L) Output interface
Vibration Liquid spray Input interface
Glow plug
1-3,4-5
3 39 LW
2 5
Engine charge warning Engine oil pressure Hydraulic filter
1
18 LY
4
27 GY
18 LY
WATER SPRAY MODE SELECT SWITCH 70 P
Illumination LED
WATER SPRAY TIMER
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Parking brake
1-2,4-6
Except ROPS type
Backlight
Flood lamp
CONNECTION
CONT
39 LW
Position lamp
Water spray
VIBRATION
6
Output interface
Engine speed 3
B
CPU
Engine speed 2
G
EEPROM
Input interface
Engine speed 1
18 3LY
B
18 3LY
BATT (12V)
12V
B
B
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
1
2
3 4
70 P
39 LW
70 P
B
ROPS type
R
F
Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram The circuit in the dashed box is not mounted.
F-R LEVER SWITCH
COMBINATION METER
R
W
B
27 GY
24 RY
9 2BrW
20 2BrR
1 11
12
FUSE BOX
1
5A
STARTER SWITCH B
2 5WR
FUSE
R 1 R 2 A CC B R C
HEAT
C
ACC B
R2
3 LgR BR
R1
F.L.
45A
5 3GW
65A
11 BrB
11 BrB 2 WR
F.L.
B
TW354,504
12 Y
6 3G
M
R
LIQUID SPRAY PUMP
7 5WR
9 BrW
8 5R
LIQUID SPRAY SWITCH
B 12 Y
13
3 2
9 BrW
39 LW
9 BrW
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
2
18 3LY
20 2BrR
G
4
YR YW
5
Y
W GY RB GB OG LgY WB OW
6
B
BrW GR GW
7
L
24 RY
YL
LB
Br
8
R
9
O
LR
LW
27 GY
TO INTERLOCK RELAY
10
P
WR GL
NO COM
302 LgR
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW
NC
3
Note:
OFF ON ST
AV60
STARTER SWITCH
+
BR
3 LgR
15A
4 LgW
AV60
COM
NO
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A F.L.
10-065
1 5W
SW354-10008
TROUBLESHOOTING
2-6-16. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 2-6-4 Check point
Check/Cause
Action
1. Harness
• Measure resistance between water spray mode select switch terminal 2 wire LW and combination meter connector terminal wire No.39 wire LW. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
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 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, water spray mode select switch is “CONT”, measure voltage between combination meter water spray terminal wire No.39 inlet wire LW and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and water spray indicator lamp does not light, combination meter is faulty.
2-6-17. Liquid spray indicator lamp does not light (TW354, 504) • Check that liquid spray pump can be activated. Reference Fig. : 2-6-4 Check point
Check/Cause
Action
1. Harness
• Measure resistance between liquid spray switch terminal 2 wire BrW and combination meter connector terminal wire No.9 wire BrW. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Liquid spray indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, liquid spray switch pressed, measure voltage between combination meter liquid spray terminal wire No.9 inlet wire BrW and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and liquid spray indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-066
TROUBLESHOOTING
Fig.: 2-6-5 12V
Temperature meter
TA pulse (square wave)
LCD
Hour meter
Fuel sensor Temperature sensor
Engine speed 4
LIGHTING SWITCH LIGHTING SWITCH POSITION CONNECTION 34 GY
Turn signal (L)
GY G GR
Input interface
Flood lamp Glow plug Parking brake
R
FOOT BRAKE SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
NC NO COM
R
Liquid spray
N
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
1-3,4-5 TURN SIGNAL SWITCH
L
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Water spray
L
TURN SIGNAL SWITCH
Illumination LED
Backlight
1-3,4-6
G GR
Turn signal (R)
1-2,4-6
GY R
36 GR
Position lamp
19 3R 4
5
35 G
Output interface
Engine speed 3
19 3R
1
6
38 Or
CPU
Engine speed 2
3 2
38 Or
EEPROM
Input interface
Engine speed 1
37 2GB
TO PARKING BRAKE SOLENOID
B
Movement
TO HEAD LAMP, TAIL LAMP, COMBINATION METER
W
Fuel meter
60 BrY
Movement
24 RY
Tachometer
STOP
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup)
12V
Movement
Input interface
KEY SW
CAN interface
12V
5V power supply
Power excitation circuit
41 RW
BATT (12V)
Lamp check
TO PARKING INTERLOCK RELAY
Coolant temperature 1 Coolant temperature 2 System configuration diagram
3 2 6
15 YL
1
2
3
4
10 14
35 G 36 GR
FUSE BOX
11
38 Or
12
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
5
G
19 3R
21 RG
15 YL
34 GY
36 GR
35 G
38 Or
YR YW
6
Y
W GY RB GB OG LgY WB OW
7
B
BrW GR GW
13
L
24 RY
O YL
LB
Br
TO BRAKE LAMP RELAY
8
R
B
PARKING BRAKE SWITCH
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW P LR
LW
41 RW
4
5
The circuit in the dashed box is not mounted.
COMBINATION METER
WR GL
1
9
Note:
40 WB 301 Y
TO TURN SIGNAL LAMP(L)
11 BrB
12 Y
34 GY
35 G
5A
2 WR
B
8 5R
FLASHER UNIT
B
21 RG
36 GR
STARTER SWITCH
11 BrB 12 Y
E
B
2 5WR
R 1 R 2 A CC B R C
HEAT ACC
C
FUSE
OFF ON R2
B
AV60
ST NO
3 LgR BR
F.L.
TO TURN SIGNAL LAMP(R)
B
L
38 Or
65A
TO FLOOD LAMP
7 5WR
15 YL
36 GR
35 G
38 Or
15 YL
R1
3 LgR
STARTER SWITCH
15A
+
BR
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A F.L.
10-067
1 5W
SW354-10009
TROUBLESHOOTING
2-6-18. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 2-6-5 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 5 wire Or and combination meter connector terminal wire No.38 wire Or. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Flood lamp indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “ ”, measure voltage between combination meter flood lamp terminal wire No.38 inlet wire Or and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and flood lamp indicator lamp does not light, combination meter is faulty.
2-6-19. Parking brake indicator lamp does not light Reference Fig. : 2-6-5 Check point
Check/Cause
Action
1. Harness
• Measure resistance between parking brake switch terminal 5 wire YL and combination meter connector terminal wire No.15 wire YL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Parking Brake Switch
• When parking brake switch is applied, check continuity between parking brake switch terminal 5 wire YL and terminal 4 wire B. There is continuity in normal condition. • If there is no continuity, parking brake switch is faulty.
Replace parking brake switch.
3. Combination Meter (Parking brake indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen parking brake switch is applied and starter switch is ON, check continuity between combination meter parking brake terminal wire No.15 inlet wire YL and chassis ground. There is continuity in normal condition. • If above items (1) and (2) are OK and parking brake indicator lamp does not light, combination meter is faulty.
10-068
TROUBLESHOOTING
Fig.: 2-6-5 12V
Temperature meter
TA pulse (square wave)
LCD
Hour meter
Fuel sensor Temperature sensor
Engine speed 4
LIGHTING SWITCH LIGHTING SWITCH POSITION CONNECTION 34 GY
Turn signal (L)
GY G GR
Input interface
Flood lamp Glow plug Parking brake
R
FOOT BRAKE SWITCH
Engine charge warning Engine oil pressure Hydraulic filter
NC NO COM
R
Liquid spray
N
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
1-3,4-5 TURN SIGNAL SWITCH
L
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Water spray
L
TURN SIGNAL SWITCH
Illumination LED
Backlight
1-3,4-6
G GR
Turn signal (R)
1-2,4-6
GY R
36 GR
Position lamp
19 3R 4
5
35 G
Output interface
Engine speed 3
19 3R
1
6
38 Or
CPU
Engine speed 2
3 2
38 Or
EEPROM
Input interface
Engine speed 1
37 2GB
TO PARKING BRAKE SOLENOID
B
Movement
TO HEAD LAMP, TAIL LAMP, COMBINATION METER
W
Fuel meter
60 BrY
Movement
24 RY
Tachometer
STOP
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup)
12V
Movement
Input interface
KEY SW
CAN interface
12V
5V power supply
Power excitation circuit
41 RW
BATT (12V)
Lamp check
TO PARKING INTERLOCK RELAY
Coolant temperature 1 Coolant temperature 2 System configuration diagram
3 2 6
15 YL
1
2
3
4
10 14
35 G 36 GR
FUSE BOX
11
38 Or
12
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
5
G
19 3R
21 RG
15 YL
34 GY
36 GR
35 G
38 Or
YR YW
6
Y
W GY RB GB OG LgY WB OW
7
B
BrW GR GW
13
L
24 RY
O YL
LB
Br
TO BRAKE LAMP RELAY
8
R
B
PARKING BRAKE SWITCH
B GROUND WATER SPRAY Br BrW LAMP CHECK ENGINE OIL PRESSURE WARNING G GB REV. RATIO SEL.2 GL TURN SIGNAL(R) PARKING BRAKE GR HYDRAULIC OIL FILTER WARNING GW PREHEATING GY L VIBRATOR LB LIQUID SPRAY LR TURN SIGNAL(L) LW FLOOD LAMP LgY REV. RATIO SEL.4 REV. PULSE INPUT 1 O REV. RATIO SEL.3 OG COOLANT TEMP. SEL.2 OW STARTER SWITCH(ACC) P BATTERY 12V(+) R REV. RATIO SEL.1 RB CHARGE WARNING W COOLANT TEMP. SEL.1 WB COMBINATION METER ILLUMINATION WR REV. PULSE INPUT 2 Y SIDE MARKER LAMP YL YR FUEL METER TEMPERATURE METER YW P LR
LW
41 RW
4
5
The circuit in the dashed box is not mounted.
COMBINATION METER
WR GL
1
9
Note:
40 WB 301 Y
TO TURN SIGNAL LAMP(L)
11 BrB
12 Y
34 GY
35 G
5A
2 WR
B
8 5R
FLASHER UNIT
B
21 RG
36 GR
STARTER SWITCH
11 BrB 12 Y
E
B
2 5WR
R 1 R 2 A CC B R C
HEAT ACC
C
FUSE
OFF ON R2
B
AV60
ST NO
3 LgR BR
F.L.
TO TURN SIGNAL LAMP(R)
B
L
38 Or
65A
TO FLOOD LAMP
7 5WR
15 YL
36 GR
35 G
38 Or
15 YL
R1
3 LgR
STARTER SWITCH
15A
+
BR
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A F.L.
10-069
1 5W
SW354-10009
TROUBLESHOOTING
2-6-20. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig. : 2-6-5 Check point
Check/Cause
Action
1. Harness
(1) M easure resistance between turn signal switch terminal Repair or replace wire No.36 wire GR and combination meter connector harness. terminal wire No.36 wire GR. Standard resistance : 10 Ω or less (2) M easure resistance between turn signal switch terminal wire No.35 wire G and combination meter connector terminal wire No.35 wire G. Standard resistance : 10 Ω or less • If above item (1) or (2) is NG, harness is faulty.
2. Turn Signal Switch
• When turn signal switch lever is moved, check continuity between turn signal switch terminals. Turn signal (L) : Between wire No.34 wire GY and wire No.36 wire GR Turn signal (R) : Between wire No.34 wire GY and wire No.35 wire G There is continuity in normal condition. • If there is no continuity, turn signal switch is faulty.
3. Combination Meter (Turn signal indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.11 inlet wire BrB and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and turn signal switch is moved, measure voltage between combination meter terminal wires and chassis ground. • Turn signal (L) terminal wire No.36 inlet wire GR and chassis ground • Turn signal (R) terminal wire No.35 inlet wire G and chassis ground Standard voltage : 12 V or more with constant intervals • If above items (1) and (2) are OK and turn signal indicator lamp does not light, combination meter is faulty.
Replace turn signal switch.
10-070
TROUBLESHOOTING
Fig.: 2-6-6
29 BY
R
308 Br
B
BACKUP BUZZER
R
F
BACKUP BUZZER SWITCH
B 21 RG 30 Lg
HORN
30 Lg
308 Br
21 RG
31 LgW G
NO NC
W
COM
5
3
2
1
21 RG
HORN RELAY
1
2
3
4
5
6
7
8
9
11
12
FUSE BOX
B ACC B
OFF
R2
ON
3 LgR BR
R1
R 1 R 2 A CC B R C
HEAT 7 5WR
C
65A
STARTER SWITCH
2 5WR
F.L.
8 5R
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
21 RG
HORN SWITCH
STARTER SWITCH
ST
AV60 NO
+
BR
3 LgR
15A
4 LgW
AV60
COM
BATTERY RELAY
B
12V 80AH 95D31R
BATTERY
B
FUSE 2 5WR
65A
1 5W
F.L.
SW354-10010
10-071
TROUBLESHOOTING
2-6-21. Horn does not sound Reference Fig. : 2-6-6 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 chassis ground side. • If horn does not sound, horn is faulty.
Replace horn.
2. Horn Relay
(1) W hen starter switch is ON, measure voltage between horn relay terminal 1 and 3 inlet wire RG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and horn switch pressed, measure voltage between horn relay terminal 5 outlet wire 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.
3. Horn Switch
• When horn switch is ON, check continuity between horn switch terminals. There is continuity in normal condition. • If there is no continuity, horn switch is faulty.
Replace horn switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-6-22. Backup buzzer does not sound Reference Fig. : 2-6-6 Check point
Check/Cause
Action
1. Backup Buzzer
• Disconnect backup buzzer and directly connect battery Replace backup buzzer. positive terminal to backup buzzer terminal wire BY side and negative terminal to backup buzzer terminal wire B side. • If backup buzzer does not sound, backup buzzer is faulty.
2. Backup Buzzer Switch
(1) W hen starter switch is ON, measure voltage between Replace backup buzzer backup buzzer switch terminal inlet wire RG 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 backup buzzer switch terminal outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, backup buzzer switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-072
TROUBLESHOOTING
3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting • The largest factor in the majority of failures of hydraulic devices operating under conditions of higher pressure and greater precision is the entry of dirt (foreign substances) into the hydraulic circuit. Particular caution is required when supplying hydraulic oil or when disassembling and assembling hydraulic devices. 1) Pay attention to the work environment. As much as possible, avoid performing tasks such as supplying hydraulic oil, replacing filters and repair work on rainy days, when there is strong wind, or in locations where there is much dust. 2) Disassembly and maintenance work in the field There is the danger of dust entry when disassembly and maintenance work for hydraulic components is performed in the field. In addition, because performance verification after repairs are completed is difficult, replacement of the entire assembly is preferred. Perform disassembly and maintenance of hydraulic components in a special room protected from dust, and use special testers to verify the performance. 3) Sealing of openings Use caps, tape, plastic bags or other means to seal the openings of removed pipes and components in order to prevent foreign substances from entering. Never leave the openings exposed or put a shop cloth into them. There is the danger of foreign substances entering or of leaking oil causing environmental contamination. Do not dispose of waste oil on-site. Either deliver it to the customer and request disposal or take it back with you and dispose of it. 4) Prevent entry of foreign substances when supplying oil. Take care that foreign substances do not enter when supplying hydraulic oil. Clean the oil supply port and the area around it, as well as the supply pump, oilcan and other items. A more reliable method is to use oil cleaning equipment, which can filter out the contamination that occurred during storage. 5) Change hydraulic oil while the temperature is still high. All oils, including hydraulic oil, flow more readily when they are warm. Higher temperatures also make it easier to eject the sludge and other substances outside the circuit together with the oil. For these reasons, oil changes should be performed while the oil temperature is high. When changing the oil, it is necessary to drain out as much of the old hydraulic oil as possible. (In addition to the hydraulic oil tank, also drain the oil from the filter and circuit drain plugs.) If old hydraulic oil remains in the system, the contaminants and sludge in the old oil will mix with the new oil and shorten the hydraulic oil lifetime.
10-073
TROUBLESHOOTING
3-2. Propulsion System If a problem occurs in the propulsion systems such as the propulsion pump, propulsion motor and brakes, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.
3-2-1. Machine moves neither forward nor backward 1/2 Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Bypass Valve
Bypass valve is open.
Close bypass valve.
3. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
4. Charge Circuit Pressure
Propulsion pump does not discharge oil because charge pressure is low.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply circuit with charge circuit. • Parking brake solenoid valve • Speed change solenoid valve
• When solenoid is energized, check if oil flows in return circuit to tank. • If oil is flowing, repair solenoid valve or replace it if necessary.
5. Suction Filter for Steering • Charge Pump
Steering • charge pump flow is reduced due Clean suction filter or replace it if necessary. to clogged filter.
6. Propulsion Circuit Pressure
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.
7. Propulsion Motor
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.
10-074
TROUBLESHOOTING
3-2-1. Machine moves neither forward nor backward 2/2 Check point
Cause
Check/Action
8. 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.
9. 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.
10. Brake Inlet Pressure
Brake cannot be released because brake inlet pressure is low.
• Measure brake release pressure. • If low, repair or replace propulsion motor.
11. Coupling
Drive torque is not transmitted to pump due to faulty coupling.
Replace coupling.
3-2-2. Machine moves in one direction only (forward or backward) Check point
Cause
Check/Action
1. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
2. High Pressure Relief Valve
Low circuit pressure due to incorrect high • Interchange two high pressure relief pressure relief setting or internal leakage of valves. high pressure relief valve. • If faulty condition is accordingly reversed, check and adjust high pressure relief valve or replace it if necessary.
3-2-3. Slow machine speed or small drive force 1/2 Check point
Cause
Check/Action
1. Bypass Valve
Bypass valve is slightly open.
Close bypass valve completely.
2. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
3. Charge Circuit Pressure
Stroke of propulsion pump swash plate is small because charge pressure is low, decreasing discharge rate of propulsion pump.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply circuit with charge circuit. • Parking brake solenoid valve • Speed change solenoid valve
• When solenoid is energized, check if oil flows in return circuit to tank. • If oil is flowing, repair solenoid valve or replace it if necessary.
Flow rate of steering • charge pump decreases as well as charge pressure decreases due to clogged filter.
Clean suction filter or replace it if necessary.
4. Suction Filter for Steering • Charge Pump
10-075
TROUBLESHOOTING
3-2-3. Slow machine speed or small drive force 2/2 Check point 5. Propulsion Motor
6. Propulsion Pump
Cause
Check/Action
Propulsion motor inlet pressure is low.
• Measure propulsion motor inlet pressure. • If low, check and adjust high pressure relief valve or replace it if necessary.
Propulsion circuit pressure is not held in propulsion motor case.
• Measure propulsion motor case pressure. • If case pressure is not within allowable pressure, repair propulsion motor or replace it if necessary.
Output of propulsion motor decreases and number of revolutions decreases due to internal leakage of propulsion motor.
• Measure drain quantity from propulsion motor. • If drain quantity is larger than standard value, repair propulsion motor or replace it if necessary.
Discharge flow rate is insufficient due to efficiency degradation of propulsion pump.
• Measure discharge flow rate of propulsion pump with flow meter. • If discharge flow rate is not within specified range, repair propulsion pump or replace it if necessary.
Discharge flow rate is insufficient due to Replace propulsion pump. wear of propulsion pump drive shaft splines. Propulsion circuit pressure is not held in propulsion pump case.
• Measure propulsion pump case pressure. • If case pressure is not within allowable pressure, repair propulsion pump or replace it if necessary.
3-2-4. Machine speed cannot be switched Check point 1. Charge Circuit Pressure
Cause
Check/Action
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. • Speed change solenoid valve • 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.
2. Speed Change Solenoid Valve
Machine speed does not change because spool of speed change solenoid valve does not change.
Repair speed change solenoid valve or replace it if necessary.
3. Propulsion Motor Speed Change Spool
Propulsion motor speed change spool is faulty.
Replace speed change spool.
3-2-5. Machine does not stop completely with F-R lever in “N” Check point
Cause
Check/Action
1. F-R lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
2. Propulsion Pump Servo Cylinder
Faulty propulsion pump servo cylinder or faulty pump swash plate setting.
Repair propulsion pump or replace it if necessary.
10-076
TROUBLESHOOTING
3-2-6. Driving not possible with differential locked (TW354, 504) Check point 1. Differential Lock Valve
Cause
Check/Action
Flow control valve is clogged or check valve Inspect flow control valve and check valve is faulty. or replace it if necessary.
3-2-7. 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 (Propulsion motor (F))
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 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 valve or replace it if necessary.
4. Propulsion Circuit Pressure
Fill tank until correct oil level is obtained.
If circuit pressure setting is excessively low, • Measure propulsion circuit pressure. relief valve opens, causing temperature of • If low, increase relief setting pressure. hydraulic oil in circuit to rise. If load is excessively heavy, relief valve opens, causing temperature of hydraulic oil in circuit to rise.
• Measure propulsion circuit pressure. • If high, decrease propulsion load.
5. Suction Filter for Steering • Charge Pump
Load of steering • charge pump increases Clean suction filter or replace it if necessary. due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
6. Hydraulic Oil Filter
Charge circuit pressure increases due to clogged filter.
Clean hydraulic oil filter or replace it if necessary.
3-2-8. Abnormal noise from propulsion system Check point
Cause
Check/Action
1. Axle Bearings
Axle bearings supporting front and rear drums are damaged.
Replace axle bearings.
2. Hydraulic Hose Clamp
Vibrator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose.
Tighten bolts of loose hydraulic hose clamp to specified torque.
3. Suction Filter for Steering • Charge Pump
Cavitation is occurring in steering • charge pump due to clogged filter.
Clean suction filter or replace it if necessary.
4. Charge Circuit Pressure
If charge pressure is low, brake cannot be released completely, which causes brake drag.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
5. Propulsion Motor
Internal bearing of propulsion motor is damaged.
Repair propulsion motor or replace it if necessary.
10-077
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. Suction Filter for Vibrator Pump
Vibrator pump flow is reduced due to clogged filler.
Clean suction filter or replace it if necessary.
3. Vibrator Circuit Pressure
Circuit does not obtain required pressure because setting pressure of relief valve is low.
• Measure vibrator circuit pressure. • If low, check and clean relief valve or replace it if necessary.
Because spool of vibrator solenoid valve 4. Vibrator Solenoid Valve (SW/TW354) does not shift, oil flows in return circuit to tank.
5. Vibrator Solenoid Valve (TW504)
6. Vibrator Motor
Repair or replace vibrator solenoid valve if valve does not shift.
Decrease in circuit pressure due to faulty setting of relief valve or internal leakage.
• Measure vibrator circuit pressure. • If low, check and clean relief valve or replace it if necessary.
Because spool of vibrator solenoid valve does not shift, oil flows in return circuit to tank in neutral position.
Repair or replace vibrator solenoid valve if valve does not shift.
Decrease in circuit pressure due to faulty setting of relief valve or internal leakage.
• Measure vibrator circuit pressure. • If low, check and clean 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.
Internal leakage of vibrator motor.
• Measure drain quantity from vibrator motor. • If drain quantity is larger than standard value, repair vibrator motor or replace it if necessary.
Output torque is not transmitted due to worn Replace vibrator motor. spline of vibrator motor output shaft. 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.
8. Vibrator Bearing
Although vibrator motor output shaft rotates, Remove vibrator motor and check rotation. no vibration is generated because vibrator If no vibration is generated, replace vibrator bearing is damaged or seized. bearing.
9. Power Transmission Sleeve
Although vibrator motor output shaft rotates, Remove vibrator motor and check rotation. no vibration is generated due to worn spline If no vibration is generated, replace power of power transmission sleeve. transmission sleeve.
10-078
TROUBLESHOOTING
3-3-2. Vibrator frequency is too low Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Suction Filter for Vibrator Pump
Flow rate of vibrator pump decreases as well as charge pressure decreases due to clogged filter.
Clean suction filter or replace it if necessary.
3. Vibrator Motor
Vibrator motor inlet pressure is low.
• Measure vibrator motor inlet pressure. • If low, check and adjust high pressure relief valve or replace it if necessary.
Vibrator circuit pressure is not held in vibrator motor case.
• Measure vibrator motor case pressure. • If case pressure is not within allowable pressure, repair vibrator motor or replace it if necessary.
Decrease in vibrator motor rpm due to internal leakage in vibrator motor.
• Measure drain quantity from vibrator motor. • If drain quantity is larger than standard value, repair vibrator motor or replace it if necessary.
Insufficient discharge rate from vibrator pump due to reduced efficiency of vibrator pump.
• Measure discharge flow rate of vibrator pump with flow meter. • If discharge flow rate is not within specified range, repair vibrator pump or replace it if necessary.
Insufficient pump discharge due to wear of vibrator pump drive shaft spline.
Replace vibrator pump.
4. Vibrator Pump
3-3-3. Vibratory drum does not changeover vibrating (SW354 ROPS) 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.
3-3-4. Vibration mode does not switch (TW504) Check point 1. Vibrator Solenoid Valve
Cause Vibrator solenoid valve spool does not change.
Check/Action Repair vibrator solenoid valve or replace it if necessary.
3-3-5. Vibrator does not stop Check point
Cause
Check/Action
Vibrator solenoid valve spool does not 1. Vibrator Solenoid Valve (SW/TW354) change.
Repair vibrator solenoid valve or replace it if necessary.
Vibrator solenoid valve spool does not return to neutral position.
Repair vibrator solenoid valve or replace it if necessary.
2. Vibrator Solenoid Valve (TW504)
10-079
TROUBLESHOOTING
3-3-6. Vibrator system is overheating Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
2. Oil Cooler
Cooling efficiency is reduced due to clogged Clean oil cooler fins. oil cooler fins.
3. 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.
4. Suction Filter for Vibrator Pump
Fill tank until correct oil level is obtained.
If load is excessively heavy, relief valve opens, causing temperature of hydraulic oil in circuit to rise.
• Measure vibrator circuit pressure. • If high, decrease vibration load.
Load of vibrator pump increases due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
Clean suction filter or replace it if necessary.
3-3-7. Abnormal noise from vibrator system Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Pump suction pressure is high because oil level of hydraulic oil tank is low, causing cavitation in vibrator circuit.
Fill tank until correct oil level is obtained.
2. Vibrator Circuit
Cavitation is caused by air in circuit.
Bleed circuit.
3. Vibrator Bearings
Vibrator bearings supporting eccentric shaft Replace vibrator bearings. are damaged.
4. 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.
5. Suction Filter for Vibrator Pump
Cavitation is occurring in vibrator pump due to clogged filter.
Clean suction filter or replace it if necessary.
6. Vibrator Motor
Internal bearing of vibrator motor is damaged.
Repair vibrator motor or replace it if necessary.
7. Power Transmission Sleeve
Noise is generated from power transmission If wear of sleeve spline is large, replace shaft because sleeve backlash is large. sleeve.
10-080
TROUBLESHOOTING
3-4. Steering System If a problem occurs in the steering systems such as the steering • charge pump and orbitrol, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.
3-4-1. Steering wheel is hard to turn Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Orbitrol
Relief valve is open or setting pressure is low.
• Measure steering circuit pressure. • If low, check and clean relief valve or replace it if necessary.
Flow to steering cylinder circuit is insufficient Check and clean check valve or replace it if due to leakage from check valve. necessary. Spool and sleeve of orbitrol are contaminated or clearance is incorrect.
Check and clean orbitrol or replace it if necessary.
3. Steering Circuit Pressure
Pressure in return circuit from orbitrol Clean hydraulic filter or replace it if increases due to clogged charging hydraulic necessary. filter.
4. Steering Cylinder
Cylinder thrust decreases due to internal leakage of steering cylinder.
Repair steering cylinder or replace it if necessary.
5. Suction Filter for Steering • Charge Pump
Steering • charge pump discharge rate decreases due to clogged filter.
Clean suction filter or replace it if necessary.
6. Steering • Charge Pump
Discharging pressure is insufficient due to efficiency degradation of steering • charge pump.
• Measure steering circuit pressure. • If low, replace steering • charge pump.
7. Steering Column
Column shaft and orbitrol shaft center are misaligned.
Align column shaft with orbitrol shaft center or replace it if necessary.
Column shaft bearing is worn or damaged.
Repair column shaft or replace it if necessary.
3-4-2. Steering response is slow Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Orbitrol
Oil is bypassing because relief valve is open.
• Measure steering circuit pressure. • If low, check and clean relief valve or replace it if necessary.
3. Steering Cylinder
Internal leakage of steering cylinder.
Repair steering cylinder or replace it if necessary.
4. Suction Filter for Steering • Charge Pump
Steering • charge pump discharge rate decreases due to clogged filter.
Clean suction filter or replace it if necessary.
5. Steering • Charge Pump
Discharging pressure is insufficient due to efficiency degradation of steering • charge pump.
• Measure steering circuit pressure. • If low, replace steering • charge pump.
10-081
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
Check/Action
1. Oil Level of Hydraulic Oil Tank
Pump suction pressure is high because oil level of hydraulic oil tank is low, causing cavitation in steering circuit system.
Fill tank until correct oil level is obtained.
2. Steering Circuit
Cavitation is caused by air in circuit.
Bleed circuit.
3. Hydraulic Hose Clamp
Vibrator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose.
Tighten bolts of loose hydraulic hose clamp to specified torque.
4. Suction Filter for Steering • Charge Pump
Cavitation is occurring in steering • charge pump due to clogged filter.
Clean suction filter or replace it if necessary.
10-082
TROUBLESHOOTING
3-5. Cooling System If a problem occurs in the cooling systems such as the vibrator pump and cooling fan drive motor, 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.
3-5-1. Cooling fan does not rotate Check point
Check/Cause
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. Cooling Circuit Pressure
Circuit does not obtain required pressure because setting pressure of relief valve is low.
• Measure cooling circuit pressure. • If low, check and clean relief valve or replace it if necessary.
3. Suction Filter for Vibrator Pump (also used for cooling system)
Vibrator pump discharge rate decreases due to clogged filter.
Clean suction filter or replace it if necessary.
4. Vibrator Pump (also used for cooling system)
Discharge flow rate is insufficient due to efficiency degradation 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.
5. Cooling Fan Drive Motor
Internal leakage or internal failure of cooling Repair or replace cooling fan drive motor. fan drive motor. Output torque is not transmitted due to worn Replace cooling fan drive motor. spline of cooling fan drive motor output shaft.
3-5-2. Cooling system is overheating Check point
Check/Cause
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. Oil Cooler
Cooling efficiency is reduced due to clogged Clean oil cooler fin. oil cooler fins.
3. Pressure Setting in If circuit pressure setting is excessively low, • Measure cooling circuit pressure. Cooling Circuit relief valve open, causing temperature of • If low, check and clean relief valve or hydraulic oil in circuit to rise. replace it if necessary.
4. Suction Filter for Vibrator Pump
10-083
If load is excessively heavy, relief valve open, causing temperature of hydraulic oil in circuit to rise.
• Measure cooling circuit pressure. • If high, decrease vibrator load.
Load of vibrator pump increases due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
Clean suction filter or replace it if necessary.
SW504
TROUBLESHOOTING
4. ELECTRICAL SYSTEM TROUBLESHOOTING (SW504) 4-1. Engine Diagnosis Trouble Code 4-1-1. Description of diagnostic trouble code (SPN, FMI) 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. 1) Set the start switch to “ON”. 2) Set and hold the diagnostic switch to “DIAG.”
Diagnostic switch DIAG. OFF
VIEW A A No fault code.
Self-diagnosis in progress.
Occurrence of fault code.
SW504-10011
10-084
SW504
TROUBLESHOOTING
4-1-2. Table of the diagnostic trouble code (DTC) J1939-73 SPN
Detection Item
3
Accelerator position sensor 2: High
• Battery short circuit out of sensor / harness
4
Accelerator position sensor 2: Low
• Ground short circuit or open circuit of sensor / harness
2
Accelerator position sensor correlation error
• Deviation from designed correlation in two sensors
3
Accelerator position sensor 1: High
• Battery short circuit out of sensor / harness
4
Accelerator position sensor 1: Low
• Ground short circuit or open circuit of sensor / harness
1
Oil pressure error
• Oil pressure switch
3
Boost pressure sensor: High
• Open circuit or +B short circuit of sensor / harness • Failure of sensor
4
Boost pressure sensor: Low
• Ground short circuit of sensor / harness • Failure of sensor
3
Barometric pressure sensor error (High side)
• Sensor / ECU internal circuit short to +B
4
Barometric pressure sensor error (Low side)
• Sensor / ECU internal circuit short to ground
0
Engine overheat
• Overheat of engine coolant temperature
3
Coolant temperature sensor: High
• Open circuit or +B short circuit of sensor / harness
4
Coolant temperature sensor: Low
• Ground short circuit of sensor / harness
1
Intake air volume: Low
• Engine inlet air mass flow rate lacking (Disconnect turbo blower • Insufficient output intake hose)
3
MAF sensor: High
• +B short circuit of sensor / harness
4
MAF sensor: Low
• Open circuit or ground short circuit of sensor / harness
15
Boost pressure low
• Disconnect the hose between the turbo blower out and intake flange • Boost pressure sensor error
• Insufficient output
0
High rail pressure
• Actual pressure exceeds the command pressure
• Insufficient output • Worsening exhaust gas performance
3
Rail pressure sensor: High
4
Rail pressure sensor: Low
FMI
29
91
100
102
108
110
132
157
10-085
Behaviour During
DTC Name
Malfunction
• Insufficient output
• Engine stops
• Insufficient output
• Insufficient output • Overheat • Amount of white smoke increases at low temperatures • Insufficient output • Worsening exhaust gas performance
• Insufficient output • Worsening exhaust gas performance
• Open circuit or +B short circuit of • Insufficient output sensor / harness • Worsening exhaust gas • Failure of sensor performance • Ground short circuit of sensor / • Worsening running noise • Increase in white smoke harness • Engine stops • Failure of sensor
SW504
TROUBLESHOOTING
J1939-73 SPN
FMI
DTC Name
Detection Item
Behaviour During Malfunction
Battery voltage: High
• Open circuit, short circuit or damage of harness • Failure of battery
• Faulty starting • Insufficient output • Worsening exhaust gas performance
4
Battery voltage: Low
• Open circuit, short circuit or damage of harness • Failure of battery
• Faulty starting • Insufficient output • Worsening exhaust gas performance • Engine stops in some case
3
Intake air temperature built-in MAF sensor: High
• Open circuit or +B short circuit of sensor / harness
4
Intake air temperature built-in MAF sensor: Low
• Ground short circuit of sensor / harness
3
Intake air temperature error: High
4
Intake air temperature error: Low
• Open circuit or +B short circuit of • Amount of white sensor / harness smoke increases at low • Ground short circuit of sensor / temperatures harness
190
0
Engine overrun
• Engine speed exceeds threshold • Overrun speed
628
2
ECU FLASH ROM error
• FLASH ROM error
633
7
Pressure limiter emergency open
• Insufficient output • Pressure limiter emergency open • Worsening exhaust gas performance
2
NE sensor (Crankshaft position sensor) pulse number error
• Open circuit or short circuit of sensor / harness • Failure of sensor
(Running only with G signal) • Faulty starting • Vibration is slightly large • Insufficient output
7
NE-G phase shift
• Large phase shift between NE (crankshaft position sensor) pulse and G (camshaft position sensor) pulse
(Invalid G signal) • Engine hesitates at start-up
8
No input of NE sensor (Crankshaft position sensor) pulse
• Open circuit or short circuit of sensor / harness • Failure of sensor
(Running only with G signal) • Faulty starting • Vibration is slightly large • Insufficient output
651
3
Open circuit of harness/coil in 1st cylinder injector
652
3
Open circuit of harness/coil in 2nd cylinder injector
653
3
Open circuit of harness/coil in 3rd cylinder injector
• Open circuit of harness • Open circuit of injector coil
• Insufficient output • Large vibration • Worsening exhaust gas performance
654
3
Open circuit of harness/coil in 4th cylinder injector
0
Glow heater relay driving circuit • Overheat of glow plug driving overheat circuit
5
Open circuit of glow relay driving circuit
• Open circuit of air glow relay
4
Ground short of starter relay driving circuit
• Ground short of starter relay driving circuit
3 168
171
172
636
676
677
• None
• Engine stops
(At low temperature) • Faulty starting • Increase in white smoke • Faulty starting
10-086
SW504
TROUBLESHOOTING J1939-73 SPN
FMI
DTC Name
7
Pressure limiter not open
• Rail pressure value is sticking or too low engine power not to open PL valve forcibility
16
Rail pressure failure after pressure limiter open
• Rail pressure value is too high or low despite the existence of response that the pressure limiter opened
2
G sensor (Camshaft position sensor) pulse number error
679
723 8
1077
1239
1347
1485
3242
3246
10-087
Detection Item
• Open circuit or short circuit of sensor / harness No input of G sensor (Camshaft • Failure of sensor position sensor) pulse
Behaviour During Malfunction
• Engine stops
(Invalid G signal) • Engine hesitates at start-up
2
ECU CPU (Main IC) error
• Failure of CPF and/or IC
12
Injector drive IC error or Open circuit
• Injector drive IC error or Open circuit of No.1 and 4 cylinder injector or Open circuit of No.2 and 3 cylinder injector
1
Fuel leak (in high pressured fuel system)
• Fuel leak from high pressured fuel system (Fuel consumption is • Insufficient output calculated from the difference of • Worsening exhaust gas fuel pressure of before and after performance the injection, and the error will • Engine stops in some be detected when excess fuel case consumption is found)
3
+B short circuit of SCV (MPROP)
• +B short circuit of SCV
4
SCV (MPROP) drive system error
• Open circuit or ground short circuit of SCV
5
Open circuit of SCV (MPROP)
• Open circuit of SCV
7
SCV (MPROP) stuck
• SCV stuck at open position • Insufficient output (Actual rail pressure continuously • Worsening exhaust gas exceeds the command rail performance pressure) • Engine stops in some case
2
Main relay is locked in closed position
• Failure of main relay
• Dead battery
0
Emergency Exhaust gas temperature sensor 1: High
• DPF inlet temperature (T1) high
• Engine stops • Inhibit cranking until down to 300 °C (572 °F)
3
Exhaust gas temperature sensor 1: High
• Open circuit or +B short circuit of sensor / harness
4
Exhaust gas temperature sensor 1: Low
• Ground short circuit of sensor / harness
0
Emergency Exhaust gas temperature sensor 2: High
• DPF outlet temperature (T2) high
3
Exhaust gas temperature sensor 2: High
• Open circuit or +B short circuit of sensor / harness
4
Exhaust gas temperature sensor 2: Low
• Ground short circuit of sensor / harness
• Engine stops
• Insufficient output • Worsening exhaust gas performance
• None • Engine stops • Inhibit cranking until down to 300 °C (572 °F) • None
SW504
TROUBLESHOOTING
J1939-73 SPN
Detection Item
3
Differential pressure sensor 1: High
• Open circuit or +B short circuit of sensor / harness
4
Differential pressure sensor 1: Low
• Ground short circuit of sensor / harness
0
Emission deterioration
• DOC is heated up due to unburned fuel
3
Sensor supply voltage 1: High
4
Sensor supply voltage 1: Low
3
Sensor supply voltage 2: High
4
Sensor supply voltage 2 Low
3
Sensor supply voltage 3: High
4
Sensor supply voltage 3: Low
• Sensor supply voltage 3 error or • Faulty starting recognition error
0
Excessive PM5
• PM accumulation level5
15
Excessive PM3
• PM accumulation level3
16
Excessive PM4
• PM accumulation level4
0
Emergency Exhaust gas temperature sensor 0: High
• Engine stops • DOC inlet temperature (T0) high • Inhibit cranking until down to 300 °C (572 °F)
3
Exhaust gas temperature sensor 0: High
• Open circuit or +B short circuit of sensor / harness
4
Exhaust gas temperature sensor 0: Low
• Ground short circuit of sensor / harness
3
1 & 4 cylinder injector short to +B or all cylinder injector short to +B
• Wiring harness short to +B
4
1 & 4 cylinder injector short to ground, or all cylinder injector short to ground
• Wiring harness short to ground
3
2 & 3 cylinder injector short to +B or all cylinder injector short to +B
• Wiring harness short to +B
4
2 & 3 cylinder injector short to ground, or all cylinder injector short to ground
• Wiring harness short to ground • Insufficient output • Worsening exhaust gas performance • Engine stops
FMI
3251
3252
3509
3510
3511
3701
4765
Behaviour During
DTC Name
523523
523524
Malfunction • None
• Insufficient output
• Faulty starting • Insufficient output • Sensor supply voltage 1 error or • Worsening exhaust gas recognition error performance • Engine stops in some case • Faulty starting • Sensor supply voltage 2 error or • Insufficient output recognition error • Worsening exhaust gas performance
• Insufficient output
• None
• Insufficient output • Large vibration • Worsening exhaust gas performance • Engine stops in some case
523525
1
Injector charge voltage: Low
• Injector charge voltage: Low • Failure of charge circuit of ECU
523527
2
ECU CPU (Monitoring IC) error
• Failure of monitoring IC of CPU
• Engine stops
• Injector charge voltage: High
• Insufficient output • Worsening exhaust gas performance • Engine stops
523535
0
Injector charge voltage: High
10-088
SW504
TROUBLESHOOTING J1939-73 SPN
FMI
DTC Name
Detection Item
Behaviour During Malfunction
2
QR (IQA) data error
• QR data read error
7
No QR (IQA) data
• QR data is unwritten
2
Accelerator position sensor error (CAN)
• Accelerator position sensor • Insufficient output signal error (sensor / harness open circuit, ground short circuit etc)
3
+B short of glow relay driving circuit
• +B short of glow relay driving circuit
4
Ground short of glow relay driving circuit
• Ground short of air glow relay driving circuit
523547
2
CAN2 Bus off
• CAN2 +B / GND short circuit or high traffic error
• Insufficient output • Transmitted data is invalid
523548
2
CAN-KBT frame error
• CAN-KBT original frame open circuit error
• Insufficient output
523572
4
EGR position sensor failure
• EGR position sensor failure
3
EGR actuator open circuit
• EGR actuator open circuit
4
EGR actuator coil short
• EGR actuator coil short
523575
7
EGR actuator valve stuck
• EGR actuator valve stuck
523576
2
EGR (DC motor) overheat
• EGR (DC motor) overheat
523577
2
EGR (DC motor) temperature sensor failure
• EGR (DC motor) temperature sensor failure
523578
2
No communication with EGR
• No communication with EGR
523580
2
Intake throttle feedback error
• Intake throttle feedback error
3
Intake throttle lift sensor: High
• Intake throttle lift sensor high
4
Intake throttle lift sensor: Low
• Intake throttle lift sensor low
523589
17
Low coolant temperature in parked regeneration
• During regeneration mode, engine warm-up condition is not satisfied (coolant temperature is low)
523590
16
Parked regeneration time out
• Time out error: regeneration incomplete due to low temperature of DPF
523591
2
CAN CCVS (Parking SW and Vehicle Speed) frame error
• CAN_CCVS communication stopping
523592
2
CAN CM1 (Regen SW) frame error
• CAN_CM1 communication stopping
523595
2
CAN ETC5 (Neutral SW) frame error
• CAN_ETC5 communication stopping
523596
2
CAN TSC1 frame error
• CAN_TSC1 communication stopping
523598
2
CAN EBC1 frame error
• CAN_EBC1 communication stopping
523599
0
All exhaust gas temperature sensor failure
• All exhaust gas temperature sensor failure simultaneously
523538
523543
523544
523574
523582
10-089
(At low temperature) • Faulty starting • Increase in white smoke
• Insufficient output • Worsening exhaust gas performance
• None
SW504
TROUBLESHOOTING
J1939-73
DTC Name
Detection Item
Behaviour During Malfunction
SPN
FMI
523601
0
High exhaust gas temperature after emergency high temperature DTC
• Exhaust gas temperature sensor • None 0, 1, 2 output
523602
0
High frequency of regeneration
• Time interval from the end time to the start time of the regeneration
523603
15
Over heat pre-caution
• Coolant temperature
523604
2
CAN1 Bus off
• CAN1 +B / GND short circuit or high traffic error
• Worsening exhaust gas performance (NOx) • Insufficient output • Transmitted data is invalid
523605
6
Short circuit in injector driver IC • Open circuit of air glow relay
• Insufficient output • Large vibration • Worsening exhaust gas performance • Engine stops in some case
523700
13
EEPROM check sum error
• None
• KBT-EEPROM check sum error
10-090
SW504
TROUBLESHOOTING
Fig.: 4-2-1 R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
NO COM
27 GY
1
NC
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W f 302 LgR
301 Y
85
86
85 LY
STARTER RELAY
B a
30
b
FUSE BOX
98 LR
16 3W 3 LgR
f
27 GY
B
R1
b
STARTER SWITCH
a
NEUTRAL RELAY
TO COMBINATION METER
L
IG
E
B
7 5WR
13 2Y 17 WR
1
99 LY
c
e
R2
B BR
11
ACC
C
14 WL
65A
FUSE
2 5WR
8 5R
5A
2 WR
16 3W
12 Y
12
14
5A FUSE
F.L.
TO COMBINATION METER
11 BrB
8 5R
ST 314 BY
2
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
ON
3
OFF
4
R 1 R 2 A CC B R C
B
5
STARTER SWITCH HEAT
6
PARKING INTERLOCK RELAY
7
INTERLOCK RELAY
13
1
26 5BR 87
24 RY
2
e
86 L
86 L
8
3
c
25 3W
5
87 LR
9
B
87 LR
10
300 BW
28 8WY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241 O_S_STRTL(ST-REL) 136 O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250
5A
80 WG
ALTERNATOR
FUSE
84 WY 300 BW 85 LY
312 5BY
90 GW 89 G
D1803 ECU
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227
100 L 101 G 102 B 103 W 104 Y 105 Br
POWER GND 252 POWER GND 254
GND2
P
FUEL PUMP
+V1 OUT1 GND1
3 LgR
S
4 LgW
15A
312 5BY
161 1.25B
I_A_MAS(SIG) 205
110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
AV60
COM BR B
(5) TEMP.SENSOR(-)
AV60
NO
BATTERY RELAY
B
+
12V BATTERY
STARTER MOTOR
-
B
DIODE
F.L.
84 WY
D1803 ECU
GLOW PLUGS
311 5BW
65A
162 1.25B
109 0.5Gr
AV60
FUSE
160 1.25B
2 5WR 313 5WB
82 3WL
G_R_AMS(GND) 203
9
R 82 WL
OUT2
D1803 ECU
I_A_IATS(SIG temp) 204
e
89 G
5W +V2
POTENTIOMETER POWER GND 251
G
7
99 LY
W
V_V_5VAPP1(5V) 201 G_R_GND1(GND) 240
98 LR
Lg
I_S_TRO_N(SW) 217
82 1.25WL
4
V_V_BAT3(+BP) 253 G_R_GND1(GND) 209
82 1.25WL
28 8WY
V_V_BAT2(+BP) 255
B
GLOW RELAY
82 1.25WL
26 5BR
V_V_BAT1(+BP) 256
10 5WG
90 GW
5
3
2
1
313 WB
25A
2 3WR
2 8WR
75A
1 8W
F.L.
FUSE
ECU MAIN RELAY
(4) TEMP.SENSOR(+) (3) OUTPUT SIG. VO (2) GRAUND G (1) BATTERY VO. VB
AIR FLOW SENSOR
SW504-10001
10-091
SW504
TROUBLESHOOTING
4-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked.
4-2-1. Engine will not start (Starter motor does not run) 1/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 4-2-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. Starter Switch
• Check continuity between O-O according to starter switch connection table. Switch is OK if there is continuity between connection O-O. • If there is no continuity, starter switch is faulty.
Replace starter switch.
3. Starter Motor
(1) W hen starter switch is ON, measure voltage between starter motor terminal B and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter motor terminal S and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and starter motor does not run, starter motor is faulty.
Replace starter motor.
4. Starter Relay
(1) W hen starter switch is START, measure voltage between Replace starter relay. starter relay terminal 86 inlet wire LY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter relay terminal 87 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 30 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 relay is faulty.
5. Battery Relay
(1) W hen starter switch is OFF, measure voltage between battery relay primary terminal COM and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between battery relay coil terminal BR inlet wire LgW and coil ground terminal outlet wire B. 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.
Replace battery relay.
10-092
SW504
TROUBLESHOOTING
Fig.: 4-2-1 R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
NO COM
27 GY
1
NC
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W f 302 LgR
301 Y
85
86
85 LY
STARTER RELAY
B a
30
b
FUSE BOX
98 LR
16 3W 3 LgR
f
27 GY
B
R1
b
STARTER SWITCH
a
NEUTRAL RELAY
TO COMBINATION METER
L
IG
E
B
7 5WR
13 2Y 17 WR
1
99 LY
c
e
R2
B BR
11
ACC
C
14 WL
65A
FUSE
2 5WR
8 5R
5A
2 WR
16 3W
12 Y
12
14
5A FUSE
F.L.
TO COMBINATION METER
11 BrB
8 5R
ST 314 BY
2
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
ON
3
OFF
4
R 1 R 2 A CC B R C
B
5
STARTER SWITCH HEAT
6
PARKING INTERLOCK RELAY
7
INTERLOCK RELAY
13
1
26 5BR 87
24 RY
2
e
86 L
86 L
8
3
c
25 3W
5
87 LR
9
B
87 LR
10
300 BW
28 8WY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241 O_S_STRTL(ST-REL) 136 O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250
5A
80 WG
ALTERNATOR
FUSE
84 WY 300 BW 85 LY
312 5BY
90 GW 89 G
D1803 ECU
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227
100 L 101 G 102 B 103 W 104 Y 105 Br
POWER GND 252 POWER GND 254
GND2
P
FUEL PUMP
+V1 OUT1 GND1
3 LgR
S
4 LgW
15A
312 5BY
161 1.25B
I_A_MAS(SIG) 205
110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
AV60
COM BR B
(5) TEMP.SENSOR(-)
AV60
NO
BATTERY RELAY
B
+
12V BATTERY
STARTER MOTOR
-
B
DIODE
F.L.
84 WY
D1803 ECU
GLOW PLUGS
311 5BW
65A
162 1.25B
109 0.5Gr
AV60
FUSE
160 1.25B
2 5WR 313 5WB
82 3WL
G_R_AMS(GND) 203
9
R 82 WL
OUT2
D1803 ECU
I_A_IATS(SIG temp) 204
e
89 G
5W +V2
POTENTIOMETER POWER GND 251
G
7
99 LY
W
V_V_5VAPP1(5V) 201 G_R_GND1(GND) 240
98 LR
Lg
I_S_TRO_N(SW) 217
82 1.25WL
4
V_V_BAT3(+BP) 253 G_R_GND1(GND) 209
82 1.25WL
28 8WY
V_V_BAT2(+BP) 255
B
GLOW RELAY
82 1.25WL
26 5BR
V_V_BAT1(+BP) 256
10 5WG
90 GW
5
3
2
1
313 WB
25A
2 3WR
2 8WR
75A
1 8W
F.L.
FUSE
ECU MAIN RELAY
(4) TEMP.SENSOR(+) (3) OUTPUT SIG. VO (2) GRAUND G (1) BATTERY VO. VB
AIR FLOW SENSOR
SW504-10001
10-093
SW504
TROUBLESHOOTING
4-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 4-2-1 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 inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal outlet wire LgR 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.
Replace F-R lever switch.
7. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire RW 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.
8. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between parking brake switch terminal 1 inlet wire RW 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 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.
9. Interlock Relay
(1) W hen starter switch is ON, measure voltage between interlock Replace interlock relay terminal a inlet wire LgR and chassis ground. relay. Standard voltage : 12 V or more (2) W hen starter switch is START, check continuity between interlock relay terminal e inlet wire LR and c outlet wire L. There is continuity in normal condition. • If above items (1) is OK and item (2) is NG, interlock relay is faulty.
10. Parking Interlock Relay
(1) W hen starter switch is ON, measure voltage between parking Replace parking interlock relay terminal 1 inlet wire Y and chassis ground. interlock relay. Standard voltage : 12 V or more (2) W hen starter switch is START, check continuity between parking interlock relay terminal 3 inlet wire LR and 5 outlet wire BW. There is continuity in normal condition. • If above items (1) is OK and item (2) is NG, parking interlock relay is faulty.
10-094
SW504
TROUBLESHOOTING
Fig.: 4-2-1 R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
NO COM
27 GY
1
NC
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W f 302 LgR
301 Y
85
86
85 LY
STARTER RELAY
B a
30
b
FUSE BOX
98 LR
16 3W 3 LgR
f
27 GY
B
R1
b
STARTER SWITCH
a
NEUTRAL RELAY
TO COMBINATION METER
L
IG
E
B
7 5WR
13 2Y 17 WR
1
99 LY
c
e
R2
B BR
11
ACC
C
14 WL
65A
FUSE
2 5WR
8 5R
5A
2 WR
16 3W
12 Y
12
14
5A FUSE
F.L.
TO COMBINATION METER
11 BrB
8 5R
ST 314 BY
2
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
ON
3
OFF
4
R 1 R 2 A CC B R C
B
5
STARTER SWITCH HEAT
6
PARKING INTERLOCK RELAY
7
INTERLOCK RELAY
13
1
26 5BR 87
24 RY
2
e
86 L
86 L
8
3
c
25 3W
5
87 LR
9
B
87 LR
10
300 BW
28 8WY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241 O_S_STRTL(ST-REL) 136 O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250
5A
80 WG
ALTERNATOR
FUSE
84 WY 300 BW 85 LY
312 5BY
90 GW 89 G
D1803 ECU
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227
100 L 101 G 102 B 103 W 104 Y 105 Br
POWER GND 252 POWER GND 254
GND2
P
FUEL PUMP
+V1 OUT1 GND1
3 LgR
S
4 LgW
15A
312 5BY
161 1.25B
I_A_MAS(SIG) 205
110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
AV60
COM BR B
(5) TEMP.SENSOR(-)
AV60
NO
BATTERY RELAY
B
+
12V BATTERY
STARTER MOTOR
-
B
DIODE
F.L.
84 WY
D1803 ECU
GLOW PLUGS
311 5BW
65A
162 1.25B
109 0.5Gr
AV60
FUSE
160 1.25B
2 5WR 313 5WB
82 3WL
G_R_AMS(GND) 203
9
R 82 WL
OUT2
D1803 ECU
I_A_IATS(SIG temp) 204
e
89 G
5W +V2
POTENTIOMETER POWER GND 251
G
7
99 LY
W
V_V_5VAPP1(5V) 201 G_R_GND1(GND) 240
98 LR
Lg
I_S_TRO_N(SW) 217
82 1.25WL
4
V_V_BAT3(+BP) 253 G_R_GND1(GND) 209
82 1.25WL
28 8WY
V_V_BAT2(+BP) 255
B
GLOW RELAY
82 1.25WL
26 5BR
V_V_BAT1(+BP) 256
10 5WG
90 GW
5
3
2
1
313 WB
25A
2 3WR
2 8WR
75A
1 8W
F.L.
FUSE
ECU MAIN RELAY
(4) TEMP.SENSOR(+) (3) OUTPUT SIG. VO (2) GRAUND G (1) BATTERY VO. VB
AIR FLOW SENSOR
SW504-10001
10-095
SW504
TROUBLESHOOTING
4-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 4-2-1 Check point
Check/Cause
Action
11. Neutral Relay
(1) W hen starter switch is ON, measure voltage between neutral relay terminal a inlet wire GY and chassis ground. There is no electricity in normal condition. (2) W hen starter switch is ON, check continuity between neutral relay terminal c inlet wire LY and f outlet wire LR. There is continuity in normal condition. • If above items (1) is OK and item (2) is NG, neutral relay is faulty.
Replace neutral relay.
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.
4-2-2. Engine will not start (But starter motor runs) • In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate. • Check that fuel is supplied to inlet of fuel pump. Reference Fig.: 4-2-1 Check point 1. Fuel Pump
Check/Cause
Action
• When starter switch is ON, measure voltage between fuel pump terminal inlet wire WL and chassis ground. Standard voltage : 12 V or more • If above item is OK and fuel pump does not operate, fuel pump is faulty.
Repair or replace fuel pump.
2. ECU Main Relay (1) M easure voltage between ECU main relay terminal 1, 3 inlet wire Replace ECU main WB and chassis ground. relay. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between ECU main relay terminal 5 outlet wire WL and chassis ground. Standard voltage : 12 V or more • If above items (1) is OK and item (2) is NG, ECU main relay is faulty. 3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
• No charging
Refer to (P.10-018).
Repair or replace harness.
10-096
SW504
TROUBLESHOOTING
Fig.: 4-2-1 R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
NO COM
27 GY
1
NC
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W f 302 LgR
301 Y
85
86
85 LY
STARTER RELAY
B a
30
b
FUSE BOX
98 LR
16 3W 3 LgR
f
27 GY
B
R1
b
STARTER SWITCH
a
NEUTRAL RELAY
TO COMBINATION METER
L
IG
E
B
7 5WR
13 2Y 17 WR
1
99 LY
c
e
R2
B BR
11
ACC
C
14 WL
65A
FUSE
2 5WR
8 5R
5A
2 WR
16 3W
12 Y
12
14
5A FUSE
F.L.
TO COMBINATION METER
11 BrB
8 5R
ST 314 BY
2
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
ON
3
OFF
4
R 1 R 2 A CC B R C
B
5
STARTER SWITCH HEAT
6
PARKING INTERLOCK RELAY
7
INTERLOCK RELAY
13
1
26 5BR 87
24 RY
2
e
86 L
86 L
8
3
c
25 3W
5
87 LR
9
B
87 LR
10
300 BW
28 8WY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241 O_S_STRTL(ST-REL) 136 O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250
5A
80 WG
ALTERNATOR
FUSE
84 WY 300 BW 85 LY
312 5BY
90 GW 89 G
D1803 ECU
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227
100 L 101 G 102 B 103 W 104 Y 105 Br
POWER GND 252 POWER GND 254
GND2
P
FUEL PUMP
+V1 OUT1 GND1
3 LgR
S
4 LgW
15A
312 5BY
161 1.25B
I_A_MAS(SIG) 205
110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
AV60
COM BR B
(5) TEMP.SENSOR(-)
AV60
NO
BATTERY RELAY
B
+
12V BATTERY
STARTER MOTOR
-
B
DIODE
F.L.
84 WY
D1803 ECU
GLOW PLUGS
311 5BW
65A
162 1.25B
109 0.5Gr
AV60
FUSE
160 1.25B
2 5WR 313 5WB
82 3WL
G_R_AMS(GND) 203
9
R 82 WL
OUT2
D1803 ECU
I_A_IATS(SIG temp) 204
e
89 G
5W +V2
POTENTIOMETER POWER GND 251
G
7
99 LY
W
V_V_5VAPP1(5V) 201 G_R_GND1(GND) 240
98 LR
Lg
I_S_TRO_N(SW) 217
82 1.25WL
4
V_V_BAT3(+BP) 253 G_R_GND1(GND) 209
82 1.25WL
28 8WY
V_V_BAT2(+BP) 255
B
GLOW RELAY
82 1.25WL
26 5BR
V_V_BAT1(+BP) 256
10 5WG
90 GW
5
3
2
1
313 WB
25A
2 3WR
2 8WR
75A
1 8W
F.L.
FUSE
ECU MAIN RELAY
(4) TEMP.SENSOR(+) (3) OUTPUT SIG. VO (2) GRAUND G (1) BATTERY VO. VB
AIR FLOW SENSOR
SW504-10001
10-097
SW504
TROUBLESHOOTING
4-2-3. Glow plug is not heated (Engine starting performance is bad in cold weather) Reference Fig. : 4-2-1 Check point
Check/Cause
Action
1. Glow Plug
• When starter switch is ON, measure voltage between glow plug terminal inlet wire WG and chassis ground. Standard voltage : 12 V or more • If voltage is OK, glow plug is faulty.
2. Glow Relay
Replace glow relay. (1) W hen starter switch is ON, measure voltage between glow relay terminal g inlet wire G and chassis ground. There is electricity in normal condition. (2) M easure voltage between glow relay terminal B inlet wire BY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between glow relay terminal G outlet wire WG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, glow relay is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
• Starter motor runs even when F-R lever is not at “N”
Replace glow plug.
Repair or replace harness.
Refer to (P.10-020).
10-098
SW504
TROUBLESHOOTING
Fig.: 4-2-1 R
STOP
F
FOOT BRAKE SWITCH
F-R LEVER SWITCH
TO COMBINATION METER
R
W
B
B
24 RY
41 RW
4
NO COM
27 GY
1
NC
302 LgR
2 6
15 YL
B
3
W
40 WB 301 Y
24 RY
TO PARKING BRAKE SOLENOID
60 BrY
R
NC NO COM
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W f 302 LgR
301 Y
85
86
85 LY
STARTER RELAY
B a
30
b
FUSE BOX
98 LR
16 3W 3 LgR
f
27 GY
B
R1
b
STARTER SWITCH
a
NEUTRAL RELAY
TO COMBINATION METER
L
IG
E
B
7 5WR
13 2Y 17 WR
1
99 LY
c
e
R2
B BR
11
ACC
C
14 WL
65A
FUSE
2 5WR
8 5R
5A
2 WR
16 3W
12 Y
12
14
5A FUSE
F.L.
TO COMBINATION METER
11 BrB
8 5R
ST 314 BY
2
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
ON
3
OFF
4
R 1 R 2 A CC B R C
B
5
STARTER SWITCH HEAT
6
PARKING INTERLOCK RELAY
7
INTERLOCK RELAY
13
1
26 5BR 87
24 RY
2
e
86 L
86 L
8
3
c
25 3W
5
87 LR
9
B
87 LR
10
300 BW
28 8WY
I_S_T50(ST-SW) 216 O_S_MRLY(M-REL) 241 O_S_STRTL(ST-REL) 136 O_S_STRTH(POW.) 121 O_S_IMPH(G-REL) 135 O_V_RH02(POW.) 250
5A
80 WG
ALTERNATOR
FUSE
84 WY 300 BW 85 LY
312 5BY
90 GW 89 G
D1803 ECU
I_A_APP1(SIG) 229 V_V_5VAPP2(5V) 202 I_A_APP2(SIG) 214 G_R_GND2(GND) 227
100 L 101 G 102 B 103 W 104 Y 105 Br
POWER GND 252 POWER GND 254
GND2
P
FUEL PUMP
+V1 OUT1 GND1
3 LgR
S
4 LgW
15A
312 5BY
161 1.25B
I_A_MAS(SIG) 205
110 0.5G 111 0.5L 109 0.5Gr 82 0.5WL
AV60
COM BR B
(5) TEMP.SENSOR(-)
AV60
NO
BATTERY RELAY
B
+
12V BATTERY
STARTER MOTOR
-
B
DIODE
F.L.
84 WY
D1803 ECU
GLOW PLUGS
311 5BW
65A
162 1.25B
109 0.5Gr
AV60
FUSE
160 1.25B
2 5WR 313 5WB
82 3WL
G_R_AMS(GND) 203
9
R 82 WL
OUT2
D1803 ECU
I_A_IATS(SIG temp) 204
e
89 G
5W +V2
POTENTIOMETER POWER GND 251
G
7
99 LY
W
V_V_5VAPP1(5V) 201 G_R_GND1(GND) 240
98 LR
Lg
I_S_TRO_N(SW) 217
82 1.25WL
4
V_V_BAT3(+BP) 253 G_R_GND1(GND) 209
82 1.25WL
28 8WY
V_V_BAT2(+BP) 255
B
GLOW RELAY
82 1.25WL
26 5BR
V_V_BAT1(+BP) 256
10 5WG
90 GW
5
3
2
1
313 WB
25A
2 3WR
2 8WR
75A
1 8W
F.L.
FUSE
ECU MAIN RELAY
(4) TEMP.SENSOR(+) (3) OUTPUT SIG. VO (2) GRAUND G (1) BATTERY VO. VB
AIR FLOW SENSOR
SW504-10001
10-099
SW504
TROUBLESHOOTING
4-2-4. Engine speed does not change when operating throttle lever • Engine warning lamp must not be lighting. • Refer to voltage measurement method when voltage is to be measured without disconnecting connector. Reference Fig. : 4-2-1 Check point
Check/Cause
Action
1. Connector
• Check for corrosion, break, bend, or loosening on potentiometer connector terminals. • If there are any above mentioned abnormalities, the connector is faulty.
Replace connector or terminal.
2. Potentiometer
(1) W hen starter switch is ON, measure voltage between potentiometer terminal +V1 wire W and potentiometer terminal GND1 wire Br. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between potentiometer terminal +V2 wire L and potentiometer terminal GND2 wire B. Standard voltage : 5 ± 0.5 V (3) W hen starter switch is ON, measure voltage between potentiometer terminal OUT1 wire Y and potentiometer terminal GND1 wire Br. When throttle lever is at IDLE position Standard voltage : 0.5 to 1.0 V When throttle lever is at FULL position Standard voltage : 4.0 to 4.5 V (4) W hen starter switch is ON, measure voltage between potentiometer terminal OUT2 wire G and potentiometer terminal GND2 wire B. When throttle lever is at IDLE position Standard voltage : 4.0 to 4.5 V When throttle lever is at FULL position Standard voltage : 0.5 to 1.0 V • If above items (1) and (2) are OK and item (3) or (4) is NG, potentiometer is faulty.
Replace potentiometer.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
(NOTICE) • Because three-wire shield cable is used between potentiometer and ECU, it is impossible to repair it. It must be replaced.
10-100
SW504
4-3. Propulsion
TROUBLESHOOTING Refer to (P.10-022).
10-101
SW504
TROUBLESHOOTING
Fig.: 4-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
4
23 RL
VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION
CONNECTION 1-2,4-6 1-3,4-6
AUTO
45 Br
1-3,4-5 NC
C Br
NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
VIBRATION Lo-Hi CHANGE SWITCH
NC
C Br
NO
POSITION
B
G
TO COMBINATION 46 BrR METER 46 BrR
51 Br 46 BrR
43 RW 45 Br 44 BrY
1-2,4-5
23 RL 5
3
2
1
23 RL
1
VIBRATOR LAMP RELAY
B
27 GY
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH
62 BrW
6
47 LgR
2
5
B
POSITION
1
1 HI
SOL
2
46 BrR
VIBRATOR SOLENOID (F) 46 BrR
HI
2
SOL
1
CONNECTION
LOW 2
2
VIBRATORY DRUM SELECT SWITCH
R
F
G E D
4
2
3
VIBRATORY DRUM SELECT SWITCH
VIBRATOR RELAY
F
63 BrB
3
23 RL 1 23 RL 4
H
CONNECTION 1-3,4-6
F-R LEVER VIBRATION SWITCH (L)
LOW 1
1-2,4-6 VIBRATOR SOLENOID (R)
1-3,4-6 1-3,4-5 ROPS
F-R LEVER SWITCH
B
23 RL 1
24 RY
R
27 GY
302 LgR
NO COM
W
NC
23 RL 4
3
47 LgR
2
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
1
1 HI
SOL
2
LOW 2 46 BrR
VIBRATOR SOLENOID (F) 46 BrR
VIBRATION Lo-Hi CHANGE SWITCH POSITION
CONNECTION
23 RL
24 RY
1-3,4-6
2
2 HI 1
SOL
LOW 1
1-2,4-5 VIBRATOR SOLENOID (R)
1
2
3
4
5
6
7
8
9
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
Except ROPS
FUSE BOX
7 5WR
2 5WR
STARTER SWITCH C
ACC B
R2
B
AV60
OFF R1
ON
STARTER SWITCH
3 LgR
ST
2 8WR
15A 75A F.L.
10-102
NO
COM
BR
B
AV60
+
4 LgW
FUSE 2 5WR
F.L.
R 1 R 2 A CC B R C
HEAT
3 LgR BR
8 5R
65A
BATTERY RELAY
12V BATTERY
-
B
DIODE 1 8W
SW504-10002
SW504
TROUBLESHOOTING
4-4. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle lever must be “FULL”. • Check any ground circuit which belongs to components to be checked.
4-4-1. No vibration occurs 1/3 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 4-4-1 Check point
Check/Cause
Action
1. Vibrator Solenoid
• Disconnect harness and measure resistance of coil. Standard resistance: 4.6 Ω • If measured resistance is abnormal, vibrator solenoid is faulty.
Replace vibrator solenoid.
2. Vibration Mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace vibration mode vibration mode select switch terminal 4 inlet wire RL select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration mode select switch terminal 5 outlet wire BrY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration mode select switch is faulty.
3. Vibratory Drum Select Switch (ROPS)
(1) W hen starter switch is ON, measure voltage between vibratory drum select switch terminal 1, 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire BrW, terminal 3 outlet wire BrB and chassis ground. Standard voltage : 12 V or more (4) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 3 outlet wire BrB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibratory drum select switch is faulty.
Replace vibratory drum select switch.
10-103
SW504
TROUBLESHOOTING
Fig.: 4-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
4
23 RL
VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION
CONNECTION 1-2,4-6 1-3,4-6
AUTO
45 Br
1-3,4-5 NC
C Br
NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
VIBRATION Lo-Hi CHANGE SWITCH
NC
C Br
NO
POSITION
B
G
TO COMBINATION 46 BrR METER 46 BrR
51 Br 46 BrR
43 RW 45 Br 44 BrY
1-2,4-5
23 RL 5
3
2
1
23 RL
1
VIBRATOR LAMP RELAY
B
27 GY
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH
62 BrW
6
47 LgR
2
5
B
POSITION
1
1 HI
SOL
2
46 BrR
VIBRATOR SOLENOID (F) 46 BrR
HI
2
SOL
1
CONNECTION
LOW 2
2
VIBRATORY DRUM SELECT SWITCH
R
F
G E D
4
2
3
VIBRATORY DRUM SELECT SWITCH
VIBRATOR RELAY
F
63 BrB
3
23 RL 1 23 RL 4
H
CONNECTION 1-3,4-6
F-R LEVER VIBRATION SWITCH (L)
LOW 1
1-2,4-6 VIBRATOR SOLENOID (R)
1-3,4-6 1-3,4-5 ROPS
F-R LEVER SWITCH
B
23 RL 1
24 RY
R
27 GY
302 LgR
NO COM
W
NC
23 RL 4
3
47 LgR
2
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
1
1 HI
SOL
2
LOW 2 46 BrR
VIBRATOR SOLENOID (F) 46 BrR
VIBRATION Lo-Hi CHANGE SWITCH POSITION
CONNECTION
23 RL
24 RY
1-3,4-6
2
2 HI 1
SOL
LOW 1
1-2,4-5 VIBRATOR SOLENOID (R)
1
2
3
4
5
6
7
8
9
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
Except ROPS
FUSE BOX
7 5WR
2 5WR
STARTER SWITCH C
ACC B
R2
B
AV60
OFF R1
ON
STARTER SWITCH
3 LgR
ST
2 8WR
15A 75A F.L.
10-104
NO
COM
BR
B
AV60
+
4 LgW
FUSE 2 5WR
F.L.
R 1 R 2 A CC B R C
HEAT
3 LgR BR
8 5R
65A
BATTERY RELAY
12V BATTERY
-
B
DIODE 1 8W
SW504-10002
SW504
TROUBLESHOOTING
4-4-1. No vibration occurs 2/3 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 4-4-1 Check point
Check/Cause
Action
hen starter switch is ON and vibratory drum select Replace vibration Lo-Hi 4. Vibration Lo-Hi Change (1) W Switch switch is in “ ”, measure voltage between vibration change switch. (ROPS) Lo-Hi change switch terminal 1 inlet wire BrW, terminal 4 inlet wire BrB and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, vibratory drum select switch is in “ ” and vibration Lo-Hi change switch is “ ”, measure voltage between vibration Lo-Hi change switch terminal 3 outlet wire LgR, terminal 6 outlet wire LgB and chassis ground. Standard voltage : 12 V or more. (3) W hen starter switch is ON, vibratory drum select switch ”, is in “ ” and vibration Lo-Hi change switch is “ measure voltage between vibration Lo-Hi change switch terminal 2 outlet wire LgY, terminal 5 outlet wire LgW and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2) or (3) is NG, vibration Lo-Hi change switch is faulty. hen starter switch is ON, measure voltage between Replace vibration Lo-Hi 5. Vibration Lo-Hi Change (1) W Switch vibration Lo-Hi change switch terminal 1, 4 inlet wire RL change switch. (except ROPS) and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration Lo-Hi change switch is “ ”, measure voltage between vibration Lo-Hi change switch terminal 3 outlet wire LgR, terminal 6 outlet wire LgB and chassis ground. Standard voltage : 12 V or more. (3) W hen starter switch is ON and vibration Lo-Hi change ”, measure voltage between vibration switch is “ Lo-Hi change switch terminal 2 outlet wire LgY, terminal 5 outlet wire LgW and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2) or (3) is NG, vibration Lo-Hi change switch is faulty. 6. Vibrator Relay
(1) W hen starter switch is ON, measure voltage between vibrator relay terminal E inlet wire GY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibrator relay terminal G inlet wire BrY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, check continuity between vibrator relay terminal B inlet wire BrR and terminal D outlet wire B. There is continuity in normal condition. • If above items (1) and (2) are OK and item (3) is NG, vibrator relay is faulty.
Replace vibrator relay.
10-105
SW504
TROUBLESHOOTING
Fig.: 4-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
4
23 RL
VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION
CONNECTION 1-2,4-6 1-3,4-6
AUTO
45 Br
1-3,4-5 NC
C Br
NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
VIBRATION Lo-Hi CHANGE SWITCH
NC
C Br
NO
POSITION
B
G
TO COMBINATION 46 BrR METER 46 BrR
51 Br 46 BrR
43 RW 45 Br 44 BrY
1-2,4-5
23 RL 5
3
2
1
23 RL
1
VIBRATOR LAMP RELAY
B
27 GY
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH
62 BrW
6
47 LgR
2
5
B
POSITION
1
1 HI
SOL
2
46 BrR
VIBRATOR SOLENOID (F) 46 BrR
HI
2
SOL
1
CONNECTION
LOW 2
2
VIBRATORY DRUM SELECT SWITCH
R
F
G E D
4
2
3
VIBRATORY DRUM SELECT SWITCH
VIBRATOR RELAY
F
63 BrB
3
23 RL 1 23 RL 4
H
CONNECTION 1-3,4-6
F-R LEVER VIBRATION SWITCH (L)
LOW 1
1-2,4-6 VIBRATOR SOLENOID (R)
1-3,4-6 1-3,4-5 ROPS
F-R LEVER SWITCH
B
23 RL 1
24 RY
R
27 GY
302 LgR
NO COM
W
NC
23 RL 4
3
47 LgR
2
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
1
1 HI
SOL
2
LOW 2 46 BrR
VIBRATOR SOLENOID (F) 46 BrR
VIBRATION Lo-Hi CHANGE SWITCH POSITION
CONNECTION
23 RL
24 RY
1-3,4-6
2
2 HI 1
SOL
LOW 1
1-2,4-5 VIBRATOR SOLENOID (R)
1
2
3
4
5
6
7
8
9
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
Except ROPS
FUSE BOX
7 5WR
2 5WR
STARTER SWITCH C
ACC B
R2
B
AV60
OFF R1
ON
STARTER SWITCH
3 LgR
ST
2 8WR
15A 75A F.L.
10-106
NO
COM
BR
B
AV60
+
4 LgW
FUSE 2 5WR
F.L.
R 1 R 2 A CC B R C
HEAT
3 LgR BR
8 5R
65A
BATTERY RELAY
12V BATTERY
-
B
DIODE 1 8W
SW504-10002
SW504
TROUBLESHOOTING
4-4-1. No vibration occurs 3/3 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 4-4-1 Check point
Check/Cause
Action
7. F-R Lever Switch
(1) W hen starter switch is ON, measure voltage between F-R lever switch terminal inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal outlet wire GY 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.
Replace F-R lever switch.
8. 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.
• Vibration mode cannot be switched (F-R lever vibration switch does not work)
Refer to (P.10-034).
10-107
SW504
TROUBLESHOOTING
Fig.: 4-4-1
46 BrR
3 43 RW
2 6
44 BrY
5
1
23 RL
4
23 RL
VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION
CONNECTION 1-2,4-6 1-3,4-6
AUTO
45 Br
1-3,4-5 NC
C Br
NO
B G
F-R LEVER VIBRATION SWITCH (R) 45 Br
VIBRATION Lo-Hi CHANGE SWITCH
NC
C Br
NO
POSITION
B
G
TO COMBINATION 46 BrR METER 46 BrR
51 Br 46 BrR
43 RW 45 Br 44 BrY
1-2,4-5
23 RL 5
3
2
1
23 RL
1
VIBRATOR LAMP RELAY
B
27 GY
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH
62 BrW
6
47 LgR
2
5
B
POSITION
1
1 HI
SOL
2
46 BrR
VIBRATOR SOLENOID (F) 46 BrR
HI
2
SOL
1
CONNECTION
LOW 2
2
VIBRATORY DRUM SELECT SWITCH
R
F
G E D
4
2
3
VIBRATORY DRUM SELECT SWITCH
VIBRATOR RELAY
F
63 BrB
3
23 RL 1 23 RL 4
H
CONNECTION 1-3,4-6
F-R LEVER VIBRATION SWITCH (L)
LOW 1
1-2,4-6 VIBRATOR SOLENOID (R)
1-3,4-6 1-3,4-5 ROPS
F-R LEVER SWITCH
B
23 RL 1
24 RY
R
27 GY
302 LgR
NO COM
W
NC
23 RL 4
3
47 LgR
2
48 LgY
6
49 LgB
5
50 LgW
VIBRATION Lo-Hi CHANGE SWITCH TO INTERLOCK RELAY
1
1 HI
SOL
2
LOW 2 46 BrR
VIBRATOR SOLENOID (F) 46 BrR
VIBRATION Lo-Hi CHANGE SWITCH POSITION
CONNECTION
23 RL
24 RY
1-3,4-6
2
2 HI 1
SOL
LOW 1
1-2,4-5 VIBRATOR SOLENOID (R)
1
2
3
4
5
6
7
8
9
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
10
Except ROPS
FUSE BOX
7 5WR
2 5WR
STARTER SWITCH C
ACC B
R2
B
AV60
OFF R1
ON
STARTER SWITCH
3 LgR
ST
2 8WR
15A 75A F.L.
10-108
NO
COM
BR
B
AV60
+
4 LgW
FUSE 2 5WR
F.L.
R 1 R 2 A CC B R C
HEAT
3 LgR BR
8 5R
65A
BATTERY RELAY
12V BATTERY
-
B
DIODE 1 8W
SW504-10002
SW504
TROUBLESHOOTING
4-4-2. Vibratory drum cannot be switched (ROPS) Reference Fig.: 4-4-1 Check point
Check/Cause
Action
1. Vibratory Drum Select Switch
(1) W hen starter switch is ON, measure voltage between vibratory drum select switch terminal 1, 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 6 outlet wire LgR, terminal 3 outlet wire LgB and chassis ground. Standard voltage : 12 V or more (4) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 3 outlet wire LgB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibratory drum select switch is faulty.
Replace vibratory drum select switch.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-109
SW504
4-5. Water Spray
TROUBLESHOOTING Refer to (P.10-040).
• Refer to ROPS type for water spray timer.
10-110
SW504
TROUBLESHOOTING
Fig.: 4-6-1 TO HEAD LAMP TAIL LAMP
System configuration diagram +BAT Battery 12V (+)
+ -
DC/DC Converter
5V LDO
37 2GB 3
37 2GB
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
4
5
LIGHTING SWITCH POSITION CONNECTION
LIGHTING SWITCH
TEMP
1-2,4-6
Fuel meter
REV. ratio SEL.1
19 3R
6
38 Or
TO FLOOD LAMP
FUEL
CAN Transceiver
Pull up Resistor 31KΩ x4
19 3R
1
2
TACHO
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
1-3,4-6
Dot Matrix LCD
REV. ratio SEL.2
1-3,4-5
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
Illumination LED
DTC display
Engine oil pressure indicator
COMBINATION METER
DEF (SCR) Quality (Green) DEF (SCR) Quality (Red) DEF Tampering
Over heat Manual regeneration
Buzzer
DEF low level Engine warning +BAT
Engine stop
Water splay
HYD. oil filter warning
Liquid spray
Parking brake
Vibrator
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
Flood lamp
1
High beam
Exhaust system high temperature
Pull down Resistor 4.7KΩ x7
5
8
9
25 26 27 28 29 30 31
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
32 33 34 35
10 11 12
30
B
D1803 ECU
Y
HYDRAULIC OIL FILTER SWITCH
12 Y 11 BrB
R 1 R 2 A CC B R C
4
5
6
2
1
22
314 BY
314 BY
15
12 Y
1 11
B
12
E
13
IG
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
L
14
13 2Y
ST
STARTER SWITCH
7
10
ON R1
8
R2
B BR
9
OFF
2
19 3R
B HEAT
3 LgR
10
5A
3
ACC
C
FUEL GAUGE UNIT
FUSE
STARTER SWITCH
2 5WR
17 WR
53 LR
55 YG
93 L
O_T_ESL(LAMP) 224
5A
B
92 W
O_S_WELP(LAMP) 245
FUSE
B
52 YW
O_T_IMPHL(LAMP) 246
2 WR
17 WR
5
17
24
16
55 YG
53 LR
93 L
92 W
37 GB
37 GB
18
COMBINATION METER 13
3
Pull down Resistor 4.7KΩ x5
4
20
Hour meter
3
24 25 26 27 28
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
2
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
13 14 15 16 17 18 19 20 21 22 23
Turn signal (R)
Head lamp
8
+BAT
13 14 15 16 17 18 19 20 21 22 23 24
30
CPU
Charge warning
1 2 3 4 5 6 7 8 9 10 11 12
19
Preheating
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
52 YW
LYS pin
28 8WY
65A
13 2Y
TO STARTER MOTOR
7 5WR
ALTERNATOR
F.L.
8 5R
FUSE BOX 17 WR
AV60 NO
COM
BR
B
AV60
+
3 LgR
15A
4 LgW
FUSE 2 5WR
2 8WR
75A
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
F.L.
SW504-10003
10-111
SW504
TROUBLESHOOTING
4-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses.
• Head lamp and tail lamp do not light • Flood lamp does not light • Turn signal lamp does not blink • Hazard lamp does not light (Turn signal blinks) • Stop lamp does not light
Refer to (P.10-046). Refer to (P.10-046). Refer to (P.10-048). Refer to (P.10-050). Refer to (P.10-052).
4-6-1. Illumination of combination meter does not light Reference Fig. : 4-6-1 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 3 wire GB and combination meter connector terminal wire No.37 wire GB. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Combination meter illumination)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “ ”, measure voltage between combination meter illumination terminal wire No.37 inlet wire GB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and combination meter does not turn on, combination meter is faulty.
Replace combination meter.
10-112
SW504
TROUBLESHOOTING
Fig.: 4-6-1 TO HEAD LAMP TAIL LAMP
System configuration diagram +BAT Battery 12V (+)
+ -
DC/DC Converter
5V LDO
37 2GB 3
37 2GB
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
4
5
LIGHTING SWITCH POSITION CONNECTION
LIGHTING SWITCH
TEMP
1-2,4-6
Fuel meter
REV. ratio SEL.1
19 3R
6
38 Or
TO FLOOD LAMP
FUEL
CAN Transceiver
Pull up Resistor 31KΩ x4
19 3R
1
2
TACHO
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
1-3,4-6
Dot Matrix LCD
REV. ratio SEL.2
1-3,4-5
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
Illumination LED
DTC display
Engine oil pressure indicator
COMBINATION METER
DEF (SCR) Quality (Green) DEF (SCR) Quality (Red) DEF Tampering
Over heat Manual regeneration
Buzzer
DEF low level Engine warning +BAT
Engine stop
Water splay
HYD. oil filter warning
Liquid spray
Parking brake
Vibrator
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
Flood lamp
1
High beam
Exhaust system high temperature
Pull down Resistor 4.7KΩ x7
5
8
9
25 26 27 28 29 30 31
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
32 33 34 35
10 11 12
30
B
D1803 ECU
Y
HYDRAULIC OIL FILTER SWITCH
12 Y 11 BrB
R 1 R 2 A CC B R C
4
5
6
2
1
22
314 BY
314 BY
15
12 Y
1 11
B
12
E
13
IG
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
L
14
13 2Y
ST
STARTER SWITCH
7
10
ON R1
8
R2
B BR
9
OFF
2
19 3R
B HEAT
3 LgR
10
5A
3
ACC
C
FUEL GAUGE UNIT
FUSE
STARTER SWITCH
2 5WR
17 WR
53 LR
55 YG
93 L
O_T_ESL(LAMP) 224
5A
B
92 W
O_S_WELP(LAMP) 245
FUSE
B
52 YW
O_T_IMPHL(LAMP) 246
2 WR
17 WR
5
17
24
16
55 YG
53 LR
93 L
92 W
37 GB
37 GB
18
COMBINATION METER 13
3
Pull down Resistor 4.7KΩ x5
4
20
Hour meter
3
24 25 26 27 28
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
2
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
13 14 15 16 17 18 19 20 21 22 23
Turn signal (R)
Head lamp
8
+BAT
13 14 15 16 17 18 19 20 21 22 23 24
30
CPU
Charge warning
1 2 3 4 5 6 7 8 9 10 11 12
19
Preheating
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
52 YW
LYS pin
28 8WY
65A
13 2Y
TO STARTER MOTOR
7 5WR
ALTERNATOR
F.L.
8 5R
FUSE BOX 17 WR
AV60 NO
COM
BR
B
AV60
+
3 LgR
15A
4 LgW
FUSE 2 5WR
2 8WR
75A
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
F.L.
SW504-10003
10-113
SW504
TROUBLESHOOTING
4-6-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 4-6-1 Check point 1. Combination Meter (Lamp check)
Check/Cause (1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, check that parking brake indicator lamp, hydraulic oil filter warning lamp, engine oil pressure warning lamp and charge warning lamp illuminate and then go out after starting engine. • If above item (1) is OK and item (2) is NG, combination meter is faulty.
Action Replace combination meter.
(NOTICE) • Since engine cannot start unless parking brake switch is applied, parking brake indicator lamp does not go out even after starting engine.
4-6-3. Tachometer reading is abnormal Reference Fig. : 4-6-1 Check point
Check/Cause
Action
1. C ombination Meter (Tachometer)
(1) W hen starter switch is ON, measure voltage between Replace tachometer combination meter terminal wires and ground terminal sensor or combination wire. meter. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) C heck that combination meter terminal wires B (rev. ratio sel. 2, 3, 4) are grounded. • If above items (1) and (2) are OK and tachometer reading is NG, combination meter is faulty.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-114
SW504
TROUBLESHOOTING
Fig.: 4-6-1 TO HEAD LAMP TAIL LAMP
System configuration diagram +BAT Battery 12V (+)
+ -
DC/DC Converter
5V LDO
37 2GB 3
37 2GB
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
4
5
LIGHTING SWITCH POSITION CONNECTION
LIGHTING SWITCH
TEMP
1-2,4-6
Fuel meter
REV. ratio SEL.1
19 3R
6
38 Or
TO FLOOD LAMP
FUEL
CAN Transceiver
Pull up Resistor 31KΩ x4
19 3R
1
2
TACHO
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
1-3,4-6
Dot Matrix LCD
REV. ratio SEL.2
1-3,4-5
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
Illumination LED
DTC display
Engine oil pressure indicator
COMBINATION METER
DEF (SCR) Quality (Green) DEF (SCR) Quality (Red) DEF Tampering
Over heat Manual regeneration
Buzzer
DEF low level Engine warning +BAT
Engine stop
Water splay
HYD. oil filter warning
Liquid spray
Parking brake
Vibrator
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
Flood lamp
1
High beam
Exhaust system high temperature
Pull down Resistor 4.7KΩ x7
5
8
9
25 26 27 28 29 30 31
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
32 33 34 35
10 11 12
30
B
D1803 ECU
Y
HYDRAULIC OIL FILTER SWITCH
12 Y 11 BrB
R 1 R 2 A CC B R C
4
5
6
2
1
22
314 BY
314 BY
15
12 Y
1 11
B
12
E
13
IG
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
L
14
13 2Y
ST
STARTER SWITCH
7
10
ON R1
8
R2
B BR
9
OFF
2
19 3R
B HEAT
3 LgR
10
5A
3
ACC
C
FUEL GAUGE UNIT
FUSE
STARTER SWITCH
2 5WR
17 WR
53 LR
55 YG
93 L
O_T_ESL(LAMP) 224
5A
B
92 W
O_S_WELP(LAMP) 245
FUSE
B
52 YW
O_T_IMPHL(LAMP) 246
2 WR
17 WR
5
17
24
16
55 YG
53 LR
93 L
92 W
37 GB
37 GB
18
COMBINATION METER 13
3
Pull down Resistor 4.7KΩ x5
4
20
Hour meter
3
24 25 26 27 28
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
2
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
13 14 15 16 17 18 19 20 21 22 23
Turn signal (R)
Head lamp
8
+BAT
13 14 15 16 17 18 19 20 21 22 23 24
30
CPU
Charge warning
1 2 3 4 5 6 7 8 9 10 11 12
19
Preheating
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
52 YW
LYS pin
28 8WY
65A
13 2Y
TO STARTER MOTOR
7 5WR
ALTERNATOR
F.L.
8 5R
FUSE BOX 17 WR
AV60 NO
COM
BR
B
AV60
+
3 LgR
15A
4 LgW
FUSE 2 5WR
2 8WR
75A
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
F.L.
SW504-10003
10-115
SW504
TROUBLESHOOTING
4-6-4. Hour meter is abnormal Reference Fig. : 4-6-1 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 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Replace combination meter.
4-6-5. Fuel meter is abnormal Reference Fig. : 4-6-1 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”) 80.0 Ω (with float in “E”) • If resistance is abnormal, fuel gauge unit is faulty.
2. Combination Meter (Fuel meter)
• When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Replace combination meter.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-116
SW504
TROUBLESHOOTING
Fig.: 4-6-1 TO HEAD LAMP TAIL LAMP
System configuration diagram +BAT Battery 12V (+)
+ -
DC/DC Converter
5V LDO
37 2GB 3
37 2GB
Ground
+BAT
MOTOR driver
Starter switch (ACC) CAN (+) CAN (-)
4
5
LIGHTING SWITCH POSITION CONNECTION
LIGHTING SWITCH
TEMP
1-2,4-6
Fuel meter
REV. ratio SEL.1
19 3R
6
38 Or
TO FLOOD LAMP
FUEL
CAN Transceiver
Pull up Resistor 31KΩ x4
19 3R
1
2
TACHO
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
1-3,4-6
Dot Matrix LCD
REV. ratio SEL.2
1-3,4-5
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
Illumination LED
DTC display
Engine oil pressure indicator
COMBINATION METER
DEF (SCR) Quality (Green) DEF (SCR) Quality (Red) DEF Tampering
Over heat Manual regeneration
Buzzer
DEF low level Engine warning +BAT
Engine stop
Water splay
HYD. oil filter warning
Liquid spray
Parking brake
Vibrator
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
Flood lamp
1
High beam
Exhaust system high temperature
Pull down Resistor 4.7KΩ x7
5
8
9
25 26 27 28 29 30 31
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
32 33 34 35
10 11 12
30
B
D1803 ECU
Y
HYDRAULIC OIL FILTER SWITCH
12 Y 11 BrB
R 1 R 2 A CC B R C
4
5
6
2
1
22
314 BY
314 BY
15
12 Y
1 11
B
12
E
13
IG
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
L
14
13 2Y
ST
STARTER SWITCH
7
10
ON R1
8
R2
B BR
9
OFF
2
19 3R
B HEAT
3 LgR
10
5A
3
ACC
C
FUEL GAUGE UNIT
FUSE
STARTER SWITCH
2 5WR
17 WR
53 LR
55 YG
93 L
O_T_ESL(LAMP) 224
5A
B
92 W
O_S_WELP(LAMP) 245
FUSE
B
52 YW
O_T_IMPHL(LAMP) 246
2 WR
17 WR
5
17
24
16
55 YG
53 LR
93 L
92 W
37 GB
37 GB
18
COMBINATION METER 13
3
Pull down Resistor 4.7KΩ x5
4
20
Hour meter
3
24 25 26 27 28
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
2
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
13 14 15 16 17 18 19 20 21 22 23
Turn signal (R)
Head lamp
8
+BAT
13 14 15 16 17 18 19 20 21 22 23 24
30
CPU
Charge warning
1 2 3 4 5 6 7 8 9 10 11 12
19
Preheating
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
52 YW
LYS pin
28 8WY
65A
13 2Y
TO STARTER MOTOR
7 5WR
ALTERNATOR
F.L.
8 5R
FUSE BOX 17 WR
AV60 NO
COM
BR
B
AV60
+
3 LgR
15A
4 LgW
FUSE 2 5WR
2 8WR
75A
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
F.L.
SW504-10003
10-117
SW504
TROUBLESHOOTING
4-6-6. Hydraulic oil filter warning lamp remains ON Reference Fig. : 4-6-1 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between combination meter and Repair or replace hydraulic oil filter switch. harness. • Measure resistance between terminals and chassis ground. • Hydraulic oil filter switch terminal wire LR and chassis ground. • Combination meter connector terminal wire No.53 wire LR and chassis ground. Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
2. Hydraulic Oil Filter Switch
• When starter switch is OFF, check continuity between Replace hydraulic oil hydraulic oil filter switch inlet terminal wire LR and chassis filter switch. ground. There is no continuity in normal condition. • If there is continuity, hydraulic oil filter switch is faulty.
3. Combination Meter (Hydraulic oil filter warning)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter hydraulic oil filter warning terminal inlet wire No.53 wire LR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK but hydraulic oil filter warning lamp remains on after starting engine, combination meter is faulty.
Replace combination meter.
4-6-7. Charge warning lamp remains ON • Check with engine running. Reference Fig. : 4-6-1 Check point 1. Harness
Check/Cause • Disconnect connectors between combination meter and alternator terminal L. • Measure resistance between terminals and chassis ground. • Combination meter connector terminal wire No.17 wire WR and chassis ground. • Alternator terminal L wire WR and chassis ground Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
• Measure voltage between combination meter charge 2. Combination Meter (Charge warning lamp) warning terminal wire No.17 outlet wire WR and chassis ground. Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Repair or replace harness.
Replace combination meter.
10-118
SW504
TROUBLESHOOTING
Fig.: 4-6-2 TO VIBRATOR SOLENOID (F), VIBRATOR SOLENOID (R)
System configuration diagram
46 BrR
+BAT Battery 12V (+)
+ -
5V LDO
DC/DC Converter
TACHO
Ground MOTOR driver
Starter switch (ACC)
43 RW
CAN (+) CAN (-)
Pull up Resistor 31KΩ x4
2
TEMP
CAN Transceiver
6
44 BrY
Fuel meter
REV. ratio SEL.1
3
FUEL
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
23 RL
4
23 RL
ROPS: TO VIBRATORY DRUM SELECT SWITCH
VIBRATION MODE SELECT SWITCH
Dot Matrix LCD
REV. ratio SEL.2
5
1
Except ROPS: TO VIBRATION Lo-Hi CHANGE SWITCH
23 RL
+BAT
VIBRATION MODE SELECT SWITCH
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
POSITION
Illumination LED
DTC display
CONNECTION 1-2,4-6
Engine oil pressure indicator
LYS pin
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning Pull up Resistor 3.6KΩ x9
Preheating
1-3,4-6
DEF (SCR) Quality (Green)
AUTO
DEF (SCR) Quality (Red) CPU
Charge warning
1-3,4-5
DEF Tampering
Over heat Manual regeneration
Buzzer
TO F-R LEVER VIBRATION SWITCH (L), F-R LEVER VIBRATION SWITCH (R)
DEF low level Engine warning +BAT
Engine stop
Water splay
HYD. oil filter warning
Liquid spray
Parking brake
Vibrator
51 Br
High beam
Exhaust system high temperature
Turn signal (R)
Head lamp
46 BrR
Turn signal (L)
ECO mode COMBI. meter ILLUMI. Pull down Resistor 4.7KΩ x5
45 Br
5
3
2
1
23 RL
VIBRATOR LAMP RELAY
B
44 BrY
23 RL
46 BrR
43 RW
Pull down Resistor 4.7KΩ x7
Hour meter
46 BrR
23 RL
Flood lamp
+BAT
27 GY
VIBRATOR RELAY G E H
F
D
B
4 15
14 26
17
16 27
8
28
18
19
9 20
10 21
11 22
F-R LEVER SWITCH NC
12 23
NO COM
30
302 LgR
25
5
32 33 34 35
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
B
13 24
3
25 26 27 28 29 30 31
R
2
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
W
1
13 14 15 16 17 18 19 20 21 22 23 24
24 RY
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
27 GY
1 2 3 4 5 6 7 8 9 10 11 12
R
F
COMBINATION METER
B
24 RY
23 RL
9
8
1
2
3
4
5
6
12
13
14
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
7
10
2
22
1 12 Y
314 BY
51 Br
314 BY
20
8
19
COMBINATION METER
27
3
TO INTERLOCK RELAY
FUSE BOX 314 BY
5A
11 BrB 7 5WR
FUSE 12 Y
5A
2 WR
B
C
FUSE
ACC
HEAT
R2
OFF
B 3 LgR
R 1 R 2 A CC B R C
AV60 NO
COM
BR
B
R1
ST
STARTER SWITCH 3 LgR
15A
4 LgW
FUSE 2 8WR
AV60
+
ON BR
2 5WR
8 5R
F.L.
STARTER SWITCH
2 5WR
65A
75A
BATTERY RELAY
12V BATTERY
-
B
DIODE 1 8W
F.L.
SW504-10004
10-119
SW504
TROUBLESHOOTING
4-6-8. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 4-6-2 Check point
Check/Cause
Action
1. Harness
• Measure resistance between vibrator lamp relay terminal 5 wire Br and combination meter connector terminal wire No.51 wire Br. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Vibrator Lamp Relay
(1) W hen starter switch is ON, measure voltage between vibrator lamp relay terminal 1, 3 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, check continuity between vibrator lamp relay terminal 2 outlet wire BrR and chassis ground. F-R lever : “F” or “R” Vibration mode select switch : “AUTO” There is continuity in normal condition. (3) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, measure voltage between vibrator lamp relay terminal 5 outlet wire Br and chassis ground. F-R lever : “F” or “R” Vibration mode select switch : “AUTO” Standard voltage : 12 V or more. If above items (1) and (2) are OK and item (3) is NG, vibrator lamp relay is faulty.
Replace vibrator lamp relay.
3. Combination Meter (Vibration indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, F-R lever and vibration mode select switch in below position, measure voltage between combination meter vibration terminal wire No. 51 inlet wire Br and chassis ground. F-R lever : “F” or “R” Vibration mode change switch : “AUTO” Standard voltage : 12 V or more • If above items (1) and (2) are OK and vibration indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-120
SW504
TROUBLESHOOTING
Fig.: 4-6-3 System configuration diagram +BAT Battery 12V (+)
+ -
5V LDO
DC/DC Converter
TACHO
Ground 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
42 3LB
REV. ratio SEL.3 REV. ratio SEL.4 Lamp check
Illumination LED
DTC display
Engine oil pressure indicator
LYS pin
Or B
B
WATER SPRAY PUMP
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning DEF (SCR) Quality (Green)
Pull up Resistor 3.6KΩ x9
Preheating
42 3LB
DEF (SCR) Quality (Red) CPU
Charge warning
DEF Tampering
B
Over heat Manual regeneration
18 3LY G
B
e
g
39 LW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY RELAY
Buzzer
DEF low level Engine warning
POSITION
CONNECTION
CONT
1-2,4-6 1-3,4-6
+BAT
Engine stop
Water splay
HYD. oil filter warning
AUTO
Liquid spray
Parking brake
1-3,4-5
18 3LY
+BAT
Vibrator Flood lamp
+BAT
3
High beam
Exhaust system high temperature
39 LW
Turn signal (R)
Head lamp
39 LW
ECO mode COMBI. meter ILLUMI.
39 LW
Pull down Resistor 4.7KΩ x7
Hour meter Pull down Resistor 4.7KΩ x5
22
R
W
11 BrB
11 6 3G
F.L.
5A
B 24 RY
65A
8 5R 314 BY
1
2
3 12
14 2
1
22
FUSE BOX
314 BY
314 BY
25
12 Y
39 LW
4
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
COMBINATION METER
20
8
19
B
3
27 GY
23
18 3LY
21
30
F.L.
20
27 GY
45A
19
18 LY
NO COM
TO INTERLOCK RELAY
12
5
18
11
6
28
10
7
17
16 27
9
10
26
8
13
15
14 25
5
32 33 34 35
NC
302 LgR
4
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
24 RY
13 24
3
25 26 27 28 29 30 31
8
2
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
4
27 GY
F-R LEVER SWITCH
9
1
13 14 15 16 17 18 19 20 21 22 23 24
18 LY
R
COMBINATION METER Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
5
1
WATER SPRAY MODE SELECT SWITCH
F
1 2 3 4 5 6 7 8 9 10 11 12
2 6
Turn signal (L)
2 5WR
STARTER SWITCH C
FUSE
ACC R2
B 3 LgR BR
R1
STARTER SWITCH
B
5 3GW
5A
2 WR
7 5WR
FUSE 12 Y
R 1 R 2 A CC B R C
HEAT OFF
AV60
ON ST
BR
3 LgR
15A
4 LgW
FUSE 2 5WR
2 8WR
75A F.L.
10-121
AV60
COM
NO
+ BATTERY RELAY
B
12V BATTERY
-
B
DIODE 1 8W
SW504-10005
SW504
TROUBLESHOOTING
4-6-9. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 4-6-3 Check point
Check/Cause
Action
1. Harness
• Measure resistance between water spray mode select switch terminal 2 wire LW and combination meter connector terminal wire No.39 wire LW. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
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 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, water spray mode select switch is “CONT”, measure voltage between combination meter water spray terminal wire No.39 inlet wire LW and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and water spray indicator lamp does not light, combination meter is faulty.
10-122
SW504
TROUBLESHOOTING
Fig.: 4-6-4 System configuration diagram +BAT Battery 12V (+)
+ -
5V LDO
DC/DC Converter
TACHO
Ground MOTOR driver
REV. ratio SEL.1
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
37 2GB
38 Or
LIGHTING SWITCH
REV. ratio SEL.4 Lamp check
LIGHTING SWITCH POSITION CONNECTION
Illumination LED Engine oil pressure indicator
LYS pin
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning
34 GY
DEF (SCR) Quality (Green)
Pull up Resistor 3.6KΩ x9
CPU
Charge warning
35 G
DEF Tampering
GR
Manual regeneration
Buzzer
Engine warning +BAT
Engine stop
TURN SIGNAL SWITCH
Water splay
GY G GR
Liquid spray
Parking brake
Exhaust system high temperature
1-3,4-5
L
TURN SIGNAL SWITCH
DEF low level
HYD. oil filter warning
1-3,4-6
R G
36 GR
Over heat
+BAT
1-2,4-6
GY
DEF (SCR) Quality (Red)
Vibrator
L
Flood lamp
N
High beam
R
STOP
Preheating
4
5
REV. ratio SEL.3
DTC display
19 3R
6
38 Or
Turn signal (R)
Head lamp
FOOT BRAKE SWITCH
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
Pull down Resistor 4.7KΩ x7
Hour meter
NC NO COM
41 RW
R
Pull down Resistor 4.7KΩ x5
19 3R
1
2
Dot Matrix LCD
REV. ratio SEL.2
3
B
Fuel meter Pull up Resistor 31KΩ x4
TO HEAD LAMP, TAIL LAMP, COMBINATION METER
TEMP
CAN Transceiver
W
CAN (+) CAN (-)
FUEL
60 BrY
Starter switch (ACC)
24 RY
+BAT
TO PARKING BRAKE SOLENOID TO PARKING INTERLOCK RELAY
COMBINATION METER
1
2
3
4
5
8
9
32 33 34 35
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
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY
15 YL
25 26 27 28 29 30 31
34 GY
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
36 GR
13 14 15 16 17 18 19 20 21 22 23 24
35 G
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
38 Or
1 2 3 4 5 6 7 8 9 10 11 12
10 11 12
13 14 15 16 17 18 19 20 21 22 23 30 3
1 34 GY
2 6
TO FLOOD LAMP TO TURN SIGNAL LAMP(R)
35 G
TO TURN SIGNAL LAMP(L)
36 GR
12 Y
5A
2 WR
FUSE
L
34 GY
B
B
1
19 3R
FLASHER UNIT
21 RG
11
11 BrB
STARTER SWITCH
2 5WR ACC
C
FUSE
B
R 1 R 2 A CC B R C
HEAT R2
B
AV60
OFF ON
3 LgR BR
R1
STARTER SWITCH
3 LgR
2 8WR
NO
COM
BR
B
15A 75A F.L.
AV60
+
ST
4 LgW
FUSE 2 5WR
10-123
E
7 5WR
15 YL
65A
36 GR 38 Or
F.L.
8 5R
35 G
5A
2
FUSE BOX 38 Or
314 BY
3
4
5
12
14
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
6
24 RY 10
ROPS
2
22
1 12 Y
314 BY
26 38 Or
HAZARD SWITCH
314 BY
20 23
8
19
3 14
4
36 GR
35 G
15 YL
34 GY
COMBINATION METER
21 RG
4 34 GY
5
7
36 GR
B
8
35 GB
9
24 25 26 27 28
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
SW504-10006
SW504
TROUBLESHOOTING
4-6-10. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 4-6-4 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 5 wire Or and combination meter connector terminal wire No.38 wire Or. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Flood lamp indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “ ”, measure voltage between combination meter flood lamp terminal wire No.38 inlet wire Or and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and flood lamp indicator lamp does not light, combination meter is faulty.
4-6-11. Parking brake indicator lamp does not light Reference Fig. : 4-6-4 Check point
Check/Cause
Action
1. Harness
• Measure resistance between parking brake switch terminal 5 wire YL and combination meter connector terminal wire No.15 wire YL. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Parking Brake Switch
• When parking brake switch is applied, check continuity between parking brake switch terminal 5 wire YL and terminal 4 wire B. There is continuity in normal condition. • If there is no continuity, parking brake switch is faulty.
Replace parking brake switch.
3. Combination Meter (Parking brake indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen parking brake switch is applied and starter switch is ON, check continuity between combination meter parking brake terminal wire No.15 inlet wire YL and chassis ground. There is continuity in normal condition. • If above items (1) and (2) are OK and parking brake indicator lamp does not light, combination meter is faulty.
10-124
SW504
TROUBLESHOOTING
Fig.: 4-6-4 System configuration diagram +BAT Battery 12V (+)
+ -
5V LDO
DC/DC Converter
TACHO
Ground MOTOR driver
REV. ratio SEL.1
LCD driver
Pull up Resistor 3.6KΩ x3
7 Segments LCD
37 2GB
38 Or
LIGHTING SWITCH
REV. ratio SEL.4 Lamp check
LIGHTING SWITCH POSITION CONNECTION
Illumination LED Engine oil pressure indicator
LYS pin
Inhibit the DPF Auto-vegeneration Inhibit the SCR cleaning
34 GY
DEF (SCR) Quality (Green)
Pull up Resistor 3.6KΩ x9
CPU
Charge warning
35 G
DEF Tampering
GR
Manual regeneration
Buzzer
Engine warning +BAT
Engine stop
TURN SIGNAL SWITCH
Water splay
GY G GR
Liquid spray
Parking brake
Exhaust system high temperature
1-3,4-5
L
TURN SIGNAL SWITCH
DEF low level
HYD. oil filter warning
1-3,4-6
R G
36 GR
Over heat
+BAT
1-2,4-6
GY
DEF (SCR) Quality (Red)
Vibrator
L
Flood lamp
N
High beam
R
STOP
Preheating
4
5
REV. ratio SEL.3
DTC display
19 3R
6
38 Or
Turn signal (R)
Head lamp
FOOT BRAKE SWITCH
Turn signal (L)
ECO mode COMBI. meter ILLUMI.
Pull down Resistor 4.7KΩ x7
Hour meter
NC NO COM
41 RW
R
Pull down Resistor 4.7KΩ x5
19 3R
1
2
Dot Matrix LCD
REV. ratio SEL.2
3
B
Fuel meter Pull up Resistor 31KΩ x4
TO HEAD LAMP, TAIL LAMP, COMBINATION METER
TEMP
CAN Transceiver
W
CAN (+) CAN (-)
FUEL
60 BrY
Starter switch (ACC)
24 RY
+BAT
TO PARKING BRAKE SOLENOID TO PARKING INTERLOCK RELAY
COMBINATION METER
1
2
3
4
5
8
9
32 33 34 35
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
40 WB
3
301 Y
2 6
15 YL
1
41 RW
4
B
5
PARKING BRAKE SWITCH TO BRAKE LAMP RELAY
15 YL
25 26 27 28 29 30 31
34 GY
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
36 GR
13 14 15 16 17 18 19 20 21 22 23 24
35 G
Battery 12V (+) Starter switch (ACC) Ground Turn signal (R) Engine stop Over heat REV. ratio SEL.1 REV. ratio SEL.3 Buzzer Lamp check CAN(+) CAN(-)
38 Or
1 2 3 4 5 6 7 8 9 10 11 12
10 11 12
13 14 15 16 17 18 19 20 21 22 23 30 3
1 34 GY
2 6
TO FLOOD LAMP TO TURN SIGNAL LAMP(R)
35 G
TO TURN SIGNAL LAMP(L)
36 GR
12 Y
5A
2 WR
FUSE
L
34 GY
B
B
1
19 3R
FLASHER UNIT
21 RG
11
11 BrB
STARTER SWITCH
2 5WR ACC
C
FUSE
B
R 1 R 2 A CC B R C
HEAT R2
B
AV60
OFF ON
3 LgR BR
R1
STARTER SWITCH
3 LgR
2 8WR
NO
COM
BR
B
15A 75A F.L.
AV60
+
ST
4 LgW
FUSE 2 5WR
10-125
E
7 5WR
15 YL
65A
36 GR 38 Or
F.L.
8 5R
35 G
5A
2
FUSE BOX 38 Or
314 BY
3
4
5
12
14
13
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
6
24 RY 10
ROPS
2
22
1 12 Y
314 BY
26 38 Or
HAZARD SWITCH
314 BY
20 23
8
19
3 14
4
36 GR
35 G
15 YL
34 GY
COMBINATION METER
21 RG
4 34 GY
5
7
36 GR
B
8
35 GB
9
24 25 26 27 28
BATTERY RELAY
-
12V BATTERY
B
DIODE 1 8W
SW504-10006
SW504
TROUBLESHOOTING
4-6-12. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig. : 4-6-4 Check point
Check/Cause
Action
1. Harness
(1) M easure resistance between turn signal switch terminal Repair or replace wire No.36 wire GR and combination meter connector harness. terminal wire No.36 wire GR. Standard resistance : 10 Ω or less (2) M easure resistance between turn signal switch terminal wire No.35 wire G and combination meter connector terminal wire No.35 wire G. Standard resistance : 10 Ω or less • If above item (1) or (2) is NG, harness is faulty.
2. Turn Signal Switch
• When turn signal switch lever is moved, check continuity between turn signal switch terminals. Turn signal (L) : Between wire No.34 wire GY and wire No.36 wire GR Turn signal (R) : Between wire No.34 wire GY and wire No.35 wire G There is continuity in normal condition. • If there is no continuity, turn signal switch is faulty.
3. Combination Meter (Turn signal indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.12 inlet wire Y and ground terminal wire B • Starter switch (ACC) terminal wire No.314 inlet wire BY and ground terminal wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and turn signal switch is moved, measure voltage between combination meter terminal wires and chassis ground. • Turn signal (L) terminal wire No.36 inlet wire GR and chassis ground • Turn signal (R) terminal wire No.35 inlet wire G and chassis ground Standard voltage : 12 V or more with constant intervals • If above items (1) and (2) are OK and turn signal indicator lamp does not light, combination meter is faulty.
• Horn does not sound • Backup buzzer does not sound
Replace turn signal switch.
Refer to (P.10-072). Refer to (P.10-072).
10-126
SW504
TROUBLESHOOTING
5. HYDRAULIC SYSTEM TROUBLESHOOTING (SW504)
10-127
Refer to (P.10-073).
SW/TW354,SW/TW504 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
Copyright © 2016 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. 0 K.P Printed in Japan 2016.11.50 ○ 0 K.P Printed in Japan 2016.11.10 ○ 0446-99019-0-30912-D 0449-99017-0-30245-C 1 K.P Printed in Japan 2019.07.10 ○ 0448-99031-0-30663-0