Sakai SW300 Series Shop Manual

Series
SHOP MANUAL
PREFACE
To make a machine working to maximum efficiency over a long period of time

without any machine troubles, correct OPERATION, PREVENTIVE MAINTE-
NANCE, TROUBLE-SHOOTING and REPAIR are of vital importance.
This shop manual provides instructions, for the most part, on GENERAL
INFORMATION, STRUCTURE/FUNCTION, CHECKING/ADJUSTMENT, and
TROUBLE-SHOOTING of the SAKAI SW300 Series Vibrating Rollers.
This manual is designed to serve as a guide for the operator and maintenance
personnel to acquire correct information and repair procedure on these
machines in order to give a correct decision on problems which the machines
will confront, thus leading to quality repair. Fully understand the contents of the
manual and make the best of it.
We will make utmost efforts to make this manual more useful for you through
revisions.
Your opinions and advices will be particularly welcome and will be
carefully considered.
CONTENTS
SPECIFICATIONS 1-001
STRUCTURE & OPERATION 2-001
INSPECTION & ADJUSTMENT 3-001
TROUBLE-SHOOTING 4-001
SPECIFICATIONS
SPECIFICATIONS
1. External Views and Specifications
1-1. SW300 1-002
1-2. SW320 1-003
1-3. SW330 1-004
1-001
SPECIFICATIONS
1. External Views and Specifications

1-1. SW300
Unit in mm {in}
1130 (44")
1750 (69")
(10")
250

70
0
(2
7.
5"
) 1950 (77")
1000 (39") 1000 (39")
2650 (104")
SW3001001
Model SW300 Vibrating power:

Weight: Frequency 66.7 Hz {4,000 vpm}
Gross weight 2,700 kg {5,955 lbs} 27.5 kN
Centrifugal force (6,175 lbs)
Empty weight 2,525 kg {5,570 lbs} {2,800 kgf}
Dimension: Engine:
Overall length 2,650 mm {104"} Model KUBOTA D1703 Diesel Engine
Overall width 1,130 mm {44"} Total displacement 1,647 cc {100.5 cu.in}
Overall height 1,750 mm {69"} 25.4 kW/2,800 rpm
Wheelbase 1,950 mm {77"} Rated output (34.5 PS/2,800 rpm)
Wheel {34.0 HP/2,800 rpm}
Roll (width x dia.) 108 Nm/1,600 rpm
Front
1,000 x 700 mm {39" x 28"} Max. torque (11.0 kgfm/1,600 rpm)
Roll (width x dia.) {79.6 lbfft/1,600 rpm}
Rear
1,000 x 700 mm {39" x 28"} Tank capacity:
Performance: Fuel tank 50 liters {13.2 gal}
Travel speed Hydraulic tank 42 liters {11.1 gal}
0 ~ 12 km/h {0 ~ 7.5mile/h}
(forward/reverse) Sprinkler tank 180 liters {48 gal}
Gradability 24 degrees
Rolling width 1,000 mm {39"}
Minimum turning
3.7 m {146"}
radius
NOTE: Gradability is the calculated value. It may vary with ground surface conditions.
1-002
SPECIFICATIONS
1-2. SW320
Unit in mm {in}
1330 (52")
1750 (69")
(10")
250

7
0
0
(2
7
.5
1200 (47") ") 1950 (77") 1200 (47")
2650 (104")
SW3001002

Dimension: Engine:
Front
Rear
0 ~ 12 km/h {0 ~ 7.5 mile/h}
Minimum turning
3.8 m {150"}
radius
1-003
SPECIFICATIONS
1-3. SW330
Unit in mm {in}
1430 (56")
1750 (69")
(10")
250

70
0(
27
.5
")
1300 (51") 1950 (77") 1300 (51")
2650 (104")
SW3001003

Dimension: Engine:
Front
Rear
0 ~ 12 km/h {0 ~ 7.5 mile/h}
Minimum turning
3.8 m {150"}
radius
1-004
STRUCTURE & OPERATION
STRUCTURE & OPERATION
1. Location of Engine-related Key Units
1-1. Engine mount 2-003
1-2. Intake system 2-004
1-3. Exhaust system 2-005
1-4. Cooling piping & radiator 2-006
1-5. Fuel piping & fuel tank 2-007
1-6. Fuel controls 2-008
2. Description and Operation of Hydraulic System

2-1. Description and operation of hydraulic pump and motor
2-1-1. Propulsion pump ass'y 2-009
2-1-2. Propulsion motor 2-010
2-1-3. Description and operation of cam motor 2-011
2-1-4. Vibrator pump 2-013
2-1-5. Vibrator motor 2-014
2-1-6. Description and operation of vibrator motor2-015
2-1-7. Steering pump 2-016
2-1-8. Hydraulic circuit 2-017
2-2. Propulsion line
2-2-1. Hydraulic piping [1] 2-019
2-2-3. Propulsion controls 2-021
2-2-4. Propulsion circuit 2-022
2-2-5. Description and operation of propulsion system 2-023
2-3. Vibrating system
2-3-3. Vibrating system (SW300) 2-026
2-3-4. Vibrating system (SW320, SW330)2-027
2-3-5. Vibrator circuit2-028
2-3-6. Description and operation of vibrating system 2-029
2-4. Steering system
2-4-1. Hydraulic piping 2-030
2-4-2. King pin 2-031
2-4-3. Steering valve (Orbitrol) 2-032
2-4-4. Description and operation of Orbitrol 2-033
2-4-5. Steering cylinder ass'y 2-037
2-4-6. Steering circuit 2-038
2-001
3. Brake System
3-1. Brake pedal 2-039
3-2. Description and operation of brake circuit 2-040
4. Sprinkler & Scraper

4-1. Sprinkler piping 2-041
4-2. Scraper 2-042
5.Electric System
5-1. Location of instrument panel and relays 2-043
5-2. Location of electric components 2-044
5-3. Electric wiring diagram 2-045
2-002
Engine-related Units
1.Location of Engine-related Key Units

1-1. Engine mount
1
1
SW3002001
1. Engine mount (front)

2. Engine mount (rear)
2-003
1-2. Intake system
3
2
3
3
SW3002002
1. Duct hose
2. Air cleaner
3. Intake hose
2-004
1-3. Exhaust system
VIEW A
1
1
3 3
SW3002003
1. Exhaust pipe
2. Muffler
3. Exhaust pipe
2-005
1-4. Cooling piping & radiator
4
1
2
3
6 6
7
7
SW3002004
1. Reservoir 5. Radiator outlet hose

2. Radiator 6. Drain hose (radiator)
3. Oil cooler 7. Drain hose (cylinder block)
4. Radiator inlet hose 8. Drain cock
2-006
1-5. Fuel piping & fuel tank
SW3002005
1. Suction hose
2. Filter
3. Fuel pump
4. Return hose
5. Fuel gauge unit
6. Fuel tank
2-007
1-6. Fuel controls
3
4
DETAIL A VIEW B
B 1
A
SW3002006
1. Throttle lever
2. Control cable
3. Control lever (fuel injection pump)
4. Operating force adjusting nut
2-008
Description and Operation of Hydraulic System
2. Description and Operation of Hydraulic System

2-1. Description and operation of hydraulic pump and motor
2-1-1. Propulsion pump ass'y
7
7
6
1 5
8
3
10
SW3002007
1. Port A (forward travel)
2. Port B (reversing)
Specifications
3. High pressure relief valve (forward travel)
Model : DVN28-504
4. High pressure relief valve (reversing)
5. Charge relief valve Displacement : 28cm3/rev
6. Control lever Relief valve setting
7. Brake release solenoid valve : 34.5MPa (5000psi) {350kgf/cm2}
8. Circuit pressure gauge port (forward travel) Charge circuit pressure setting
9. Circuit pressure gauge port (reversing) : 1.9MPa (280psi) {20kgf/cm2}
10. Charge pressure gauge port
2-009
2-1-2. Propulsion motor
2 4
5 6 7 8 9 10 11 12 13
14
15
17
23
16
22 21 20 19 18 24
SW3002008
1. Port A 9. Roller 18. Separate plate

2. Port B 10. Piston 19. Roller bearing
3. Drain port 11. Cylinder block 20. Oil seal
4. Brake release pressure 12. Distributor 21. Roller bearing
gauge port 13. Brake shaft 22. Dust seal
5. Large flange 14. Brake spring 23. Output shaft
6. Piston ring 15. Brake cover 24.Brake housing
7. Journal bearing 16. Brake piston
8. Cam ring 17. Friction plate
Specifications
Model : DCM0280-517
Displacement : 417cm3/rev
Circuit pressure setting : 34.5MPa (5000psi) {350kgf/cm2 }
To be set on propulsion pump side
2-010
2-1-3. Description and operation of cam motor
Construction of cam motor

Made up of brake cover (15), brake housing (24), cam ring (8), large flange (5), cylinder block (11),
distributor (12) and output shaft (23).
Eight sets of pistons (10) are assembled into cylinder block (11), while brake housing (24) houses
spring-applied hydraulically released brake.
Brake cover (15), brake housing (24), cam ring (8) and large flange (5) form one body fixed with
fixing bolts.
Cylinder block (11) is spline fitted to output shaft (23) and rotates when under hydraulic pressure.
Cylinder block (11) has twelve oil holes to align with the holes in distributor (12).
Distributor (12) fitted to large flange (5) with dowel pin feeds oil, which is supplied from port A or
port B in large flange (5), to cylinder block (11) and also displaces oil from cylinder block (11). For
this purpose, there are twelve oil holes in distributor (12). Six holes lead to port B in large flange (5)
and other six holes to port A respectively. (See page 2-012)
Inside surface of cam ring (8) are six cam profiles (see Fig.SW3002011 on page 2-012) along
which the pistons move to provide rotary motion.
Cylinder block (11) is located with eight sets of pistons inside cam ring (8).
5 8 10 11 12
23
15
24
SW3002009
2-011
Operation (It is assumed that oil is fed : High main pressure
into port B.) : Low main pressure

Pump flow to port B in large flange (5) is dis-
tributed into six holes in distributor (12)
which lead to port B.
* Oil is displaced from the remaining six
holes.
When the six holes in cylinder block (11)
align with the six holes in distributor (12), 12
pressurized oil lifts pistons (10). Distributor
(fixed)
Movement of pistons (10) which move along
High and low main pressures are
the cam profiles with rollers (9) in contact alternately distributed to twelve
with the profiles creates rotary force in cylin- holes in distributor (6).
der block (11). This force rotates output

shaft (23) spline fitted to cylinder block (11).
Simultaneously, pistons (10) which are lead-
ing to port A (discharge port) also move
along the cam formation to retract, displac-
ing oil from port A. To port A
To port B
* If pump flow is fed into port A, the output
SW3002010
shaft rotation is reversed.
8
Cam ring (fixed)
(Inner surface has six come profiles.)
Ports in distributor (twelve holes)
10 11
Piston (8 sets)
Cylinder block
(rotates)
Port B 9
Roller
23
Cylinder block ports

(8 ports)
Port A
Fp Fp : Hydraulic force
SW3002012 Fn : Vertical reaction from
cam ring
Fs : Rotary force
Fs Fn
SW3002011
2-012
2-1-4. Vibrator pump
9 8 10 7 9 11
4
13 6 12 5
3
1 2
SW3002013
1. Outlet port (Pump No.1) 6. Drive gear (pump No.2) 11. Front cover
2. Outlet port (Pump No.2) 7. Driven gear (pump No.1) 12. Body
3. Suction port 8. Driven gear (pump No.2) 13. Rear cover
4. Drive gear (pump No.1) 9. Bush
5. Oil seal 10. Bush
Specifications
Model : DIA1414R270
Displacement : 13.7+13.7cm3/rev
Pressure setting : 12.7MPa (1840psi) {130kgf/cm2}
To be set by valve
2-013
2-1-5. Vibrator motor
1 3
5 6 7 8 9 13
4
A
A 15
SECTION A-A
14 11 12 10
SW3002014
1. Suction port (port A) 6. Ball bearing 11. Piston ring

2. Outlet port (port B) 7. Timing ring 12. Piston retainer
3. Drain port 8. Timing pin 13. Ball bearing
4. Drive shaft 9. Cylinder block 14. Casing
5. Oil seal 10. Piston 15. Pintle
Specifications
Model : SHM1
Displacement : 9cm3/rev
Pressure setting : 12.7MPa (1840psi) {130kgf/cm2}
To be set by valve
2-014
2-1-6. Description and operation of vibrator motor
* See figures on page 2-014 for construction.

7 8 9
Pressurized oil fed from a port provided at
rear of pintle (15) flows through the low-high
pressure selecting section and radiated oil
ways of cylinder block (9) into one end of the
pistons.
* In the center drawing, oil is occupying
spaces shown black in pistons 10-1, 10-2
and 10-3. 15
Point O is the rotating center of drive shaft
(4), and point P shows the center of pintle 10
(15). The center line of all pistons point to SW3002015
point P. Resultant forces F1, F2 and F3 gen-
erated by pistons 10-1, 10-2 and 10-3
(center and bottom drawings) act on point P 4 7 8
and create a torque due to eccentric E. 10-3
Because pintle (15) is fixed, drive shaft (4)
which has a pentagon-shaped inner surface
spins.
Drive shaft (4) and cylinder block (9) rotate
with their respective pentagon remaining O
parallel with each other because of timing P
pins (8) provided in cylinder block (9) and
timing ring (7) in drive shaft (4).
The low-high pressure selecting section of
pintle (15) is made up of two flat faces of the 10-5
eccentric cylinder and radiated portion (five 10-2
holes into which the pistons are inserted) of 9
cylinder block (9). One of the two flat faces 10-1
SW3002016
of the eccentric cylinder leads to high pres-
sure inlet port, while the other face corre-
sponds to the low pressure outlet port. With
3
the rotation of cylinder block (9) which spins

F
O
together with drive shaft (4), pressurized oil
E
is fed into the pistons when the radiated por- P

F1
F2 23
tion of cylinder block (9) leads to the high
pressure side of eccentric cylinder. On the
F
12
F1
other hand, oil is exhausted from the pistons

if the radiated portion is open to the low
pressure side. (C) Moment created by hydraulic pressure
In this way, torque is created continuously SW3002017
through flow in and flow out processes of oil.

The motor runs continuously.
2-015
2-1-7. Steering pump
5
4
2 5
5
3
8
1
6
7 SW302018
1. Outlet port 4. Driven gear 7. Ring

2. Suction port 5. Bush 8. Body
3. Drive gear 6. Oil seal 9. Rear cover
Specifications
Displacement : 8.85cm3/rev
Pressure setting : 13MPa (1890psi) {133kgf/cm2}
To be set on Orbitrol side
2-016
2-1-8. Hydraulic circuit
2-017
2-018
2-2. Propulsion line

2-2-1. Hydraulic piping [1]
13 7
9
A
8
5
8
3 1
A
10
11
B
B
5
7
3
8
2 4
5
8
12
6
4
VIEW A-A
VIEW B-B
SW3002020
1. Propulsion pump 8. Brake release hose (rear)

2. High pressure hose (front, forward travel) 9. Drain hose (pump to oil cooler)
3. High pressure hose (front, reversing) 10. Drain hose (pump to hydraulic tank)
4. High pressure hose (rear, forward travel) 11. Oil cooler
5. High pressure hose (rear, reversing) 12. Drain hose (rear motor to hydraulic tank)
6. Charge hose 13. Drain hose (front motor to hydraulic tank)
7. Brake release hose (front)
2-019
5 7 10 6
3 1
4 9 8
2
1 6
VIEW A VIEW B
SW3002021
1. Propulsion motor 6. Propulsion motor (rear)

2. High pressure hose (forward travel) 7. High pressure hose (forward travel)
3. High pressure hose (reversing) 8. High pressure hose (reversing)
4. Brake release hose 9. Brake release hose
5. Drain hose 10. Drain hose
2-020
2-2-3. Propulsion controls
4
SECTION B-B
6
C 7
B
B
C 8
SECTION A-A SECTION C-C

D
2
1 1
SECTION E-E
E A
DETAIL D
A
E
SW3002022
1. F-R lever 5. Holder

2. Vibrator switch 6. Detent
3. Control cable 7. Reverse alarm switch
4. Pump control lever 8. Interlock switch
2-021
2-2-4. Propulsion circuit
1. Engine
2. Coupling 7
3. Propulsion pump 6
a. Control valve f
b. Servo piston
c. High pressure relief valve
d. Charge relief valve
f
e. Brake release solenoid valve 8 5
f. Bypass valve
g. Check valve
4. Vibrator pump
5. Rear propulsion motor 4
6. Rear drum
7. Front propulsion motor
8. Front drum
9. Steering pump
10. Steering valve (Orbitrol)
11. Line filter d
12. Oil cooler
13. Suction filter e
f f
g g
c
11 a
b
b
3
2 12
10 1
9
13
SW3002023
2-022
2-2-5. Description and operation of propulsion system
See the hydraulic circuit on pages 2-022.
Description of propulsion system

Made up of propulsion pump (3), front propulsion motor (4), front drum (8), rear propulsion motor
(5) and rear drum (6). Brake release solenoid (e) is built into the propulsion pump.
Basic function of propulsion pump and propulsion motor

Propulsion pump
A piston pump is used which selects forward travel, neutral and backing by varying the swashplate
inclination, and thus varying the piston stroke.
Propulsion motor
A piston motor is used in which the displacement is fixed.
Operation (It is assumed that the machine travels forward.)

The spring-applied hydraulically released brake is supposed to have been released.
Assemblies such as pump ass'y and motor ass'y are indicated by numbers such as (1) and (2),
while component parts of assemblies are shown by small letters such as (a) and (b).
The circuit of the front motor and that of the rear motor connect in parallel with each other.
When the forward-reverse lever (F-R lever) is moved forward, control valve (a) functions to tilt the
pump swashplate in the forward travel direction.
Propulsion pump (3) feeds oil from its port A into the forward travel circuit, then the oil flow branches
into two lines; one line connecting to forward travel port B of front motor (7) and the other line
connecting to port A of rear motor (5).
The oil fed to the forward travel ports of the motors drives the motors, flowing out from the opposite
side ports and joins again to flow into suction port B in propulsion pump (3).
NOTE: Because the propulsion circuit is a closed loop circuit, the relationship between the
suction port and discharge port is reversed when the travel direction is reversed. (The
direction of oil flow is reversed.)
Releasing of spring-applied hydraulically released brake

When brake release solenoid valve (e) is energized, it functions to feed oil from the charge circuit
into brake release ports in the propulsion motors.
Oil then flows into the cylinder built in brake unit (h). The piston inside the cylinder of the brake unit
releases brake against the spring compression.
Circuit protection against high pressure:

Multi-function valve (c) fitted in the propulsion pump relieves pressure if the circuit pressure
exceeds the setting of the valve, thus protecting the circuit.
Charge circuit
The propulsion circuit is of a closed circuit, which needs feeding of oil into it for making up deficien-
cy, cooling off or for other purposes.
In the charge circuit, oil from steering pump (9) flows into steering valve (10) (Orbitrol), then the
whole oil goes to propulsion pump (3) via filter (11) irrespective of the steering wheel operation.
The pressure adjustment is achieved by charge relief valve (d) built in the propulsion pump (3).
2-023
Vibrating System
2-3. Vibrating system

10
10 11
1 12
B
2
11
4
B
A
9 8 7 VIEW A-A
2
6 14
VIEW B-B
DETAIL C
5 13
2
1
VIEW D
SW3002024
1. Vibrator pump 9. Drain hose (front motor to hydraulic tank)

2. Suction hose 10. High pressure hose (rear motor rotating side)
3. Outlet hose (pump No.1) 11. Return hose (rear motor to hydraulic tank)
4. Outlet hose (pump No.2) 12. Drain hose (rear motor to hydraulic tank)
5. Vibration mode selector solenoid valve (front) 13. Return hose (front solenoid valve to hydraulic
6. Vibration mode selector solenoid valve (rear) tank)
7. High pressure hose (front motor rotating side) 14. Return hose (rear solenoid valve to hydraulic
8. Return hose (front motor to hydraulic tank) tank)
2-024
Vibrating System
4 4 8
3 3 7
2 6
1
5
1 5
VIEW A VIEW B
SW3002025
1. Vibrator motor (front) 5. Vibrator motor (rear)

2. High pressure hose [B] (high pressure side) 6. High pressure hose [B] (high pressure side)
3. Return hose (motor to hydraulic tank) 7. Return hose (motor to hydraulic tank)
4. Drain hose (motor to hydraulic tank) 8. Drain hose (motor to hydraulic tank)
2-025
Vibrating System
2-3-3. Vibrating system (SW300)
12,13
19 18 16 17 16 15 14 11
10
10
8
20
6,7
1 2 3 4 5
Oil filler plug
Level plug
Drain Plug
Vibrator motor side
VIEW A
SW3002026
1. Vibrator shaft 8. Vibrator motor 15. Plug

2. Boss 9. Damper 16. Roller bearing
3. Oil seal 10. Plate 17. Drum
4. Taper roller bearing 11. Breather 18. Holder
5. Cover 12. Sleeve 19. Propulsion motor
6. Cover 13. Spring pin 20. Disc
7. Shim 14. Disc
2-026
Vibrating System
2-3-4. Vibrating system (SW320,SW330)
19 18 16 17 16 15 14
12,13
11
10
9
8
10
6,7
20
1 2 3 4 5
Oil Filler plug
Level Plug
Drain Plug
Vibrator motor side
SW3002027
1. Vibrator shaft 8. Vibrator motor 15. Plug

2. Boss 9. Damper 16. Roller bearing
3. Oil seal 10. Plate 17. Drum
4. Taper roller bearing 11. Breather 18. Holder
5. Cover 12. Sleeve 19. Propulsion motor
6. Cover 13. Spring pin 20. Disc
7. Shim 14. Disc
2-027
Vibrating System
2-3-5. Vibrator circuit
1. Engine Front Rear

2. Coupling
11 7
3. Propulsion pump
4. Vibrator pump 10 6
5. Vibrator solenoid valve (rear) 12 8
a. Pressure relief valve
6. Vibrator motor (rear)
7. Vibrator shaft (rear)
8. Check valve
9. Vibrator solenoid valve (front)
a a
10. Vibrator motor (front) 9 5
11. Vibrator shaft (front)
12. Check valve
13. Suction filter 4
2
1
13
SW3002028
2-028
Vibrating System
2-3-6. Description and operation of vibrating system
Description of vibrator circuit

Made up of vibrator pump (4), front vibrator
solenoid valve (9), front vibrator motor (10),
front vibrator shaft (11), rear vibrator
solenoid valve (5), rear vibrator motor (6)
and rear vibrator shaft (7).
Basic function of vibrator pump and

motor:
Vibrator pump
A gear pump is in use. With a gear pump, its
displacement is not variable.
Vibrator motor
A radial piston motor is used.
Operation
The vibrator pump discharges oil as long as
it is driven, as it is of a gear type. When the
vibrator is not in use, the pump is put under
no load by vibrator solenoid valves (5) and
(9).
With the vibrator switch ON, valves (5) and
(9) close the unload circuit, making the
vibrator operative. Vibrator motors (6) and
(10) are driven. Oil displaced from the
motors is dumped to the tank via check
valves (8) and (12).
Circuit protection against high pres-

sure
Pressure relief valve (a) built in vibrator
solenoid valves (5) and (9) opens to relieve
the pressure if the system pressure exceeds
the setting of valve (a).
2-029
Steering System
2-4. Steering system

2-4-1. Hydraulic piping
2
7
A
DETAIL A
4
2
5
1
6
SW3002029
1. Steering pump 6. High pressure hose (right turn)

2. Outlet hose 7. Steering cylinder
3. Suction hose 8. Charge circuit hose
4. Steering valve (Orbitrol) 9. Line filter
5. High pressure hose (left turn)
2-030
Steering System
2-4-2. King pin
6 5
3
1
2 4
6 5 SW3002030
1. Yoke
2. Bearing assy
3. Bracket (upper )
4. Bracket (lower)
5. Ball bearing
6. Cover
7. Grease fitting
2-031
Steering System
2-4-3. Steering valve (Orbitrol)
22
21
A A
20
19
18
SECTION A-A
9 10 11
7 23
4
14
3 15
16
17
1
12
13
SW3002031
1. Stator 12. Rotor Specifications

2. Drive 13. End cap Valve system
3. Spool 14. Guide : Open center non-load
4. Sleeve 15. Poppet reaction
5. Cross pin 16. Spring Displacement : 96.0cc/rev
6. Centering spring 17. Body Relief valve setting
7. Thrust needle 18. Valve seal : 13MPa (1890psi) {133kgf/cm2}
19. Poppet
8. Retaining ring
20. Spring
9. Oil seal
21. Plug
10. Dust seal
22. O-ring
11. Seal gland bush
23. Housing
2-032
Steering System
2-4-4. Description and operation of Orbitrol
The steering valve (Orbitrol) is of a load-

sensing type which allows the steering pump
to feed an amount of oil into the valve
corresponding to the speed at which the
steering wheel is rotated.
Description
* Valve section
The valve section makes itself a rotary type 8
direction control valve consisting of spool
(1) and sleeve (2) as main components. The
steering wheel is spline-connected to spool
(1). 6
When the steering wheel is not operated, 7
spool (1) and sleeve (2) stay in the neutral 1 Valve section
2
position with each other due to centering
springs (6) with the oil grooves in spool (1) 5
and oil holes in sleeve (2) not aligned. This
blocks oil flow to the steering cylinder. 4
When the steering wheel is turned, the oil 3
Roter section
grooves in spool (1) and oil holes in sleeve
(2) are aligned to feed oil to the cylinder.
SV4002042
* Rotor section
The rotor is an external gear which meshes
3
with the internal gear of stator (3). When the
valve section (spool-sleeve assy) opens,
4
the rotor-stator assy acts as a hydraulic
motor.
The rotation of rotor (4) is conveyed to the
valve section through drive shaft (5) spline-
connected to rotor (4). An extent to which
the valve opens is controlled by the speed SV4002043
at which the steering wheel is rotated.
1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
4. Rotor 8. Check valve
1 2
To tank
Oil groove To steering
cylinder
Oil hole To steering
cylinder
From pump
SV4002044
2-033
Steering System
Operation 6
* Neutral state (Steering wheel not 1
operated)
Centering springs (6) (flat springs) are locat-
2
ed in spring notches provided at end of
spool (1) and sleeve (2).
With the steering wheel not operated, cen- Oil hole
tering springs (6) make the spool-sleeve
assy stay in neutral. Oil grooves
* This steering valve (Orbitrol) is of a load-
sensing, non-load reaction, normal close SV4002045
type. In the neutral position, the oil grooves
and oil holes are not aligned, blocking oil
flow to the steering cylinder.
* Turning (Steering wheel operated)

8
* In neutral, all the valve holes stay closed
and oil remains trapped in the space
between rotor (4) and stator (3). Rotor (4) is
6 To tank
in a fixed state, being unable to rotate in any
7
direction. Sleeve (2) is also unable to rotate,
1
as it is connected to rotor (4) through cross 2
pin (7) and drive shaft (5).
5
When the steering wheel is spined, the
4 From pump
rotating force is conveyed to spool (1).
Spool (1) compresses centering springs (6). 3
Then, there is a relative movement between SV4002046
spool (1) and sleeve (2). This aligns the oil
1. Spool 5. Drive shaft
grooves with oil holes.
2. Sleeve 6. Centering spring
As a result, the whole ports (pump port, tank
3. Stator 7. Cross pin
port and cylinder ports) open, allowing oil
4. Rotor 8. Check valve
flow to related components. Rotor (4) spins.
6
1
Oil hole
Oil groove
SV4002047
2-034
Steering System
Operation of feed back mechanism

Operation of the steering wheel creates an
angular divergence in circumferential direc-
tions between spool (1) and sleeve (2) due
to centering springs (6). This makes the oil
grooves align with oil holes, allowing pump
flow into the steering valve (Orbitrol). Rotor
(4) spins and feeds oil into the steering
cylinder.
As a result, sleeve (2) rotates trailing spool
(1) with an angular divergence maintained
between the two components. This enables
spool (1) to spin continuously with the rota-
tion of the steering wheel. The machine SV4002048
makes a turn continuously.
Stopping the steering wheel operation
brings spool (1) rotation to an instant halt.
However, the spool-sleeve assy does not
get back to the neutral condition instantly.
Oil continues to flow into Orbitrol, allowing
rotor (4) to continue to rotate. This rotating
motion lets sleeve (2) catch up to spool (1),
blocking the hydraulic circuit to stop oil flow-
ing.
Finally, centering springs (6) restore the
spool-sleeve assy to the neutral position,
stopping the oil flow completely.
2-035
Steering System
Steering wheel rotating speed and Low steering speed High steering speed
controlling the flow
* In the steering mechanism, it is essential to 1
increase or decrease oil flow into the 6
steering cylinder according to the rotating 2
speed of the steering wheel.
The steering valve (Orbitrol) controls the oil

flow by varying the angular displacement
between spool (1) and sleeve (2) as stated Small angular Large angular
below: displacement displacement
SW3002041
With the steering wheel rotated, sleeve (2)
runs after spool (1) attempting to block the 1. Spool
hydraulic circuit. 2. Sleeve
The angular displacement between spool 6. Centering spring
(1) and sleeve (2) increases with increasing
rotating speed of the steering wheel. The oil
flow increases.
Pump flow and force required to rotate

steering wheel
When the pump allows sufficient oil flow, the
force to rotate the steering wheel equals the
sliding resistance offered by sleeve (2) and
rotor (4), etc. The steering wheel is light to
rotate.
If pump flow is insufficient, the angular dis-
placement between spool (1) and sleeve (2)
stays maximum. The amount of oil fed to
rotor (4) from the pump is small. Rotor (4)
spins slowly.
For this reason, spool (1) rotates faster than
rotor (4), making the angular displacement
maximum. Spool (1) drives rotor (4) through
cross pin (7) and drive shaft (5). Then, rotor
(4) acts as a hydraulic pump. A heavy steer-
ing wheel results.
2-036
Steering System
2-4-5. Steering cylinder ass'y
11
12
6
10
9
3
11
8
12
7
SW3002034
1. Cylinder 5. Nut 9. O-ring

2. Piston rod 6. Piston seal 10. O-ring
3. Bush 7. Dust seal 11. Spherical bearing
4. Piston 8. Packing 12. Lock ring
2-037
Steering System
2-4-6. Steering circuit
2
b
1
6
3 4
7 SW3002035
1. Engine 5. Line filter

2. Steering pump 6. Propulsion pump
3. Steering valve (Orbitrol) 7. Suction filter
4. Steering cylinder
b. Piston rod
Description:
The steering system is made up of steering pump (2), steering valve (3) (Orbitrol), steering cylinder
(4) and line filter (5).
Operation
Oil from gear pump (2) enters steering valve (3). The valve feeds an amount of oil to steering cylin-
der (4). The amount of oil handled varies with the direction in which the steering wheel is rotated
and with the speed at which the steering wheel is turned.
The fluid fed into steering cylinder (4) moves the piston rod (b) to achieve steering. The oil dis-
placed from the opposite side of the piston flows, through steering valve (3) and line filter (5), to the
charge circuit for propulsion.
Refer to "Charge circuit" under "Description and operation of propulsion system".
Relief valve (a) built in steering valve (3) opens to relieve the pressure if the system pressure
exceeds the setting of the relief valve, thus protecting the circuit.
2-038
Brake System
3. Brake System
3-1. Brake pedal
VIEW A
4 3
3
4
2
A
SW3002036
1. Brake pedal
2. Return spring
3. Rod (for neutral position of F-R lever)
4. Rod (for neutral position of F-R lever)
5. Foot brake switch
2-039
Brake System
3-2. Description and operation of brake circuit

Description: Parking brake switch set to position
Consists of brake pedal (1), foot brake switch RELEASE:
(brake release switch) (5), F-R levers (6), The contacts in parking brake switch (7) close
return-to-neutral rods (3), (4), parking brake the circuit of brake release solenoid (8) and
switch (7), brake release solenoid (8) and open the indicator lamp circuit.
parking brakes (negative brakes) (9), (10). The indicator lamp comes off. The parking
brakes (9) and (10) are disengaged.
Operation: The parking brake solenoid is ener-
Parking brake switch set to position PARK- gized.
ING:
The contacts in parking brake switch (7) open Braking in an emergency:
the brake release solenoid (8) circuit and Pushing down on the brake pedal (1) as far
close the indicator lamp (on Combination as it will go breaks the contact in foot brake
meter) circuit. switch (brake release switch) (5), opening the
The indicator lamp comes on. The parking parking brake solenoid circuit. At the same
brakes (9) and (10) are applied. time, the pedal movement moves either of
The parking brake solenoid is deener- rods (3), (4) to bring F-R levers (6) to the neu-
gized. tral position.
The parking brake solenoid is deenergized to
apply the brake by means of the compression
springs, and simultaneously, hydrostatic brak-
ing takes place.
6
3
4
* Switch is OFF when

pedal is depressed. Rear wheel
5
7
9 8
From charge circuit

Fuse 1 3
Fuse 5 4
To oil tank
AC Brake released
Starter switch 10
Front wheel
1 3
Brake applied
SW3002037
2-040
Sprinkler and Scraper
4. Sprinkler and Scraper

4-1. Sprinkler piping
1/2
p
3
9
1 7
10
2
4
Sprinkler
DEATIL A Sprinker pipe (F)
pump
Check 8
Filter valve
3-way cock
P
Sprinker pipe (R)
Drain cock
VIEW B-B Sprinler diagram

9
1 3
B
A
5
7
6
2
SW3002038
1. Sprinkler pump 6. Drain cock

2. Filter 7. Hose (pump to rear sprinkler pipe)
3. Sprinkler hose (tank to 3-way cock) 8. Rear sprinkler pipe
4. 3-way cock 9. Hose (pump to front sprinkler pipe)
5. Hose (filter to pump) 10. Front sprinkler pipe
2-041
Sprinkler and Scraper
4-2. Scraper
A A
A A
3
5 5
4 1
5 5
VIEW A 2
SW3002039
1. Blade (upper)
2. Blade (lower)
3. Bracket (upper)
4. Bracket (lower)
5. Spring
2-042
Electric System
5. Electric System
5-1. Location of instrument panel and relays
2 3
VIEW A
A
D
2 B
VIEW B
7 5
10
9
11
VIEW D-D
VIEW C
SW3002040
1. Combination meter 7. Vibrator relay

2. Battery relay 8. Fuse box
3. Battery 9. Vibrator indicator lamp relay
4. Starter switch 10. Glow lamp timer
5. Horn relay 11. Engine stop timer
6. Interlock relay
2-043
Electric System
5-2. Location of electric components
3 4 5 6
8
7
2
9
11
12
10
12
16
5
14
13
15
SW3002032
1. Headlamp 7. Fuel gauge unit 13. Vibrator solenoid valve (front)

2. Brake release solenoid valve 8. Reverse alarm 14. Fuse box
3. Engine oil pressure switch 9. Engine revolution sensor 15. Fuel pump
4. Starter 10. Engine stop solenoid 16. Sprinkler pump relay
5. Alternator 11. Glow plug
6. Thermo sensor 12. Vibrator solenoid valve (rear)
2-044
Electric System
5-3. Electric wiring diagram
2-045
INSPECTION & ADJUSTMENT
INSPECTION & ADJUSTMENT
1.Standard Value Chart 3-002
2.Inspection & Adjustment

2-1. Measurement and adjustment of pressure in propulsion main circuit 3-101
2-2. Measurement of propulsion charge circuit pressure 3-103
2-3. Measurement of brake release pressure 3-104
2-4. Measurement of vibrator circuit pressure 3-105
2-5. Measurement of steering circuit pressure 3-106
2-6. Throttle linkage adjustment 3-107
2-7. Adjustment of F-R lever linkage 3-108
Precautions for Use of Standard Value Chart

1) Values in the chart are based upon ones when the machine leaves the factory. They should be
used for estimation of wear after extended operation and for guidance when the machine is
repaired.
2) Values in the chart are ones based on various test results etc. They should be used as a guide to
fault finding practice in due consideration of the past repair frequency and operating record of the
machine.
3) Values in the chart should not be used for the standard for claim application.
Precautions for Checking, Adjustment and Fault Finding

For checking, adjustment and fault finding practices, park the machine on level ground
and block with the safety pins or chocks.
When working with other workers, use hand signals positively and keep people not
concerned away from the work area.
Cool off the coolant or hydraulic fluid when removing the radiator cap or the hydraulic
tank filler cap. Hot fluids can burn you.
Do not put your hands close to parts in motion such as fan belts.
3-001
Standard Value Chart
1. Standard Value Chart

1-1. Standard value chart for roller body
Standard value Permissible
Item Measuring conditions Unit for new machine range
Low idle Coolant temp. 100050 ---------
: Green zone on gauge
min -1
Engine Speed High idle Hydraulic oil
(rpm)
280050 ---------
temperature : 50 5C
Rated speed (122 41C) 2800 ---------
Engine at full throttle
0~12
Forward Coolant temp.
(0~7.5)

Travel : Green zone on gauge km/h
speed Hydraulic oil (mile/h)
temperature : 50 5C 0~12
Reverse
(0~7.5)

(122 41C)
Engine at full throttle 34.51.0 31.7

Main circuit
Hydraulic oil (5000140) (4600)
pressure {35210} {324}
Propulsion temperature : 50 5C
(122 41C) 1.90.19 1.7
Charge circuit (27027) (240)
pressure {191.9} {17}
MPa
Oil (psi) 12.70.5 11
Vibrator Circuit pressure (184070) (1580)
pressure {kgf/cm2} {1305} {113}
13.80.5 11.9
Steering circuit pressure (200070) (1720)
{1415} {121}
1.90.19 1.7
Brake release circuit (27027) (240
pressure {191.9} {17}
3-002
Inspection & Adjustment
2. Inspection & Adjustment

2-1. Measurement and adjustment of pressure in propulsion main circuit
1. Measurement
Hydraulic oil temperature: 505C
(12241F)
Park on level ground. Stop the engine.
Block the wheels. 2
Make certain that the parking brake func-
tions correctly.
1) Remove plugs from gauge points (1) and

1
(2) in the propulsion pump and attach SW3003001
adapter 1. Fit a 0 - 60 MPa (0 - 8700 psi)
{0 - 600 kgf/cm2} pressure gauge to adapter
1.
Gauge port: 9/16-18UNF
Port (1): for forward travel
Port (2): for reversing
2) Start the engine. With the throttle lever

operated slowly, bring the engine to full
speed.
3) Ensuring that the parking brake is ON, SV5003003
operate the F-R lever slowly till the engine

reaches the rated speed. Take the gauge
reading.
4) When the measurement is complete, bring

the F-R lever to the neutral position imme-
diately.
3-101
2. Adjustment
If the measured value falls outside the per-
missible range, clean or renew pressure relief 8
valves (7) (forward travel) and (8) (reversing).
Tightening torque for valve seat plug (9):
40 - 95 Nm (30 - 70 lbfin) {300 kgfcm}
Carefully perform disassembly and
reassembly taking necessary measures
to prevent ingress of foreign matter. 7
SW3003002
SW3003003
3-102
2-2. Measurement of propulsion charge circuit pressure

1. Measurement
(12241F)
Park the machine on level ground. Stop 1
the engine and block the wheels.
Make sure, before the test, that the parking
brake works correctly.
1) Remove the plug from propulsion pump

gauge port (1) (9/16-18UNF) and mount SW3003004
adapter 1. Attach a 0 - 6.0 MPa (0 - 870
psi) {0 - 60 kgf/cm 2} pressure gauge to
adapter 1.
2) Start the engine. Slowly operate the throttle

lever to run the engine at maximum speed.
3) Ensuring that F-R lever is in the neutral

position, take the reading of the pressure
gauge.
2. Adjustment SV5003003
If the measured value is not within the permis-

sible range, adjust as follows:
1) Loosen locknut (11) on the charge relief 11
valve. Adjust by rotating screw (12).
Clockwise rotation raises the pressure.
When turned counterclockwise, the pres- 12
sure decreases.
A quarter turns (90 degrees) of the screw
increases or decreases the pressure by
0.27 MPa (39 psi) {2.8 kgf/cm2}.
Tightening torque for locknut:
47 - 57 Nm (34 - 42 lbfin) {48 - 58 kgfcm} SW3003005
2) When adjustment is complete, check for

correct setting.
3) If the valve is beyond adjustment, disas-

semble and clean or renew the pressure
relief valve assembly.
reassembly taking necessary means
to prevent ingress of foreign matter.
3-103
2-3. Measurement of brake release pressure

1. Measurement
(12241F)
Park the machine on level ground. Stop 17
Because oil is supplied from steering cir-
cuit, make sure, before the test, that the
steering system works correctly.
1) Disconnect brake release hose (17) from SW3003006

the propulsion motor and install adapter 4.
Plug the open ports of the motor.

2) Install a 0 - 6.0 MPa (0 - 870 psi) {0 - 60

kgf/cm2} pressure gauge to adapter 4.
3) Start the engine. Ensuring that the F-R

lever is in the neutral position, slowly move
the throttle lever to full throttle.
4) Set the parking brake switch to the

SV5003018
RELEASE position and take the gauge
reading.
3-104
2-4. Measurement of vibrator circuit pressure

1. Measurement
(12241F)
1
Park the machine on level ground. Stop
1) Disconnect high pressure inlet hose (1)

from the vibrator motor and mount adapter
4.
Plug the open ports of the motor. SW3003007
2) Install a 0 - 25 MPa (0 - 3600 psi) {0 - 250

3) Start the engine. Slowly operate the throttle

lever to run the engine at maximum speed.
4) Shift the vibration mode selector switch

from OFF to CONT. Switch ON the vibrator
switch on top of the F-R lever and take the
gauge reading.
SV5003018
2. Adjustment
sible range, adjust as follows: 1
1) Loosen lock nut (1) on the relief valve and
turn adjusting screw (2). Clockwise rotation
raises the pressure. The pressure lowers if
turned counter-clockwise.
2
2) When adjustment is complete, check for
correct setting.
SW3003008
3) If the valve is beyond adjustment, disas-

semble and clean or renew the pressure
relief valve assembly.
reassembly taking necessary means
to prevent ingress of foreign matter.
3-105
2-5. Measurement of steering circuit pressure

1. Measurement
(12241F)
Park on level ground. Stop the engine. 1
Because the return line of the steering cir-

cuit feeds the charge line in the propulsion
circuit, check to see if the charge pressure
in the propulsion circuit is as specified.
1) Disconnect outlet hose (1) from steering SW3003009
pump. Reconnect after installing adapter 5.

1
2) Install a 0 - 25 MPa (0 - 3600 psi) {0 - 250
3) Start the engine. Ensuring that the F-R

lever is in the neutral position, slowly move
the throttle lever to full throttle.
4) Turn the steering wheel counter-clockwise

to full lock. Take the gauge reading.
SV5003021
When rotating the steering wheel, do not
allow anyone to enter the pinch area of
the articulated frame.
2. Adjustment
sible range, disassemble and clean or renew
the relief valve assembly built in Orbitrol. The
valve is not adjustable.
reassembly taking necessary means to
avoid ingress of foreign matter.
3-106
2-6. Throttle linkage adjustment

When the throttle linkage has been
renewed (or reconnected) or if the high
idle or low idle rpm is not to specification, 1
adjust as follows:
1. Adjustment
Coolant temperature: Green area on
gauge.
1) Set throttle lever (1) to the LOW IDLE posi-

tion.
2) Connect throttle cable (2) to fuel injection

pump governor lever (3).
3) Start the engine. Slacken lock nut (4) and

adjust stop bolt (5) until correct low idle rev- 2
olution is reached.
Low idle: 100050min-1 (rpm)
4) Screw in stop bolt (6) so that it makes con-

SW3003010
tact with throttle lever (1). Then screw out
by 1/4 to 1/2 turns and fix with lock nut (7).
5) Move throttle lever (1) to full throttle side. 8 9

Loosen lock nut (8) and adjust stop bolt (9) 3
to set the high idle speed to specification.
6) Start the engine and check that the high 4

idle rpm is to specification.
High idle: 285050min-1 (rpm) 5
7) Screw in stop bolt (10) until it makes con- SW3003011

tact with throttle lever (1). Then screw out
by 1/4 to 1/2 turns and fix with lock nut (11).
1 6
11
10
SW3003012
3-107
2-7. Adjustment of F-R lever linkage

When the F-R lever linkage has been 1
renewed (or reconnected) or if the F-R (2)
levers fail to move smoothly, adjust as

described below:
1. Adjustment
(12241F)
Inspect the stroke of pump control lever
as described below. Positions of F-R
levers are positively determined by notch
balls.
Check that the F-R lever operates smooth-
ly.
1) With F-R levers (1), (2) in the neutral

position, connect control cable (3) to F-R
lever (1) or (2). 3
2) Connect cable (3) to propulsion pump

control lever (4).
3) Move F-R lever (1) or (2) to each detent

position and ensure pump control lever (4) SW3003013
follows in F-R lever positively.
4) To adjust the neutral position, rotate fixing

nuts (5) of cable (3), while moving the F-R
lever (neutral forward neutral
backward neutral), so that the F-R lever
travel from the neutral position to the posi-
tion in which the machine starts traveling is 3 4
equal for both forward and backward trav-
eling. 5 5
Perform this adjustment on level and SW3003014
flat concrete pavement while varying
the engine revolution in several steps
ranging from low to high idles.
3-108
TROUBLESHOOTING
TROUBLESHOOTING
1. Precautions for Troubleshooting 4-002
2. How to Diagnose the Machine 4-003
3. How to use the Troubleshooting Flow 4-004

4. Precautions for Diagnosis of Electric Circuit 4-006
5. Troubleshooting for Electric System (Mode E) 4-201
6. Fault Finding for Hydraulic and Mechanical Systems (Mode H)

4-401
4-001
Precautions for Troubleshooting
1. Precautions for Troubleshooting

Park the machine on level ground. Make sure that the safety pins are engaged, wheels
chocked and parking brake applied.
When working with other workers, use hand signals authorized, and keep people not
concerned away from the work area.
If the radiator cap is carelessly removed from a hot engine, hot coolant will gush out to
cause a burn. Remove the cap only when the engine has been cooled off.
Exercise care not to touch hot parts or not to be caught in rotating parts.
When disconnecting electric wires, disconnect the battery negative (-) cable.
When taking off plugs or caps from units which are under pressure such as hydraulic,
water and air pressures, do the works after removing residual pressure. If gauges are
to be connected, attach them surely.
Troubleshooting is to determine the root cause of troubles, repair faulty parts as quickly as prac-
ticable, and prevent recurrence of the troubles.
Important when conducting troubleshooting practice is of course to well understand the struc-
ture and function of machines to be handled. For effective troubleshooting, however, it is of
prime importance to have a clear picture of the trouble concerned by contacting the operator.
1. When a trouble has occurred, do not 3. Before-diagnosis inspection

attempt to disassemble blindly. 1) Perform daily inspections.
Disassembling in a hurry will invite disadvan- 2) Perform other inspections required for
tageous situations as described below: diagnosis.
Parts which need not be disassembled
may be disassembled. 4. Confirmation of trouble
Tracing the cause of trouble will become Know the degree of the trouble. Determine
more difficult. whether it is a trouble caused by improper
These will cause increased service costs design etc. or the trouble was caused by
because of wasteful service hours, spare incorrect handling.
parts or expendables like oil or grease. To When making the trouble recur to
make matters worse, such a careless prac- trace the cause of the trouble by
tice will invite operators (customers) dis- putting the machine in motion, use
trust. For these reasons, sufficient advance care not to cause more damages to
investigations and diagnosis in accordance the machine.
with troubleshooting procedures specified 5. Troubleshooting
are essential for efficient fault finding prac- From the results of items 2 to 4 above, nar-
tices. row down the cause of the trouble, and pin-
2. Questions to be addressed to the opera- point the source of the trouble by utilizing
tor (customer) . the diagnosis flow chart.
1) Are there any trouble other than the one The basic points of the diagnosis are:
in question? 1) Start from the portion simple.
2) Was there any abnormal condition with 2) Start from the portion having a high prob-
the machine before the trouble occurs? ability to solve the problem.
3) Did the trouble occur suddenly without 3) Investigate related matters.
signs of abnormal conditions in advance? 6. Basic remedy for the trouble
4) In what occasion did the trouble occur? Even if a trouble has been rectified, it will
5) Has the machine been repaired before develop again if its cause is not determined.
the trouble occurs? If so, when has it It is of prime importance to trace the very
been repaired? cause of the trouble.
6) Did similar trouble occur in the past?
4-002
How to Diagnose the Machine
2. How to Diagnose the Machine
Office and repair shop (Our side) Site (Customers side)
Procedure 1. Confirmation of trouble

1) Make an inquiry about the following items
upon request of repair.
Customer Work site
Customer's name
Model and serial number of machine
Work site and working condition, etc.
2) Seize outline of trouble by questioning.
Details of trouble
Details of work when trouble occured
Working environment Work shop
Information of services conducted in the
past Field repair
Shop repair
Procedure 2. Estimation of source of trouble Procedure 7.

1) Determine source of trouble by referring Troubleshooting
to "TROUBLESHOOTING" in this manual. Determination of remedy
1) Before troubleshooting, find out and rectify simple
failure.
Daily inspections
Other inspections required
2) With reference to "TROUBLESHOOTING" in this
Procedure 3. Preparation of necessary tools manual, make a diagnosis by following proper
1) Prepare tools recommended in the shop diagnosis flows best applicable to rectify the trouble.
manual.
Tester and extension cable, etc.
Procedure 6. Making the machine recur the trouble
Pressure gauge etc.
By letting the machine travel or performing the work,
2) Prepare spare parts referring to the parts
check to see if the trouble is attributable to a serious
catalogue.
cause like the defect of component parts or the
trouble was only caused by improper handling.
Procedure 5. Getting detailed information from operator

concerning the trouble
Procedure 4. Going to site where the faulty Was there any abnormal signs before the trouble
machine stays idle. occurs?

Did the trouble occur all of a sudden?
Was the machine repaired before?
4-003
How to Use this Chapter, "TROUBLESHOOTING" and How to Follow the Troubleshooting Flow
3. How to Use the Troubleshooting Flow

1. Troubleshooting codes
1) Electric system: E-01 to E-14
2) Hydraulic and mechanical systems: H-01 to H-11
2. How to follow the troubleshooting flow

1 E-08 Headlamps do not light (Example)
2 Measure the voltage with the starter switch ON.
3 a) Both headlamps do not come on.
Possible cause Remedy
Wire GB from lighting switch

YES 2 YES terminal 2 to headlamp (to Repair or renew
Is stated voltage branch point) not connected wire.
fed to lighting or incorrectly connected.
switch terminal 2
1
that carries wire
Is stated voltage GB?
Lighting switch faulty. Renew.
fed to lamp switch 10~14V
NO
terminals 1 and 4
that carry wire R?
Wire R from fuse to lighting
10~14V switch terminals 1, 4 not Repair or renew
connected or incorrectly wire.
NO
connected (including fuse).
1 Troubleshooting code No. and fault symptom

On top of the flow chart are code No. and fault symptom.
2 General precautions
Under the code No. and fault symptom are precautions (marked ) for the whole items in the
flow chart. Though these precautions are not indicated inside each box ( ) which contains
checking instructions, pay attention to the precautions when making inspections described in the
box ( ).
3 Sub classification
To make diagnosis easier or for simplified flow chart, fault symptom is subclassified. Ex. a)
Starter does not run
4 How to forward the diagnosis

Each box ( ) contains diagnosis procedure. Depending upon the results of inspection or
measurement, proceed to YES or NO line.
Normally, if the result is YES then proceed to upper line. If NO then go to the lower line.
NOTE: The number above each box ( ) is a reference number. It does not mean a diagnosis
order.
YES
1
NO
4-004
How to Use this Chapter, "TROUBLESHOOTING" and How to Follow the Troubleshooting Flow
As a result of diagnosis, if YES line or NO line directly goes to the description in POSSIBLE
CAUSE column, take necessary action as indicated in REMEDY column.
Under each box ( ) are normal values and conditions necessary for inspection and
adjustment. If the result gives an affirmative answer to the question in the box ( ) or agrees
to the normal value indicated under the box, go to YES line. Otherwise, go to NO line.
The normal values were taken from the standard value list.
For locations of component parts such as relay mentioned in the flow chart, see "Location of
key units". Line colors mentioned in the flow charts are indicated in the electric wiring diagram
shown under the flow charts. In the machine, each harness is identified by color.
4-005
Precautions for Diagnosis of Electric Circuit
4. Precautions for Diagnosis of Electric Circuit

1. When disconnecting or connecting connectors or harnesses, cut the power supply.
2. Before making a diagnosis, check the connectors or harnesses for poor connection.
If a connector is at fault, check it by repeating connection and disconnection several
times.
3. Before proceeding to the next step, reconnect removed connectors or harnesses in place.
Care must be used for the controller circuit. If the power source is switched on with the
connector disconnected, this can cause an incorrect measurement.
4. When making a diagnosis of circuits (measurement of voltage, resistance, current, test for conti-
nuity, etc.), check to see if tester readings vary by shaking connectors or harnesses.
If readings vary, a possible cause is a poor connection of the circuit.
5. For voltage measurement, turn the starter switch ON. For resistance checking, let the switch stay
in the Off position.
If necessary to take a measurement of resistance by energizing relays or other units with
the starter switch ON, necessary instructions are given in the flow charts.
4-006
Troubleshooting for Electric System
5. Troubleshooting for Electric System (Mode E)
E-01 Engine does not start 4-202

E-02 Engine does not stop 4-205
E-03 Glow plug does not become red-hot (difficult starting) 4-206
E-04 No charging (charge lamp stays bright) 4-207
E-05 Fuel pump does not work 4-207
E-06 Reverse alarm does not sound 4-208
E-07 Horn does not sound4-209
E-08 Headlamps do not light 4-210
E-09 Vibrator does not operate4-211
E-10 Sprinkler does not work 4-215
E-11 Parking brake not released 4-216
E-12 Fuel gauge reads wrong 4-217
E-13 Water temperature gauge reads wrong 4-218
E-14 Tachometer reads wrong 4-219
Wire color code

Brown/ Light green/ Yellow/
B Black BrY
Yellow stripe
L Blue LgY
Yellow stripe
W White YL
Blue stripe
Black/ Blue/ White/ Yellow/
BR G Green LR R Red WB YR
Red stripe Red stripe Black stripe Red stripe
Black/ Green Blue/ Red/ White/ Yellow/
BW GB LW RB WL YW
White stripe Black stripe White stripe Black stripe Blue stripe White stripe
Black/ Green Blue/ Red/ White/
BY GL LY RG WR Gy Gray
Yellow stripe Blue stripe Yellow stripe Green stripe Red stripe
Green Red/ White/
Br Brown GR Lg Light green RL WY O Orange
Red stripe Blue stripe Yellow stripe
Brown/ Green Light green/ Red/
BrB GW LgB RW Y Yellow Sb Sky blue
Black stripe White stripe Black stripe White stripe
Brown/ Green Light green/ Red/ Yellow/
BrR GY LgR RY YB P Pink
Red stripe Yellow stripe Red stripe Yellow stripe Black stripe
Brown/ Light green/ Yellow/
BrW LgW YG
White stripe White stripe Green stripe
4-201
E-01 Engine does not start

Set the F-R lever to the neutral position.
For voltage measurement, turn the starter switch ON.
a) Starter motor does not operate. (1/2)
YES
Is stated voltage
YES YES
present at starter
terminal S that
carries wire BR?
10~14V 5
Turn starter switch
to START. Is stated voltage
present at interlock
relay terminal that
NO
carries wire BR?
3
10~14V
Turn starter switch
YES Is stated voltage
to START.
present at starter
terminal B? NO
10~14V
2
Does battery relay
YES give a click when 9 YES
starter switch is set
from ON to OFF Is stated voltage
and vice versa? present at battery
relay terminal that
NO
carries wire LW?
10~14V NO
1
YES
Are battery voltage
and fluid specific 10
gravity as Is stated voltage
specified? present at battery
relay terminal BR
Higher than 13V. 11 YES
NO that carries wire
LgW? Is stated voltage
Higher than 1.26
present at starter
(specific gravity) 10~14V
switch terminal BR
NO that carries wire
LgR?
10~14V NO
NO
4-202
Starter faulty. Renew.
Wire BR from interlock relay

terminal to starter terminal S Repair or renew
not connected or incorrectly wire.
connected.
7 YES Safety switch on F-R lever

Renew.
Is specified voltage defective.
YES fed to interlock
relay coil terminal
that carries wire
6 GY?
Interlock relay faulty. Renew.
10~14V NO
Is specified voltage
fed to interlock Turn starter switch
relay terminal that to START.
Wire W(W) from starter
carries wire W?
8 YES terminal C to interlock relay Repair or renew
not connected or incorrectly wire.
10~14V Is specified voltage
connected.
Turn starter switch fed to starter switch
to START. terminal C that
NO
carries wire W?
Starter switch defective
Renew.
10~14V (between B and C)
NO
Turn starter switch
to START.
Wire from battery relay to

Repair or renew
starter not connected or
wire.
incorrectly connected.
Battery relay contact faulty. Renew.
Battery relay coil faulty. Renew.
Wire LgR (LgW) from starter

switch terminal BR to battery
Repair or renew
relay terminal BR not
wire.
connected or incorrectly
To A on page 4-204.
Charge or
Battery capacity lowered.
renew battery.
4-203
a) Starter motor does not operate. (2/2)
YES Starter switch faulty

Renew.
12 (between B and BR).
Wire WR(W) from battery
fed to starter switch
A relay terminal BR to starter Repair or renew
terminal B that 13 YES
switch tereminal B not wire.
carries wire WR?
Is specified voltage connected or incorrectly Renew fuse.
10~14V fed to battery relay connected (including fuse).
terminal that
NO carries wire W? Wire from battery to battery
Repair or renew
relay not connected or
10~14V wire.
NO incorrectly connected.
Electric wiring diagram for modes E-01 and E-02
Battery
LW
Battery relay
WR 65A W
Fusible link LgW Starter

Fuse
BR 15A
LW L B
Starter BR
switch S
Fuse
B
LgR 15A Engine stop 3 4
BR solenoid Timer
GR 1 2
C
SOL
LgW LgW L
Fuse Interlock relay

20A BR
W W
F-R lever switch

Fuse
15A RY GY
SW3004001
4-204
bEngine stop solenoid inoperative (starter motor operative)
2 YES
Engine stop solenoid faulty. Renew.
Is resistance of
YES engine stop
solenoid earth wire
as specified? Engine stop solenoid earth
Repair or renew
wire not connected or
wire.
Lower than 1. NO incorrectly connected.
Disconnect wires
1
from solenoid.
4 YES
present at engine To A on this page.
stop solenoid Is stated voltage
terminal that YES present at timer
carries wire GR? connector 4 that Wire LgR (LgW) from starter
3
10~14V carries wire L? switch terminal BR to timer Repair of renew
Is stated voltage connector 3 not connected or wire.
Turn starter switch
present at timer 10~14V NO incorrectly connected Renew fuse.
to START.
connector 1 that Turn starter switch (including fuse).
NO
carries wire GR? to START.
Timer faulty or earth wire not
10~14V
connected or incorrectly Repair or renew.
Turn starter switch NO connected.
to START.
Wire LW (L) from battery

Repair of renew
5 YES relay to timer connector 4 not
wire.
Is specified voltage Renew fuse.
present at timer
A
connector 3 that
Wire GR from solenoid to
carries wire LgW? Repair of renew
timer connector 1 not
wire.
10~14V connected or incorrectly
NO Renew fuse.
Turn starter switch
to START.
E-02 Engine does not stop
1 YES
Engine stop solenoid faulty. Renew.
present at engine
stop solenoid
terminal BR that
carries wire L?
Battery relay defective. Renew.
Lower than 1V.
NO
Starter switch: OFF
4-205
E-03 Glow plugs do not become red-hot (difficult starting)

It is assumed that the starter is normal.
Measure the voltage with the starter switch ON.
a) Glow lamp does not become bright. (Other lamps light up.)
The glow indicator should become bright when the starter switch is turned to the
HEAT position, and come off when preheating is complete.
YES
Glow lamp relay faulty. Renew.
2
Does stated
YES voltage appear at Wire YW from combination

glow lamp timer
3 YES meter to glow lamp timer Repair or renew
connector 6 that
Does stated connector 6 not connected or wire.
carries wire YW?
voltage appear at incorrectly connected.
Starter switch
1 combination meter
ON: 10 to 14V
Does stated terminal that
HEAT: Lower NO
voltage appear at carries wire YW?
than 1V. Glow indicator faulty. Renew.
glow lamp timer Starter switch NO
connector 4 that ON: 10 to 14V
carries wire WG. HEAT: Lower than 1V.
Wire WG from starter switch
10~14V
4 YES terminal R2 to glow plug not Repair or renew
Turn starter switch connected or incorrectly wire.
Does stated
to HEAT. connected.
voltage appear at
starter switch
NO terminal R2 that
carries wire WG? Starter switch faulty
Renew.
10~14V (between B and R2).
NO
Turn starter switch
to HEAT.
b) Glow indicator becomes bright but hard starting
1 YES
Glow plug faulty. Renew.
Does stated
voltage appear at
glow plug terminal
that carries wire Wire WG from starter switch
WG? terminal R2 to glow plug not Repair or renew
10~14V
NO connected.
Turn starter switch
to HEAT.
Electric wiring diagram for mode E-03
Glow lamp
timer
3 4 5 6
Starter switch
WL Combination meter
From battery WG Glow indicator
relay
YW
C
WG
Glow plugs 5A Y
B R2
ACC
R1
Fuse
BrB SW3004002
4-206
E-04 No charging (charge lamp stays bright.)

YES
Regulator faulty. Renew.
1
Does specified
voltage appear at
alternator terminal
2 YES
IG that carries wire Alternator faulty. Renew.
Does specifed
Y?
voltage appear at
13.5~14.5V
alternator terminal
Run engine at NO
B that carries wire Wire WY from alternator
higher than
WY? terminal B to starter terminal Repair or renew
medium speed.
B not connected or wire.
10~14V NO

Starter switch Starter
From battery BrB
relay B ACC B
Y
Combination meter
Charge lamp WY B
Y
IG Alternator
WR WR
L
Y 5A E
Fuse SW3004003
E-05 Fuel pump does not work

2 YES
Fuel pump faulty. Renew.
YES Is resistance of fuel

pump earth wire as
specified?
1 Fuel pump earth wire not
Repair or renew
Does specified connected or incorrectly
wire.
voltage appear at Lower than 1. NO connected.
fuel pump terminal Disconnect wires

that carries wire from pump.
RB?
10~14V Wire RB from fuse to fuel

Repair or renew
pump not connected or
wire.

15A RB R
Fuse
B
SW3004004
4-207
E-06 Reverse alarm does not sound

First, check that the fuse is not blown.
The voltage measurement should be taken with the starter switch ON.
2 YES
Reverse alarm faulty. Renew.
YES Is resistance of
reverse alarm
ground wire as
specified? Reverse alarm earth wire not
1 Repair or renew
Does specified wire.
Less than 1 NO connected.
voltage appear at
Disconnect wire from
reverse alarm
reverse alarm.
terminal that
Wire BY from back-up switch
carries wire BY? YES Repair or renew
to reverse alarm not connected
wire.
10~14V 3 or incorrectly connected.
Move F-R lever
Does specified
BACKWARD.
voltage appear at
back-up switch that 4 YES
NO carries wire BY? Back-up switch faulty. Renew.
10~14V present at back-up
Move F-R lever switch terminal that
BACKWARD. NO carries wire RG? Wire RG from back-up switch

Repair or renew
to fuse not connected or
wire.
10~14V NO incorrectly connected.
Back-up switch
Fuse NO
Reverse alarm
15A RG BY BY R
SW3004005
4-208
E-07 Horn does not sound

First, check that fuse is not blown.
The voltage measurement should be taken with the starter switch ON.
2 YES
Horn faulty. Renew.
YES
Is resistance of
horn earth wire as
spcified?
1 Horn earth wire not connected Repair or renew
or incorrectly connected. wire.
Is stated voltage Lower than 1. NO
present at horn Disconnect wire
terminal that from horn.
carries wire Lg? Wire Lg from horn to horn
YES Repair or renew
wire.
10~14V 3 incorrectly connected.
Switch on horn Is stated voltage
switch. present at horn
relay terminal that 4 YES
NO carries wire Lg? To A on this page.
Is stated voltage
10~14V present at horn

relay terminal that
Switch on horn
switch. NO carries wire RG? Wire RG from fuse to horn
Repair or renew
relay terminal not connected
wire.
10~14V NO or incorrectly connected.
7 YES
Horn relay faulty. Renew.
horn switch earth
6 wire as specified?
Horn switch earth wire not
Repair or renew
YES Is resistance connected or incorrectly
between horn Lower than 1. wire.
NO connected.
switch terminals Disconnect wires
normal? from horn switch.
5
Lower than 1
Horn switch faulty. Renew.
Is stated voltage
when switched ON. NO
present at horn
A Disconnect wires
switch terminal that
from horn switch.
carries wire LgW?
Wire LgW from horn relay coil
8 YES Repair or renew
to horn switch not connected
10~14V Is stated voltage wire.
or incorrectly connected.
Switch OFF horn present at horn
switch. relay coil terminal
Horn relay coil defective or
that carries wire
NO wire RG from horn relay coil
LgW?
to fuse ( from branch point) Renew.
10~14V NO not connected or incorrectly
Switch OFF horn connected.
switch.

Fuse Horn relay Horn
15A RG RG Lg Lg
RG
Horn button
LgW
SW3004006
4-209
E-08 Headlamps do not light

a) Both headlamps do not come on.
Wire GB from lighting switch

YES 2 YES terminal 2 to headlamp (to Repair or renew
Is stated voltage branch point) not connected wire.
fed to lighting or incorrectly connected.
switch terminal 2
1
that carries wire
Is stated voltage GB?
Lighting switch faulty. Renew.
fed to lamp switch 10~14V
NO
terminals 1 and 4
that carry wire R?
Wire R from fuse to lighting
10~14V switch terminals 1, 4 not Repair or renew
NO
b) Either left or right headlamp does not come on.
YES
Filament is burnt. Renew.
1
Is filament of bulb
burnt? Poor contact of bulb or earth Repair.
2 YES
wire not connected or Repair or renew
Is stated voltage incorrectly connected. wire.
fed to inoperative
lamp terminal that Wire GB from lighting switch
NO carries wire GB? terminal 2 to headlamps
(from branch point) not
10~14V Repair or renew
NO connected or incorrectly
Lighting switch: connected. wire.
Select headlamp.

Lighting switch
Fuse 1
3 Headlamp
30A R 2 GB GB R
4 6
5
Instrument panel lamp

Headlamp
GB R
Combination meter
SW3004007
4-210
E-09 Vibrator does not operate

a) Inoperative in MANUAL mode.

Diagnose with vibration mode selector switch set to MANUAL.

Vibrator switch (R)
Br Br
Vibrator switch (L)

Br Br
Vibrator solenoid (R)

Vibrator relay Vibration mode
B B BrR
BrY selector switch
(F)
Br 3
GY G H 1 RL BrB B B
RW RW 2
E F
6
X D 4 RL Vibrator solenoid (F)
BrR BrY
X B 5
F-R lever switch
Vibrator indicator
Vibrator indicator lamp relay Fuse
lamp 15A
Rr RL RL
BrR
Fuse
15A
BrR
SW3004008
4-211
YES
5
Is resistance of wire RW
YES from vibration mode
selector switch terminal 2
to vibrator relay
connector F as specified?
4
Lower than 1.
Is stated voltage
YES present at vibration Disconnect wire.
mode selector switch

terminal 2 that carries
wire RW? NO
3
Is resistance of wire 10~14V
BrR from solenoid to Selector switch:

YES
vibrator relay MANUAL
connector B as NO
2 specified?
Is stated voltage present at Lower than 1.
YES solenoid and vibration

mode selector switch
terminal 1 which carry wire NO
1 BrB and RL respectively?
10~14V
Is resistance of
solenoid as stated
and is insulated
NO
from body?
About 11.
Disconnect wire.
NO
4-212
7 YES
Vibrator switch faulty. Renew.
Is resistance of
YES
vibrator switch
earth wire as
specified? Vibrator switch earth wire not
6 Repair or renew
wire.
Is stated voltage Lower than 1. NO connected.
present at vibrator Disconnect wires.
switch that carries
wire Br?
8 YES
Vibrator relay faulty. Renew.
10~14V Is resistance of wire
Br from vibrator
switch to vibrator
NO relay connector H Wire Br from vibrator switch
as specified? to vibrator relay connector H
Repair or renew
not connected or incorrectly
Lower than 1. NO wire.
connected.
Disconnect wires.
Wire RW from vibration mode
selector switch to vibrator
Repair or renew
relay connector F not
wire.
connected.
Vibration mode selector switch

Renew.
faulty.
Wire BrR from vibrator

solenoid to vibrator relay Repair or renew
connector B not connected or wire.
Wire RL (BrB) from vibration

mode selector switch terminal Repair or renew
1 to fuse not connected or wire.
Solenoid faulty. Renew.
4-213
b) Inoperative in AUTO mode (Operative in MANUAL mode)

Set vibration mode selector switch to AUTO.
3 YES
To A on this page.
Is resistance of wire BrY
YES from vibration mode
selector switch terminal 5
2 to vibrator relay connector Wire BrY from vibrator relay
Is stated voltage G as specified? connector G to selector Repair or renew
YES present at vibration Lower than 1. switch not connected or wire.
NO
mode selector switch Disconnect wires. incorrectly connected.
1
terminal 5 that carries
Is stated voltage
wire BrY?
present at vibration
10~14V Vibration mode selector switch
mode selector Renew.
NO faulty.
switch terminal 4
that carries wire RL?
10~14V Wire RL from vibration mode

Repair or renew
selector switch termianl 4 to
wire.
NO fuse not connected or
Renew fuse.
4 YES
Vibrator relay faulty. Renew.
Is resistance of wire
GY from vibrator
A relay connector E to
F-R lever switch as Wire GY from vibrator relay
specified? connector E to F-R lever Repair or renew
switch not connected or wire.
Lower than 1. NO
Disconnect wires.
4-214
E-10 Sprinkler does not work

2 YES
Sprinkler motor faulty. Renew.
sprinkler motor
earth wire as
specified? Sprinkler motor earth wire not
1 Repair or renew
wire.
Is specified voltage Lower than 1. NO connected.
present at sprinkler Disconnect wire
motor that carries from motor.
Wire LB from sprinkler relay
wire LB?
YES to sprinkler motor not Repair or renew
10~14V 3
connected.
Operate sprinkler
switch.
present at sprinkler
relay terminal that 4 YES
NO carries wire LB? To A on this page.
10~14V present at sprinkler
Operate sprinkler relay terminal that
switch. NO carries wire LY? Wire LY from fuse to sprinkler
Repair or renew
wire.
10~14V NO incorrectly connected.
6 YES
Sprinkler relay faulty. Renew.
Is resistance of
YES
sprinkler relay
earth wire as
specified? Sprinkler relay earth wire not
Repair or renew
5 connected or incorrectly
Lower tnan 1. wire.
NO connected.
Is specified voltage Disconnect wire
present at sprinkler from relay.
A relay coil that Wire LW from sprinkler switch
carries wire LW? YES terminal 2 to sprinkler relay Repair or renew
7 coil not connected or wire.
10~14V Is specified voltage incorrectly connected.
Operate sprinkler present at sprinkler
switch. switch terminal 2
8 YES
that carries wire Renew.
NO Sprinkler switch faulty.
LW? Is specified voltage
10~14V present at sprinkler
Operate sprinkler switch terminal 1

NO that carries wire Wire LY from fuse to sprinkler
switch.
LY? switch terminal 1 (from Repair or renew
branch point) not connected wire.
10~14V NO

Fuse Sprinkler relay Sprinkler motor
20A LY LY LB Or B Combination meter
M
Sprinkler switch LW Sprinkler
3 indicator
LY lamp
1 LW LW
2
SW3004009
4-215
E-11 Parking brake not released

Set the parking brake to DISENGAGE and keep the foot brake pedal not depressed.
3 YES Hydraulic system faulty

(Use H-08.)
solenoid earth wire
2 as specified?
Is solenoid Brake release solenoid earth
YES Repair or renew
resistance as wire not connected or
Lower than 1. wire.
specified and is
Disconnect wires
solenoid insulated
from solenoid
1 from body?
Is stated voltage About 8.5 .
Brake release solenoid faulty. Renew.
present at brake Disconnect wires
NO
release solenoid from solenoid. Wire WB from brake release
terminal that
solenoid to parking brake
carries wire WB? YES Repair or renew
switch terminal 3 not
wire.
10~14V 4 connected or incorrectly
Set parking brake Is stated voltage connected.
switch to RELEASE. present at parking
brake switch
5 YES
terminal 3 that Parking brake switch faulty. Renew.
NO Is stated voltage
carries wire WB?
present at parking
10~14V brake switch
terminal 1 that
NO
carries wire RW?
To A on this page.
10~14V NO
Wire RW from parking brake

YES switch terminal 1 to foot Repair or renew
brake switch not connected wire.
6
Is stated voltage
present at foot
A
brake switch that 7 YES
carries wire RW? Foot brake switch faulty. Renew.
Is stated voltage
10~14V present at foot
brake switch that
NO carries wire RY? Wire RY from fuse to foot
Repair or renew
brake switch not connected
10~14V NO wire.
Electric wiring diagram for modes E-11

Parking brake
release solenoid Parking brake swistch Foot brake switch Fuse
WB 3 1 RW NC RY 15A
5 4
Combination meter
Parking brake
indicator lamp
YL
SW3004010
4-216
E-12 Fuel gauge reads wrong

Other gauges and lamps are normal.
Repair or
3 Fuel unit earth wire incorrectly renew wire.
YES
connected or fuel unit Repair fuel unit
YES Is resistance of fuel malfunctioning. mounting or
renew fuel unit.
unit as shown in
2 table 2?
YES Fuel unit is faulty. Renew.

Does fuel gauge *Measure with related NO
indicate as table 1? parts disconnected
from fuel unit.
1
Is specified voltage Fuel gauge faulty. Renew.
NO
fed to fuel unit
terminal that
carries wire YG?
Wire YG from fuel gauge to fuel
4 YES Repair or renew
1~7V unit not connected or incorrectly
wire.
Disconnect wire Is specified voltage connected.
from fuel unit. fed to fuel gauge
terminal T that
NO carries wirer YG?
Fuel gauge faulty. Renew.
1~7V NO
Disconnect wire
from fuel unit.
Table 1 Table 2
Fuel unit wire YG Gauge reading Fuel unit float Resistance ()
Full 10~17.5
Disconnected Empty
Empty 82.5~90
Grounded Full

Fuel gauge
Starter switch Fuse
BrB 5A Y
AC
Y
Fuel unit B
YG YG
SW5004013
4-217
E-13 Water temperature gauge reads wrong

Other gauges and lamps operate correctly.
Repair or
Thermo unit earth wire renew wire.
3 YES incorrectly connected or Repair mounting
YES Is resistance of thermo unit faulty. or renew thermo
unit.
thermo unit as
2 shown in table 2?
YES Does water Thermo unit faulty. Renew.

temperature gauge *Measure unit with NO
indicate as shown other parts removed.
in table 1?
1
Water temperature gauge
Renew.
Is stated voltage faulty.
NO
present at thermo
unit terminal that
carries wire Sb? Wire Sb from water temperature
4 YES gauge to thermo unit not Repair or renew
3~8V Is stated voltage connected or incorrectly wire.
Disconnect wire present at water connected.
from thermo unit. temperature gauge
NO terminal T that
carries wire Sb? Water temperature gauge
Renew.
3~8V NO faulty.
Disconnect wires
from thermo unit.
Table 1 Table 2
Thermo unit termi- Thermo unit
Gauge reading Resistance ()
nal wire Sb temperature
Disconnected Lowest 50C 150~158
Grounded Highest 100C About 27.4

Temperature gauge
Starter switch Fuse
BrB 5A Y
AC
Y
Thermo unit B
Sb Sb
SW5004014
4-218
E-14 Tachometer reads wrong

Other gauges and lamps operate correctly.
YES Tachometer unit incorrectly

Refit correctly.
fitted.
2
YES Is fault corrected if

tachometer unit is
refitted? 3 YES
To A on this page.
Is resistance of
1 wire YR between
Is continuity of tachometer sensor
tachometer sensor NO and tachometer as Wire YR from tachometer
normal (gives 4 specified? sensor to tachometer not Repair or renew
signals per connected or incorrectly wire.
Lower than 1. NO
rotation)? connected.
Disconnect wires.
Remove unit and
rotate its shaft by
hand.
Tachometer sensor faulty. Renew.
NO
Renew
4 YES Tachometer sensor
combination
malfunctions.
Is specifed voltage meter.
fed to tachometer
A
terminal (+) that
carries wire Y? Renew
Feed wire inside combination
combination
10~14V meter is faulty
NO meter.
Tachometer
Starter switch Fuse
BrB 5A
AC
Y +
Tachometer sensor B -
YR YR
P
SW5004015
4-219
MEMO
Fault Finding for Hydraulic and Mechanical Systems
6. Fault Finding for Hydraulic and Mechanical Systems

(Mode H)
H-01 Noisy (unusual sounds) 4-404

H-02 Hot hydraulic oil 4-404
H-03 Not propelled 4-405
H-04 Speed not gained or low traction 4-407
H-05 Vibrator does not work 4-409
H-06 Weak vibration force 4-409
H-07 Steering not performed 4-410
H-08 Heavy or slow steering 4-410
H-09 Parking brake not released 4-411
H-10 Parking brake is not applied sufficiently4-411
H-11 No sprinkling on tires 4-412
4-401
Trouble modes for hydraulic and mechanic systems and sources of trouble
Trouble mode Propulsion
Hydraulic
Unusual Not propelled Speed not gained or low traction
fluid too
sounds a) Forward and b) Either forward a) Forward and b) Either forward
hot
Source-of-trouble units reverse or reverse reverse or reverse
Propulsion pump
Charge pump
(Steering pump)

Servo valve/servo
Pump
linkage

High pressure relief
valve

Charge relief valve
Propulsion Motor unit
Front Negative brake
motor (parking brake)

Drum
Motor unit
Rear Negative brake
motor (parking brake)

Drum
Brake valve
Pump
Motor unit
Rear Vibrator
Vibrator solenoid valve
(pressure relief valve)
Vibrator
Pump
Motor unit
Front Vibrator
Vibrator solenoid valve
(pressure relief valve)
Steering pump
Steering valve (Orbitrol)
Pressure relief valve
Steering
Steering cylinder
Steering mechanism
Steering column
Sprinkler pump
Sprinkler
Hose/Valve/Nozzle/Filter
F-R lever linkage
Oil cooler
Others
Coupling
Filter/piping, etc.
Diagnosis code H-01 H-02 H-03a H-03b H-04a H-04b
4-402
Steering Parking brake

Vibrator does Week vibrating Parking brake No sprinkling
is not applied
not work force is not released on tires
Not performed Heavy or slow sufficiently
H-05 H-06 H-07 H-08 H-09 H-10 H-11
4-403
H-01 Noisy (Unusual sounds)
YES
Coupling faulty. Repair or renew.
2
Is noise
coming from
Around pump.
front of
3 YES
pump? Loose suction hose clamp. Retighten.
Is pump
suction hose
NO loose?
To A on this page.
NO
1
YES
Filter clogged. Clean or renew.
Where is 4
noise coming
from? Is suction
A filter
clogged? 5 YES Propulsion pump or motor
Inspect.
Are foreign faulty.
materials or
metal chips
NO noticeable in
Operate machine for some
hydraulic oil?
time and inspect change of
NO faulty condition.
6 YES Loose bearings or fixing bolts, Remove drum

etc. and inspect.
Are bearings
Around drum. or bolts
loose?
Internal fault of propulsion
motor (Diagnose from item
NO 4 above.)
H-02 Hot hydraulic oil
YES Diagnose by using related

trouble mode.
2
YES Are other fault

symptons
noticeable? 3 YES
Oil cooler clogged. Clean or renew.
1
Such as slow speed Is oil cooler
Is machine and low traction clogged?
NO
handled as
instructed by Collaped or clogged piping. Clean or renew.
operators manual? NO
Improper handling.
Handle correctly.
(Overload operation etc.)
NO
4-404
H-03 Not Propelled

Diagnose electric systems first then proceed as follows.
First, check the oil level of the hydraulic tank.
a) Not propelled in both directions.
3 YES
To A on this page.
Do pump servo
YES valve and servo
linkage function
2
correctly?
Servo valve and servo linkage
Repair or renew.
YES Does F-R lever NO malfunction.
move adequately?
1
F-R lever linkage not adjusted

Is bypass valve Adjust.
correctly.
completely closed? NO
Bypass valve partly open. Clean or renew.

NO
Adjust or renew.
6 YES
Parking brake faulty. Repair or renew.
Release brake by
YES screwing release
bolt. Does machine
5
run?
To B on this page.
YES Is parking brake Do this work NO
release pressure
separately for left
as specified?
and right brake units.
4
See STANDARD
Brake valve faulty. Repair or renew.
Is charge pressure VALUE CHART. NO
A
normal?
Charge relief valve

See STANDARD 7 YES
malfunctions due to presence Repair or renew.
VALUE CHART. Disassemble and
of dust etc.
clean charge relief
valve. Is it restored
NO to normal
condition? Charge pump performance
Renew.
lowered.
NO
YES
Front motor faulty. Repair or renew.
8
Block port A and

port B of front
B
motor. Does rear 9 YES
motor run? Rear motor faulty. Repair or renew.
Block port A and
Engine: Low idle . port B of rear
Raise rear of motor. Does front
NO
machine. motor run?
Rear motor or coupling faulty. Renew.
Engine: Low idle . NO
Raise rear of
machine.
4-405
b) Machine travels in one direction only, either forward or in reverse.
3 YES
Leaky pump servo system. Repair or renew.
With F-R lever operated,
YES is there any diffrence in
charge pressure
2 between forward travel
Do servo valve and and reversing? To A on this page.
YES servo linkage of NO
pump function
1 properly?

Does F-R lever Repair or renew.
NO of pump are faulty.
mover adequately?
F-R lever linkage faulty. Adjust or renew.

NO
Clean or adjust.
YES High pressure relief valve
Renew as
faulty.
4 necessary.
Exchange high
pressure relief valve for
A forward travel with that
5 YES
for reversing. Is faulty Front motor faulty. Repair or renew.
condition reversed? Disconnect high
pressure hose from
front motor and block
NO the hose. Does rear
motor run?
Rear motor faulty. Repair or renew.
Engine: Low idle . NO
Raise rear of
machine.
4-406
H-04 Speed not gained or low traction

Diagnose electric systems first then use procedures as listed below.
Check oil level in hydraulic tank in advance.
a) Speed not gained in both directions; forward and reverse.
3 YES To A on this page.

Do servo valve and
YES servo system of
pump function
2 correctly?
YES Does F-R lever NO are faulty.
1 move properly?
Does bypass valve F-R lever linkage incorrectly Adjust.
stay closed NO adjusted.
completely?
Bypass valve partly open. Clean or renew.

NO
Adjsut or renew.
6 YES Parking brake drags. Repair or renew.
Release parking
brake by screwing
YES release bolt. Is
5 machine
propelled? To B on this page.
Is parking brake
YES release Release left and NO
pressure right brakes
as specified? separately.
4
Is propulsion See STANDARD Brake valve malfunctions. Repair or renew.
A charge pressure as VALUE CHART. NO
specified?
See STANDARD 7 YES Brake valve malfunctions. Clean or renew.
VALUE CHART. Disassemble and
clean charge relief
valve. Is it restored
NO to normal
condition? Charge pump performance Renew.
NO lowered.
YES Use procedures in H-01. Repair or renew.

8
Does motor give
B off unusual sounds
9 YES Excessive leakage.
when operating? Repair or renew.
Is there any
difference in
internal leakage
NO between left and
right motors? Propulsion pump faulty. Renew.
Check both motors NO
separately.
4-407
b) Faulty in one travel direction only.
3 YES
Leaky pump servo system. Repair or renew.
With F-R lever operated,
YES is there any diffrence in
charge pressure
2 between forward travel
Do servo valve and and reversing? To A on this page.
YES servo linkage of NO
pump function
1 properly?

Does F-R lever Adjust or renew.
NO of pump are faulty.
move adequately?
F-R lever linkage faulty. Adjust or renew.

NO
Clean or adjust.
YES High pressure relief valve
Renew as
faulty.
4 necessary.
Exchange high
pressure relief valve for
A forward travel with that
5 YES
for reversing. Is faulty Excessive internal leakage. Repair or renew.
condition reversed? Is there any difference
in internal leakage in
motor between forward
NO
travel and reversing? Propulsion motor performance
Repair or renew.
lowered.
Check both motors NO
separately.
4-408
H-05 Vibrator does not work

Diagnose electric systems first then use procedures as listed bellow.
Both Vibrator pump faulty. Repair of renew.
1
Which is
faulty? Front
vibrator or 2 Vibrator solenoid valve faulty. Renew.
rear or both? Disconnect outlet
hoses from vibrator
Front solenoid valve and
or reconnect so that
their connecting 3 YES
rear Vibrator motor faulty. Repair of renew.
locations are changed Is relief pressure
with each other. as specified with
hose blocked at
motor inlet port?
Vibrator pump faulty. Repair of renew.
12.7MPa NO
(1840psi)
2
{130kgf/cm )
H-06 Weak vibratory force

Diagnose electric systems first then use procedures as listed bellow.
YES
1 Vibrator solenoid valve faulty. Renew.
Disconnect outlet hoses

from vibrator solenoid
valve and reconnect so
that their connecting 2 YES Lowered performance of vi-
locations are changed Repair of renew.
brator motor.
Is relief pressure
with each other.
as specified with
hose blocked at
NO
motor inlet port?
Lowered performance of vi-
Repair of renew.
See STANDARD NO brator pump.
VALUE CHART.
4-409
H-07 Steering not performed

Check oil level in hydraulic tank first.
YES
Steering mechanism faulty. Repair.
Is relief pressure as Foreign matter in Orbitrol Clean and adjust.

YES
specified? relief valve or low pressure Renew as
2 setting. necessary.
Does Orbitrol
See STANDARD
restore normal
VALUE CHART.
condition if
NO disassembled and 3 YES
Orbitrol faulty. Repair or renew.
cleaned?
Disconnect inlet
hose from Orbitrol.
NO Does oil flow out?
Steering pump faulty. Renew.

NO
H-08 Heavy or slow steering

Check oil level in hydraulic tank first.
Disassemble
3 YES and clean.
Steering column faulty.
Does steering Renew as
necessary.
YES become light if
steering column is
disassembled and
repaired?
1 Steering mechanism faulty. Repair.
NO
Is relief pressure as
specified?
YES Foreign matter in Orbitrol relief
Clean or renew.
valve or low pressure setting.
3
See STANDARD
Does Orbitrol
VALUE CHART.
restore normal
condition if
NO 4 YES Lowered performance of
disassembled and Renew.
steering pump.
cleaned?
Is leak at steering
cylinder normal?
NO
Steering cylinder faulty. Repair or renew.

NO
4-410
H-09 Parking brake not applied sufficiently

Diagnose electric systems first then use procedure as listed below.
1 YES Worn inner parts of parking

Repair or renew.
brake.
Is brake release
pressure as
specified?
Parking brake release
Clean or renew.
solenoid valve faulty.
See STANDARD NO
VALUE CHART.
Parking brake
switch: release position.
H-10 Parking brake not released

Parking brake piston seal

1 YES
faulty or warped discs or Renew motor.
plates.
Is brake release
pressure as
specified?
Clean and repair.
Brake release solenoid valve
Renew as
faulty.
See STANDARD NO necessary.
VALUE CHART.
Parking brake
switch: release position.
4-411
H-11 No sprinkling on tires

2 YES
Filter clogged. Renew.
YES
Does filter stay
1 clogged?
Diconnect outlet Hoses or nozzles clogged. Clean or renew.

hose from sprinkler NO
pump. Does oil
flow out?
Sprinkler pump faulty. Renew.

NO
4-412
No. 98056-0
Head office: 1-4-8, Shiba-Daimon, Minato-ku

Tokyo, Japan
Telephone: Tokyo(03) 3431-9971
Facsimile: (03) 3431-6212
Printed in Japan 2001.11.100 0 C.D

Sakai SW300 Series Shop Manual

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Sakai SW300 Series Shop Manual

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Series

To make a machine working to maximum efficiency over a long period of time

INSPECTION & ADJUSTMENT 3-001

1. External Views and Specifications

Model SW300 Vibrating power:

Model SW320 Vibrating power:

Model SW330 Vibrating power:

2. Description and Operation of Hydraulic System

4. Sprinkler & Scraper

1.Location of Engine-related Key Units

1. Engine mount (front)

1-2. Intake system

1-3. Exhaust system

1-4. Cooling piping & radiator

1. Reservoir 5. Radiator outlet hose

1-5. Fuel piping & fuel tank

1-6. Fuel controls

2. Description and Operation of Hydraulic System

2-1-2. Propulsion motor

1. Port A 9. Roller 18. Separate plate

2-1-3. Description and operation of cam motor

Construction of cam motor

Operation (It is assumed that oil is fed : High main pressure

into port B.) : Low main pressure

der block (11). This force rotates output

Ports in distributor (twelve holes)

Cylinder block ports

2-1-4. Vibrator pump

2-1-5. Vibrator motor

1. Suction port (port A) 6. Ball bearing 11. Piston ring

2-1-6. Description and operation of vibrator motor

* See figures on page 2-014 for construction.

the rotation of cylinder block (9) which spins

is fed into the pistons when the radiated por- P

other hand, oil is exhausted from the pistons

through flow in and flow out processes of oil.

2-1-7. Steering pump

1. Outlet port 4. Driven gear 7. Ring

2-1-8. Hydraulic circuit

2-2. Propulsion line

1. Propulsion pump 8. Brake release hose (rear)

2-2-2. Hydraulic piping [2]

1. Propulsion motor 6. Propulsion motor (rear)

2-2-3. Propulsion controls

SECTION A-A SECTION C-C

1. F-R lever 5. Holder

2-2-4. Propulsion circuit

2-2-5. Description and operation of propulsion system

See the hydraulic circuit on pages 2-022.

Description of propulsion system

Basic function of propulsion pump and propulsion motor

Operation (It is assumed that the machine travels forward.)

Releasing of spring-applied hydraulically released brake

Circuit protection against high pressure:

2-3. Vibrating system

1. Vibrator pump 9. Drain hose (front motor to hydraulic tank)

2-3-2. Hydraulic piping [2]

1. Vibrator motor (front) 5. Vibrator motor (rear)

2-3-3. Vibrating system (SW300)

Oil filler plug

Vibrator motor side

1. Vibrator shaft 8. Vibrator motor 15. Plug

2-3-4. Vibrating system (SW320,SW330)