SV412 Shop Manual

SV412
SHOP MANUAL
3498-64047-0
Introduction
This manual provides important information to familiarize you with safe operating
and maintenance procedures for your SAKAI roller. Even though you may be
familiar with similar equipment you must read and understand this manual before
operating or servicing this unit.
Safety is everyone’s business and it is one of your primary concerns. Knowing the
guidelines presented in this manual will help provide for your safety, for the safety
of those around you and for the proper operation and maintenance of the machine.
Improper operation is dangerous and can result in injury or death.
Sakai Heavy Industries cannot foresee all possible circumstances or varying

conditions to which the operator, serviceman or machine may be exposed to that
might lead to a potential hazard. Therefore, the warnings and cautions listed in
this manual and those placed on the machine are not intended to be all inclusive
and liability for personal injury or damage to equipment or property cannot be
assumed.
All information, specifications and illustrations in this publication are based on

the product information available at the time that the publication was written. The
contents may change without prior notice due to modifications of the model.
SV412 ○
0
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. SV412D
 2-001
1-2. SV412T
 2-003
1-3. SV412TF
 2-005
1-4. SV412TB
 2-007
1-5. SV412FB
 2-009
2. TABLE OF STANDARD VALUES
2-1. Engine
 2-011
2-2. Propulsion
 2-011
2-3. Hydraulic Systems
 2-011
2-4. Steering
 2-012
2-5. Brakes
 2-012
2-6. Capacities
 2-012
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating
 2-013
3-2. Recommended Lubricants
 2-013
4. TIGHTENING TORQUE CHART
 2-014
SV412 ○
0
3. ENGINE AND CONTROLS

1. ENGINE
1-1. Engine Mount
 3-001
1-2. Engine Exterior
 3-002
2. CONTROL SYSTEM
2-1. Forward-reverse Control
 3-003
3. PUMP MOUNT
3-1. Pump Mount
 3-004
3-1-1. Installation of pump 
 3-005
4. HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM
1-1. Graphic Symbols for Hydraulic Circuits
 4-001
1-2. Hydraulic Circuit Diagram 4-003
1-2-1. Hydraulic circuit diagram (SV412D, T, TF)
 4-003
1-2-2. Hydraulic circuit diagram (SV412TB, FB)
 4-004
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping
 4-005
2-1-1. Propulsion hydraulic piping (Front)
 4-005
2-1-2. Propulsion hydraulic piping (Rear)
 4-006
2-2. Hydraulic Component Specifications
 4-007
2-2-1. Hydraulic pump assembly (propulsion + vibrator • steering)
(SV412D, T, TF) 
 4-007
2-2-2. Hydraulic pump assembly (propulsion + vibrator • steering)
(SV412TB, TF) 
 4-009
2-2-3. Propulsion hydraulic motor (Front)
 4-011
2-2-4. Propulsion hydraulic motor (Rear)
 4-012
2-2-5. Servo bypass solenoid valve 4-013
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping
 4-014
3-2. Hydraulic Component Specification
 4-015
3-2-1. Vibrator hydraulic motor
 4-015
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping
 4-016
4-1-1. Steering hydraulic piping (SV412D, T, TF)
 4-016
4-1-2. Steering hydraulic piping (SV412TB, FB)
 4-017
4-2. Steering Wheel
 4-018
4-3. Hydraulic Component Specifications
 4-019
SV412 ○
0
4-3-1. Orbitrol 
 4-019
4-3-2. Valve (SV412TB, FB)
 4-020
4-4. Frame (Center Pin)
 4-021
5. BLADE SYSTEM (SV412TB, FB)
5-1. Blade Hydraulic Piping
 4-022
5-2. Hydraulic Component Specification
 4-023
5-2-1. Valve
 4-023
6. HIGH TORQUE TYPE ONLY
6-1. Hydraulic Circuit Diagram (SV412D, T, TF)
 4-024
6-2. Hydraulic Circuit Diagram (SV412TB, FB)
 4-025
6-3. Propulsion Hydraulic Piping (Front)
 4-026
6-4. Propulsion Hydraulic Piping (Rear)
 4-027
6-5. Propulsion Hydraulic Motor (Front)
 4-028
6-6. Gear Box
 4-029
6-7. Propulsion Hydraulic Motor (Rear)
 4-031
5. ELECTRICAL SYSTEM
1. Precautions for work
1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in
Electrical Circuit Diagrams, Wiring Harness Layout and Wiring Harnesses
 5-001
1-2. Electrical Equipment Installation
 5-002
2-1. Electrical Circuit Diagram
 5-003
3. ELECTRICAL COMPONENTS
3-1. Battery Layout
 5-004
3-2. Wiring Harness Layout (1)
 5-005
3-3. Wiring Harness Layout (2)
 5-006
4. WIRING HARNESSES
4-1. Main Frame Harness
 5-007
4-2. Engine Harness 
 5-009
4-3. Dashboard Harness
 5-011
4-4. Starter Switch Harness
 5-013
4-5. Throttle Switch Harness
 5-014
4-6. Vibrator Solenoid Harness 
 5-015
4-7. Hydraulic Oil Filter Harness
 5-016
4-8. Speed Change Switch Harness
 5-017
4-9. Starter Relay Harness
 5-018
4-10. Speed Change Solenoid Harness 5-019
4-11. Vibration Select Switch Harness
 5-020
SV412 ○
0
4-12. Parking Brake Switch Harness

 5-021
4-13. Diagnostic Switch Harness
 5-022
5. ELECTRICAL COMPONENT SPECIFICATIONS
5-1. Fuse Box
 5-023
5-2. Combination Meter
 5-024
6-1. Electrical Circuit Diagram
 5-025
6-2. Wiring Harness Layout
 5-026
6-3. Travel Mode Select Switch Harness
 5-027
6-4. Front Motor Solenoid Harness
 5-028
6. VIBRATORY DRUM • REAR AXLE

1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY
 6-001
2. VIBRATORY DRUM
2-1. Removal and Installation of Vibratory Drum
 6-003
2-1-1. Removal of vibratory drum
 6-003
2-1-2. Installation of vibratory drum
 6-007
2-2. Vibratory Drum Assembly 6-008
2-3. Disassembly and Reassembly of Vibratory Drum
 6-009
2-3-1. Disassembly of vibratory drum
 6-009
2-3-2. Reassembly of vibratory drum
 6-015
3. AXLE
3-1. Rear Axle (SV412D)
 6-023
3-2. Rear Axle (SV412T, TF, TB, FB)
 6-024
3-3. Rear Axle Lubrication
 6-025
3-4. Rear Axle Structure
 6-026
3-4-1. Center housing
 6-026
3-4-2. Differential
 6-027
3-4-3. Hub reduction gear
 6-028
3-4-4. Brake
 6-029
4-1. Vibratory Drum Assembly 6-030
4-2. Disassembly and Reassembly of Vibratory Drum
 6-031
4-2-1. Disassembly of vibratory drum
 6-031
4-2-2. Reassembly of vibratory drum
 6-037
SV412 ○
0
7. BRAKE
1. BRAKE SYSTEM
1-1. Brake Pedal
 7-001
2. BRAKE HYDRAULIC PIPING
 7-002
3. BRAKE SYSTEM
 7-003
4. HYDRAULIC COMPONENT SPECIFICATION
4-1. Brake Solenoid Valve
 7-004
8. INSPECTION AND ADJUSTMENT

1-1. Safety Precautions for Inspection and Adjustment
 8-001
1-2. Preparation for Inspection and Adjustment
 8-001
1-3. Precautions for Inspection and Adjustment
 8-001
1-4. Warm-up
 8-001
1-5. Inspection and Adjustment of Engine Related Items
 8-001
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement
 8-002
2-2. Adjustment
 8-003
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
 8-004
3-1. Measurement
 8-005
3-2. Adjustment
 8-006
4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1. Measurement
 8-007
5. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE
5-1. Measurement
 8-008
6. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
6-1. Measurement
 8-009
7. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE
7-1. Measurement
 8-010
7-2. Inspection
 8-011
8. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT
PRESSURE
 8-012
8-1. Measurement
 8-013
8-2. Adjustment
 8-014
9. MEASUREMENT OF VIBRATOR HIGH/LOW CHANGE CIRCUIT PRESSURE
9-1. Measurement
 8-015
SV412 ○
0
10. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE

10-1. Measurement
 8-016
10-2. Inspection
 8-017
11. MEASUREMENT AND INSPECTION OF BLADE CIRCUIT PRESSURE (SV412TB, FB)
 8-018
11-2. Inspection
 8-019
12. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
 8-020
13. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
13-1. Measurement of Front Propulsion Motor
 8-021
13-2. Measurement of Rear Propulsion Motor
 8-022
14. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
 8-023
15. ADJUSTMENT OF F-R LEVER LINKAGE
15-1. Adjustment
 8-024
16. BRAKE ADJUSTMENT
16-1. Manually Releasing the Brake 8-025
16-2. Adjustment after Manual Release of Brake
 8-026
16-3. Brake Clearance Adjustment 
 8-027
17-1. Measurement of Propulsion Motor Case Pressure
 8-028
17-1-1. Measurement of front propulsion motor
 8-028
9. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting
 9-001
1-2. Important Information for Troubleshooting
 9-001
1-3. Before Starting
 9-002
1-4. Wire Number and Color Code 
 9-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING
2-1. When Performing Electrical System Fault Diagnosis
 9-003
2-1-1. Precautions to take during electrical circuit fault diagnosis
 9-003
2-1-2. Inspection procedures using a tester
 9-004
2-1-3. Inspection of electrical system
 9-009
2-2. Fault Codes 9-011
2-2-1. Fault detection
 9-011
2-2-2. Fault lamps
 9-011
2-2-3. Flash out of fault codes
 9-012
2-2-4. Fault code list
 9-013
SV412 ○
0
2-3. Engine
 9-024
2-3-1. Engine will not start (Starter motor does not run) 1/3
 9-024
 9-026
 9-028
2-3-2. Engine will not start (But starter motor runs)
 9-030
2-3-3. No charging
 9-032
2-3-4. Grid heater does not work (Engine starting performance is bad in cold
weather)
 9-032
2-3-5. Starter motor runs even when F-R lever is not at “N” and parking brake is
not applied
 9-034
2-3-6. Engine speed cannot be switched
 9-034
2-4. Propulsion
 9-036
2-4-1. Machine moves neither forward nor backward 1/2
 9-036
 9-038
2-4-2. Machine speed cannot be changed
 9-040
2-4-3. Brake cannot be released 1/2
 9-042
2-4-3. Brake cannot be released 2/2
 9-044
2-4-4. Brake does not work
 9-046
2-5. Vibration
 9-048
2-5-1. No vibration occurs
 9-048
2-5-2. Amplitude does not change (Remains either Low or High)
 9-050
2-5-3. Vibration mode cannot be switched (F-R lever vibration switch does
not work)
 9-052
2-6. Lighting
 9-054
2-6-1. Illumination of combination meter does not turn on
 9-054
2-6-2. Combination meter warning lamp or indicator lamp is abnormal
 9-056
2-6-3. Tachometer reading is abnormal
 9-058
2-6-4. Hour meter is abnormal
 9-058
2-6-5. Temperature meter is abnormal
 9-060
2-6-6. Fuel meter is abnormal
 9-060
2-6-7. Hydraulic oil filter warning lamp remains ON
 9-062
2-6-8. Engine oil pressure warning lamp remains ON
 9-064
2-6-9. Vibration indicator lamp does not light
 9-066
2-6-10. Parking brake indicator lamp does not light
 9-068
2-6-11. Horn does not sound
 9-070
2-6-12. Backup buzzer does not sound
 9-070
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting
 9-071
SV412 ○
0
3-2. Propulsion System

 9-072
 9-072
 9-073
3-2-2. Machine moves in one direction only (forward or backward)
 9-073
3-2-3. Slow machine speed or small drive force 1/2
 9-073
3-2-3. Slow machine speed or small drive force 2/2
 9-074
3-2-4. Machine speed cannot be switched
 9-074
3-2-5. Machine does not stop completely with F-R lever in “N”
 9-074
3-2-6. Propulsion system is overheating 
 9-075
3-2-7. Abnormal noise from propulsion system
 9-075
3-3. Vibrator System
 9-076
3-3-1. No vibration 
 9-076
3-3-2. Vibrator frequency is too low
 9-077
3-3-3. Amplitude does not switch between high and low
 9-077
3-3-4. Vibrator does not stop
 9-078
3-3-5. Vibrator system is overheating
 9-078
3-3-6. Abnormal noise from vibrator system
 9-078
3-4. Steering System
 9-079
3-4-1. Steering wheel is hard to turn
 9-079
3-4-2. Steering response is slow
 9-079
3-4-3. Steering wheel backlash or play is large
 9-080
3-4-4. Steering system is overheating
 9-080
3-4-5. Abnormal noise from steering system
 9-080
3-5. Blade (SV412TB, FB)
 9-081
3-5-1. Blade up/down operation not possible
 9-081
3-5-2. Blade movement is slow or force is small
 9-081
3-5-3. Blade floating operation not possible
 9-082
3-5-4. Blade hydraulic system is overheating
 9-082
3-5-5. Abnormal noise from blade hydraulic system
 9-082
4-1. Electrical System Troubleshooting (Propulsion)
 9-084
4-1-1. Travel mode cannot be changed 1/2 
 9-084
4-1-1. Travel mode cannot be changed 2/2 
 9-086
4-2. Hydraulic System Troubleshooting (Propulsion)
 9-087
4-2-1. Machine moves neither forward nor backward 1/2 
 9-087
4-2-1. Machine moves neither forward nor backward 2/2 
 9-088
4-2-2. Travel mode cannot be switched
 9-088
4-2-3. Propulsion system is overheating
 9-089
4-2-4. Abnormal noise from propulsion system
 9-089
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: Indicates an imminently hazardous situation or condition which if not avoided

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

can result in serious personal injury or death.
CAUTION: Indicates 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): Indicates 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.
★: Indicates standard value to judge whether measured value is good or not.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
In the assembly operation, tightening torque in locations that require particular
N•m attention.
1-2. General
• Operators and maintenance personnel must be alert to recognize and avoid potential
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
• The machine must only be used for its intended purpose as described in the Operator’s
Manual. It must be operated by safety-conscious persons who are fully aware of the risks
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
1-001
SAFETY
• The machine is designed specifically for the compaction of asphalt or soil road construction
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
• Operating the machine within the limits of its designated use also involves compliance with
the inspection and maintenance requirements contained in the Operation and Maintenance
Manual.
1-3. Qualifications of Operators and Maintenance Personnel

• Work on the machine must be performed by qualified personnel only. Individual
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
• Define the operator’s responsibilities; the operator should have authority to refuse
instructions that are contrary to safety.
• Do not allow persons being trained to operate or perform maintenance on the machine
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies

• Keep the manuals in the container provided on the machine. Manuals must always be
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
and protective equipment and traffic or jobsite regulations.
• Machine operating instructions should also be supplemented with detailed instructions
pertaining to the specific jobsite or work location.
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
• Wear close fitting garments and always tie back and secure long hair, also avoid wearing
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.
1-002
SAFETY
• Observe all safety instructions and warnings attached to the machine.

• Make sure all safety instructions and warnings on the machine are complete and perfectly
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position and the parking
brake is applied.
• Never make any modifications to the machine which might affect safety without the
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection

• Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly
performed. Repair or replace any malfunctioning, broken or missing parts before using the
machine. Refer to the maintenance schedule in the Operator’s Manual.
• Check that all instructions and safety stickers are in place and readable.
• Never fill the fuel tank with the engine running or while near an open flame or while smoking.
• Always clean up any spilled fuel.
• Check for any warning tags placed on the machine, do not operate the machine until all
repairs have been made and warning tags have been removed by authorized personnel.
• Check the seat belt for wear or damage; inspect the belt hardware and fabric. Replace
if hardware is damaged or the belt is frayed or nicked or stitching is loose. Check that
mounting hardware is tight.
• Clean the steps and operating platform of dirt and foreign matter to reduce danger of
slipping.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed, gradeability, steering
and braking.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions

• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
• Operate the machine only if all protective and safety devices are in place and fully
functional.
• Always use the hand rails and steps to get on and off your machine maintaining 3-point
contact (using both hands).
1-003
SAFETY
1-7. Starting
• Start the machine only from the driver’s seat and always wear the seat belt.
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
• Check that braking, steering, signals and lights are fully functional before starting work or
traveling with the machine.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Never climb on and off the machine while it is in motion.
• Always remain seated with the seat belt fastened when traveling, compacting or loading or
unloading the machine.
• Use caution and be very observant when operating in close quarters and congested areas.
• Obey all traffic regulations when working on public roads and make sure machine is
compatible with these regulations.
• Never carry passengers.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
• Do not work close to edges or in the vicinity of overhanging banks or on grades that could
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
(travel control) lever in low speed range when climbing or descending hills or steep grades.
• Make sure there is sufficient clearance when crossing underpasses, bridges and tunnels or
when passing under overhead power lines.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
• Always switch on the lighting system (if equipped) during poor visibility conditions and after
dark.
• Do not attempt to control the compactor travel speed with the throttle control. Maintain
engine speed at the full operating RPM.
• Do not run the engine in a closed building for an extended period of time. Exhaust fumes
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground. If this is not possible,
always park at a right angle to the slope and block the drums or tires.
• Do not leave the operator’s platform with the engine running. Always move the travel lever
to neutral position and apply the parking brake then turn the starter switch to OFF.
• Lock all lockable compartments.
• Park behind a safe barrier, use proper flags, and warning devices, especially when parking
in areas of heavy traffic.
1-004
SAFETY
1-10. Maintenance
• In any performing any work concerning the operation, adjustment or modification of the
machine or it’s safety devices or any work related to maintenance, inspection or repair,
always follow the start-up and shut-down procedures in the Operator’s Manual and the
Maintenance Manual.
• Ensure that the maintenance area is safe and secure.
• If the machine is shut down for maintenance or repair work
it must be secured against inadvertent starting by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground
with the drums or tires blocked to prevent inadvertent
movement.
• Immediately after the engine has stopped, the exhaust
system, engine, radiator coolant, engine oil, hydraulic fluid
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
or draining oil or changing filters can cause serious burns.
Wait until the machine has cooled down.
• Use care when attaching and securing lifting tackle to
individual parts and large assemblies being removed
or repositioned for repair purposes to avoid the risk of
accident. Use lifting devices that are in perfect condition and
of sufficient lifting capacity. Never stand under suspended
loads.
• Always use the proper tools and workshop equipment in
good condition when performing maintenance or repairs on
the machine.
• Always use specially designed safety ladders and working
platforms when working above floor level. Never use
machine parts as a climbing aid.
• Keep all steps, handles, handrails, platforms and ladders free from mud, dirt, grease, ice or
snow.
• Clean the machine, especially threaded connections of any traces of oil or fuel before
carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free
cleaning rags.
• Examine all fuel, lubricant and hydraulic fluid lines and connectors for leaks, loose
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Whenever possible, avoid servicing or maintenance when the engine is running unless the
drums or tires are adequately blocked, the articulation lock bar is in the locked position and
the parking brake is applied.
• Never fill the fuel tank with the engine running, while near an open flame or while smoking.
Always clean up any spilled fuel.
• Ensure safe operation, optimum performance of the machine and its warranty by using only
genuine SAKAI replacement parts.
1-005
SAFETY
• Use only the specified fluids and lubricants. Substitute only products known to be equivalent
from reputable manufacturers.
• Disconnect the battery cables when working on the electrical system
or when welding on the compactor.
• Be sure the battery area is well ventilated (clear of fumes) should it be
necessary to connect a jumper cable or battery charger. Fumes can
ignite from a spark and may explode.
• Be sure battery charger is OFF when making connections if charging is required.
• Use only original fuses with the specified rating. Switch off the machine immediately if
trouble occurs in the electrical system.
• Work on the electrical system may only be carried out by a qualified electrician or by a
specially trained person according to electrical engineering principles.
• Inspect the electrical equipment of the machine at regular intervals. Defects such as loose
connections or burnt or scorched wires must be repaired or replaced immediately.
• Do not weld, flame cut or perform grinding on the machine unless expressly authorized,
as there may be a risk of fire or explosion. Disconnect the battery when welding on the
machine.
• Clean the machine and its surrounding from dust or other flammable substances and make
sure the area is adequately ventilated before beginning welding, flame cutting or grinding
operations.
• Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of
chafing, cracking, brittleness, deformation, blistering, fitting separation, leakage, corrosion
or other damage which may affect their function or strength.
• Do not work on hydraulic system while the engine is running and the system is under
pressure. The hydraulic system remains pressurized even after the engine has stopped.
• Do not disconnect hydraulic hoses or fittings until the pressure has been properly relieved.
• Wait until the systems and fluid have cooled down before disconnecting.
• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece
of cardboard and always wear gloves and safety glasses.
• Get immediate medical attention if fluid has been injected under your skin. Fluid penetration
from a pin hole leak can cause severe injury or death.
• Ensure that hydraulic lines and hoses are routed and fitted properly. Ensure that no
connections are interchanged. All fittings, lengths and specifications of hoses must comply
with the technical requirements.
• Observe all product safety regulations when handling fuel, oils, grease, engine coolant and
other chemical substances. Be careful especially when these items are hot as there is a risk
of burning or scalding.
• Operate internal combustion engines and fuel operated heating systems
only in adequately ventilated premises. Before starting the engine in an
enclosed area, make sure there is sufficient ventilation.
1-006
SAFETY
1-11. Transporting the Machine

• Use only suitable and approved trailers and haul vehicles and lifting equipment of sufficient
capacity.
• Entrust to experienced personnel the fastening and lifting of loads and instructing of crane
operators.
• Only experienced persons familiar with the operation of the machine may load and unload
the machine.
• Use ramps or a loading dock when loading or unloading the machine. Ramps must be the
proper strength, low angle and the proper height and width.
• Block the drums or tires (front and rear) of the hauling vehicle when loading and unloading
the compactor. Ensure that the haul vehicle is on level ground and approach the loading
ramps squarely to make sure that the compactor does not slide off the edge of the ramp.
• Keep the deck clear of mud, oil, ice or snow or other materials that can make the deck
slippery.
• Position the compactor on the trailer or transport vehicle centered from side to side, and
apply the brake. Shut off the engine and lock all lockable compartments.
• Block the drums or tires and lock the articulation lock bar. Chain the machine down properly
using the appropriate tackle.
• Know the overall height of the compactor and hauling vehicle. Observe height and weight
regulations and be sure you can pass safely at overhead obstructions.
• Obey all traffic regulations and be sure that the proper clearance flags, lights and warning
signs including “Slow Moving Vehicle” emblem are displayed when traveling on public roads.
• Know the approximate stopping distance at any given speed.
• Drive Safely. Never turn corners at excessive speeds.
1-007
SPECIFICATIONS
SPECIFICATIONS
1. SPECIFICATION DATA
1-1. SV412D
Φ1
30
2815
0
2040
2070
420
315
1700 920 2650 1410

1920 4980 1300
0404-99048-0-11945-0
Model SV412D
Operating weight 7,540 kg ( 16,620 lbs. )
Weight Front axle 3,600 kg ( 7,935 lbs. )
Rear axle 3,940 kg ( 8,685 lbs. )
Overall length 4,980 mm ( 196 in. )
Overall width 1,920 mm ( 76 in. )
Steering wheel 2,040 mm ( 80 in. )
Overall height
ROPS 2,815 mm ( 111 in. )
Dimensions
Wheelbase 2,650 mm ( 104 in. )
Compaction width 1,700 mm ( 67 in. )
Minimum height above ground 315 mm ( 12.0 in. )
Curb clearance 420 mm ( 16.5 in. )
1st 0 to 6 km/h ( 0 to 3.7 mph )
Speed
2nd 0 to 10 km/h ( 0 to 6.2 mph )
Low amplitude 38 Hz
Frequency
High amplitude 30 Hz
Vibration Centrifugal Low amplitude 93 kN ( 20,905 lbs. )
performance force High amplitude 118 kN ( 26,525 lbs. )
Low amplitude 0.70 mm ( 0.028 in. )
Amplitude
High amplitude 1.40 mm ( 0.055 in. )
Minimum turning radius 4.9 m ( 193 in. )
Gradability *1 61 % ( 32 ° )
*1: The gradability is the calculated value. It may vary based on the ground surface conditions.
2-001
SPECIFICATIONS
CUMMINS QSB3.3 Diesel Engine

Name
with turbocharger (EPA Interim Tier 4)
Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted,
Model
overhead valve, direct injection type
Bore × Stroke 95 mm × 115 mm (3.740 in. × 4.528 in.)
Displacement 3.262 L ( 199 cu.in )
Rated speed 2,400 min-1 ( 2,400 rpm )
82 kW ( 110 HP )
Rated output
at 2,400 min-1
Performance 415 N·m ( 306 lbf·ft )
Max. torque
at 1,600 min-1
Engine 233 g/kW·h ( 0.383 lb/HP·h )
Fuel consumption
at rated speed
Governor Full electronic control
Lubrication system Pressure lubrication by gear pump
Oil filter Full-flow: stratapore (synthetic)
Air cleaner Dry type
Cooling system Centrifugal pump forced feeding system (pressure type)
Cooling fan Inhaling type
Alternator 12 V 60 A
Electrical
Starter 12 V 2.7 kW
system
Battery 12 V CCA 620 × 1 pcs. (12 V)
Dry weight 361 kg ( 795 lbs. )
Type Hydrostatic transmission
Transmission
Speeds 2 speed shifts
Power line Reverser Switching the direction of flow delivered from the variable pump
Differential Auto lock type
Final drive Planetary gear
Transmission Hydrostatic transmission
Vibrating system
Vibrator Eccentric shaft type
Service brake Hydrostatic and mechanical type
Braking device
Parking brake Mechanical type
Steering control type Hydraulic type (Articulated type)
Steering system Steering control angle ± 37 °
Oscillation angle ±7°
Front drum Vibrate & drive × 1
Use
Rear tires Drive × 2
Front drum width × diameter 1,700 mm × 1,300 mm (67 in. × 51 in.)
Drum and wheels Dimension
Rear tires size 16.9-24 6PR (A)
Suspension Front Rubber damper type
system Rear Rigid
Others Rops Steel frame
2-002
SPECIFICATIONS
1-2. SV412T
Φ1
35
2835
0
2055
2060
435
325
1700 935 2650 1415

1920 5000 1300
0404-99049-0-11946-0
Model SV412T
Rear axle 3,960 kg ( 8,730 lbs. )
Overall height
ROPS 2,835 mm ( 112 in. )
Dimensions
Curb clearance 435 mm ( 17 in. )
1st 0 to 6 km/h ( 0 to 3.7 mph )
Speed
2nd 0 to 10 km/h ( 0 to 6.2 mph )
Low amplitude 38 Hz
Frequency
Amplitude
Gradability *1 60 % ( 31 ° )
2-003
SPECIFICATIONS

Name
Model
82 kW ( 110 HP )
Rated output
at 2,400 min-1
Max. torque
at 1,600 min-1
Fuel consumption
at rated speed
Electrical
Starter 12 V 2.7 kW
system
Transmission
Vibrating system
Braking device
Use
width × diameter 1,700 mm × 1,350 mm (67 in. × 53 in.)
Front Number of pads 140
Pad
Drum and wheels Dimension drum Pad height 75 mm ( 3.0 in. )
Pad area 102 cm2 ( 16 sq.in. )
system Rear Rigid
2-004
SPECIFICATIONS
1-3. SV412TF
Φ1
40
2850
0
2070
2050
450
340
1700 935 2650 1415

1920 5000 1300
0404-99050-0-11947-0
Model SV412TF
Rear axle 3,940 kg ( 8,685 lbs. )
Overall height
ROPS 2,850 mm ( 112 in. )
Dimensions
1st 0 to 6 km/h ( 0 to 3.7 mph )
Speed
2nd 0 to 10 km/h ( 0 to 6.2 mph )
Low amplitude 38 Hz
Frequency
Amplitude
Gradability *1 46 % ( 25 ° )
2-005
SPECIFICATIONS

Name
Model
82 kW ( 110 HP )
Rated output
at 2,400 min-1
Max. torque
at 1,600 min-1
Fuel consumption
at rated speed
Electrical
Starter 12 V 2.7 kW
system
Transmission
Vibrating system
Braking device
Use
Smooth width × diameter 1,700 mm × 1,400 mm (67 in. × 55 in.)
Front
Number of pads 140
Drum and wheels Dimension drum Pad
Pad height 75 mm ( 3.0 in. )
Pad area 102 cm 2
( 16 sq.in. )
system Rear Rigid
2-006
SPECIFICATIONS
1-4. SV412TB
Φ1
35
2835
0
2055
2060
425
325
1700 1265 2650 1415

1920 5330 1300
2250
0404-99051-0-11948-0
Model SV412TB
Rear axle 3,860 kg ( 8,510 lbs. )
Overall height
ROPS 2,835 mm ( 112 in. )
Dimensions
1st 0 to 6 km/h ( 0 to 3.7 mph )
Speed
2nd 0 to 10 km/h ( 0 to 6.2 mph )
Low amplitude 38 Hz
Frequency
Amplitude
Gradability *1 55 % ( 29 ° )
2-007
SPECIFICATIONS

Name
Model
82 kW ( 110 HP )
Rated output
at 2,400 min-1
Max. torque
at 1,600 min-1
Fuel consumption
at rated speed
Electrical
Starter 12 V 2.7 kW
system
Transmission
Vibrating system
Braking device
Use
Front Number of pads 140
Pad
Drum and wheels Dimension drum Pad height 75 mm ( 3.0 in. )
Pad area 102 cm2 ( 16 sq.in. )
system Rear Rigid
2-008
SPECIFICATIONS
1-5. SV412FB
Φ1
40
2850
0
2070
2050
445
340
1700 1260 2650 1415

1920 5330 1300
2250
0404-99052-0-11949-0
Model SV412FB
Rear axle 3,830 kg ( 8,445 lbs. )
Overall height
ROPS 2,850 mm ( 112 in. )
Dimensions
1st 0 to 6 km/h ( 0 to 3.7 mph )
Speed
2nd 0 to 10 km/h ( 0 to 6.2 mph )
Low amplitude 38 Hz
Frequency
Amplitude
Gradability *1 44 % ( 24 ° )
2-009
SPECIFICATIONS

Name
Model
82 kW ( 110 HP )
Rated output
at 2,400 min-1
Max. torque
at 1,600 min-1
Fuel consumption
at rated speed
Electrical
Starter 12 V 2.7 kW
system
Transmission
Vibrating system
Braking device
Use
Smooth width × diameter 1,700 mm × 1,400 mm (67 in. × 55 in.)
Front
Number of pads 140
Drum and wheels Dimension drum Pad
Pad height 75 mm ( 3.0 in. )
Pad area 102 cm 2
( 16 sq.in. )
system Rear Rigid
2-010
SPECIFICATIONS
2. TABLE OF STANDARD VALUES

2-1. Engine
Item Standard value Remarks
CUMMINS QSB3.3 T4i Diesel Engine
Engine model with turbocharger
Rated output 82/2,400 kW/ min-1 ( 110/2,400 HP/rpm )
Max. rpm under no load 2,400 rpm
Min. rpm under no load 750 rpm
1st 69 N·m ( 51 lbf·ft )
Cylinder head
2nd 108 N·m ( 80 lbf·ft )
tightening torque
3rd Tighten additional 90°
Intake manifold tightening torque 65 N·m ( 48 lbf·ft )
Exhaust manifold tightening torque 45 N·m ( 33 lbf·ft )
Valve clearance (intake) 0.35 mm ( 0.014 in. )
Valve clearance (exhaust) 0.50 mm ( 0.020 in. )
101.6 mm of H2O ( 4.0 in. of H2O ) Use mano meter
Crankcase blowby
58 L/min ( 2.048 cfm/min )
2-2. Propulsion
Travel speed 1st 0 to 6 km/h ( 0 to 3.7 mph )
(Forward/reverse) 2nd 0 to 10 km/h ( 0 to 6.2 mph )
Rear wheel/hub nut 785 N·m ( 579 lbf·ft )
Tire inflation pressure 137 kPa ( 20 psi )
2-3. Hydraulic Systems

High pressure relief valve setting 41.8 ± 1.0 MPa ( 6,061 ± 145 psi ) at 1,800 min-1
Charge relief valve setting 2.5 ± 0.2 MPa ( 363 ± 29 psi )
Charge relief valve setting
2.67 MPa ( 387 psi ) at 19 L/min
(Rear motor)
Pump 0.3 MPa ( 43.5 psi ) or less
Case pressure Front motor 0.3 MPa ( 43.5 psi ) or less
Propulsion
Rear motor 0.3 MPa ( 43.5 psi ) or less
Front motor —
Brake release
Rear motor —
pressure
Rear axle 1.5 to 3.0 MPa ( 218 to 435 psi )
Motor Front motor 5.5 L/min ( 1.5 gal./min )
drainage Rear motor 5.0 L/min ( 1.3 gal./min )
High pressure relief valve setting 25.0 ± 1.0 MPa ( 3,625 ± 145 psi )
Charge relief valve setting 2.5 ± 0.2 MPa ( 363 ± 29 psi )
Pump 0.3 MPa ( 43.5 psi ) or less
Vibration Case pressure
Motor 0.17 MPa ( 24.7 psi ) or less
Motor drainage 6.3 L/min ( 1.7 gal./min )
(orbitroll relief pressure +

Steering oil pressure 17.5 ± 1.0 MPa ( 2,538 ± 145 psi )
charge relief pressure)
2-011
SPECIFICATIONS
2-4. Steering
Steering wheel
5 to 10 mm ( 0.2 to 0.4 in. )
circumference
Play in steering wheel
Steering column shaft
0.5 mm ( 0.02 in. ) or less
direction
2-5. Brakes
Clearance between brake pedal and 169 mm (6.7 in.)

floorboard (as released) Note 1: See dimensions
1
Note
Note
Clearance between brake pedal and 145 mm (5.7 in.)
floorboard (when pressed down) Note 2: See dimensions
SV700-02001
4.5 mm (0.18 in.)

Brake disc wear limit
(S)
S
SV700-02003
2-6. Capacities
Engine oil pan 7L ( 1.8 gal. )
Fuel tank 172 L ( 45 gal. )
Coolant 20 L ( 5.3 gal. )
Reduction gear (front motor) 3.2 L ( 0.8 gal. )
Center housing (rear axle) 7.3 L ( 1.9 gal. )
Hub reduction gear case (rear left and right) 1.25 L ×2 ( 0.3 gal. ×2 )
Hydraulic oil tank 50 L ( 13 gal. )
Vibrator case (front) 21 L ( 5.5 gal. )
2-012
SPECIFICATIONS
3. FUEL AND LUBRICANTS SPECIFICATION

3-1. Rating
Ambient temp. and applicable viscosity rating
Service -15 to 30°C 0 to 40°C 15 to 55°C Applicable
Lubricant
classification (5 to 86°F) (32 to 104°F) (59 to 131°F) Standards
Cold Moderate Tropical
Engine oil API grade CH-4 SAE10W-30 SAE15W-40 SAE15W-40 MIL-L-2104B
Gear oil API grade GL4 SAE80W-90 SAE90 SAE140 MIL-L-2105
ISO-VG32 ISO-VG46 ISO-VG68

Hydraulic oil Anti wear ISO-3448
Over VI 140 Over VI 140 Over VI 110
Grease Lithium type extreme pressure NLGI-2
Fuel Diesel oil ASTM D975-2D
3-2. Recommended Lubricants

Lubricant
Engine oil Gear oil Hydraulic oil Grease
Oil API CH-4 API GL 4 VG 46 (NLGI-II)
company
Universal Rando Oil Martifack
CALTEX N/A
Thuban 90 HD 46 EP 2
Vanellus C BP Gear Oil BP Energol BP Energrease
BP
Extra EP 90 HLP 46 LS-EP 2
Esso Gear Oil Nuto Beacon
ESSO N/A
GP 90 H 46 EP 2
Mobil Pegasus Nuto Beacon
MOBIL Delvac MX
Gear oil 90 Oil 25 EP 25
Shell Spirax Shell Tellus Shell Alvania
SHELL Rimula X
90 EP Oil 46 EP Grease 2
Castrol GTX Castrol Hyspin Spherrol
CASTROL
Diesel Hypoy 90 AWS 46 ELP 2
2-013
SPECIFICATIONS
4. TIGHTENING TORQUE CHART

N·m (lbf·ft)
Nominal Strength Classification

Pitch
Dia. 6.8 8.8 10.9 12.9
5 0.8 4.9 (3.6) 5.9 (4.4) 7.8 (5.8) 7.8 (5.8)
6 1.0 7.8 (5.8) 9.8 (7.2) 13 (9.6) 13 (9.6)
8 1.25 17 (13) 23 (17) 31 (23) 31 (23)
10 1.5 39 (29) 49 (36) 59 (44) 59 (44)
Metric coarse screw
12 1.75 69 (51) 78 (58) 108 (80) 108 (80)

14 2.0 98 (72) 127 (94) 167 (123) 167 (123)
16 2.0 157 (116) 196 (145) 265 (195) 265 (195)
18 2.5 196 (145) 245 (181) 343 (253) 343 (253)
20 2.5 294 (217) 392 (289) 539 (398) 539 (398)
22 2.5 441 (325) 539 (398) 686 (506) 686 (506)
24 3.0 539 (398) 637 (470) 883 (651) 883 (651)
27 3.0 785 (579) 981 (724) 1324 (977) 1324 (977)
30 3.5 1079 (796) 1324 (977) 1765 (1302) 1765 (1302)
10 1.25 39 (29) 49 (36) 69 (51) 69 (51)
12 1.25 69 (51) 88 (65) 118 (87) 118 (87)
14 1.5 108 (80) 137 (101) 186 (137) 186 (137)
Metric fine screw
16 1.5 167 (123) 206 (152) 284 (209) 284 (209)

18 1.5 245 (181) 294 (217) 392 (289) 392 (289)
20 1.5 343 (253) 441 (325) 588 (434) 588 (434)
22 1.5 490 (361) 588 (434) 785 (579) 785 (579)
24 2.0 588 (434) 735 (542) 981 (724) 981 (724)
27 2.0 834 (615) 1030 (760) 1422 (1049) 1422 (1049)
30 2.0 1177 (868) 1422 (1049) 1961 (1446) 1961 (1446)
2-014
ENGINE AND CONTROLS
ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount
3
B A
1 2
7 8 14
6 9 13 15
17
12 11 10 16
DETAIL B DETAIL C
4 5
VIEW A
0404-01806-0-11895-0
(1) Bracket (7) Stopper (13) Plate

(2) Bracket (8) Bolt : M12×110 (14) Bolt : M18×120
(3) Engine (9) Plate (15) Damper
(4) Bracket (10) Bolt : M10× 30 (16) Bolt : M12× 35
(5) Bracket (11) Nut : M12 (17) Nut : M18
(6) Damper (12) Bolt : M12× 40
N•m
(8) Bolt M12×110 : 113 N·m ( 83 lbf·ft ) (14) Bolt M18×120 : 382 N·m ( 282 lbf·ft )
(10) Bolt M10× 30 : 59 N·m ( 44 lbf·ft ) (16) Bolt M12× 35 : 108 N·m ( 80 lbf·ft )
(12) Bolt M12× 40 : 78 N·m ( 58 lbf·ft )
3-001
ENGINE AND CONTROLS
1-2. Engine Exterior
ECM
Tachometer sensor
Flywheel housing Flywheel Crankcase breather
VIEW A
Oil level gauge Exhaust manifold Turbocharger Inlet manifold Air heater starting aid Coolant heater starting aid
Water outlet
Thermo unit Fan drive pulley
Fuel filter
Alternator
Water inlet
Fuel pump
Starter motor
Oil filter Oil filler cap Oil drain Vibration damper Oil pan
* The actual equipment may differ from that shown above. SV412-03001
3-002
ENGINE AND CONTROLS
2. CONTROL SYSTEM
2-1. Forward-reverse Control
1
N R
F 2 3
A A
5 6 7 8 Apply grease*
9
14 10
11
15
13 12 VIEW B
SECTION A-A 0404-12808-0-11885-0
(1) F-R lever (6) Nut : M16 (11) Washer (Apply grease*)
(2) F-R lever switch (7) Spring (Fill grease) (12) Washer
(3) Backup buzzer switch (8) Steel ball (13) Nut
(4) Control cable (9) Washer (Apply grease*) (14) Clevis
(5) Bolt : M16× 30 (10) Bush (Apply grease*) (15) Rod end (Apply grease*)
* Lithium-based grease
3-003
ENGINE AND CONTROLS
3. PUMP MOUNT
3-1. Pump Mount
2
A
8 7 6 5
SECTION A-A
0404-36824-0-11903-0
(1) Bolt : M10× 25 (6) Housing

(2) Bolt : M10× 35 (7) Bolt : M14× 45
(3) Retaining ring (8) Pump
(4) Hub (9) Bolt : M12× 35
(5) Flange
N•m
(1) Bolt M10× 25 : 59 N·m ( 44 lbf·ft )

(2) Bolt M10× 35 : 49 N·m ( 36 lbf·ft )
(7) Bolt M14× 45 : 167 N·m ( 123 lbf·ft )
(9) Bolt M12× 35 : 86 N·m ( 63 lbf·ft )
3-004
ENGINE AND CONTROLS
3-1-1. Installation of pump 1

• When the pump has been removed from the engine for
repair or replacement, reinstall it in accordance with the
following procedure.
2
A
① Apply adequate amount of grease to pump (8) and hub (4)
splines.
② Install retaining ring (3) of hub (4) to pump (8) and set to a 3
the specified dimension.
★ Specified dimension a: 9 mm (0.35 in.) 4
A
③ Secure hub (4) with bolts (9).
(9) Bolt M12×35 : 86 N·m (63 lbf·ft)

N•m
8 7 6 5
④ Secure flange (5) to engine flywheel with eight bolts (2).
9
(2) Bolt M10×35 : 49 N·m (36 lbf·ft)
N•m
⑤ Secure housing (6) to engine flywheel housing with twelve

bolts (1) and washers.
SECTION A-A
SV412-03002
(1)
N•m Bolt M10×25 : 59 N·m (44 lbf·ft)
⑥ Engage hub (4) with flange (5).

⑦ Secure pump (8) to housing (6) with four bolts (7), spring
washers and washers.
(7) Bolt M14×45 : 167 N·m (123 lbf·ft)

N•m
(NOTICE)
• Bolt (2) is treated with thread-locking fluid. Use new
thread-locking fluid treated bolt for installation.
3-005
HYDRAULIC SYSTEMS
HYDRAULIC SYSTEMS

1-1. Graphic Symbols for Hydraulic Circuits
Basic Symbols Pump, Motors and Cylinders

DESCRIPTION SYMBOL DESCRIPTION SYMBOL
Lines: Hydraulic pumps:
Main working Fixed displacement
Pilot control Unidirectional
Drain or bleed Bidirectional

Variable displacement
Lines, joining
Unidirectional
Not connected
Bidirectional
Component outline
Arrow indicates direction Variable displace-
of flow. ment pressure com-
pensated
Line with fixed restriction
Unidirectional
(orifice).
Hydraulic Motor:
Test port, pressure
measurement.
Unidirectional
Temperature measure-
ment gauge Bidirectional
Pressure measurement
gauge Double acting hydraulic
Reservoir (vented) cylinder
Differential cylinder
Filter or strainer
Electric motor
Heat exchanger, lines in-
dicate flow of coolant.
Quick disconnect:
Connected with mechan-
ically opened checks.
Disconnected.
Sloping arrow through a
symbol at 45° indicates
that a component can be
adjusted or varied.
4-001
HYDRAULIC SYSTEMS
Valves Methods of Operation

DESCRIPTION SYMBOL DESCRIPTION SYMBOL
Check valve Spring
Manual shut off (On-Off) Manual
Pressure compensated
Pressure relief
Reversing motor
Flow control, adjustable Pilot pressure:

Valve symbols: Internal supply
The basic valve symbol
one or more squares Remote supply
with lines representing
flow paths and flow con- Solenoid:
ditions between ports. Single winding
Multiple squares indicate
Two windings operating
a valve with as many dis-
in opposite directions.
tinct positions there are
squares providing various
Pilot directional valve is
flow path options for the
actuated by the solenoid.
fluid.
The multiple square
moves to represent how
flow paths change when
the valving element is
shifted within the compo-
nent.
Valves with infinite posi-
tioning between certain
limits are symbolized
with lines parallel to the
squares.
4-002
HYDRAULIC SYSTEMS
1-2. Hydraulic Circuit Diagram

1-2-1. Hydraulic circuit diagram (SV412D, T, TF)
Steering cylinder (Right)
70X 35-380 ST
(1/2") T
400 R (3/8") SRR SRL SRB
cc/rev
L (3/8") SLL SLR

LS1 15
P MPa SLB
Hydraulic oil filter 1
70X 35-380 ST
LO1 Orbitrol
Steering cylinder (Left)
(1/2") (1/2")
BSP BSA (1/4")
Servo bypass
solenoid valve BST
LOB (1/4") BPF Parking brake

solenoid valve (1/4")
SBP SBA (1/2") BPM
LOP
X Bypass valve
(1/4")
(1/2")
(1/4") BV1 BV2
RAM RAB
(3/4") RAP
Propulsion pump Vibrator pump

SGA SGB PPC PPA VPB SCD
Propulsion motor (Front)
i=24.457
2.5 MPa 2.5 MPa (3/4")
FMA Drum
51.0 35/28 Steering (1/2")
1350
1400
SE cc/rev SE cc/rev 25 MPa 24.9 Charge
1300
cc/rev 55.1
pump
RV RV
O O
cc/rev
ENGINE 41.8 MPa
T :
TF :
SE
RV
41.8 MPa SE
RV
O O
25 MPa
FMB
ENGINE (3/4")
CUMMINS：QSB3.3 T4i 1700
RBM
PD1 PD2 PPB VD2 VD1 VPA SCS FMD
82 kW/2400 min-1
415 Nm/1600 min-1 (3/4") RBP (3/4")
MAX min-1 :2400 min-1
RBB
PDV (1/2")
PDC
(3/4")
Rear axle assembly
Propulsion motor (Rear) Tire
(3/4")
i=6.00
A B
CS P T
RMP
(1/2") RMB 1.5 3.0 MPa
Oil cooler
i=7.286 RBR
2.67MPa
O
RV
SE
28.0
CO LS2 (1 1/4") 75.0
cc/rev
(1/4")
Hydraulic
O
RV
(3/4") (3/4")
SE
oil filter 2 (3/4")
LO2 RMA
1.5 3.0 MPa
RMD
RBL
FVA Vibrator motor
(3/4") (1/2") (1/2") TOTAL:i=43.72
(1/4")
35.0
cc/rev
i=6.00
Tire
FVB FVD
Low : 93 kN/2300vpm
(9.5 ton)
High : 118 kN/1800vpm TIRE DIA.
(12 ton) 1306
(1/2") T,TF Low : 103 kM/2300vpm
(10.5 ton) TIRE SIZE:16.9-24 6PR-OR
Suction filter
T6 T3 T5 T2 150mesh T1 High : 127 kM/1800vpm
(13 ton)
0404-99042-0-11939-0
4-003
HYDRAULIC SYSTEMS
1-2-2. Hydraulic circuit diagram (SV412TB, FB)
Blade cylinder (Right)

60X 30-260 ST
70X 35-380 ST
(1/2") T
BRD BRU 400 (3/8")
R SRR SRL SRB
cc/rev
ARD
Stack valve
ARU
SVB (3/8") AS2 L (3/8") SLL SLR
AS1 LS1 15
P SLB
SVA (3/8") MPa
ALU
ALD
(1/2") 70X 35-380 ST
LO1 Orbitrol
BLD BLU Steering cylinder (Left)
SVP (1/2")
SVT
60X 30-260 ST (1/4")
LOB BPF BSP BSA (1/4")
Blade cylinder (Left)
BPM
LOP
BST
(1/2")
Parking brake
(1/2") solenoid valve
Servo bypass
FDB FDA
1:2
Valve Bypass valve
SBP SBA (1/2")
X
FDP (1/2")
(1/4")
RAB
BV1 BV2
(1/2")
(3/4") RAP
(1/4")
RAM
Propulsion pump Vibrator pump
i=24.457
2.5 MPa 2.5 MPa (3/4")
Drum
FMA
Steering (1/2")
(FB: 1400)
51.0 35/28
cc/rev cc/rev
25 MPa
32.5 Charge
1200
1350
SE SE
cc/rev
pump 55.1
RV RV
O O
cc/rev
ENGINE SE
41.8 MPa
41.8 MPa SE
RV RV
25 MPa
O O
FMB
(3/4")
ENGINE
RBM
CUMMINS：QSB3.3 T4i PD1 PD2 VD2 VD1 VPA SCS 1700
PPB FMD
82 kW/2400 min-1
415 Nm/1600 min-1 (3/4") RBP (3/4")
RBB
PDV (1/2")
PDC
(3/4")
(3/4") Rear axle assembly

i=6.00
B
A
CS RP
P T
(1/2") RMB 1.5 3.0 MPa

Oil cooler
i=7.286 RBR
2.67 MPa
O
RV
SE
28.0
LS2 (1 1/4") 75.0
CO cc/rev
(1/4")
Hydraulic
O
RV
(3/4")
SE
(3/4") (3/4")
oil filter 2
LO2 RMA 1.5 3.0 MPa
RMD
RBL
(1/2") FVA Vibrator motor
(3/4") (1/4") (1/2") TOTAL:i=43.72
T5F
35.0
cc/rev
T5V
i=6.00
FVB FVD Tire
Low : 103 kN/2300vpm
(10.5 ton)
(13 ton) 1336
(1/2")
TIRE SIZE:16.9-24 6PR-OR
150mesh Suction filter
T6 T3 T5 T2 T1
0404-99043-0-11940-0
4-004
HYDRAULIC SYSTEMS
2. PROPULSION HYDRAULIC SYSTEM

2-1. Propulsion Hydraulic Piping
Hydraulic oil tank Hose Propulsion motor (Rear)
2-1-1. Propulsion hydraulic piping (Front) (FMD T2)
Hose
(RBM FMB)
Hose
(RAM FMA)

FMB FMA
RBM
RAM
FMD
T2
The letters and figures (such as RAM and FMA) show each port and the arrow ( ; ) symbols
show the hose connection and the direction of the flow of the oil.
0404-36825-0-11904-0
4-005
HYDRAULIC SYSTEMS
2-1-2. Propulsion hydraulic piping (Rear)
Hose
(RMD PD1)
CO Coupling :
High pressure gauge port
Hydraulic oil tank D

Servo bypass solenoid valve
A A Hose Hose
SBP (PPA PAP) (PPB RBP)
SECTION A-A
C C A A Hose
(PDC CS)
SBA
B
SECTION B-B
T6
Hose BV2 BV1 Hose CS RMD PDC Coupling :

(RBB BV2) (RAB BV1) High pressure gauge port
Hose
Oil cooler (CO T6)
RBP
Propulsion pump SECTION C-C
Bypass valve RBB PPA Hose PPB PD1 SGB SGA

(SGB SBA)
Hose Hose Hose Hose Hose

(PDC CS) (PPA RAP) (SGA SBP) (PPB RBP) (RMD PD1)
VIEW D
RAB RAP Propulsion motor (Rear) The letters and figures (such as PDC and CS) show each port and the arrow ( ; ) symbols
show the hose connection and the direction of the flow of the oil. 0404-36826-0-11905-0
4-006
HYDRAULIC SYSTEMS
2-2. Hydraulic Component Specifications

2-2-1. Hydraulic pump assembly (propulsion + vibrator • steering) (SV412D, T, TF)
3 2-1 2 2-2 1-1 1-2 1
2-5 2-4 2-3 1-4 1-3
3-1 2-6 1-5 1-6 1-7
2-7 1-8
2-8 2-9 2-10 1-9 1-10 1-12 1-13 2-12 2-13 3-2
2-11 1-11
VIEW A
1-2 1-3
BNA
1-7 1-8 1-11 1-13 2-3 2-10 2-4 2-13
2-11
3-1
3-2
2-8
1-6 1-12 1-9 1-5 2-2 2-9

Pump circuit diagram SV412-04001
4-007
HYDRAULIC SYSTEMS
(1) Propulsion pump

(1-1) Multifunction valve (For port A1)
(1-2) Charge pressure gauge port : 9/16-18UNF
(1-3) Charge supply port [PPC] : 7/ 8-14UNF
(1-4) Multifunction valve (For port B1)
(1-5) Port B1 (Forward) [PPB] : SAE 1’’
(1-6) Drain port [PD1] : 1 1/16-12UN
(1-7) Servo pressure gauge port [SGA] : 7/16-20UNF
(1-8) Servo pressure gauge port [SGB] : 7/16-20UNF
(1-9) High pressure gauge port (For port B1) : 9/16-18UNF
(1-10) Charge relief valve
(1-11) High pressure gauge port (For port A1) : 9/16-18UNF
(1-12) Drain port [PD2] : 1 1/16-12UN
(1-13) Port A1 (Reverse) [PPA] : SAE 1’’
Specifications
• Displacement : 51 cm3/rev ( 3.1 cu.in./rev )
• High pressure relief valve pressure setting : 41.8 MPa ( 6,061 psi )
• Charge relief valve pressure setting : 2.5 MPa ( 363 psi )
(2) Vibrator pump

(2-1) High pressure relief valve (For port A2)
(2-2) Drain port [VD1] : 1 5/16-12UN
(2-3) Servo pressure gauge port : 9/16-18UNF
(2-5) High pressure relief valve (For port B2)
(2-6) Solenoid valve b (Low amplitude)
(2-7) Solenoid valve a (High amplitude)
(2-8) Port B2 [VPB] : 1 1/16-12UN
(2-9) Drain port [VD2] : 1 5/16-12UN
(2-11) Port A2 [VPA] : 1 1/16-12UN
(2-13) Charge pressure gauge port : 1/ 2-20UNF
Specifications
• Displacement (Low amplitude) : 35.0 cm3/rev ( 2.1 cu.in./rev )
(High amplitude) : 28.0 cm3/rev ( 1.7 cu.in./rev )
(3) Steering pump

(3-1) Discharge port [SCD] : 1 1/16-12UN
(3-2) Suction port [SCS] : 1 5/16-12UN
Specifications
• Displacement : 24.9 cm3/rev ( 1.5 cu.in./rev )
• Allowable pump case pressure : 0.3 MPa ( 43.5 psi ) or less

• Pump assembly weight : 95 kg ( 209 lbs. )
4-008
HYDRAULIC SYSTEMS
2-2-2. Hydraulic pump assembly (propulsion + vibrator • steering) (SV412TB, TF)
3 2-1 2 2-2 1-1 1-2 1
2-5 2-4 2-3 1-4 1-3
3-1 2-6 1-5 1-6 1-7
2-7 1-8
2-8 2-9 2-10 1-9 1-10 1-12 1-13 2-12 2-13 3-2
2-11 1-11
VIEW A
1-2 1-3
BNA
1-7 1-8 1-11 1-13 2-3 2-10 2-4 2-13
2-11
3-1
3-2
2-8
1-6 1-12 1-9 1-5 2-2 2-9

Pump circuit diagram SV412-04002
4-009
HYDRAULIC SYSTEMS
(1) Propulsion pump

(1-1) Multifunction valve (For port A1)
(1-3) Charge supply port [PPC] : 7/ 8-14UNF
(1-4) Multifunction valve (For port B1)
(1-5) Port B1 (Forward) [PPB] : SAE 1’’
(1-6) Drain port [PD1] : 1 1/16-12UN
(1-7) Servo pressure gauge port [SGA] : 7/16-20UNF
(1-8) Servo pressure gauge port [SGB] : 7/16-20UNF
(1-9) High pressure gauge port (For port B1) : 9/16-18UNF
(1-11) High pressure gauge port (For port A1) : 9/16-18UNF
(1-12) Drain port [PD2] : 1 1/16-12UN
(1-13) Port A1 (Reverse) [PPA] : SAE 1’’
Specifications
(2) Vibrator pump

(2-1) High pressure relief valve (For port A2)
(2-2) Drain port [VD1] : 1 5/16-12UN
(2-5) High pressure relief valve (For port B2)
(2-6) Solenoid valve b (Low amplitude)
(2-7) Solenoid valve a (High amplitude)
(2-8) Port B2 [VPB] : 1 1/16-12UN
(2-9) Drain port [VD2] : 1 5/16-12UN
(2-11) Port A2 [VPA] : 1 1/16-12UN
(2-13) Charge pressure gauge port : 1/ 2-20UNF
Specifications
• Displacement (Low amplitude) : 35.0 cm3/rev ( 2.1 cu.in./rev )
(High amplitude) : 28.0 cm3/rev ( 1.7 cu.in./rev )
• Charge relief valve pressure setting 2.5 MPa ( 363 psi )
(3) Steering pump

(3-1) Discharge port [SCD] : Φ25
(3-2) Suction port [SCS] : Φ32
Specifications
• Allowable pump case pressure : 0.3 MPa ( 43.5 psi ) or less

• Pump assembly weight : 95 kg ( 209 lbs. )
4-010
HYDRAULIC SYSTEMS
2-2-3. Propulsion hydraulic motor (Front)
1 2 5
2
1
4 3,6
7
Motor circuit diagram
3 4 5 6 8 9
7 10
SV400-2-04007
(1) Port B [FMB] : SAE 1’’ (6) Drain port : 7/8-14UNF

(2) Port A [FMA] : SAE 1’’ (7) Drain port [FMD] : 7/8-14UNF
(3) Drain port : 7/ 8-14UNF (8) Reduction gear
(4) High pressure gauge port (For port B) : 9/16-18UNF (9) Filler cap : 7/8-14UNF
(5) High pressure gauge port (For port A) : 9/16-18UNF (10) Filler cap : 7/8-14UNF
Motor specifications
• Maximum working pressure : 41.8 MPa ( 6,061 psi )
• Allowable motor case pressure : 0.3 MPa ( 43.5 psi ) or less
Reduction gear specifications
• Reduction ratio : 1/24.457
• Weight : 167 kg ( 368 lbs. )
4-011
HYDRAULIC SYSTEMS
2-2-4. Propulsion hydraulic motor (Rear)
4 6
2
2
8
3 4 5
7
3 9
Motor ciruit diagram
8 9 9 SV505--04003
(1) Charge pressure relief valve (6) Servo pressure gauge port : 9/16-18UNF
(2) Pilot supply port [RMP] : 9/16-18UNF (7) Port B (Reverse) [RMB] : SAE 1”
(3) Drain port [RMD] : 1 1/16-12UN (8) Port A (Forward) [RMA] : SAE 1”
(4) Servo pressure gauge port : 9/16-18UNF (9) Drain port : 1 1/16-12UN
(5) Speed change solenoid valve
• Displacement (max.) : 75 cm3/rev ( 4.58 cu.in./rev )
(min.) : 28 cm3/rev ( 1.71 cu.in./rev )
• Charge relief valve pressure setting : 2.67 MPa ( 387 psi ) (at 19 L/min)
• Weight : 48 kg ( 106 lbs. )
4-012
HYDRAULIC SYSTEMS
2-2-5. Servo bypass solenoid valve
3 8
6 7
5
7
8 6
Hydraulic circuit diagram
(＋)
(−) Connection diagram
K-40146
(1) Solenoid
(2) O-ring (1B P14)
(3) Spool (J)
(4) Body
(5) Spring
(6) Port P [SBP] : 9/16-18UNF-2B
(7) Port A [SBA] : 9/16-18UNF-2B
(8) Port T : 9/16-18UNF-2B
Specifications
• Rated pressure : 4.9 MPa ( 710 psi ) (6, 7)
: 0.5 MPa ( 72.5 psi ) (8)
• Rated flow : 30 L/min ( 7.9 gal./min )
• Weight : 1.5 kg ( 3.3 lbs. )
4-013
HYDRAULIC SYSTEMS
3. VIBRATOR HYDRAULIC SYSTEM

3-1. Vibrator Hydraulic Piping
Hose
(VPA FVB)
Vibrator motor Hose
(FVD T1)
Hydraulic oil tank Hose VD2 VPB Coupling

(VD2 PDV) : High pressure
Hose
(VPB FVA)
A
SECTION A-A
A B B
Hose
B B (VD1 LS2)
Hose LO2 LS2 Hose VD1 VPA Coupling

(LO2 T5) (VD1 LS2) : High pressure
Hose Hose
Hose (VPA FVB) (VPB FVA)
(VPB FVA)
SECTION B-B
FVA FVB Hose PDV VD1
(FVD T1)
PDC PD2
PDV
VD2
VIEW C
FVD Hose Hydraulic oil filter 2 T5 T1
(VPA FVB)
The letters and figures (such as VAM and FVB) show each port and the arrow ( ; ) symbols
0404-49804-0-11907-0
4-014
HYDRAULIC SYSTEMS
3-2. Hydraulic Component Specification

3-2-1. Vibrator hydraulic motor
1 2
5 4 3
2
Cw
1
3,4,5
CCw
Flow of oil
2 1 Clockwise rotation
1 2 Counterclockwise rotation
SV400-2-04012
(1) Port B [FVB] : 1 1/16-12UN

(2) Port A [FVA] : 1 1/16-12UN
(3) Drain port [FVD] : 7/ 8-14UNF
(4) Drain port : 7/ 8-14UNF
(5) Drain port : 7/ 8-14UNF
Specifications
• Displacement : 35.0 cm3/rev ( 2.1 cu.in. )
• Working pressure : 34.5 MPa ( 5,003 psi )
• Allowable motor case pressure : 0.17 MPa ( 24.7 psi )
• Weight : 11 kg ( 24.3 lbs. )
4-015
HYDRAULIC SYSTEMS
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping Hydraulic oil tank
Hose
4-1-1. Steering hydraulic piping (SV412D, T, TF) Hose Hose (R SRR)
(SRL SLB) (SCD P)
Hose
Hose SRB PPC (SCD P) SRR SRL
(R SRR) E
Steering cylinder (R)
Hose
C C (L SLL)
E Hose
Hose
SCD (T LSO)
(SLR SRB)
A
C C
B VIEW B
C
D D SECTION A-A
A
SCS
Hose Hose
(SCD P) (Hydraulic oil tank SCS)
D D
Steering cylinder (L)
Hose Hose LOP LSO SLB Hose

(L SLL) (T LSO) (LOP PPC)
Coupling Hose
: charge pressure (Hydraulic oil tank SCS) SECTION C-C
Hose
(LOP PPC)
Steering charge pump
F
SLL SECTION D-D
T
Suction filter P
F
Orbitrol
L
R
SECTION E-E
SECTION F-F
The letters and figures (such as LOP and PPC) show each port and the arrow ( ; ) symbols
SLR Hydraulic oil filter 1 show the hose connection and the direction of the flow of the oil. 0404-32803-0-11655-A
4-016
HYDRAULIC SYSTEMS
4-1-2. Steering hydraulic piping (SV412TB, FB)
Hydraulic oil tank

Hose
Hose Hose (R SRR)
(SRL SLB) (SCD FDP)
Hose
Hose SRB PPC (FDA P) SRR SRL
(R SRR) E
Steering cylinder (R) Hose
(L SLL)
C C Hose
E (T LSO)
Hose
(SLR SRB) SCD
A
C C
B VIEW B
D D SECTION A-A
A
SCS
Hose Hose
D D (SCD FDP) (Hydraulic oil tank SCS)
Suction filter
Steering cylinder (L)
Hose Hose LOP LSO SLB Hose

(L SLL) (T LSO) (LOP PPC)
Hydraulic oil filter 1 Coupling Hose
: charge pressure (Hydraulic oil tank SCS)
SECTION C-C SECTION E-E
Hose T
Steering charge pump (LOP PPC) P
Orbitrol
L
R
F
SLL
SECTION D-D SECTION F-F
F
G
FDA Hose
(FDA P)
VIEW G
The letters and figures (such as LOP and PPC) show each port and the arrow ( ; ) symbols
SLR Valve FDP show the hose connection and the direction of the flow of the oil. 0404-32805-0-11816-0
4-017
HYDRAULIC SYSTEMS
4-2. Steering Wheel

1 2 3
4 5 6 7 8
T L
P R
A
VIEW A-A
0404-32804-021754-Ａ
(1) Column shaft (6) Bolt : M10×30

(2) Nut : M12 P=1.25 (7) Bracket
(3) Steering wheel (8) Bolt : M 8×12
(4) Nut : M10 (9) Orbitrol
(5) Damper
N•m
(2) Nut M12 P=1.25 : 35 N·m ( 26 lbf·ft )
(4) Nut M10 : 49 N·m ( 36 lbf·ft )
(6) Bolt M10×30 : 49 N·m ( 36 lbf·ft )
(8) Bolt M 8×12 : 23 N·m ( 17 lbf·ft )
4-018
HYDRAULIC SYSTEMS
4-3. Hydraulic Component Specifications

4-3-1. Orbitrol
1 2
3 4
1 2
4 3

SV510- -04010
(1) Port L [L] : 3/4-16UNF

(2) Port R [R] : 3/4-16UNF
(3) Port T [T] : 3/4-16UNF
(4) Port P [P] : 3/4-16UNF
Specifications
• Relief valve pressure setting : 15.0 MPa ( 2,175 psi )
• Weight : 7 kg ( 15 lbs. )
4-019
HYDRAULIC SYSTEMS
4-3-2. Valve (SV412TB, FB)
1 2 3
8 7
1 2
8
SV412-04003
(1) Port A [FDA] : G1/2”

(2) Port B [FDB] : G1/2”
(3) Body
(4) Spool
(5) Cover
(6) Spring
(7) O-ring
(8) Port P [FDP] : G3/4”
Specifications
• Rated pressure : 29.4 MPa ( 4,263 psi )
• Standard flow : 60 L/min ( 16 gal./min )
• Flow division ratio (A : B) : 2:1
• Weight : 5 kg ( 11 lbs. )
4-020
HYDRAULIC SYSTEMS
4-4. Frame (Center Pin)
2 3 4
5 6 7 8 9 10
12 11 0402-61802-0-10059-G
(1) Bolt : M16×60 (5) Swing bearing (9) Roller bearing

(2) Bolt : M16×80 (6) Yoke (10) Bracket (upper)
(3) Nut : M20 (7) Bolt : M16×45 (11) Bracket (lower)
(4) Bolt : M20×100 (8) Cover (12) O-ring
N•m
(1) Bolt M16×60 : 265 N·m ( 195 lbf·ft )
(2) Bolt M16×80 : 265 N·m ( 195 lbf·ft )
(3) Nut M20 : 539 N·m ( 398 lbf·ft )
(7) Bolt M16×45 : 265 N·m ( 195 lbf·ft )
4-021
HYDRAULIC SYSTEMS
5. BLADE SYSTEM (SV412TB, FB)

5-1. Blade Hydraulic Piping
Hose Hose ARU ARD
(ARD BRD) (ARU BRU)
Blade cylinder (R) BRU BRD Hose
(SVA AS1) AS1
Hydraulic oil tank Hose

(SVA AS1)
ALU
AS2
Hose
ALD (SVB AS2)
B
A DETAIL A SECTION B-B
SVA
B
Valve SVT
SVP
Hose
(SVB AS2)
Down Neutral
SVB
Floating UP
Blade cylinder (L) BLU BLD
Hose Hose
(ALD BLD) (ALU BLU)
VIEW C
C
Hose
(SVP FDB) FDB
D
Valve
Hose
(SVT T5)
VIEW D
T5
The letters and figures (such as SVT and T5) show each port and the arrow ( ; ) symbols
4-022
HYDRAULIC SYSTEMS
5-2. Hydraulic Component Specification

5-2-1. Valve
1
6 2
5
4
56
2
SV201-1-04010
(1) Relief valve (4) Pressure gauge port : Rc 1/4

(2) Port T [SVT] : G3/4 (5) Port B [SVB] : G1/2
(3) Port P [SVP] : G3/4 (6) Port A [SVA] : G1/2
Specifications
• Rated flow : 70 L/min ( 18 gal./min )
• Maximum working pressure : 20.6 MPa ( 2,987 psi )
• Relief valve pressure setting : 13.7 MPa ( 1,987 psi ) at 30 L/min ( 7.9 gal./min )
• Weight : 7.1 kg ( 15.7 lbs. )
4-023
HYDRAULIC SYSTEMS

6-1. Hydraulic Circuit Diagram (SV412D, T, TF) Steering cylinder (Right)
70X 35-380 ST
(1/2") T
400 (3/8") SRR SRL SRB
cc/rev R
L (3/8") SLL SLR

LS1 15
P MPa SLB
70X 35-380 ST
LO1 Orbitrol
(1/2") (1/2")
BSP BSA (1/4")
Servo bypass
BST
solenoid valve
LOB (1/4") BPF Parking brake
BPM
SBP SBA (1/2") LOP
X
Bypass valve
(1/4")
(1/2")
(1/4") BV1 BV2
RAM RAB
(3/4") RAP
Propulsion pump
Vibrator pump Propulsion motor (Front)
(3/4")
A B
2.5 MPa 2.5 MPa i=47.00
P T
51.0 Steering Drum (1/2")

35/28 60 26
cc/rev cc/rev 25 MPa 24.9 Charge FMA
1350
1400
SE SE
cc/rev cc/rev
pump
RV RV
2.5MPa
O O
ENGINE 41.8 MPa
1300
SE
RV
41.8 MPa SE
RV
T :
TF :
O O
25 MPa
ENGINE (3/4") FMB

CUMMINS：QSB3.3 T4i PD1 PD2 PPB VD2 VD1 VPA SCS
RBM
1700
82 kW/2400 min-1 FMD
415 Nm/1600 min-1 (3/4") RBP (3/4")
RBB
PDV (1/2")
PDC
(3/4")
Rear axle assembly
(3/4")
i=6.00
A B
CS P T
RMP
(1/2") RMB 1.5 3.0 MPa
Oil cooler
i=7.286 RBR
2.67MPa
O
RV
SE
35.0
CO LS2 (1 1/4") 75.0
cc/rev
(1/4")
Hydraulic
O
RV
(3/4") (3/4")
SE
oil filter 2 (3/4")
LO2 RMA
1.5 3.0 MPa
RMD
RBL
(3/4") FVA Vibrator motor
(1/4") (1/2") (1/2") TOTAL:i=43.72
35.0
cc/rev
i=6.00
FVB FVD Tire
Low : 93 kN/2300vpm
(9.5 ton)
(12 ton) 1306
(1/2") T,TF Low : 103 kM/2300vpm
(10.5 ton) TIRE SIZE:16.9-24 6PR-OR
Suction filter
T6 150mesh High : 127 kM/1800vpm
T3 T5 T2 T1 (13 ton)
0404-99044-0-11941-0
4-024
HYDRAULIC SYSTEMS
6-2. Hydraulic Circuit Diagram (SV412TB, FB)

Blade cylinder (Right)
60X 30-260 ST
70X 35-380 ST
(1/2") T
BRD BRU 400 R (3/8") SRR SRL SRB
cc/rev
ARD
Stack valve
ARU
SVB (3/8") AS2 L (3/8") SLL SLR
AS1 LS1 15
P SLB
SVA (3/8") MPa
ALU
ALD
(1/2") 70X 35-380 ST
LO1 Orbitrol
BLD BLU
(1/2")
SVP SVT
60X 30-260 ST (1/4") BPF BSP
LOB BSA (1/4")
Blade cylinder (Left)
BPM
LOP
BST
(1/2")
Parking brake
(1/2") solenoid valve
Servo bypass
FDB FDA
1:2 Bypass valve
(1/2") Valve
SBP SBA
X
FDP (1/2")
(1/4")
RAB
(1/2") BV1 BV2
(1/4") (3/4") RAP
RAM
Propulsion pump Vibrator pump Propulsion motor (Front)
A B
2.5 MPa 2.5 MPa i=47.00
P T
Drum
(3/4")
51.0 35/28
Steering (1/2")
Charge FMA
(FB: 1400)
60 75.0
cc/rev cc/rev 32.5
SE SE
25 MPa cc/rev 2.5 MPa
cc/rev
pump
1200
1350
RV RV
O O
ENGINE SE
41.8 MPa
41.8 MPa SE
RV
RV
25 MPa
O O
(3/4") FMB
ENGINE
RBM
CUMMINS：QSB3.3 T4i PD1 PD2 PPB VD2 VD1 VPA SCS 1700
82 kW/2400 min-1 FMD
415 Nm/1600 min-1 (3/4") RBP (3/4")
RBB
PDV (1/2")
PDC
(3/4")
(3/4") Rear axle assembly

i=6.00
B
A
CS P T RMP
(1/2") RMB
1.5 3.0 MPa
Oil cooler
2.67 MPa i=7.286 RBR
O
RV
SE
35.0
CO (1 1/4")
LS2 75.0
cc/rev
(1/4")
Hydraulic
O
RV
(3/4")
SE
(3/4") (3/4")
oil filter 2
RMA
LO2 1.5 3.0 MPa
RMD
RBL
(3/4") (1/2") FVA Vibrator motor
(1/4") (1/2") TOTAL:i=43.72
T5F
35.0
cc/rev
T5V
i=6.00
Tire
FVB FVD Low : 103 kN/2300vpm
(10.5 ton)
(13 ton) 1336
(1/2")
Suction filter TIRE SIZE:16.9-24 6PR-OR

150mesh
T6 T3 T5 T2 T1
0404-99045-0-11942-0
4-025
HYDRAULIC SYSTEMS
6-3. Propulsion Hydraulic Piping (Front)

Hydraulic oil tank Hose Propulsion motor (Rear)
(FMD T2)
Gear box
Hose
(RBM FMB)
Hose
(RAM FMA)
RBM
RAM
FMA FMD FMB T2

The letters and figures (such as RAM and FMA) show each port and the arrow ( ; ) symbols
0404-36829-0-11911-0
4-026
HYDRAULIC SYSTEMS
6-4. Propulsion Hydraulic Piping (Rear)

Hose
(RMD PD1)
CO Coupling :
High pressure gauge port
Hydraulic oil tank D

Servo bypass solenoid valve
A A Hose Hose
SBP (PPA PAP) (PPB RBP)
SECTION A-A
C C A A Hose
(PDC CS)
SBA
B
SECTION B-B
T6
Hose BV2 BV1 Hose CS RMD PDC Coupling :

(RBB BV2) (RAB BV1) High pressure gauge port
Hose
Oil cooler (CO T6)
RBP
Propulsion pump SECTION C-C
Bypass valve RBB PPA Hose PPB PD1 SGB SGA

(SGB SBA)
Hose Hose Hose Hose Hose

(PDC CS) (PPA RAP) (SGA SBP) (PPB RBP) (RMD PD1)
VIEW D
RAB RAP Propulsion motor (Rear) The letters and figures (such as PDC and CS) show each port and the arrow ( ; ) symbols
4-027
HYDRAULIC SYSTEMS
6-5. Propulsion Hydraulic Motor (Front)
2
9
4 3
6
3 5 1
Motor circuit diagram
6 7 8
9 11 12
10
VIEW A
SV410-2-04001
(1) Port B (Forward) [FMB] : SAE 3/4” (7) Loop flushing shuttle valve
(2) Servo pressure gauge port (max.) : 9/16-18UNF (8) Charge pressure relief valve
(3) Control pressure gauge port : 9/16-18UNF (9) Port A (Reverse) [FMA] : SAE 3/4”
(4) Drain port [FMD] : 1 1/16-12UN (10) Speed pickup
(5) Servo pressure gauge port (min.) : 9/16-18UNF (11) Gauge port (For Port A) : 7/8-14UNF
(6) Drain port : 1 1/16-12UN (12) Gauge port (For Port B) : 7/8-14UNF
• Displacement (max.) : 60.0 cm3/rev ( 3.66 cu.in./rev )
(min.) : 26.0 cm3/rev ( 1.59 cu.in./rev )
• Weight : 28 kg ( 62 lbs. )
4-028
HYDRAULIC SYSTEMS
6-6. Gear Box
1
LY
ITA
IN
DE
s
ive strie
MA
y dr du
s
in
mer
tar
ne
co
pla
P.
TY
D.
CO
SV410-2-04002
(1) Gear box
Specifications
• Reduction ratio : 1/47.00
• Weight : 90 kg ( 198 lbs. )
4-029
HYDRAULIC SYSTEMS
1) Structure of gear box

1-10
1-9
1-8
1-7
1-6
1-5
1-4
1-3
1-2
1-11
1-1
1-12
1-21
1-13
1-20
1-14
1-14
1-15 1-22
1-16 1-18
1-17 1-23
1-13
1-24
1-25
1-18 1-26
1-19 1-27
1-28
1-29
1-30
1-31
1-32
1-33
SV410-2-04003
(1) Gear box

(1-1) Plug : 9/16-18UNF (1-18) Plug : 9/16-18UNF
(1-2) Hub (1-19) Cover
(1-3) Spacer (1-20) Pad
(1-4) Plate (1-21) Shim
(1-5) Snap ring (1-22) Bolt : M10×120
(1-6) Housing (1-23) Cover
(1-7) Bearing nut : M190 (1-24) Sun gear
(1-8) Ring gear (1-25) Snap ring
(1-9) Plug (1-26) Bearing washer
(1-10) Needle bearing (1-27) Planetary gear
(1-11) Snap ring (1-28) Needle
(1-12) Planetary gear (1-29) Bearing washer
(1-13) O-ring (1-30) Snap ring
(1-14) Taper bearing (1-31) Carrier
(1-15) Coupling (1-32) Gear pin
(1-16) Bolt : M6×16 (1-33) Sun gear
(1-17) Floating seal kit
4-030
HYDRAULIC SYSTEMS
6-7. Propulsion Hydraulic Motor (Rear)

1
4 6
2
2
8
3 4 5
7
3 9
Motor ciruit diagram
8 9 9 SV505--04003
(1) Charge pressure relief valve (6) Servo pressure gauge port : 9/16-18UNF
(2) Pilot supply port [RMP] : 9/16-18UNF (7) Port B (Reverse) [RMB] : SAE 1”
(3) Drain port [RMD] : 1 1/16-12UN (8) Port A (Forward) [RMA] : SAE 1”
(4) Servo pressure gauge port : 9/16-18UNF (9) Drain port : 1 1/16-12UN
(5) Speed change solenoid valve
• Displacement (max.) : 75 cm3/rev ( 4.58 cu.in./rev )
(min.) : 35 cm3/rev ( 2.14 cu.in./rev )
• Charge relief valve pressure setting : 2.67 MPa ( 387 psi ) (at 19 L/min)
• Weight : 55 kg ( 121 lbs. )
4-031
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
24 1.25 BR
7 5G C 4 5BY
R2 B
Wire color
24 1.25BR
R1
ACC
BR
AVS wire size
STARTER Wire number Fuel sensor
(BrR),(GL)
28 LgW
SWITCH
26 Lg Wire color
Reference page
J
(P.5-005)
Mark S Marking
Type of terminal Starter relay harness
(P.5-017)
58X-2F
Reference page
9 38
Wire number Wire color
2BrW 3LY
58X-2M (Indicated inconnectors
in case of wires)
AVS Size
50
9 38 70
Corrugate Ǟ70
2BrW 3LY
Length
Marking "C" between
200
* 38 38 * Marking CB104
* LY LY * 120 770 GB,100
C 9 63 63 9
C Corrugate Ǟ13 Corrugate Ǟ10
63
Brw GB GB Brw Wire

number
SWP-4㧲 SWP-4M 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
Switch terminal number Switch terminal number
5BY,70 BW,150
4 LA305 (B) 94 (1)
BR,70 WG,150
Throttle switch
Starter switch
24 LA105 (BR) 93 (3)
2Lg,70 RY,150
26 LA205 (C) 30 (4)
1.25LgW,70 RW,150
28 LA105 (ACC) 97 (5)
5-001
ELECTRICAL SYSTEM
• Wire color code chart
Black/ Black/ Black/ Black/ Black/ Yellow/

B Black BW BY BR BG BL O Orange YO
White stripe Yellow stripe Red stripe Green stripe Blue stripe Orange stripe
White/ White/ White/ White/ White/ Blue/
W White WR WB WL WY WG LO
Red stripe Black stripe Blue stripe Yellow stripe Green stripe Orange stripe
Red/ Red/ Red/ Red/ Red/ Green/
R Red RW RB RY RG RL GO
White stripe Black stripe Yellow stripe Green stripe Blue stripe Orange stripe
Green/ Green/ Green/ Green/ Green/ Gray/
G Green GW GR GY GB GL Gy Gray GyR
White stripe Red stripe Yellow stripe Black stripe Blue stripe Red stripe
Yellow/ Yellow/ Yellow/ Yellow/ Yellow/ Gray/
Y Yellow YR YB YG YL YW GyL
Red stripe Black stripe Green stripe Blue stripe White stripe Blue stripe
Brown/ Brown/ Brown/ Brown/ Brown/ Brown/
Br Brown BrW BrR BrY BrB BrG BrL Sb Sky blue
White stripe Red stripe Yellow stripe Black stripe Green stripe Blue stripe
Blue/ Blue/ Blue/ Blue/ Blue/ Pink/
L Blue LW LR LY LB LG P Pink PB
White stripe Red stripe Yellow stripe Black stripe Green stripe Black stripe
Light green/ Light green/ Light green/ Light green/ Light green/
Lg Light green LgR LgY LgB LgW LgL Pu Purple
Red stripe Yellow stripe Black stripe White stripe Blue stripe
1-2. Electrical Equipment Installation

When wiring electrical components to this machine (for example, additional lighting or electrical devices), connect
all grounds to a common ground location and then return to the negative side of the battery. Do not wire to the
engine block, starter or alternator terminals. Reference picture is below.
Attention! Do NOT wire to

engine, alternator or starter motor.
Alternator
nator
tor
Engine
Eng
Sta
Starter
tarte
motor
moto
mo
Lighting Lighting
- +
Battery
Electrical Common
device ground
5-002
ELECTRICAL SYSTEM

2-1. Electrical Circuit Diagram
2 GB
FOOT BRAKE
X B
SWITCH
3 37 BrW 66 LY X B STOP
36 LgR 36 LgR 1 SOL
2 BACKUP BUZZER
38 GR PARKING REVERSE FORWARD
4 X B
5 BRAKE
SOLENOID
PARKING BRAKE
SWITCH NC NO COM
DIODE UNIT
12 R
BACKUP F G H
36 LgR
BUZZER
67 BrY A E B C D I
SWITCH
65 GW 66 LY 66 LY X B
SOL A B C D
3 5
X B 37 BrW SERVO BYPASS E F G H I
N
C
SOLENOID
N
2 1
O
W
C
O
M
SERVO BYPASS 2 GB
F-R LEVER
B
RELAY (R5) 13 W
65 GW 12 R SWITCH
NC NO COM 65 GW
COMBINATION METER SET 5 3
R B 31 Br
66 LY X B
110 PULSE/REV SET(NO.5) TEMP. 50-103͠ SET(NO.0)
12 R
1 2
13 W
12 R
REV RATIO SEL. TEMP.CURVE SEL.
PROPULSION PUMP 9 YR
1 2 3 4 1 2 NEUTRAL HOLDING
GND OPEN GND OPEN OPEN OPEN RELAY (R6) 10 YB
(ENGINE:110 PULSE/REV)
65 GW
THROTTLE SWITCH
42 RY 42 RY
POSITION ENGINE SPEED CONNECTION
LEFT HAND IDLE 1-2,4-6
3 CENTER
COMBINATION METER 39 L MIDDLE 1-3,4-6
HORN X B 50 LW 2 RIGHT HAND
1 FULL 1-3,4-5
SOL
BrW
LgY
HYDRAULIC OIL FILTER WARNING GW
COOLANT TEMP. SEL.2 OW
COMBINATION METER ILLUMINATION WR

COOLANT TEMP. SEL.1 WB
TEMPERATURE METER YW
OG
GR
GB
GY
LW
RB
YR
SPEED CHANGE
GL
LR
SPEED CHANGE
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
ENGINE OIL PRESSURE WARNING G
REV. PULSE INPUT 1 O
R
B
STARTER SWITCH(ACC) P
REV. PULSE INPUT 2 Y

L
SOLENOID SWITCH
6
X B 34 LgW 30 1.25RY 30 RY 4 3 81 RG Br
G
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1
5 97 RW 97 RW 1
TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
3 1
BATTERY 12V(+)
5 25 2BW 2 11 Y 2
WATER SPRAY
LIQUID SPRAY
33 Lg 30 RY
LAMP CHECK
3 93 WG
FLOOD LAMP
PREHEATING
30 1.25RY
FUEL METER
1 94 BW 1 VIBRATION MODE F-R LEVER

VIBRATOR
35 YW
B
42 RY
2 VIBRATION
11 Y
CHANGE SWITCH
12 R
39 L
HORN
HORN SWITCH SWITCH
GND
RELAY (R3) THROTTLE

31 Br SWITCH
HIGH
35 YW 6
11 Y 4
10
2
7
9
5
6
1
5 9 YR a X B
13 W
92 WL f
R P O B Y YR YW 93 WG 3
SOL
20A
20A
20A
20A
20A
1
15A
15A
15A
15A
15A
c 2 10 YB X B
WR GL LR YL BrW GR GW G 26 2Lg 20 2LgR 25 2BW e
91 LW
5 5 X B 97 RW b
LW Br LB L W GY RB GB 3 3 VIBRATION
13 W X B X B 67 BrY b a SELECT
OG LgY WB OW LOW
1 2 2 1 THROTTLE SWITCH VIBRATOR
FUSE BOX RELAY (R9)
INTERLOCK PARKING INTERLOCK SOLENOID
RELAY (R1) RELAY (R2) F.L. 45A
16 2W
23 3RG 23 3RG 75 3G
3 5R
35 YW 26 2Lg
3 5R F.L. 65A 76 5WR
31 Br
FUSE
70 WR 4 BY 61 8W F.L. 45A
5A 74 8WY
38 GR
35 YW
61 8W F.L. 45A 74 8WY

31 Br
4 BY
X B
X B
B R 1 R 2 A CC B R C C 4 5BY 4 5BY F.L. 65A 77 5BW

X B
B
HEAT AV30
42 RY 24 BR
OFF BR
8 YL ACC 78 3WB 86 3WL 86 3WL
ON 30A
STARTER
32 BY
FUSE 18 2RW
ST SWITCH 16 2W 14 5R 15 5RB
28 1.25LgW
70 WR STARTER SWITCH ENGINE ECM.(CM2250) 3 5
GB
3 5
NO COM
107 LgY 108 18 2RW X 2B
‫ޓ‬ J3(60PIN) 1 2 1 2 AV60
32 BY X B 78 WB 79 B
21 YG 1 (+) BATTERY BATTERY (-) 21 STARTER LOCKOUT STARTER
AV60
24 BR
3 5 78 WB 79 B RELAY (R8) RELAY
X B 29 LgB 28 LgW 2 (+) BATTERY BATTERY (-) 22 14 5R
79 B BR
2 78 WB
6 YB 1 11 (+) BATTERY BATTERY (-) 31 +
LAMP CHECK 78 WB 79 B 50 15 5RB BATTERY
22 Y RELAY (R4) 12 (+) BATTERY BATTERY (-) 32 30 RELAY
28 LgW 88 GY 95D31R
E
X B
8 STOP LAMP
X 2B
89 Y G BATTERY
16 WARNING LAMP
HYDRAULIC 90 YG STARTER MOTOR -
6 WAIT TO START LAMP AV60
OIL FILTER AV60
SWITCH 1 FUSE
28 1.25LgW 62 1.25WB 62 1.25WB 98 BL 79 3B AV60
22 Y 5A 3 KEY SW. SIGNAL B
3 5 87 B
AV20
92 WL DIAGNOSTIC
B 36 LgR X B ISC 2 SW (MID) 38 SWITCH
1 2 91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE STOP ENGINE 94 BW 61 8W
22 Y SW AND TEMP SENSOR RETURN 19 1 94 BW
RELAY (R7) HARNESS CYLINDER
96 Br 96 Br 62 WB
B 133 GL DIAGNOSTIC 59 2 BLOCK
21 YG
17 YR
3
8 YL
HYDRAULIC 107 LgY 29 LgB

134 BrR STARTER LOCKOUT 15 AV20
OIL FILTER 108 GB
SWITCH 2 8 YL X B FUEL SENSOR OUTPUT RETURN 1 (-) 13
TACHO 7 WG
LAMP
BATTERY
IGNITION
PHASE
GROUND
3 5 INTAKE AIR HEATER (+) 4
METER 6 YB X B 108 GB 109 RB 109 RB
SENSOR 2 14 DUAL OUTPUT A (+)
1
FOR OIL PRESS.
ENGINE OIL
X B
TERMINATING TERMINATING 130 BR

B PRESSURE C
RESISTOR RESISTOR 43 OEM SENSOR (SIGNAL RETURN)
RELAY (R10) 131 LgR FUSE
B ALTERNATOR
120Ω 120Ω SENSOR 44 COOLANT LEVEL (SIGNAL) AV30 AV30
THERMO 132 RW 250A
ENGINE 5 3
UNIT A 52 SENSOR SUPPLY (POWER) GB
7 WG 108
FUEL UNIT DIAGNOSIS 82 G
17 CAN A (+) 1 2
D
E C GRID HEATER
F A B 83 L RELAY
36 LgR J 18 CAN A (-)
G
H
FUSE
118 1.25WR 86 1.25WL
10A B
87 B GRID HEATER
0404-99046-0-11943-0
5-003
ELECTRICAL SYSTEM
3. ELECTRICAL COMPONENTS
3-1. Battery Layout
C
5
A
7 6 4
C
3
10 9
Terminal 30
Terminal G From To grid
battery (+) heater relay
To grid heater
Starter
motor To battery (-)
From From To cylinder block
fuse (250A) 11 14 13 12
battery (+)
VIEW A VIEW B SECTION C-C
0404-09821-0-11924-0
(1) Backup buzzer (8) Battery

(2) Cord (Battery – Battery relay) (9) Cord (Starter motor – Ground)
(3) Cord (Fuse – Grid heater relay) (10) Cord (Battery (+) – Starter motor (terminal 30))
(4) Cord (Battery (-) – Starter motor (terminal G)) (11) Grid heater relay
(5) Cord (Battery (-) – Ground) (12) Fuse (250A)
(6) Cord (Grid heater relay – Grid heater) (13) Battery relay
(7) Grid heater (Air heater) (14) Cord (Battery relay – Fuse)
5-004
ELECTRICAL SYSTEM
3-2. Wiring Harness Layout (1)

Ground
A B
Engine ECM
Dashboard harness Mark A Mark R Mark P Main frame harness Servo bypass
(P.5-011) (P.5-007) solenoid (LY),(B) GB
Backup buzzer Terminating

(+ : HI) resistor
VIEW B
WG
Tachometer
sensor (YG),(B)
Backup buzzer
B Grid heater relay
Grid heater relay
VIEW D
GB
C VIEW C
Speed change
solenoid harness
(P.5-019) J
(P.5-006)
65A (black) 65A (black) 45A (red)
Hydraulic oil filter switch 2 Parking brake solenoid E Mark S
(R),(WR) (BY),(BW) (W),(WY)
(Y) (LY),(B)
Hydraulic oil filter harness Hydraulic oil filter switch 1 Engine harness Starter relay harness 45A (red) 45A (red)
(P.5-016) (Y) (P.5-009) (P.5-018) (RG),(G) (W),(WY)
F-R lever switch Starter relay
COM(R),NC(W)
F-R lever vibration switch Backup buzzer switch Coolant level sensor MAF sensor
1(RG),2(Y) COM(R),NO(GB) (BR),(LgR),(RW)
F Engine harness MAF connector

Fuse (5A×2)
Engine oil DETAIL E
Engine harness WIF connector (Fusible link)
pressure (BrR),(GL)
relay R10 Fuse (30A,10A)
(GB),(RB)
F Alternator Thermo unit
(P.5-006) Fuel sensor
(YL),(B) B(W) (YR)
(BrR),(GL)
Ground(AV20,B)
G L
Connector(LgB,WB)
(P.5-006) M (P.5-006) Vibrator solenoid harness
(P.5-006)
(P.5-015)
D Vibrator solenoid b
(YB),Ground(B)
(P.5-006)
Mark H H
N (P.5-006)
Horn K
+ : (LgW) (P.5-006)
- : (B)
Foot brake switch

COM(R),NO(LgR)
Vibrator solenoid a Mark P
Cylinder block (YR),Ground(B)
(B)
Mark A Mark R Speed change solenoid Mark S VIEW A
(LW),Ground(B)
0404-09822-0-11927-0
5-005
ELECTRICAL SYSTEM
3-3. Wiring Harness Layout (2)
WL
Mark K Mark T Combination meter ENGINE STOP lamp BW
(P.5-024) (GY),(LgW) To starter motor terminal G Terminal B
Speed change switch (W) G WY
1(L),2(LW) WARNING lamp
WR WY
(Y),(LgW)
Speed change switch harness
(P.5-017) Vibration select switch NO COM
1(Y),2(YB),4(Y),5(YR)
Throttle switch
1(BW),3(WG),4(RY),5(RW)
WAIT TO START lamp
Throttle switch harness (YG),(LgW)
(P.5-014)
Parking brake switch Battery relay
1(LgR),2(BrY),3(BrW),4(GR),5(B)
Vibration mode change switch Ignition (WB) Ground BR
Parking brake switch haness 1(RW),2(Y),3(RG) Lamp (LgB) B
(P.5-021) BR
Alternator Ground
Vibration select switch harness
Starter switch (P.5-020)
B(BY),BR(BR),C(Lg),ACC(LgW) VIEW H DETAIL J
Starter switch haness Mark C Mark E Horn switch Mark B

(P.5-013) (Lg)
VIEW F-F
Parking interlock relay R2 Horn relay R3 R(50)
RB(30)
(BrY),(B),(LgR),(BW) (RY),(Lg),(RY),(LgW) Terminal 50
Terminal 30
Lamp check relay R4
Interlock relay R1 B
(LgW),(LgB),(BY),(B)
(W),(B),(Lg),(LgR) RB
R
Diode unit
(W),(GW),(Br),(YB),(YR)
RW From alternator ground
Starter motor
Servo bypass relay R5 Engine stop relay R7
(BrW),(B),(GW),(LY) Starter relay Terminal G
(LgR),(B),(LgW),(WB)
Throttle relay R9
(B),(RW),(WG),(LW),(WL)
VIEW K DETAIL L
Hydraulic pump neutral holding relay R6
(LY),(B),(R),(GW)
Starter lockout relay R8
(LgY),(GB),(W),(RW)
Fuse box
Terminating resistor (P.5-023)
Fuse (5A) Fuse (5A) Fuse (30A) Fuse (10A)
(BY),(WR) (WB),(BL) (WL),(WB) (WL),(WR)
Diagnostic switch
2(BW),3(Br)
Diagnostic switch haness
(P.5-022)
Mark D
Datalink interface connector
VIEW M VIEW N
VIEW G
0404-09822-0-11977-0
5-006
ELECTRICAL SYSTEM
4. WIRING HARNESSES
4-1. Main Frame Harness
Speed change solenoid
harness (P.5-019)
Backup buzzer
SWP-2F Vibrator solenoid harness (P.5-015)
SWP-4F 3WL,200 LA208
86 (COM)
50 X Ground
LW B 9 10 LA104 LA104
10 9 6 2 YR YB 5BW,200 LA308
YB YR YB GB
R X X
2 X 77 (COM)
B B Servo bypass
24 22 21 17 120
SWP-12M solenoid LA308
8WY,200
H
50
BR Y YG YR Tape 74 (COM)
SWP-2F
66 62 50 29
B,50
GB,50
LY WB LW LgB X 66 LA308
Battery relay
8WY,200
74 (COM)
50
B LY
5WR,200 LA308
50
76 (NO)
90 89 88 87
Corrugate
450
YG Y GY B 100
7
SWP-8M
7
108 98 94 3G,200 LA208
Tape 75 (NO)
Corrugate
Corrugate
7
300
250
GB BL BW
Corrugate
200
2B,150 LA204
X (Ground)
Dashboard harness (P.5-011)
96 92 91
Br WL LW 50 250 1150 1500 550 450 200 750 300 BR,150 LA104
SWP-6F
118 109 107 Tape
A Corrugate Corrugate 19 Corrugate 19 Corrugate 15 Corrugate 13 Corrugate 13 Corrugate 13 Corrugate 19
24 (BR)
19 Co 2
1.25WR RB LgY rru 00 350 2B,50 LA208
X Ground bolt
gat
7 e Corrugate 7 Tape
0 22
13
15 ate
B,50 g
Starter relay harness (P.5-018)

Twist pair cable rr u 200
CA104 X Co
Corrugate
Co rru
200
(With shield : AVSSCS 0.75)
Fuel unit
gat
7
e 50 18 X
22 50
S
200
58X-2F
Tape
YB,50
100
Tape
gat
83 82 50 CB104 6 2RW 2B
SWP-2F
rru
7
L G Tape
P
Co
Corrugate
500
50 14 15
100 58Y-2F
23 18 50 5R 5RB
15 pe
120 Tap
Ta 0
58X-2F e
Tap
Ta
e
Tape
10
0
pe
10
3RG 2RW Tape
WG,100
GB,100
13
22
134 133
7
Corrugate
3 4 70 BrR GL
Corrugate 19 or
86 1.25WL,70
e
200
58Y-2㧲
300
ugat
5R 5BY Tape 10A Fuse holder

Fuel sensor
200
96 92 91 83 82 89 88 87 21 17 7 108
Corr
118 1.25WR,70
Y GY B YG YR Twist
Br WL LW L G
7 cable LA105 LA105 86 3WL,70
0 X 109 107 98 94 90 62 29
LA208 2B,50 25 te 30A Fuse holder
X u ga B RB LgY SWP-2㧹 BL BW YG WB LgB
Ground bolt r
or (Twist pair cable 78 3WB,70
0
C Grid heater relay
ate 1
with shield SWP-6F SWP-4㧲
Tape
100
SWP-6M AVSSCS0.75㧕
M 23
Corrug
140 3RG
15 0
Tape 75 45A
Y,50
Engine harness (P.5-009) 3G
X 66 3
120 5R
22 B LY Tape 76 65A
5WR
Tape
Tape
Tape
Tape
Tape
100
150
150
CB104 SWP-2F
50
50
Hydraulic oil filter Parking brake
Fusible link
4
harness (P.5-016) solenoid 100 5BY
134 133 108 7 61 61 78 14 15 Tape 77 65A
BrR GL 3WB 5R 5BW
GB WG 8W 8W 5RB
61
SWP-2F SWP-2M 58Y-2M 58Y-2F 58Y-1㧹 120 8W
Twist cable Tape 74 45A
8WY
Engine harness (P.5-009)
61
140 8W
Tape 74 45A
8WY
SV412-05003
5-007
ELECTRICAL SYSTEM
CONTACT CONTACT
NO. SIZE, COLOR CONNECTION NO. SIZE, COLOR CONNECTION
POINTS POINTS
Fuel unit, Battery relay-coil, Backup buzzer, 74 8WY 4 Fusible link 45A × 2, Battery relay-COM × 2
X B, 2B 12 Parking brake solenoid, Servo bypass solenoid, 3G 2 Fusible link 45A, Battery relay-NO
75
Ground bolt × 2, S , R , P , H × 2
76 5WR 2 Fusible link 65A, Battery relay-NO
2 GB 2 A , Backup buzzer
77 5BW 2 Fusible link 65A, Battery relay-COM
3 5R 2 A , Fusible link 65A
78 3WB 2 Fuse 30A, M
4 5BY 2 A , Fusible link 65A
82 G 2 A, P
6 YB 2 A , Fuel unit
83 L 2 A, P
7 WG 2 Grid heater relay, M
86 1.25WL, 3WL 3 Fuse 10A, Fuse 30A, Battery relay-COM
9 YR 2 A, H
87 B 2 A, P
10 YB 2 A, H
88 GY 2 A, P
14 5R 2 M, S
89 Y 2 A, P
15 5RB 2 M, S
90 YG 2 A, P
17 YR 2 A, P
91 LW 2 A, P
18 2RW 2 A, S
92 WL 2 A, P
21 YG 2 A, P
94 BW 2 A, P
22 Y 2 A , Hydraulic oil filter switch harness
96 Br 2 A, P
23 3RG 2 A , Fusible link 45A
98 BL 2 A, P
24 BR 2 A , Battery relay-BR
107 LgY 2 A, P
29 LgB 2 A, P
108 GB 3 A , Grid heater relay, M
50 LW 2 A, R
109 RB 2 A, P
61 8W 4 Fusible link 45A × 2, M × 2
118 1.25WR 2 A , Fuse 10A
62 WB 2 A, P
133 GL 2 Fuel sensor, M
66 LY 3 A , Parking brake solenoid, Servo bypass solenoid
134 BrR 2 Fuel sensor, M
5-008
ELECTRICAL SYSTEM
4-2. Engine Harness
Engine ECM
Twist pair cable Twist cable

(with shield:AVSSCS 0.75)
10 9 8 7 6 5 4 3 2 1
88 90 7 98 78 78 Coolant level sensor
GY YG WG BL WB WB Twist cable
78 78 78 78 79 79 79 79
94 83 82 89 16
WB WB WB WB 㧮㧮㧮㧮 20 15 107 109 108 78 78 11
BW L G Y LgY RB GB WB WB
130 131 132
79 79 21 BR LgR RW
30 26 25
B B
91 92 79 79
50
40 36 35 31
LW WL B B
Starter motor
50 46 45 131 130 41
3WB 3B LgR BR
78 79 96 132
Br RW LA305 LA310
Connection status
60 59 58 57 56 55 54 53 52 51 14 15
Twist cable
Corrugate
Corrugate
7
120
120
17 21
Corrugate
1200
5RB,70
5R,70
YR YG 100
SWP-4M
29 62 Tape Terminating resistor
82 83
LgB WB A B (Use twist pair cable
Corrugate 15 G L with shield : AVSSCS 0.75)
X
0 B
10 e 10
300
p 0
Ta C 10 ate
87 88 89 g
ru
Cor
B GY Y 50 600 350 450 550
SWP-6M P
Main frame harness (P.5-007)
90 94 98 Tape Corrugate 13 Corrugate 13 Corrugate 15 Corrugate 13

7
YG BW BL
Corrugate
100
35 Co 35
Co 0 rru 0
rru
Co
ga YR,70
Corrugate 13
ga
20 ate
te 17 LA105 Thermo unit
rru
te Tape
0
13
g
7
500
Tape
82 83 100
10
SWP-2F
7
G L Tape
Co 10 8W,70 LA306
rru 0 61
X 21 Tape (BATTERY)
Twist pair cable ga
B YG te
Tape
(With shield : AVSSCS 0.75) 13 8W,70 LA306
50
61
Alternator
Tachometer sensor Co 1 Tape (BATTERY)
rru 00
M ga
te
B,50
91 92 96
3B,50
134 133 60 29 62
LW WL Br 7
SWP-6F 150 BrR GL Tape LgB WB
107 109 X Tape
LgY RB B DT04-2P-CE03
Engine side harness
(WIF connector) 79 87
LA210 LA110
Tape
Tape
Tape
Tape
Tape
100
150
150
50
50
133 134 7 108 61 61 15 Cylinder block stud

14 78
GL BrR WG GB 8W 8W 5R 3WB 5RB
SWP-2M SWP-2F 58Y-2F 58Y-2M 58Y-1F

Twist cable
Main frame harness (P.5-007) SV412-05004
5-009
ELECTRICAL SYSTEM
CONTACT CONTACT
POINTS POINTS
X B 3 P , Terminating-C, Tachometer sensor 89 Y 2 P , Engine ECM-16
7 WG 2 Engine ECM-4, M 90 YG 2 P , Engine ECM-6
14 5R 2 Starter motor-50, M 91 LW 2 P , Engine ECM-39
15 5RB 2 Starter motor-30, M 92 WL 2 P , Engine ECM-38
17 YR 2 P , Thermo unit 94 BW 2 P , Engine ECM-19
21 YG 2 P , Tachometer sensor 96 Br 2 P , Engine ECM-59
29 LgB 2 P , Alternator-LAMP 98 BL 2 P , Engine ECM-3
61 8W 4 Alternator-BATTERY × 2, M × 2 107 LgY 2 P , Engine ECM-15
62 WB 2 P , Alternator-IGNITION 108 GB 2 Engine ECM-13, M
78 WB, 3WB 5 Engine ECM-1, 2, 11, 12, M 109 RB 2 P , Engine ECM-14
79 B, 3B 5 Engine ECM-21, 22, 31, 32, Cylinder block stud 130 BR 2 Engine ECM-43, Coolant level sensor-C
82 G 3 P , Engine ECM-17, Terminating resistor-A 132 LgR 2 Engine ECM-44, Coolant level sensor-B
83 L 3 P , Engine ECM-18, Terminating resistor-B 132 RW 2 Engine ECM-52, Coolant level sensor-A
87 B 2 P , Cylinder block stud 133 GL 2 Engine side harness (WIF connector), M
88 GY 2 P , Engine ECM-8 134 BrR 2 Engine side harness (WIF connector), M
5-010
ELECTRICAL SYSTEM
4-3. Dashboard Harness
Combination meter
Parking brake switch Throttle switch Speed change switch
harness (P.5-021) harness (P.5-014) harness (P.5-017)
SWP-16M
1 GY,200 SWP-6F SWP-4F SWP-2F
CA104 88
ENGINE STOP lamp LgW,200 6 X
X 20 28 17 30 93 39 50
CB104 36 38
SWP-12F YR YB B
B 2LgR 300 LgR GR RY WG L LW
Interlock relay R1 CA104 89
Y,200
21 35 70 8 22 38 32 94 97
13 26 Tape WARNING lamp
CB104 28
LgW,200
YG YW WR YL Y GR BY
37 67
BrW BrY
X
B BW RW
K
W 2Lg
42 X
1
CA104 90
YG,200
RY B C T
WAIT TO START lamp LgW,200
X 25 CB104 28 31 X
B 2BW Br B
Parking interlock 280 250 200 250
relay R2 Tape 97 81
Tape
67 20 Vibration select switch Tape Tape
RW RG
Tape
200
50 110
BrY 2LgR Vibration mode change switch SWP-6F
11 9 10
B Tape Tap
e
1 (P.5-020) F-R lever vibration switch Backup buzzer switch F-R lever switch
Ta 0
5
pe
Y YR YB
1 (2) (1) (COM) (NO) (COM) (NC)
33 34 CB104 CB104 CB104 CA104 CB104 CA104
Lg LgW 250 109 X 12 2 12 13
Horn relay
30 30
R3 Tape LCR RL-1B 4
5BY,70
80 RB B Engine oil
11 81
RY 1.25RY 70 e Tape R10 108 8 pressure relay

p
Ta
1
E GB YL
Starter switch harness 26 24
GB,50
RG,70
29 X
W,50
R,50
R,50
7
(P.5-013)
Y,70
2Lg BR 70 4 BY,70
LgB B 220 58X-3F
Lamp check relay R4
Corrugate
5A Fuse holder
100
Tape 28
28 32 70 WR,70
1.25LgW 50
LgW BY
Tape
Corrugate 7
1
7
0 50
10 ate 7
19
62 1.25WB,70 e 2 6 9 10
66 g gat
50
X r u 5A Fuse holder u
or orr GB YB YR YB
Corrugate
300
B LY 150 2B,300 C 98 BL,70 C
Orbitrol mouting bolt LA210 X
Servo bypass relay
37 65
R5 Tape 50 17 21 22 24
SWP-12F
Tape YR YG Y BR
10
Relay box
BrW GW
Corrugate 7
29 50 62 66
1 Lg,100
200
Corrugate
Horn switch CB104 33 LgB LW WB LY
650
X 65
Hydraulic pump B GW 120 550 150 450 400 350 87 88 89 90
neutral holding relay 66 12
R6 Tape Corrugate 22 Corrugate 19 Corrugate 19 Corrugate 19 Corrugate 19 A 70 B GY Y YG
SWP-8F
LY R 82 83 Tape 94 98 108
A B
10 gat
BW BL GB
or
1 G L 100 94 96
0 e
150
ru
80 39 D
Main frame harness (P.5-007)

5 SWP-2M X Tape Tape BW Br
Corrug
X 62 L B
7
91 92 96
300
B 1.25WB 100 C SWP-2F
Engine stop relay R7
ate 7
36 28 Tape Terminating resistor Diagnostic switch harness (P.5-022) 120 LW WL Br
80 35 SWP-6M
LgR 1.25LgW 7 YW
SWP-2M (Use twist pair cable Twist pair cable
Tape 107 109 118
LgR,50
with shield LgY RB 1.25WR
R,50
1 (With shield : AVSSCS 0.75)
AVSSCS 0.75)
Vinyl 6
Twist pair cable
350
108 18 D
110 30
GB 2RW 200
8 1.25RY
SWP-2M E 83 (With shield : AVSSCS 0.75)
Starter lockout relay
107 16
R8 Tape
L
82
C
G 120 82 83
LgY 2W 87 118 SWP-2M
110 12 F A B 12 36 Tape G L
9 R
SWP-2M B 1.25WR
LgW,50
2 CB104 CA104
B,50
Fuse box (COM) (NO)
18 23
Corrug
J 50
2 5 5R,110 G Foot brake switch 58X-2M
150
X 93 91 3 LCR RL-1B Tape 2RW 3RG
COIL NO H
ate 7
B WG LW 180
Throttle relay
97 92
R9 Tape
1 3 Datalink interface connector
2W,110
COIL COM 16 LCR RL-1B 100 4 3
RW WL 58Y-2M
1 : Pin position Tape 5BY 5R
3RG,80 34 X
23 LCR RL-1B
10 LA108 2B,50 LA208
a c e PB104 Horn X
Ground bolt
YB 2BW,110
Diode unit
300
Tape
COIL COM NO 10 25 LCT RL-1A Horn ground
13 65 31 9 b f
W GW Br YR COIL NC RY,80
3 42 LCT RL-1A
2 : Pin position SV412-05005
5-011
ELECTRICAL SYSTEM
CONTACT CONTACT
POINTS POINTS
C , Relay box- R1 , R2 , R4 , R5 , R6 , R7 , R9 , Relay- R10 , 35 YW 2 Combination meter, Fuse box- 7
X B, 2B 16 Combination meter × 3, Horn ground, Orbitrol mount, Ground bolt, 36 LgR 3 C , Relay box- R7 , Foot brake switch-NO
Terminating resistor-C
37 BrW 2 C , Relay box- R5
2 GB 2 A , Backup buzzer switch-NO
38 GR 2 C , Combination meter
3 5R 2 A , Fuse box
39 L 2 K , Fuse box- 5
4 BY, 5BY 3 A , E , Fuse 5A
42 RY 2 Combination meter, Fuse box- 3
6 YB 2 A , Combination meter
50 LW 2 A, K
8 YL 2 Relay- R10 , Combination meter
62 WB, 1.25WB 3 A , Fuse holder 5A, Relay box- R5
9 YR 3 A , B , Diode unit-E
65 GW 3 Relay box- R5 , R6 , Diode unit
10 YB 3 A , B , Diode unit-A
66 LY 3 A , Relay box- R5 , R6
11 Y 2 B , F-R lever vibration switch-2
67 BrY 2 C , Relay box- R2
Fuse box- 9 , Relay box- R6 , Foot brake switch-COM,
12 R 5 70 WR 2 Combination meter, Fuse 5A
Backup buzzer switch-COM, F-R lever switch-COM
13 W 3 F-R lever switch-NC, Relay box- R1 , Diode unit 81 RG 2 F-R lever vibration switch-1, B
16 2W 2 Relay box- R8 , Fuse box 82 G 3 A , Datalink interface connector-C, Terminating resistor-A
17 YR 2 A , Combination meter 83 L 3 A , Datalink interface connector-D, Terminating resistor-B
18 2RW 2 A , Relay box- R8 87 B 2 A , Datalink interface connector-A
20 2LgR 2 Relay box- R1 , R2 88 GY 2 A , ENGINE STOP lamp
21 YG 2 A , Combination meter 89 Y 2 A , WARNING lamp
22 Y 2 A , Combination meter 90 YG 2 A , WAIT TO START lamp
23 3RG 2 A , Fuse box 91 LW 2 A , Relay box- R9

92 WL 2 A , Relay box- R9
24 BR 2 A, E
25 2BW 2 Fuse box- 10 , Relay box- R2 93 WG 2 T , Relay box- R9
26 2Lg 2 E , Relay box- R1 94 BW 3 A, D, T
E , Relay box- R4 , R7 , ENGINE STOP lamp, WARNING lamp, 96 Br 2 A, D

28 LgW, 1.25LgW 6
WAIT TO START lamp 97 RW 3 T , B , Relay box- R9
29 LgB 2 A , Relay box- R4 98 BL 2 A , Fuse 5A
30 RY, 1.25RY 4 T , Fuse box- 8 , Relay box- R3 × 2 107 LgY 2 A , Relay box- R8
31 Br 2 Relay box-Diode unit, Combination meter 108 GB 3 A , Relay box- R8 , Relay- R10
32 BY 2 Relay box- R4 , Combination meter 109 RB 2 A , Relay- R10
33 Lg 2 Relay box- R3 , Horn switch 118 1.25WR 2 A , Datalink interface connector-B
34 LgW 2 Relay box- R3 , Horn
5-012
ELECTRICAL SYSTEM
4-4. Starter Switch Harness
5BY,70
4 LA305 (B)
5BY,70
4
BR,70
LCT RL-1A 24 LA105 (BR)
Dashboard
70 Starter
harness
(P.5-011)
E Tape switch
2Lg,70
26 LA205 (C)
24 26
BR 2Lg 70 1.25LgW,70
28 28 LA105 (ACC)
1.25LgW
58X-3M
SV412-05006
CONTACT
NO. SIZE, COLOR CONNECTION
POINTS
4 5BY 2 E , Starter switch-B
24 BR 2 E , Starter switch-BR
26 2Lg 2 E , Starter switch-C
28 2LgW 2 E , Starter switch-ACC
5-013
ELECTRICAL SYSTEM
4-5. Throttle Switch Harness
BW,150
94 (1)
93 30 WG,150
93 (3)
Dashboard
WG RY 100 Throttle
harness
(P.5-011) 97 94 T Tape switch
RY,150
RW BW 30 (4)
SWP-4M RW,150
97 (5)
SV412-05007
CONTACT
POINTS
30 RY 2 T , Throttle switch-4
93 WG 2 T , Throttle switch-3
94 BW 2 T , Throttle switch-1
97 RW 2 T , Throttle switch-5
5-014
ELECTRICAL SYSTEM
4-6. Vibrator Solenoid Harness
Vibrator solenoid a
LA103 LA103
10 X
0
B,70
YB,7
9 LA103
10 9 0
Main frame YR,5
YB YR 250 250 Vibrator
harness
X X
H Corrugate 7 Corrugate 7 B,50 solenoid b
(P.5-007)
B B
X LA103
SWP-4M
SV412-05008
CONTACT
POINTS
X B 4 H × 2, Vibrator solenoid-a,b
9 YR 2 H , Vibrator solenoid-b (VIB. Hi)
10 YB 2 H , Vibrator solenoid-a (VIB. Lo)
5-015
ELECTRICAL SYSTEM
4-7. Hydraulic Oil Filter Harness
50
22 LE105
00
Y,1 e
p
Main frame 100 Ta Hydraulic oil filter
22
harness (P.5-007) Tape Y,1 switch
0
CA104 Ta 0
pe 50
22 LE105
SV412-05009
CONTACT
POINTS
22 Y 3 Hydraulic oil filter switch × 2
5-016
ELECTRICAL SYSTEM
4-8. Speed Change Switch Harness
39 (1)
00
L,1
Dashboard 50 39 150 Speed change
harness (P.5-011) LW L
K Tape LW switch
,10
0
SWP-2M
50 (2)
SV412-05010
CONTACT
POINTS
39 L 2 K , Speed change switch-1
50 LW 2 K , Speed change switch-2
5-017
ELECTRICAL SYSTEM
4-9. Starter Relay Harness
5R,100
14 LA308
X 18 50
2B 2RW 5RB,100
15 LA308
58X-2M 100 Starter
Main frame
harness (P.5-007)
S Corrugate 10 relay
2RW,100
18 LA205
15 14 50
5RB 5R
2B,100
X LA205
58Y-2M
SV412-05011
CONTACT
POINTS
X 2B 2 S , Starter relay
14 5R 2 S , Starter relay
15 5RB 2 S , Starter relay
18 2RW 2 S , Starter relay
5-018
ELECTRICAL SYSTEM
4-10. Speed Change Solenoid Harness
50 LA103
,50
LW
Main frame X 50 200 Speed change
harness (P.5-007) B LW R Corrugate 7 B,5 solenoid
0
SWP-2M
X LA103
SV412-05012
CONTACT
POINTS
X B 2 R , Speed change solenoid
50 LW 2 R , Speed change solenoid
5-019
ELECTRICAL SYSTEM
4-11. Vibration Select Switch Harness
YR,150
9 (5)
YB,150
10 (2)
Vibration select
switch
Y,150
11 (1)
81 97
Dashboard RG RW 150 Y,150
harness (P.5-011) 10 9 11
B Tape
11 (4)
YB YR Y Y,150
11 (2)
SWP-6M RG,150 Vibration mode

81 (3) change switch
RW,150
97 (1)
SV412-05013
CONTACT
POINTS
9 YR 2 B , Vibration select switch-5
10 YB 2 B , Vibration select switch-2
11 Y 4 B , Vibration select switch-1, 4, Vibration mode change switch-2
81 RG 2 B , Vibration mode change switch-3
97 RW 2 B , Vibration mode change switch-1
5-020
ELECTRICAL SYSTEM
4-12. Parking Brake Switch Harness
LgR,150
36 (1)
BrY,150
16 (2)
38 36
Dashboard GR LgR 150 BrW,150 Parking brake
harness (P.5-011)
X 16 37
C Tape
37 (3)
switch
B BrY BrW GR,150
38 (4)
SWP-6M B,150
X (5)
SV412-05014
CONTACT
POINTS
X B 2 C , Parking brake switch-5
16 BrY 2 C , Parking brake switch-2
36 LgR 2 C , Parking brake switch-1
37 BrW 2 C , Parking brake switch-3
38 GR 2 C , Parking brake switch-4
5-021
ELECTRICAL SYSTEM
4-13. Diagnostic Switch Harness
BW,100
94 LA104 (2)
Dashboard 96 94 100
harness (P.5-011)
Br BW
D Tape
Diagnostic switch
Br,100
96 LA104 (3)
SWP-2M
SV412-05015
CONTACT
POINTS
94 BW 2 D , Diagnostic switch-2
96 Br 2 D , Diagnostic switch-3
5-022
ELECTRICAL SYSTEM
5. ELECTRICAL COMPONENT SPECIFICATIONS

5-1. Fuse Box
Throttle switch (RY) (YW) Combination meter

Horn relay
F-R lever switch (R)

Backup buzzer switch (L) Speed change switch
Propulsion pump neutral holding relay
Foot brake switch
Parking interlock relay (BW) (RY) Combination meter
10 9 8 7 6 5 4 3 2 1
20A 15A 15A 15A 15A 15A 20A 20A 20A 20A
Starter lockout relay (W) Battery relay (R) (RG) Battery relay
SV412-05001
Harness color codes

W : White RY : Red/Yellow stripe
R : Red RG : Red/Green stripe
L : Blue YW : Yellow/White stripe
BW : Black/White stripe
5-023
ELECTRICAL SYSTEM
5-2. Combination Meter
SWP-16F 8 G, Engine oil pressure warning GB, REV. ratio SEL.2
17 YW, Coolant temp. meter OW, Coolant temp. SEL. 2
22 GW, Hydraulic oil filter warning X RB, REV. ratio SEL.1
6 YR, Fuel meter WB, Coolant temp. SEL. 1
Y, REV. pulse input.2 LgY, REV. ratio SEL.4

SWP-12M (square wave)
38 GR, Parking brake GY, Preheating
X B, Ground X OG, REV. ratio SEL.3
32 BrW, Lamp check W, Charge warning

SWP-16F
Harness side
12V X 32 * X
B BY * B
Battery (+12V) Power 5V
excitation power * 38 * *
circuit supply GR
Movement Tachometer * * *
Starter switch (ACC) 6 22 X *
12V Input
interface
YB Y B *
17 8 * *
YR YL
CAN interface
Movement Fuel meter * *
SWP-16M
Temperature
Movement meter
REV. pulse input.1
Frequency divider
AD input interface TA input interface
(pickup)
selector
REV. pulse input.2

(square wave) LCD Hour meter
EEPROM
Fuel sensor
Coolant temp. sensor
REV. ratio SEL.1 21 O, REV. pulse input.1 YL, Side maker lamp
(pickup)
Input interface
REV. ratio SEL.2

31 L, Vibrator
REV. ratio SEL.3 LR, Turn signal (left)
CPU
REV. ratio SEL.4 LB, Liquid spray

interface
Output
Illumination LED 35 P, Starter switch (ACC)

Br, Water spray
12V Side marker lamp Not in use
Water spray
Combination meter indicator GL, Turn signal (right)
ilumination Liquid spray 70 R, Battery (12V)
indicator
Turn signal (right)
Side marker lamp 42 WR, Combination meter
indicator LW, Flood lamp
Turn signal (left)
Vibrator
Flood lamp indicator illumination SWP-12M
Vibration indicator
Output interface
Liquid spray Turn signal indicator

(left) Harness side
Water spray
Input interface
Turn signal indicator

(right) 70 42 *
Flood lamp WR RY
Parking brake *
indicator * * *
Preheating
Engine oil pressure * * *
Parking brake warning indicator
Charge warning 35 * *
Charge warning indicator YW * *
Hydraulic oil filter
Engine oil pressure warning indicator 21 * 31
warning YG * Br
Preheating indicator
warning
Lamp check SWP-12F
Coolant temp. SEL.1
Coolant temp. SEL.2
System configuration diagram
Note: The circuit in the dashed box is not mounted.

SV412-05002
5-024
ELECTRICAL SYSTEM

6-1. Electrical Circuit Diagram
TRAVEL MODE SELECT SWITCH
POSITION MODE CONNECTION
2 GB LEFT HAND 1-2,4-6

FOOT BRAKE
SWITCH X B
CENTER 1-3,4-6
3 37 BrW 66 LY X B STOP
36 LgR 36 LgR 1 SOL
2 BACKUP BUZZER
PARKING REVERSE FORWARD RIGHT HAND 1-3,4-5
38 GR 4
5 X B BRAKE
SOLENOID
PARKING BRAKE 2 51 G
SWITCH NC NO COM 1
3 53 WG 53 WR X B
SOL
12 R
36 LgR BACKUP 5
4 FRONT MOTOR
BUZZER 52 LR
67 BrY 6
59 LW
SWITCH SOLENOID
39 L
65 GW 66 LY 66 LY X B DIODE UNIT
SOL TRAVEL MODE F G H
3 5 SELECT SWITCH
X B 37 BrW SERVO BYPASS
N
X B
C
SOLENOID 52 LR 50 LW 50 LW A E B C D I
N
2 1
O
SOL
C

O

M
SERVO BYPASS 2 GB 51 G X B REAR MOTOR A B C D
F-R LEVER
B
RELAY (R5) SWITCH SOLENOID
65 GW 12 R E F G H I
NC NO COM
COMBINATION METER SET 5 3 TRAVEL MODE
R B
66 LY X B RELAY (R11)
110 PULSE/REV SET(NO.5) TEMP. 50-103͠ SET(NO.0)
12 R
1 2
13 W
13 W
12 R
REV RATIO SEL. TEMP.CURVE SEL. PROPULSION PUMP
1 2 3 4 1 2 NEUTRAL HOLDING 65 GW
GND OPEN GND OPEN OPEN OPEN RELAY (R6) 31 Br
65 GW
THROTTLE SWITCH
9 YR
42 RY 42 RY 10 YB
COMBINATION METER CENTER MIDDLE 1-3,4-6
HORN RIGHT HAND FULL 1-3,4-5
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
6
X B 34 LgW 30 1.25RY 30 RY 4 3 81 RG Br
G
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1
5 97 RW 97 RW 1
TURN SIGNAL(R)
PARKING BRAKE
3 1
TURN SIGNAL(L)
5
BATTERY 12V(+)
25 2BW 2 11 Y 2
WATER SPRAY
LIQUID SPRAY
33 Lg 30 RY
LAMP CHECK
FLOOD LAMP
PREHEATING
30 1.25RY
3 93 WG
FUEL METER
1 94 BW 1 VIBRATION MODE F-R LEVER

VIBRATOR
35 YW
B
42 RY
VIBRATION
11 Y
2 CHANGE SWITCH
12 R
39 L
HORN
HORN SWITCH SWITCH
RELAY (R3)
GND
THROTTLE
31 Br SWITCH
HIGH
6
35 YW 11 Y 4
10
2
7
9
5
6
1
9 YR a X B
5
13 W 92 WL 㨒
R P O B Y YR YW 93 WG 3
SOL
20A
20A
20A
20A
20A
1
15A
15A
15A
15A
15A
㨏 2 10 YB X B
WR GL LR YL BrW GR GW G 26 2Lg 20 2LgR 25 2BW 㨑
91 LW
5 5 X B 97 RW b
LW Br LB L W GY RB GB 3 3 VIBRATION
13 W X B X B 67 BrY 㨎㨍 SELECT LOW
OG LgY WB OW
1 2 2 1 THROTTLE SWITCH
FUSE BOX VIBRATOR
INTERLOCK PARKING INTERLOCK RELAY (R9) SOLENOID
RELAY (R1) RELAY (R2) F.L. 45A
16 2W
23 3RG 23 3RG 75 3G
3 5R
35 YW 26 2Lg
3 5R F.L. 65A 76 5WR
31 Br
FUSE
70 WR 4 BY F.L. 45A
61 8W 74 8WY
5A
38 GR
35 YW
61 8W F.L. 45A 74 8WY

31 Br
4 BY
X B
X B

X B
B
HEAT AV30
42 RY 24 BR
OFF BR
8 YL ACC 78 3WB 86 3WL 86 3WL
ON 30A
STARTER
32 BY
FUSE 18 2RW
ST SWITCH 16 2W 14 5R 15 5RB
28 1.25LgW
STARTER SWITCH ENGINE ECM.(CM2250) 3 5
GB
3 5
NO COM
70 WR 107 LgY 108 18 2RW X 2B
J3(60PIN) 1 2 1 2 AV60
32 BY X B 78 WB 79 B
21 YG 1 (+) BATTERY BATTERY (-) 21 STARTER LOCKOUT STARTER AV60
24 BR
3 5 78 WB 79 B RELAY (R8) RELAY
X B 29 LgB 28 LgW 2 (+) BATTERY BATTERY (-) 22 14 5R
79 B BR
2 78 WB
6 YB 1 11 (+) BATTERY BATTERY (-) 31 +
LAMP CHECK 78 WB 79 B 50 15 5RB BATTERY
22 Y RELAY (R4) 12 (+) BATTERY BATTERY (-) 32 30 RELAY
28 LgW 88 GY 95D31R
8 STOP LAMP E
X B
X 2B
89 Y G BATTERY
16 WARNING LAMP
HYDRAULIC 90 YG -
6 WAIT TO START LAMP STARTER MOTOR
OIL FILTER AV60 AV60
SWITCH 1 FUSE
28 1.25LgW 62 1.25WB 62 1.25WB 98 BL 79 3B AV60
22 Y 5A 3 KEY SW. SIGNAL B
3 5 87 B
AV20
92 WL DIAGNOSTIC
B 36 LgR X B ISC 2 SW (MID) 38 SWITCH
1 2 91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE STOP ENGINE 94 BW 61 8W
22 Y SW AND TEMP SENSOR RETURN 19 1 94 BW
RELAY (R7) HARNESS CYLINDER
96 Br 96 Br 62 WB
B 133 GL DIAGNOSTIC 59 2 BLOCK
21 YG
17 YR
LgY 3
8 YL
HYDRAULIC
107 29 LgB
134 BrR STARTER LOCKOUT 15 AV20
OIL FILTER 108 GB
SWITCH 2 8 YL X B FUEL SENSOR OUTPUT RETURN 1 (-) 13
TACHO 7 WG
LAMP
BATTERY
IGNITION
PHASE
GROUND
3 5 INTAKE AIR HEATER (+) 4
METER 6 YB X B 108 GB 109 RB 109 RB
SENSOR 14 DUAL OUTPUT A (+)
1 2
FOR OIL PRESS.
ENGINE OIL
X B
TERMINATING TERMINATING 130 BR

B PRESSURE C 43 OEM SENSOR (SIGNAL RETURN)
RELAY (R10) RESISTOR RESISTOR 131 LgR FUSE
B ALTERNATOR AV30
120Ω 120Ω SENSOR 44 COOLANT LEVEL (SIGNAL) AV30
THERMO 132 RW 250A
ENGINE 5 3
UNIT A 52 SENSOR SUPPLY (POWER) GB
DIAGNOSIS 82 G 7 WG 108
FUEL UNIT 17 CAN A (+) 1 2
D
E C GRID HEATER
F A B 83 L RELAY
36 LgR J 18 CAN A (-)
G
H
FUSE
118 1.25WR 86 1.25WL
10A B
GRID HEATER
87 B
0404-99047-0-11944-0
5-025
ELECTRICAL SYSTEM
6-2. Wiring Harness Layout
Mark T
Front motor solenoid

(WR),(B)
Mark K
Travel mode select switch

1(L),2(G),3(WR),4(L),5(LW),6(LR)
Travel mode select switch harness

(P.5-027)
Front motor solenoid harness

(P.5-028)
A
Travel mode relay R11
(G),(B),(LR),(LW)
VIEW A-A
Mark T
0404-09824-0-11932-0
0404-09824-0-12020-0
5-026
ELECTRICAL SYSTEM
6-3. Travel Mode Select Switch Harness
Travel mode relay

(P.5-026, to R11 )
1
X 50
B LW
Rear motor solenoid 51 52

SWP-2M G LR
R7
50 39
LW L
7
L,150
(1) 39
Corrugate
550
G,150
(2) 51
Tape
50
WR,150 Front motor
(3) 53
250 300 1350 X 53 solenoid
Travel mode
select switch L,150 Tape Tape Corrugate 7 T B WR harness
(4) 39 (P.5-028)
SWP-2M
LW,150
2B
(5) 50
,30
0
LR,150
(6) 52
2 5
X
COIL NO
1 3 LA210
COIL COM Orbitrol mounting bolt
1 : Pin position
SV410-2-05001
CONTACT
POINTS
X B 3 T , R7 , Orbitrol mounting bolt
39 L 3 K , Travel mode select switch-1,4
50 LW 3 K , R7 , Travel mode select switch-5
51 G 2 R7 , Travel mode select switch-2
52 LR 2 R7 , Travel mode select switch-6
53 WR 2 T , Travel mode select switch-3
5-027
ELECTRICAL SYSTEM
6-4. Front Motor Solenoid Harness
LA103 53
WR
,50
SWP-2F
Travel mode
Front motor 2700 53 X
solenoid Corrugate 7 T WR B
select switch
harness (P.5-027)
0
B,5
LA103 X
SV410-2-05002
CONTACT
POINTS
X B 2 T , Front motor solenoid (-)
53 BR 2 T , Front motor solenoid (+)
5-028
VIBRATORY DRUM • REAR AXLE
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 cotter pins, and lock plates with new parts.
• Properly bend split cotter pins and lock plates.
• When applying an adhesive, first clean and remove oil/grease from the surfaces properly. Then
apply two or three drops to the threaded areas.
• When applying a liquid gasket, first clean and remove oil/grease from the application surface
properly, and confirm that the surface is free of dust and damage. Then apply the product evenly.
• Clean parts well. Repair scratches, dents, burrs, rust, etc.
• Apply gear oil to rotating and sliding components.
• Apply grease to the surfaces of press-fit parts.
• After installing snap rings, confirm that they are properly seated in the grooves.
• Connect wiring connectors securely after cleaning off adhering oil, dust and water.
• Use lifting bolts that are not fatigued or deformed. Screw them in fully.
• When tightening a split flange, tighten screws alternately to prevent uneven tightening.
• Before installing hydraulic parts, confirm that they are free of damage and dust, etc.
6-001
3) Precautions when work is completed

• If coolant has been drained, securely retighten the drain cock and fill with coolant (mixing in long-
life 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
2. VIBRATORY DRUM
2-1. Removal and Installation of Vibratory Drum
2-1-1. Removal of vibratory drum
1) Using the steering lock bar (1), connect the front
and rear frames. Firmly secure it so that the
front and rear frames do not move.
1
SV400-2-06001
2) As shown in the figure on the right, lift the rear

frame with a crane. Firmly secure the vehicle
body by placing support stands and/or wooden Lift with crane
blocks at the rear end of the rear frame.
Do not allow the rear wheel tires to leave
the ground. (The tires must support the
vehicle’s body weight, too.)
Wooden
block
Rear lift weight
SV412D : 3,940 kg (8,685 lbs.)
SV412T : 3,960 kg (8,730 lbs.)
SV412TF : 3,940 kg (8,685 lbs.) Support stand
SV412TB : 3,860 kg (8,510 lbs.)
SV412FB : 3,830 kg (8,445 lbs.) SV400-2-06002
When lifting the vehicle, use an appropriate

hoist of sufficient strength. Confirm that the
surrounding area is safe, and work in a natural,
unstrained posture.
Also, to firmly secure the vehicle body, use a
support stand of sufficient strength.
6-003
3) Lift the front frame with a crane. With the drum Lift with crane
slightly above the ground surface, place support
stands at the right and left sides of the front
frame. Firmly secure the vehicle body.
Front axle weight

SV412D : 3,600 kg ( 7,935 lbs.)
SV412T : 3,820 kg ( 8,420 lbs.)
SV412TF : 5,110 kg ( 11,265 lbs.)
SV412TB : 4,340 kg ( 9,570 lbs.)
SV412FB : 5,630 kg (12,410 lbs.)
Support stand Support stand
SV400-2-06003
4) With the crossmember (3) lifted by the crane,

Lift with crane
loosen the two bolts (2) (both right and left).
Then remove the crossmember from the front
frame.
3
Crossmember
SV412D : 210 kg (463 lbs.) 2
SV412T : 285 kg (628 lbs.)
SV412TF : 340 kg (750 lbs.)
SV412TB : 285 kg (628 lbs.)
SV412FB : 340 kg (750 lbs.)
• When installing
SV400-2-06004
(2) M20×100: 540 N·m (398 lbf·ft)
5) Disconnecting piping
➀ Propulsion motor piping
Disconnect the hydraulic hoses (4, 5 and 6)
that are connected to the propulsion motor.
Either plug both sides of disconnected
connections or take other steps to
prevent dust from getting inside.
Immediately after the vehicle has stopped,

the hydraulic oil will be hot and under builtup
pressure. If, under these conditions, you try
to disconnect the piping, you may get burned. 4 5 6 SV400-2-06005
Therefore, wait until the oil has cooled before

engaging in this task.
6-004
➁ Vibrator motor piping

7 8 9
Disconnect the hydraulic hoses (7, 8 and 9)
that are connected to the vibrator motor.
Either plug both sides of disconnected
connections or take other steps to
prevent dust from getting inside.
SV400-2-06006
6) Lift the drum (11) with a crane. Ensuring that no Lift with crane
load is applied to the eight bolts (10), loosen
and remove the bolts (10). (Similarly, remove
the bolts from the opposite side, too.) Separate 11
the drum assembly and front frame. 10
• When installing
(10) M20×90: 540 N·m (398 lbf·ft)
SV400-2-06007
7) As shown in the figure on the right, use support

stands or other means to firmly secure the side
of the vehicle body on which the drum was
removed. Ensure that the vehicle body does not
move.
Support stand
Support stand Wooden block
Support stand
SV400-2-06008
6-005
8) Place chock blocks at the front and rear

11
of the removed drum assembly (11) to
prevent the drum assembly from moving.
Chock block Chock block
SV400-2-06009
6-006
2-1-2. Installation of vibratory drum

1) Install the vibratory drum in the reverse
order in which it was removed.
• Tightening torque for bolts in locations requiring
particular attention during reinstallation of the
vibratory drum:
(10) M20×90: 540 N·m (398 lbf·ft)

(2) M20×100: 540 N·m (398 lbf·ft)
2) When installing the vibratory drum, pay

particular attention to the items mentioned
below.
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 work
is completed, the piston packing or other
items may be damaged by air entering into the
cylinder.
F
ill the hydraulic oil tank to the specified level
to make up for any oil leakage.
Start the engine and circulate the oil through
the piping. Then check the oil level again,
ensuring that the oil is at the specified level.
6-007
2-2. Vibratory Drum Assembly
(1) Drum
1 (2) O-ring
8
45 2 3 4 5 6 7 9 10 11 12 13 14 15 (3) Vibrator bearing
16 (4) Eccentric shaft
(5) Shaft
44
17 (6) Bolt (M10×40)
43 (7) Sleeve
(8) Spring pin
18
(9) Bolt (M16×50)
42 19 (10) Plug
(11) Housing
(12) Oil seal
41
20 (13) Roller bearing
(14) Disc
40 21 (15) Bolt (M12×40)
A 22 (16) Bolt (M20×50)
23 (17) Bolt (M12×40)
46 (18) Damper
(19) Holder
A 24 (20) Bolt (M20×90)
39 (21) Breather
25
(22) Cover
38
(23) Bolt (M14×40)
26
(24) Bolt (M14×40)
37 (25) O-ring
36 27 (26) Shim
28
(27) Cover
(28) Oil seal
35 29
(29) Bolt (M12×40)
30 (30) Holder
34
(31) Shim
(32) Axle shaft
33 32 31 (33) Vibrator bearing
(34) Bolt (M16×50)
10-1
(35) O-ring
10-3
(Oil filler plug) (36) Axle shaft
(Level plug)
(37) Bolt (M16×50)
(38) Disc
(39) Bolt (M20×90)
(40) Bolt (M16×50)
Vibrator mode is Low Vibrator mode is High (41) Holder
with motor rotating with motor rotating 10-2
(42) Damper
clockwise counterclockwise (Drain plug)
(43) Bolt (M12×25)
SECTION A-A Propulsion motor side Vibrator motor side
(44) Bolt (M12×40)
0404-43801-0-10002-H (45) Propulsion motor
(46) Vibrator motor
6-008
2-3. Disassembly and Reassembly of Vibratory Drum

• Leader numbers appearing in the vibratory
drum disassembly and reassembly procedure
illustrations shown below correspond to the
numbers indicating the parts of the vibratory
drum assembly (page 6-008).
2-3-1. Disassembly of vibratory drum

1) Remove the plugs (10-1 and 10-2).
• Drain the gear oil from the vibrator case. 10-1
• Gear oil quantity: 21 L (5.5 gal.)
10-2
SV400-2-06012
2) Lift the vibratory drum with a crane. As shown in

the figure on the right, stand it up with the
propulsion motor side facing downward.
After standing up the drum, place wooden

blocks that have sufficient strength underneath.
Stabilize the drum so that it is not unsteady.
Wooden
block
Vibratory drum assembly
SV412D : 2,685 kg (5,919 lbs.)
SV412T : 2,890 kg (6,371 lbs.) Wooden block SV400-2-06013
SV412TF : 4,230 kg (9,325 lbs.)
SV412TB : 2,890 kg (6,371 lbs.)
SV412FB : 4,230 kg (9,325 lbs.)
6-009
3) Remove the two bolts (24). 46

• Remove the vibrator motor (46). 21 24
• Remove the breather (21).
Use aids such as work stepladders when

working, and work with a natural, unstrained
posture.
SV400-2-06014
4) Remove the sixteen bolts (16). Lift with crane

• Attach the lifting bolts/nuts (M20×2.5) as shown
in the figure on the right. 19 16 30
• Using a crane, lift and remove the holder (19), 18
damper (18) and disc (14) together.
14
Total of lifted parts (19, 30, 18 and 14)

: 135 kg (298 lbs.)
SV400-2-06015
5) Remove the sixteen bolts (9). 7

• Remove the sleeve (7).
9
SV400-2-00016
6-010
6) Attach the lifting bolts (M16×2.0) as shown in Lift with crane

the figure on the right.
• Using a crane, slowly lift and remove the axle 32 Wooden block Wooden hammer
shaft (32).
At this time, to ensure that the vibrator
shaft does not follow along with the axle
shaft (32), lift the end of the vibrator shaft
while lightly tapping with a wooden
hammer through a wood block.
Axle shaft: 150 kg (331 lbs.)
When attaching the lifting bolts, screw in the

threads fully before using. SV400-2-06017
7) Attach a lifting bolt (M10×1.5) to the end of the

vibrator shaft (4). Then lift with a crane and
remove.
Vibrator Shaft: 140 kg (309 lbs.)
SV400-2-06018
8) In the figure on the right, the vibrator motor side

is up. From the top, the figure shows the
condition with the part removed.
6-011
9) Lift and invert the drum with a crane. Stand it up

with the propulsion motor side upward.
Lifted weight in figure on the right

SV412D : 2,240 kg (4,938 lbs.)
SV412T : 2,440 kg (5,379 lbs.)
SV412TF : 3,780 kg (8,333 lbs.)
SV412TB : 2,440 kg (5,379 lbs.)
SV412FB : 3,780 kg (8,333 lbs.)
Inverting the drum can be dangerous work.

Therefore, be very careful, confirm that the SV400-2-06020
surrounding area is safe and work in a natural,
unstrained posture.
Lift with crane

40 42
• As shown in the figure on the right, attach the 38
lifting bolt (M20×2.5) to the holder (41) and
slowly lift. Remove together with the damper (42)
and disc (38).
Total of lifted parts (41, 42 and 38)

: 115 kg (255 lbs.)
SV400-2-06021
11) Remove the sixteen bolts (37). 37 45

• Remove the propulsion motor (45).
Propulsion motor: 185 kg (408 lbs.)
SV400-2-06022
6-012
12) Remove the sixteen bolts (34).

• Remove the axle shaft (36). 34 36
SV400-2-06023
13) The figure on the right shows the condition in

which all parts have been removed from the
vibratory drum assembly.
SV400-2-06024
14) The figure on the right shows the axle shaft

subassembly removed from the vibratory drum. 22 29
• Remove the six bolts (29).
• Remove the cover (22).
SV400-2-06025
6-013
15) Remove the eight bolts (23).

23 27
SV400-2-06026
16) Place the plate at the end of the axle shaft. With
the puller against the housing (11), separate the Puller
housing, including the roller bearing, from the
axle shaft.
11 Plate
SV400-2-06027
6-014
2-3-2. Reassembly of vibratory drum

efore reassembling, confirm that each part
B
that was disassembled has been well cleaned
and is free of any abnormality.
1) Lightly apply gear oil to the press-fitting surface
of the roller bearing (13) outer race.
13
• Drive the outer race of the roller bearing (13) 11
into the housing (11).
• Attach the oil seal (12).
13
12
SV400-2-06028
2) As shown in the figure on the right, firmly secure

the axle shaft (32) with support stands and/or
wooden blocks. 33 32
• Lightly apply gear oil to the press-fitting surface
of the vibrator bearing (33). Wooden block
• Drive in the vibrator bearing (33).
Wooden block
Support stand
SV400-2-06029
3) Using a crane, lift and invert the axle shaft (32)

subassembly.
Axle shaft subassembly: 90 kg (198 lbs.) 13

32
of the roller bearing.
• Attach the inner race of the roller bearing (13).
Wooden block
SV400-2-06030
6-015
4) Apply an ample amount of lithium-based grease

11
to the rolling surfaces of the roller bearing (13).
• Lightly apply the same grease to the lip surfaces
of the oil seal (12).
• Join the axle shaft (32) subassembly and
housing (11). 12
13
32
Housing: 40 kg (88 lbs.)
SV400-2-06031
5) After applying an ample amount of lithium-based

grease to the inner race of the roller bearing
(13), drive it in until the inner race’s rolling
surface makes contact with the outer race.
13
SV400-2-06032
6) As shown in the figure on the right, insert

shims (31) approximately 1 mm to create a gap
23 27
between the axle shaft end face and cover (27)
interior surface. Then install the cover (27). 31
Gap
• Install washers to the four bolts (23), and tighten 11

to a tightening torque of 108 N·m (80 lbf·ft).
• Rotate the housing (11) two or three times. Then
tighten the same bolts again to a tightening
torque of 108 N·m (80 lbf·ft).
• Repeat this procedure two or three times until
the bolt tightening torque no longer varies.
hen tightening the bolts (23), alternately

W
tighten by using four of the eight bolts
positioned diagonally from each other. SV400-2-06033
6-016
7) Roller bearing preload adjustment 23

➀ Remove the four bolts (23).
• Remove the cover (27) and shim (31).
27
31
SV400-2-06034
➁ Without inserting shims, install the cover (27).

Then install washers to the four bolts (23) and
There must be no gap
tighten.
• Using a thickness gauge, measure the gap at 23 27
dimension A. A
reload adjustment shim thickness =

P
(A+0.1) mm
SV400-2-06035
➂ Remove the bolts (23).

• Insert the shim (31) whose preload 23 27
31
adjustment shim thickness equal to (A+0.1)
mm. Then firmly secure the cover (27) again
by installing washers to the eight bolts (23).
(23) M14×40: 170 N·m (125 lbf·ft)
SV400-2-06036
6-017
8) Install the oil seal (28) to the cover (22).

• Lightly apply grease to the lip surfaces of the oil
seal (28). 22 29
28
• Using the six bolts (29) and spring washers,
firmly secure the cover (22) to the housing.
(29) M12×40: 108 N·m (80 lbf·ft)
SV400-2-06037

of the vibrator bearing (3).
• Drive the vibrator bearing (3) into the axle shaft
3
(36).
36
Axle shaft : 100 kg (220 lbs.)
Vibrator bearing : 10 kg (22 lbs.)
SV400-2-06038
10) Install the O-ring (35) to the axle shaft (36). 36 35

• Lightly apply grease to the entire circumference
of the O-ring (35). 34
• Using the sixteen bolts (34) and washers, firmly
secure the axle shaft (36) to the drum.
(34) M16×50: 270 N·m (199 lbf·ft)
NOTE : W
hen installing, make sure that the
O-ring does not protrude from the
groove.
Use aids such as work stepladders when SV400-2-06039

posture.
6-018
11) Attach the O-ring (2) to the propulsion motor 37 45

(45).
secure the propulsion motor (45) to the axle
shaft.
NOTE: W hen attaching, make sure that the
groove.
Propulsion motor: 185 kg (408 lbs.)
(37) M16×50: 270 N·m (199 lbf·ft) SV400-2-06040
12) Using the sixteen bolts (40) and washers, firmly 41

40
secure the subassembly of the holder (41), 42
damper (42) and disc (38) to the propulsion
motor.
38
: 115 kg (255 lbs.)
(40) M16×50: 270 N·m (199 lbf·ft)
SV400-2-06041
13) Lifting with a crane, invert the drum as shown in


SV412D : 2,240 kg (4,938 lbs.)
SV412T : 2,440 kg (5,379 lbs.)
SV412TF : 3,780 kg (8,333 lbs.)
SV412TB : 2,440 kg (5,379 lbs.)
SV412FB : 3,780 kg (8,333 lbs.)

Therefore, be very careful, confirm that the SV400-2-06019
unstrained posture.
6-019
14) Attach a lifting bolt (M10×1.5) to the end of the Lower with crane
vibrator shaft (4). Then lift with a crane, slowly 4
lower and attach.
When inserting the vibrator shaft into the

vibrator bearing for attachment, be careful
not to allow the inner race of the vibrator
bearing to lean.
Vibrator Shaft: 140 kg (309 lbs.)
SV400-2-06042
15) Attach the O-ring (35) to the axle shaft (32) Lower with crane
subassembly.
• Lightly apply grease to the entire circumference 32
• Lift and slowly lower the axle shaft (32)
subassembly with a crane.
hen attaching the axle shaft, move the

W
vibrator shaft until the center of the
vibrator bearing inner race is aligned with
the center of the shaft. Be careful not to
allow the vibrator bearing to lean.
Axle shaft (32) subassembly

SV400-2-06043
: 150 kg (331 lbs.)

secure the axle shaft subassembly to the drum.
groove.
(21) M16×50: 270 N·m (199 lbf·ft)
SV400-2-06044
6-020
17) Attach a lifting bolt (M10×1.5) to the vibrator Lift with crane
shaft end. Then slowly lift with a crane. Confirm Shaft must move 1 to 3 mm
that 1 to 3 mm (0.04 to 0.12 in.) of play exists in
the axial direction.
SV400-2-06045
18) Using a crane, lift and slowly lower the Lower with crane
subassembly of the holder (19 and 30), damper
(18) and disc (14). 19 30
18
14
: 135 kg (298 lbs.)
SV400-2-06046
19) Using the sixteen bolts (16) and washers, firmly 16 7

secure the holder subassembly to the housing.
• Apply a molybdenum-based grease to the spline
surface of the sleeve (7), and attach it to the
spline shaft at the end of the vibrator shaft.
(16) M20×50: 540 N·m (398 lbf·ft)
SV400-2-06047
6-021
20) Attach the breather (21). 46

• Attach the O-ring (25) to the vibrator motor (46). 21 24
Using the two bolts (24) and washers, firmly
secure it to the cover. 25
A
ttach by aligning the top side of the
vibrator motor (46) and breather (21) with
the top side of the propulsion motor.
(24) M14×40: 170 N·m (125 lbf·ft)
SV400-2-06048
21) Lift the vibratory drum assembly with a crane,

and set it sideways at the position of the plug 10-1
shown in the figure on the right. (Oil filler plug)
• Remove the oil filler plug and level plug.
• From the oil filler plug hole, add approximately
21 L (5.5 gal.) of gear oil until gear oil drips from
the level plug hole.
• Attach the oil filler plug and level plug.
10-3
Vibrator motor side
(Level plug)
SV400-2-06049
6-022
3. AXLE
3-1. Rear Axle (SV412D)
9
(1) Tire {Tire inflation pressure: 137.34 kPa (20 psi)}
(2) Nut (M22 p=1.5)
785 N·m (579 lbf·ft)
(3) Hub reduction gear
(4) Brake
(5) Differential
10 (6) Center housing
10 (7) Bolt (for brake release)
11 (8) Plug (for brake component lubrication)
1 (9) Plug (for brake and differential component lubrication and level gauge)
(10) Bolt (for brake adjustment)
(11) Plug (for differential component lubrication)
(12) Plug (for differential component drain)
(13) Plug (for brake component drain)
15 (14) Bolt (M20×220)
5
4 540 N·m (398 lbf·ft)
6
4
2 (15) Valve
3 (16) Plug (for hub reduction gear component lubrication, level gauge and drain)
• Rear axle assembly weight : 660 kg (1,455 lbs.)

• Tire assembly weight : 145 kg ( 320 lbs.)
2 3
8
9
16
14
1 7 7
12
13 13
0404-27804-0-11494-A
6-023
3-2. Rear Axle (SV412T, TF, TB, FB)
9
(1) Tire {Tire inflation pressure: 137.34 kPa (20 psi)}
(2) Nut (M22 p=1.5)
785 N·m (579 lbf·ft)
(3) Hub reduction gear
(4) Brake
(5) Differential
10 (6) Center housing
10 (7) Bolt (for brake release)
11 (8) Plug (for brake component lubrication)
1 (9) Plug (for brake and differential component lubrication and level gauge)
(10) Bolt (for brake adjustment)
(11) Plug (for differential component lubrication)
(12) Plug (for differential component drain)
(13) Plug (for brake component drain)
15 (14) Bolt (M20×220)
5
4 540 N·m (398 lbf·ft)
6
4
2 (15) Valve
3 (16) Plug (for hub reduction gear component lubrication, level gauge and drain)
• Rear axle assembly weight : 630 kg (1,389 lbs.)

• Tire assembly weight : 130 kg ( 287 lbs.)
2 3
8
9
16
14
1 7 7
12
13 13
0404-27805-0-11495-0
6-024
3-3. Rear Axle Lubrication
Center housing
1,2 (differential + brake) 1,2 1,2
3 3 3
Drain
Hub reduction gear
1,2
Supply
3
Drain
SV201-1-06094
(1) Filler port

(2) Level gauge
(3) Drain port
• Change oil : Gear oil API-grade GL4 SAE90 (See recommended lubrication.)
• Change oil quantity
Center housing : 6.8 L ( 1.8 gal. )
Hub reduction gear : 0.75 L×2 ( 0.2 gal.×2 )
6-025
3-4. Rear Axle Structure

3-4-1. Center housing
1
7
3
8
2 4
1 5 9
6
10
1
2
SV201-1-06095
(1) O-ring (5) Vent (9) Snap ring

(2) Cover (6) Housing (10) Magnet plug
(3) Bolt (7) Plug
(4) Seal washer (8) Plug
6-026
3-4-2. Differential
1
2
3
4 5
3
10 2
13
12 1
11
10
9
8
SV400-2-06053
(1) Cylinder bolt (6) No spin differential (11) Spacer

(2) Ring nut (7) Bolt (12) Shim
(3) Taper roller bearing (8) Bevel gear set (13) Shim
(4) Cylinder bolt (9) Ring nut
(5) Differential carrier (10) Taper roller bearing
6-027
3-4-3. Hub reduction gear
2 7
3
8
20
28
21
4
21 10
5
2
27 1
12
6
13
11
14
9
29
15 11
17
16
18
23
19
25
24
4
26
21
22
SV400-2-06054
(1) Axle case (11) Bearing (21) Seal washer

(2) Spring washer (12) Circlip (22) Countersunk bolt
(3) Bolt (13) Ring gear (23) Planetary gear carrier
(4) Plug (14) Ring gear support (24) Nut
(5) Plug (15) Lock plate (25) Stud bolt
(6) Seal (16) Circlip (26) Friction washer
(7) Axle shaft (17) Planetary gear (27) Nut
(8) Hub bolt (18) Bearing (28) Stud bolt
(9) Wheel hub (19) Hub nut
(10) O-ring (20) Seal
6-028
3-4-4. Brake
21
20
19
1
18
3 4
5
17
6
16
8 14
9 10 15
12 13
11
SV412-06001
(1) Spring (8) Brake disc (15) O-ring

(2) O-ring (9) Ring (16) Pinion
(3) Piston (10) Lock washer (17) Intermediate brake disc
(4) O-ring (11) Nut (18) Disc
(5) Cover (12) Adjustment bolt (19) Bolt
(6) O-ring (13) Hexagon bolt (20) Seal washer
(7) Cylinder bolt (14) Sheet (21) Bolt
6-029
4. HIGH TORQUE TYPE ONLY (1) Drum

(3) Vibrator bearing
4-1. Vibratory Drum Assembly (4) Eccentric shaft
(5) Shaft
(6) Bolt (M10×40)
8
(7) Sleeve
1 50 51 52 3 4 5 6 7 9 10 11 12 13 14 15
16 (8) Spring pin
44
(9) Bolt (M16×50)
17 (10) Plug
43 (11) Housing
42 (12) Oil seal
18
(13) Roller bearing
19 (14) Disc
(15) Bolt (M12×40)
41 (16) Bolt (M20×50)
20 (17) Bolt (M12×40)
(18) Damper
21
A (19) Holder
22
(20) Bolt (M20×90)
23 (21) Breather
40
46 (22) Cover
(23) Bolt (M14×40)
45 (24) Bolt (M14×40)
24
(25) O-ring
37 A 25
(26) Shim
39 (27) Cover
26
(28) Oil seal
(29) Bolt (M12×40)
49 (30) Holder
27
(31) Shim
38 28 (32) Axle shaft
29 (33) Vibrator bearing
48
30 (34) Bolt (M16×50)
(35) O-ring
(36) Housing
47 36 35 34 33 32 31 (37) Bolt (M16×50)
(38) Disc
(39) Bolt (M20×90)
10-1
(40) Bolt (M16×50)
(Oil filler plug)
(41) Holder
(42) Damper
(43) Bolt (M12×40)
(44) Bolt (M12×40)
Vibrator mode is Low Vibrator mode is High (45) Propulsion motor
with motor rotating with motor rotating 10-3 10-2 (46) Vibrator motor
clockwise counterclockwise (Level plug) (Drain plug)
(47) Ring
SECTION A-A Propulsion motor side Vibrator motor side
(48) Bolt (M16×50)
0404-43802-0-11846-0 (49) Bolt (M22×70)
(50) Gear box
(51) Bolt (M8×16)
(52) Plug
6-030
4-2. Disassembly and Reassembly of Vibratory Drum

• Leader numbers appearing in the vibratory
drum disassembly and reassembly procedure
illustrations shown below correspond to the
numbers indicating the parts of the vibratory
drum assembly (page 6-030).
4-2-1. Disassembly of vibratory drum

1) Remove the plugs (10-1 and 10-2).
• Drain the gear oil from the vibrator case. 10-1
• Gear oil quantity: 21 L (5.5 gal.)
10-2
SV400-2-06012
2) Lift the vibratory drum with a crane. As shown in

the figure on the right, stand it up with the
propulsion motor side facing downward.
After standing up the drum, place wooden

blocks that have sufficient strength underneath.
Stabilize the drum so that it is not unsteady.
Wooden
block
Vibratory drum assembly
SV412D : 2,665 kg (5,875 lbs.)
SV412T : 2,865 kg (6,316 lbs.) Wooden block SV400-2-06013
SV412TF : 4,205 kg (9,270 lbs.)
SV412TB : 2,865 kg (6,316 lbs.)
SV412FB : 4,205 kg (9,270 lbs.)
6-031
3) Remove the two bolts (24). 46

• Remove the vibrator motor (46). 21 24
• Remove the breather (21).
Use aids such as work stepladders when

posture.
SV400-2-06014
4) Remove the sixteen bolts (16). Lift with crane

• Attach the lifting bolts/nuts (M20×2.5) as shown
in the figure on the right. 19 16 30
• Using a crane, lift and remove the holder (19), 18
damper (18) and disc (14) together.
14

: 135 kg (298 lbs.)
SV400-2-06015

• Remove the sleeve (7).
9
SV400-2-00016
6-032
6) Attach the lifting bolts (M16×2.0) as shown in Lift with crane

• Using a crane, slowly lift and remove the axle 32 Wooden block Wooden hammer
shaft (32).
At this time, to ensure that the vibrator
shaft does not follow along with the axle
shaft (32), lift the end of the vibrator shaft
while lightly tapping with a wooden
hammer through a wood block.
When attaching the lifting bolts, screw in the

threads fully before using. SV400-2-06017
7) Attach a lifting bolt (M10×1.5) to the end of the 4 Lift with crane
eccentric shaft (4). Then lift with a crane and
remove.
Eccentric shaft: 135 kg (298 lbs.)
SV400-2-06018
8) In the figure on the right, the vibrator motor side

is up. From the top, the figure shows the
condition with the part removed.
SV400-2-06019
6-033
9) Lift and invert the drum with a crane. Stand it up

with the propulsion motor side upward.

SV412D : 2,225 kg (4,905 lbs.)
SV412T : 2,425 kg (5,346 lbs.)
SV412TF : 3,765 kg (8,300 lbs.)
SV412TB : 2,425 kg (5,346 lbs.)
SV412FB : 3,765 kg (8,300 lbs.)

Therefore, be very careful, confirm that the
SV410-2-06001
unstrained posture.
Lift with crane
40 41
10) Remove the seventeen bolts (40).
• As shown in the figure on the right, attach the 42
lifting bolt/nut (M20×2.5) to the holder (41) and
slowly lift. Remove together with the damper (42) 38
and disc (38).

: 145 kg (320 lbs.)
SV410-2-06002
11) Remove the eighteen bolts (48). Propulsion motor

• Remove the propulsion motor SUBASSY. 48 SUBASSY
Propulsion motor SUBASSY

: 145 kg (320 lbs.)
SV410-2-06003
6-034
12) Remove the sixteen bolts (34). 34 36

• Remove the housing (36).
SV410-2-06004
13) The figure on the right shows the condition in

which all parts have been removed from the
vibratory drum assembly.
SV400-2-06024
14) The figure on the right shows the axle shaft

subassembly removed from the vibratory drum. 22 29
• Remove the six bolts (29).
SV400-2-06025
6-035
15) Remove the eight bolts (23).

23 27
SV400-2-06026
16) Place the plate at the end of the axle shaft. With
the puller against the housing (11), separate the Puller
housing, including the roller bearing, from the
axle shaft.
11 Plate
SV400-2-06027
6-036
4-2-2. Reassembly of vibratory drum

efore reassembling, confirm that each part
B
that was disassembled has been well cleaned
and is free of any abnormality.
of the roller bearing (13) outer race.
13
• Drive the outer race of the roller bearing (13) 11
into the housing (11).
• Attach the oil seal (12).
13
12
SV400-2-06028
2) As shown in the figure on the right, firmly secure

the axle shaft (32) with support stands and/or
wooden blocks. 33 32
of the vibrator bearing (33). Wooden block
• Drive in the vibrator bearing (33).
Wooden block
Support stand
SV400-2-06029
3) Using a crane, lift and invert the axle shaft (32)

subassembly.
Axle shaft subassembly: 90 kg (198 lbs.) 13

32
of the roller bearing.
• Attach the inner race of the roller bearing (13).
Wooden block
SV400-2-06030
6-037
4) Apply an ample amount of lithium-based grease

11
to the rolling surfaces of the roller bearing (13).
• Lightly apply the same grease to the lip surfaces
of the oil seal (12).
• Join the axle shaft (32) subassembly and
housing (11). 12
13
32
Housing: 40 kg (88 lbs.)
SV400-2-06031
5) After applying an ample amount of lithium-based

grease to the inner race of the roller bearing
(13), drive it in until the inner race’s rolling
surface makes contact with the outer race.
13
SV400-2-06032
6) As shown in the figure on the right, insert

shims (31) approximately 1 mm to create a gap
23 27
between the axle shaft end face and cover (27)
interior surface. Then install the cover (27). 31
Gap
• Install washers to the four bolts (23), and tighten 11

to a tightening torque of 108 N·m (80 lbf·ft).
• Rotate the housing (11) two or three times. Then
tighten the same bolts again to a tightening
torque of 108 N·m (80 lbf·ft).
• Repeat this procedure two or three times until
the bolt tightening torque no longer varies.
hen tightening the bolts (23), alternately

W
tighten by using four of the eight bolts
positioned diagonally from each other. SV400-2-06033
6-038
7) Roller bearing preload adjustment 23

➀ Remove the four bolts (23).
• Remove the cover (27) and shim (31).
27
31
SV400-2-06034
➁ Without inserting shims, install the cover (27).

Then install washers to the four bolts (23) and
There must be no gap
tighten.
• Using a thickness gauge, measure the gap at 23 27
dimension A. A
reload adjustment shim thickness =

P
(A+0.1) mm
SV400-2-06035
➂ Remove the bolts (23).

• Insert the shim (31) whose preload 23 27
31
adjustment shim thickness equal to (A+0.1)
mm. Then firmly secure the cover (27) again
by installing washers to the eight bolts (23).
(23) M14×40: 170 N·m (125 lbf·ft)
SV400-2-06036
6-039
8) Install the oil seal (28) to the cover (22).

• Lightly apply grease to the lip surfaces of the oil
seal (28). 22 29
• Using the six bolts (29) and spring washers, 28
firmly secure the cover (22) to the housing.
(29) M12×40: 108 N·m (80 lbf·ft)
SV400-2-06037

of the vibrator bearing (3).
• Drive the vibrator bearing (3) into the axle shaft
(36). 3
36
Axle shaft : 100 kg (220 lbs.)
Vibrator bearing : 10 kg (22 lbs.)
SV410-2-06007
10) Install the O-ring (35) to the housing (36).

34 35 36
of the O-ring (35).
secure the housing (36) to the drum.
(34) M16×50: 270 N·m (199 lbf·ft)
NOTE : W
hen installing, make sure that the
groove.
Use aids such as work stepladders when SV410-2-06005

posture.
6-040
11) Using the eighteen bolts (48) and washers, Propulsion motor
firmly secure the propulsion motor SUBASSY to 48 SUBASSY
the axle shaft.
groove.
Propulsion motor SUBASSY

: 145 kg (320 lbs.)
(48) M16×50: 270 N·m (199 lbf·ft)
SV410-2-06003
12) Using the seventeen bolts (40) and washers, 40 41

firmly secure the subassembly of the holder (41),
42
damper (42) and disc (38) to the propulsion
motor.
38

: 145 kg (320 lbs.)
(40) M16×50: 270 N·m (199 lbf·ft)
SV410-2-06006
13) Lifting with a crane, invert the drum as shown in


SV412D : 2,225 kg (4,905 lbs.)
SV412T : 2,425 kg (5,346 lbs.)
SV412TF : 3,765 kg (8,300 lbs.)
SV412TB : 2,425 kg (5,346 lbs.)
SV412FB : 3,765 kg (8,300 lbs.)

Therefore, be very careful, confirm that the
SV400-2-06019
unstrained posture.
6-041
14) Attach a lifting bolt (M10×1.5) to the end of the Lower with crane
vibrator shaft (4). Then lift with a crane, slowly 4
lower and attach.
When inserting the vibrator shaft into the

vibrator bearing for attachment, be careful
not to allow the inner race of the vibrator
bearing to lean.
Vibrator shaft: 135 kg (298 lbs.)
SV400-2-06042
15) Attach the O-ring (35) to the axle shaft (32) Lower with crane
subassembly.
• Lightly apply grease to the entire circumference 32
• Lift and slowly lower the axle shaft (32)
subassembly with a crane.
hen attaching the axle shaft, move the

W
vibrator shaft until the center of the
vibrator bearing inner race is aligned with
the center of the shaft. Be careful not to
allow the vibrator bearing to lean.
Axle shaft (32) subassembly

SV400-2-06043
: 150 kg (331 lbs.)

secure the axle shaft subassembly to the drum.
groove.
(21) M16×50: 270 N·m (199 lbf·ft)
SV400-2-06044
6-042
17) Attach a lifting bolt (M10×1.5) to the vibrator Lift with crane
shaft end. Then slowly lift with a crane. Confirm Shaft must move 1 to 3 mm
that 1 to 3 mm (0.04 to 0.12 in.) of play exists in
the axial direction.
SV400-2-06045
18) Using a crane, lift and slowly lower the Lower with crane
subassembly of the holder (19 and 30), damper
(18) and disc (14). 19 30
18
14
: 135 kg (298 lbs.)
SV400-2-06046
19) Using the sixteen bolts (16) and washers, firmly 16 7

secure the holder subassembly to the housing.
• Apply a molybdenum-based grease to the spline
surface of the sleeve (7), and attach it to the
spline shaft at the end of the vibrator shaft.
(16) M20×50: 540 N·m (398 lbf·ft)
SV400-2-06047
6-043
20) Attach the breather (21). 46

• Attach the O-ring (25) to the vibrator motor (46). 21 24
Using the two bolts (24) and washers, firmly
secure it to the cover. 25
A
ttach by aligning the top side of the
vibrator motor (46) and breather (21) with
the top side of the propulsion motor.
(24) M14×40: 170 N·m (125 lbf·ft)
SV400-2-06048
21) Lift the vibratory drum assembly with a crane,

and set it sideways at the position of the plug 10-1
shown in the figure on the right. (Oil filler plug)
• Remove the oil filler plug and level plug.
• From the oil filler plug hole, add approximately
21 L (5.5 gal.) of gear oil until gear oil drips from
the level plug hole.
• Attach the oil filler plug and level plug.
10-3
Vibrator motor side
(Level plug)
SV400-2-06049
6-044
BRAKE
BRAKE
1. BRAKE SYSTEM
1-1. Brake Pedal
5 4 3
7 6
SECTION A-A
0404-51802-0-21623-A
(1) Brake pedal (5) Return spring

(2) Foot brake switch (6) Stopper bolt : M10× 40
(3) Stopper bolt : M10× 40 (7) Nut : M10
(4) Nut : M10
7-001
BRAKE
2. BRAKE HYDRAULIC PIPING
Hydraulic oil tank T3 RMP RBR
Brake
Hose
(BPM RMP)
Hose
(RBL RBR)
Hose
(LOB BPF) Axle assembly
Brake
LOB Hose RBL

(BSA RBL)
Parking brake solenoid valve BSA BPF
BST
Hose BPM Propulsion motor (Rear)

(BST T3)
The letters and figures (such as BA and BL) show each port and the arrow ( ; ) symbols
7-002
BRAKE
3. BRAKE SYSTEM
Fuse
15A
Foot brake switch

(Condition in which
brake pedal pressed)
3
1
2 To Parking interlock relay
To combination meter 4
5
Parking brake switch
(Brake OFF condition)
3 5
2 1
Servo bypass relay (R5)
3 5
2 1
Hydraulic pump
neutral holding relay (R6)
Brake
(Brake ON condition)
Parking brake solenoid valve

when brake is ON.
Parking brake solenoid valve (without solenoid excited)
Charge pump
when brake is OFF.
(with solenoid excited)
Rear axle
࡮The arrow ( ) symbol shows the direction of the hydraulic oil flow.
SV412-07001
7-003
BRAKE
4. HYDRAULIC COMPONENT SPECIFICATION

4-1. Brake Solenoid Valve
3 8
6 7
5
7
6 8
(＋)
(−) Connection diagram
J-40146
(1) Solenoid
(2) O-ring (1B P14)
(3) Spool (J)
(4) Body
(5) Spring
(6) Port P [BSP] : 9/16-18UNF-2B
(7) Port A [BSA] : 9/16-18UNF-2B
(8) Port T [BST] : 9/16-18UNF-2B
Specifications
• Rated pressure : 4.9 MPa ( 710 psi ) (6, 7)
: 0.5 MPa ( 72.5 psi ) (8)
• Rated flow : 30 L/min ( 7.9 gal./min )
• Weight : 1.5 kg ( 3.3 lbs. )
7-004
INSPECTION AND
ADJUSTMENT
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.
8-001
2. M
EASUREMENT AND ADJUSTMENT OF PROPULSION
CIRCUIT PRESSURE
2-1. Measurement
W ARNING
Confirm that the parking brake works properly before
measurement.
• Oil temperature during measurement : 50 ± 5°C (122 ± 9°F)

① Remove plugs from couplings (1) and (2) of propulsion
pump. Attach pressure gauge with hose ⓢ and connector
ⓤ.
1
• Coupling : 9/16-18UNF×M16
• Adapter for hose ⓢ : M16 P=2.0
• Pressure gauge connector ⓤ : M16×G3/8
• High pressure gauge port (Forward) : (1)
• High pressure gauge port (Reverse) : (2)
• Pressure gauge : 0 to 50 MPa
(0 to 7,250 psi)
② Set propulsion speed change switch to “ ”. 2

③ Start the engine and set throttle switch to “Full”.
④ Establish a condition in which machine propulsion load
SV412-08001
becomes maximum.
(Pressure does not build up unless propulsion load is
applied.)
s u
⑤ With propulsion load at maximum, slowly move F-R lever
to the side to be measured.
• Then, read pressure indicated by pressure gauge.
⑥ After measuring, promptly return F-R lever to “N”.
★ Maximum circuit pressure

(high pressure relief valve setting)
PG003163
: 41.8 ± 1.0 MPa (6,061 ± 145 psi)
8-002
2-2. Adjustment
• If measurement results indicate the pressure deviating from
maximum circuit pressure range, make an adjustment in
accordance with procedure described below.
① Check nut (2) of multifunction valve (1-1) or (1-4) for

evidence of having loosened.
• Multifunction valve (Forward) : (1-4) 1-1
• Multifunction valve (Reverse) : (1-1)
② If there is evidence of nut having loosened, adjust
multifunction valve so that pressure becomes within
maximum circuit pressure range while watching pressure
gauge.
• To adjust pressure, loosen nut and turn adjustment screw
(3).
Adjustment screw turned clockwise
: Pressure rise
1-4
Adjustment screw turned counterclockwise
: Pressure drop
SV412-08002
Pressure change rate : 9 MPa/turn (1,305 psi/turn)
③ If there is no evidence of nut having loosened, remove
multifunction valve.
④ Check removed multifunction valve for trapped dirt and
scratches on its seat. 1
⑤ If trapped dirt is present, disassemble and clean
multifunction valve.
⑥ If a scratch is found on seat, replace multifunction valve.
⑦ After adjustment, measure pressure again and check that
pressure reaches maximum circuit pressure range.
N•m (1) Nut : 41 N·m (30 lbf·ft) 2 3

(2) Nut : 20 N·m (16 lbf·ft)
Multifunction valve
(1-10)
Multifunction valve : 89 N·m (66 lbf·ft)
(1-11)
SV510-‫ޓ‬-08003
(NOTICE)
• Carefully disassemble and reassemble after taking
steps to prevent foreign material from getting in.
• The numbers “1-1” and “1-4” appearing in above illustrations are consistent with lead line numbers shown in
illustration of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-003
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.
• Propulsion charge circuits and vibration charge circuits
consist of parallel circuits. Thus, in order to measure
whether propulsion charge circuit pressure is within
standard value, use following operation to ensure that oil 2-12
does not escape to the charge relief valve on vibrator pump
side.
① Loosen nut (1) from charge relief valve (2-12) on vibrator

pump side.
② Tighten adjustment screw (2) by 1/2 complete turns.
: Pressure rise
: Pressure drop
SV412-08003
Pressure change rate
: 0.54 MPa/ 1/2 turn (78.3 psi/ 1/2 turn)
SV520-08004
• The number “2-12” appearing in above illustrations is consistent with lead line numbers shown in illustration
of vibrator pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-004
3-1. Measurement
① Remove plug from coupling (1) of hydraulic oil filter 1.
Attach pressure gauge with hose ⓢ and connector ⓤ .
② Apply parking brake by pressing parking brake switch
button.
★ Standard charge relief valve setting

: 2.5 ± 0.2 MPa (363 ± 29 psi)
Hydraulic oil
filter 1 1
SV412-08004
s u
PG003163
8-005
3-2. Adjustment
standard charge relief pressure setting range, make an
adjustment in accordance with procedure described below.
① Check nut (2) of charge relief valve (1-10) for evidence of

having loosened.
② If there is evidence of nut having loosened, adjust charge
1-10
relief valve so that pressure becomes within standard
charge relief valve pressure setting range while watching
pressure gauge.
(3).
: Pressure rise
: Pressure drop
Pressure change rate : 0.39 MPa/turn (57 psi/turn)
SV412-08005
charge relief valve.
④ Check removed charge relief valve for trapped dirt and
scratches on its seat.
2
⑤ If trapped dirt is present, disassemble and clean charge
relief valve.
⑥ If a scratch is found on seat, replace charge relief valve.
pressure reaches standard charge relief valve setting
range.
(2) Nut : 52 N·m (38 lbf·ft)

N•m
(NOTICE)
3
• Carefully disassemble and reassemble after taking Charge relief valve
SV510-‫ޓ‬-08008
of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-006
4. M
EASUREMENT OF PROPULSION SERVO CIRCUIT
PRESSURE
4-1. Measurement
① Disconnect the hoses (1) and (2) from servo bypass
solenoid valve. Attach pressure gauge through adapter ⓦ .
• Adapter ⓦ : 4-4LOHL6G5TP (Parker part number)
• Pressure gauge : 0 to 5 MPa (0 to 725 psi)
1
button.
Servo bypass
③ Start the engine and set throttle switch to “FULL”. solenoid valve
④ Operate F-R lever and then read pressure indicated by
pressure gauge.
• With parking brake “ON”, measured pressures of (1)
and (2) are the same. 2
• With parking brake “OFF”, measured pressures of (1)
and (2) are different.
SV412-08023
★ Standard charge relief pressure setting
: 2.5 ± 0.2 MPa (363 ± 29 psi)
PG002060
8-007
5. M
EASUREMENT OF Machine HIGH/LOW SPEED
CHANGE CIRCUIT PRESSURE
5-1. Measurement
① Remove plugs from rear propulsion motor gauge ports (1)
1
and (2). Attach pressure gauge with the adapter ⓗ .
• Adapter ⓗ : 9/16-18UNF
• Servo pressure gauge port (Low) : (1)
• Servo pressure gauge port (High) : (2)
• Pressure gauge :0 to 5 MPa
(0 to 725 psi)
button.
③ Set propulsion speed change switch to “ ” or “ ”.
④ Start the engine and set throttle switch to “Full”.
2
Propulsion motor (Rear)
★ Standard charge relief valve setting SV505- -08001
: 2.67 ± 0.2 MPa (387 ± 29 psi)
PG001014
8-008
6. M
EASUREMENT OF PARKING BRAKE RELEASE
PRESSURE
measurement.
6-1. Measurement
① Disconnect hose (1) from brake solenoid valve. Attach
pressure gauge through adapter ⓦ . Brake solenoid
valve
• Adapter ⓦ : 4-4LOHL6G5TP (Parker part number)
1
② Confirm that F-R lever is in “N”.
③ Apply parking brake by pressing parking brake switch
button.
⑤ Release parking brake by pressing parking brake switch
button.
• Then, read brake release pressure indicated by pressure
gauge.
SV412-08006
★ Brake release pressure : 1.5 to 3.0 MPa (218 to 435 psi)
PG002060
8-009
7. M
EASUREMENT AND INSPECTION OF VIBRATOR
CIRCUIT PRESSURE
7-1. Measurement
CAUTION
Take care not to operate the vibratory drum for a
longer period of time than necessary with the machine
stationary. Otherwise, the vibrator bearing could be
seized.

① Remove plugs from couplings (1) and (2) of vibrator
pump. Attach pressure gauge with hose ⓢ and connector
ⓤ.
• Adapter for hose ⓢ : M16 P=2.0 1
• High pressure gauge port : (1)
(Low amplitude)
• High pressure gauge port : (2)
(High amplitude) 2
• Pressure gauge : 0 to 50 MPa
(0 to 7,250 psi)
button.
SV412-08007
③ Set vibration mode change switch to “ ”.
⑤ Press F-R lever vibration switch ON. s u
• Then, read pressure gauge for maximum value of vibrator
circuit pressure.
⑥ Turn F-R lever vibration switch OFF as soon as
measurement is finished.
★ Maximum circuit pressure

(high pressure relief valve setting)
PG003163
: 25.0 ± 1.0 MPa (3,625 ± 145 psi)
8-010
7-2. Inspection
maximum circuit pressure range, make an inspection in
accordance with procedure described below.
① Remove plug and valve from high pressure relief valve

port (2-1) or (2-5) of vibrator pump.
• High pressure relief valve port : (2-5) 2-1
(Low amplitude)
• High pressure relief valve port : (2-1)
(High amplitude)
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
2-5
high pressure relief valve.
⑤ After inspection, measure pressure again and check that
pressure reaches maximum circuit pressure range. SV412-08008
Plug : 40 N·m (30 lbf·ft)

N•m
(NOTICE) Plug
High pressure
relief valve
SV412-08024
• The numbers “2-1” and “2-5” appearing in above illustrations are consistent with lead line numbers shown in
illustration of vibrator pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-011
8. M
EASUREMENT AND ADJUSTMENT OF VIBRATOR
CHARGE CIRCUIT PRESSURE
measurement.
1-10
• Propulsion charge circuits and vibration charge circuits
consist of parallel circuits. Thus, in order to measure
whether vibrator charge circuit pressure is within standard
value, use following operation to ensure that oil does not
escape to the charge relief valve on propulsion pump side.
① Loosen nut (2) from charge relief valve (1-10) on

propulsion pump side.
② Tighten adjustment screw (3) by two complete turns.
: Pressure rise
SV412-08005
: Pressure drop
2
: 0.78 MPa/ 2 turns (113 psi/ 2 turns)
3
Charge relief valve
SV510-‫ޓ‬-08008
of vibrator pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-012
8-1. Measurement
① Remove plug from coupling (1) of hydraulic oil filter 1.
Attach pressure gauge with hose ⓢ and connector ⓤ .
② A
pply parking brake by pressing parking brake switch
button.
③ S
tart the engine and set throttle switch to “Full”.
Hydraulic oil
★ Standard charge relief valve setting filter 1 1
: 2.5 ± 0.2 MPa (363 ± 29 psi)
SV412-08004
s u
PG003163
8-013
8-2. Adjustment
standard charge relief pressure setting range, make an
adjustment in accordance with procedure described below.
① Check nut (1) of charge relief valve (2-12) for evidence of

having loosened.
② If there is evidence of nut having loosened, adjust charge
relief valve so that pressure becomes within standard 2-12
charge relief valve pressure setting range while watching
pressure gauge.
(2).
: Pressure rise
: Pressure drop
: 0.27 MPa/ 1/4 turn (39.2 psi/ 1/4 turn)
SV412-08003
charge relief valve.
④ Check removed charge relief valve for trapped dirt and
scratches on its seat.
⑤ If trapped dirt is present, disassemble and clean charge 1
relief valve.
⑥ If a scratch is found on seat, replace charge relief valve.
pressure reaches standard charge relief valve setting
range.
(1) Nut : 40 N·m (30 lbf·ft)

N•m
2
(NOTICE)
steps to prevent foreign material from getting in. SV520-08004
of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-007).
8-014
9. M
EASUREMENT OF VIBRATOR HIGH/LOW CHANGE
CIRCUIT PRESSURE
9-1. Measurement
① Remove plugs from servo pressure gauge ports (2-3) and
(2-10). Attach pressure gauge with the adapter ⓗ .
• Adapter ⓗ : 9/16-18UNF
• Servo pressure gauge port (Low) : (2-10) 2-3 2-10
• Servo pressure gauge port (High) : (2-3)
• Pressure gauge :0 to 5 MPa
(0 to 725 psi)
button.
④ Set vibration select switch and then read pressure
indicated by pressure gauge.
• With vibration select switch is in “ ”, measured
pressures of (2-3) and (2-10) are same.
SV412-08009
• With vibration select switch is in “ ” or “ ”,
measured pressures of (2-3) and (2-10) are different.
h
★ Standard charge relief valve setting
: 2.5 ± 0.2 MPa (363 ± 29 psi)
PG001014
8-015
10. M
EASUREMENT AND INSPECTION OF STEERING
CIRCUIT PRESSURE
10-1. Measurement
W ARNING
Make sure that there is no person around the articulated
portion of the machine before operating the steering
wheel.

① Disconnect the hose (1) or (2) from steering cylinder.
Attach pressure gauge through adapter ⓧ .
• Adapter ⓧ : 6-4LOHL6G5TP (Parker part number)
• Pressure gauge : 0 to 25 MPa (0 to 3,625 psi)
② Confirm that F-R lever is in “N” properly.
1
④ Turn steering wheel to operate relief valve.
2
★ Standard maximum circuit pressure

(orbitroll relief pressure + charge relief pressure)
: 17.5 ± 1.0 MPa (2,538 ± 145 psi)
SV412-08025
PG002090
8-016
10-2. Inspection
• If measurement results indicate the pressure deviating
from standard maximum circuit pressure range, make an
inspection in accordance with procedure described below. 2
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.
pressure reaches standard maximum circuit pressure
range.
SW880-10018
(NOTICE)
8-017
11. M
EASUREMENT AND INSPECTION OF BLADE CIRCUIT
PRESSURE (SV412TB, FB)
11-1. Measurement
W ARNING
Make sure that there is no person around the blade
portion of the machine before operating the blade
control lever.

① Disconnect hose (1) or (2) from blade cylinder. Attach
2
pressure gauge through the adapter ⓧ .
• Adapter ⓧ : 6-4LOHL6G5TP (Parker part number)
• Pressure gauge : 0 to 25 MPa (0 to 3,625 psi)
② Confirm that F-R lever is in “N” properly.
1
③ Set steering wheel to a position where vibratory drum
faces straight forward.
④ Start the engine and set throttle switch to “FULL”.
⑤ Move blade control lever to operate relief valve.
★ Standard maximum circuit pressure

(stack valve relief pressure)
: 13.7 ± 1.0 MPa (1,987 ± 145 psi)
SV412-08014
PG002090
8-018
11-2. Inspection
• If measurement results indicate the pressure deviating
from standard maximum circuit pressure range, make an
inspection in accordance with procedure described below.
① Remove relief valve (3) from stack valve.

② Check removed relief valve for trapped dirt, scratches on 3
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.
pressure reaches standard maximum circuit pressure
range.
(3) Relief valve : 39.2 ± 4 N·m (28.9 ± 3 lbf·ft)

N•m
(NOTICE)
• Carefully disassemble and reassemble after taking SV201-1-08009
8-019
12. M
easurement of HYDRAULIC pump case
pressure
12-1. Measurement
① Disconnect hose (1) from propulsion pump. Attach
pressure gauge through adapter ⓚ .
• Adapter ⓚ : 12-4LOHL6G5TP
(Parker part number)
② Set propulsion speed change switch to “ ”.

③ Start the engine and set throttle switch to “FULL”.
becomes maximum.
applied.)
⑤ With propulsion load at maximum, measure pressure
when speed change switch is in “ ” and “ ” and 1 SV412-08010
F-R lever is in “N”, “F”, and “R”, respectively.
★ Allowable pump case pressure

k
: 0.3 MPa (43.5 psi) or less
PG002190
8-020
13. M
easurement of propulsion motor case
pressure
13-1. Measurement of Front Propulsion Motor
① Remove plug from drain port (1). Attach pressure gauge
and adapter ⓙ .
• Adapter ⓙ : 7/8-14UNF

becomes maximum.
applied.)
1
when speed change switch is in “ ” and “ ” and
F-R lever is in “N”, “F”, and “R”, respectively.
SV412-08012
★ Allowable motor case pressure

j
PG001022
8-021
13-2. Measurement of Rear Propulsion Motor

and adapter ⓩ .
• Adapter ⓩ : 1 1/16-12UN

becomes maximum.
applied.)
⑤ With propulsion load at maximum, measure pressure 1
when speed change switch is in “ ” and “ ” and
Propulsion motor (rear)
F-R lever is in “N”, “F”, and “R”, respectively. SV505-‫ޓ‬-08005

: 0.3 MPa (43.5 psi) or less z
PG001027
8-022
14. M
easurement of VIBRATOR motor case
pressure
14-1. 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.

with adapter ⓙ .
• Adapter ⓙ : 7/8-14UNF

button.
③ Set vibration mode change switch to “ ”.
⑤ Press F-R lever vibration switch ON.
⑥ Measure pressure when vibration select switch is in
“ ” and “ ”, respectively.
⑦ Turn F-R lever vibration switch OFF as soon as 1
measurement is finished.
SV412-08013

j
PG001022
8-023
15. ADJUSTMENT OF F-R LEVER LINKAGE

15-1. Adjustment
• In cases such as propulsion hydraulic 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”. 1

N R
② Attach both ends of control cable (2).
F
★ Specified dimension a : 239 mm (9.41 in.)
SV412-08015
③ Confirm the strokes of propulsion pump control lever (3).

2
★ Specified dimension b : 211 mm ( 8.31 in.)
c : 26 mm ( 1.0 in.)
c
b
c
3
SV412-08016
8-024
16. BRAKE ADJUSTMENT

16-1. Manually Releasing the Brake
1) L
oosen nut (24) of bolt (25).
• Loosen nut on the opposite side.
24 25
SV510-‫ޓ‬-08027
2) Tighten bolt (25), and press it into disc (16).

• Do the same with bolt on the opposite side.
16
26 24 25
SV510-‫ޓ‬-08028
3) Alternately tighten bolts (25) 1/4 turn each, and release

brake disc.
★ After bolt end makes contact with disc (16), strictly

25
observe not tightening bolt (25) more than one
complete turn.
SV510-‫ޓ‬-08029
8-025
16-2. Adjustment after Manual Release of Brake

① Remove bolt (25), nut (24), and seal washer (26).
② Replace seal washer (26) with a new one.
③ Apply grease to bolt (25) threads.
④ As shown on the right, install bolt (25), nut (24), and seal
washer (26). 26
24
25
SV510-‫ޓ‬-08030
⑤ Adjust bolt (25) to the dimensions as shown on the right.

• Similarly, adjust the bolt on the opposite side.
★ Specified dimension a : 30 + 0.5 mm (1.34 + 0.02 in.)

0 0
SV510-‫ޓ‬-08031
⑥ Tighten nut (24), and firmly secure bolt (25).
★ When tightening nut (24), make sure that bolt (25)

does not move. After securing bolt, check the
dimensions of bolt again. 24
SV510-‫ޓ‬-08032
8-026
16-3. Brake Clearance Adjustment

• Remove bolt (2) and lock plate (3).
• Rotate adjustment pinion (4) counterclockwise to eliminate
all existing clearance between braking discs. 4
Rotate up to a torque of 8 to 10 N·m (5.9 to 7.4 lbf·ft)

N•m
SV510-‫ޓ‬-08026
• Rotate pinion (4) clockwise to determine the required

clearance of 1 mm (0.04 in.).
• Clearance change rate : 0.25 mm/turn (0.010 in./turn)
3 2
• Install lock plate (3) and lock with bolt (2).
(2) Bolt : 10 to 11 N·m (7.4 to 8.1 lbf·ft)

N•m
SV510-‫ޓ‬-08025
8-027

17-1. Measurement of Propulsion Motor Case Pressure
17-1-1. Measurement of front propulsion motor
and adapter ⓩ .
• Adapter ⓩ : 1 1/16-12UN

becomes maximum.
applied.)
when speed change switch is in “ ”, “ ” and 1
“ ” and F-R lever is in “N”, “F”, and “R”, respectively. SV410-2-08001

z
PG001027
8-028
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.
9-001
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.
1-4. Wire Number and Color Code

Refer to “1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring
Harness Layout and Wiring Harnesses” of ELECTRICAL SYSTEM.
9-002
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.
9-003
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 2 3
1 5 2 3 4
Main power source Ground of Signal from Power to

of equipment B equipment A equipment A equipment A
Battery
Equipment B
GW750-2-10003
1) Measuring resistance using tester

1-1) Measuring resistance of equipment A (measuring resistance between terminals 1 and 3)
Equipment A
Connector Harness
1 2 3
Equipment A
Ohmmeter
(tester)
1 2 3 1 2 3
1 5 2 3 4

Equipment B
GW750-2-10004
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.
9-004
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 Ohmmeter 1 2 3

(tester)
1 2 3
3 2 1 5 4 3 2 1
1 5 2 3 4

Equipment B
GW750-2-10005
① Disconnect the connectors of equipment A and equipment B.
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 5 Ohmmeter
(tester)
Main power source

of equipment B
Battery
Equipment B
GW750-2-10006
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.
9-005
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 3
Voltmeter
(tester)
1 2 3
1 5 2 3 4

Equipment B
GW750-2-10007
① Connect the connectors of equipment A and that of equipment B.
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.
9-006
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
Wire
Connector
Needle
Lead cable
GW750-2-10002
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.
9-007
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 2 3
Ammeter Harness
(tester) (connecting
1 2 3
terminals)
1 2 3 3 2 1
1 5 2 3 4

The test harness connects the of equipment B equipment A equipment A equipment A
corresponding terminals other
than those to be measured. Equipment B
GW750-2-10008
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.
9-008
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 T urn 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 T urn 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.
9-009
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.
9-010
TROUBLESHOOTING
2-2. Fault Codes

2-2-1. Fault detection
• Faults are detected while the starter switch is on, during the operation of the machine itself. If a fault becomes
active (currently detected) at this time, a fault is logged in memory and a snapshot of engine parameters is
logged. In addition, certain faults may illuminate the warning lamp (orange) or the stop lamp (red).
2-2-2. Fault lamps

• The CM2250 controller systems use 3 indicator lamps: the “ENGINE STOP”, “WARNING” and “WAIT TO
START”. If the starter switch is turned on but the diagnostic switch remains off, the indicator lamps will illuminate
for approximately two seconds and then go off, one after the other, to verify they are working and wired correctly.
They all go on and then go off one at a time, at an interval of approximately 0.5 seconds each.
• “ENGINE STOP” Lamp - The “ENGINE STOP” lamp provides critical operator messages. These messages
require immediate and decisive operator response. The “ENGINE STOP” lamp is also used to flash out
diagnostic fault codes.
• “WARNING” Lamp - The “WARNING” lamp provides important operator messages. These messages require
timely operator attention. The “WARNING” lamp is also used to delineate diagnostics fault codes.
• “WAIT TO START” Lamp - The “WAIT TO START” lamp indicates that the pre-start intake manifold heater
warm-up sequence is active. A Cummins supplied grid heater will automatically heat the intake manifold based
on the Intake Manifold Temperature when needed prior to engine starting. Intake manifold heating improves
engine starting in cold temperatures and reduces white smoke.
MID
ENGINE STOP
IDLE FULL
WARNING
n/min
CONT.
WAIT TO START
ENGINE CHECK
SV412-09010
9-011
TROUBLESHOOTING
2-2-3. Flash out of fault codes

• Fault codes can be accessed in at least two different ways; using the electronic service tool or fault code flash out.
• Fault flash out mode can be entered through the use of a diagnostic switch. The diagnostic switch may also be
multiplexed on the J1939 datalink.
Entering diagnostic mode:

1) To enter the fault flash out, the starter switch must be ON with the engine not running.
2) When a diagnostic switch is used to enter the mode, the ECM will automatically flash the first fault code
after the switch is turned on. Each active fault shall flash out twice, wrapping around to the first fault
code at the end.
Flashing of fault codes:
• The diagram below depicts the pattern of the fault code flash out scheme as indicated by the “ENGINE
STOP” lamp. A blink is equivalent to the “ENGINE STOP” lamp being on for 0.5 seconds, and off for 0.5
seconds. A pause between fault code digits has duration of 2 seconds.
ON
OFF
Diagnostic switch
VIEW A
A
SV412-09011
Example Fault Code Sequence

Fault Code 214 :
Each block represents 0.5 seconds

= “WARNING” lamp ON
= “ENGINE STOP” lamp ON
Turn ON diagnostic switch Next fault code
2 1 4 Pause Pause Pause
Fault code 214 flash out Fault code 214 repeated
SV412-09012
9-012
TROUBLESHOOTING
2-2-4. Fault code list

Fault code
Reason Effect
(Lamp)
111 Engine control module critical internal failure Engine may not start.
(Red) • Bad intelligent device or component.
115 Engine magnetic crankshaft speed/position lost Fueling to the injectors is disabled and the
(Red) both of two signals engine cannot be started.
• Data erratic, intermittent, or incorrect.
122 Intake manifold 1 pressure sensor circuit Derate in power output of the engine.
(Orange) • Voltage above normal or shorted to high
source.
123 Intake manifold 1 pressure sensor circuit Derate in power output of the engine.
(Orange) • Voltage below normal or shorted to low
source.
131 Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
(Red) circuit Limp home power only.
• Voltage above normal or shorted to high
source.
(Red) circuit Limp home power only.
• Voltage below normal or shorted to low
source.
133 Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
(Red) sensor circuit accelerator position will be set to zero percent.
source.
134 Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
(Red) sensor circuit accelerator position will be set to zero percent.
source.
135 Engine oil rifle pressure 1 sensor circuit None on performance.
(Orange) • Voltage above normal or shorted to high No engine protection for oil pressure.
source.
141 Engine oil rifle pressure 1 sensor circuit None on performance.
(Orange) • Voltage below normal or shorted to low No engine protection for oil pressure.
source.
143 Engine oil rifle pressure None on performance.
(Orange) • Data valid but below normal operation range.
• Moderately severe level.
144 Engine coolant temperature 1 sensor circuit Possible white smoke. Fan will stay ON if
(Orange) • Voltage above normal or shorted to high controlled by ECM. No engine protection for
source. engine coolant temperature.
145 Engine coolant temperature 1 sensor circuit Possible white smoke. Fan will stay ON if
(Orange) • Voltage below normal or shorted to low controlled by ECM. No engine protection for
source. engine coolant temperature.
146 Engine coolant temperature Progressive power derate increasing in severity
(Orange) • Data valid but above normal operation range. from time of alert.
147 Accelerator pedal or lever position 1 sensor Severe derate in power output of the engine.
(Red) circuit frequency Limp home power only.
• Data valid but below normal operational range.
• Most severe level.
9-013
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
(Red) • Data valid but above normal operational Limp home power only.
range.
151 Engine coolant temperature Progressive power derate increasing in severity
(Red) • Data valid but above normal operation range. from time of alert. If engine protection shutdown
• Most severe level. feature is enabled, engine will shut down 30
seconds after red stop lamp starts flashing.
153 Intake manifold 1 temperature sensor circuit Possible white smoke. Fan will stay ON if
(Orange) • Voltage above normal or shorted to high controlled by ECM. No engine protection for
source. intake manifold air temperature.
154 Intake manifold 1 temperature sensor circuit Possible white smoke. Fan will stay ON if
(Orange) • Voltage below normal or shorted to low controlled by ECM. No engine protection for
source. intake manifold air temperature.
155 Intake manifold 1 temperature Progressive power derate increasing in severity
(Red) • Data valid but above normal operation range. from time of alert. If engine protection shutdown
187 Sensor supply 2 circuit Engine power derate.
source.
195 Coolant level sensor 1 circuit None on performance.
source.
196 Coolant level sensor 1 circuit None on performance.
source.
197 Coolant level None on performance.
221 Barometric pressure sensor circuit Engine power derate.
source.
222 Barometric pressure sensor circuit Engine power derate.
source.
source.
234 Engine Crankshaft speed/position Fuel injection disabled until engine speed falls
(Red) • Data valid but above normal operation range. below the overspeed limit.
235 Coolant level Progressive power derate increasing in severity
(Red) • Data valid but below normal operation range. from time of alert. If engine protection shutdown
237 External speed input (Multiple unit Primary or secondary engine may stop running.
(Orange) synchronization)
• Data erratic, intermittent or incorrect.
238 Sensor supply 3 circuit Possible hard starting and rough running.
source.
9-014
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
239 Sensor supply 3 circuit Possible hard starting and rough running.
source.
241 Wheel based machine speed Engine speed limited to maximum engine
(Orange) • Data erratic, intermittent or incorrect. speed without VSS parameter value. Cruise
control, gear down protection and road speed
governor will not work.
245 Fan control circuit The fan can possibly stay on continuously or
(Orange) • Voltage below normal or shorted to low not run at all.
source.
271 Fuel pump pressurizing assembly 1 circuit Engine will run poorly at idle. Engine will have
(Orange) • Voltage below normal or shorted to low low power. Fuel pressure will be higher than
source. commanded.
272 Fuel pump pressurizing assembly 1 circuit Engine will not run or engine will run poorly.
source.
285 SAE J1939 multiplexing PGN timeout error One or more multiplexed devices will not
(Orange) • Abnormal update rate. operate properly. One or more symptoms will
occur.
286 SAE J1939 multiplexing configuration error At least one multiplexed device will not operate
(Orange) • Out of calibration. properly.
288 SAE J1939 multiplexing remote accelerator The engine will not respond to the remote
(Red) pedal or lever position sensor circuit throttle. Engine may only idle. The primary or
• Received network data in error. cab accelerator may be able to be used.
292 Auxiliary temperature sensor input 1 Possible engine derate.
(Red) • Special instructions.
293 Auxiliary temperature sensor input #1 circuit None on performance.
source.
294 Auxiliary temperature sensor input #1 circuit None on performance.
source.
295 Barometric pressure Engine power derate.
(Orange) • Data erratic, intermittent or incorrect.
296 Auxiliary pressure sensor input 1 Possible engine power derate.
(Red) • Special instructions
297 Auxiliary pressure sensor input #2 circuit None on performance.
source.
298 Auxiliary pressure sensor input #2 circuit None on performance.
source.
322 Injector solenoid driver cylinder 1 circuit Engine can misfire or possibly run rough.
(Orange) • Current below normal or open circuit.
9-015
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
343 Electronic control module warning internal Possible no noticeable performance effects,
(Orange) hardware failure engine dying or hard starting. Fault information,
• Bad intelligent device or component. trip information and maintenance monitor data
can be inaccurate.
349 Transmission output shaft speed Engine will run off of a default auxiliary speed.
(Orange) • Data valid but above normal operational
range.
351 Injector power supply Possible low power, engine misfire and/or
(Orange) • Bad intelligent device or component. engine will not start.
source.
source.
415 Engine oil rifle pressure Progressive power derate increasing in severity
(Red) • Data valid but below normal operation range. from time if alert. If engine protection shutdown
seconds after red engine stop lamp starts
flashing.
418 Water in fuel indicator Possible white smoke, loss of power, or hard
(Orange/ • Data valid but above normal operation range. starting.
Blinking) • Least severe level.
428 Water in fuel indicator sensor circuit None on performance.
(Orange) • Voltage above normal or shorted to high No water in fuel warning available.
source.
429 Water in fuel indicator sensor circuit None on performance.
(Orange) • Voltage below normal or shorted to low No water in fuel warning available.
source.
431 Accelerator pedal or lever idle validation switch Engine will only idle.
(Red) circuit
• Out of calibration.
435 Engine oil rifle pressure None on performance.
(Orange) • Data erratic, intermittent or incorrect. No engine protection for oil pressure.
441 Battery 1 voltage Engine may stop running or be difficult to start.
442 Battery 1 voltage Possible electrical damage to all electrical
(Orange) • Data valid but above normal operation range. components.
449 Injector metering rail 1 pressure None or possible engine noise associated with
(Red) • Data valid but above normal operation range. higher injection pressures (especially at idle or
• Most severe level. light load). Engine power is reduced.
451 Injector metering rail 1 pressure sensor circuit Power and/or speed derate.
source.
452 Injector metering rail 1 pressure sensor circuit Power and/or speed derate.
source.
9-016
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
488 Intake manifold 1 temperature Progressive power derate increasing in severity
(Orange) • Data valid but above normal operation range. from time of alert.
489 Transmission output shaft speed ECM changes engine speed to a calibration
(Orange) • Data valid but below normal operational range. dependent set point.
497 Multiple unit synchronization switch circuit Synchronization function of multiple unit is
(Orange) • Data erratic, intermittent or incorrect. disabled.
515 Sensor supply 6 circuit Possible reduced performance.
source.
516 Sensor supply 6 circuit Possible reduced performance.
source.
523 Intermediate (P.T.O) speed switch validation Intermediate speed control switch may not
(Orange) • Data erratic, intermittent or incorrect. operate correctly.
527 Auxiliary input/output 2 circuit None on performance.
source.
528 Auxiliary alternate torque validation switch Torque curve setting defaults to default curve.
529 Auxiliary input/output 3 circuit None on performance.
source.
(Orange) • Data valid but above normal operation range. higher injection pressures (especially at idle or
• Moderately severe level. light load). Engine power is reduced.
555 Crankcase pressure None on performance.
(Orange) • Data valid but above normal operating range.
556 Crankcase pressure Engine power derate.
(Red) • Data valid but above normal operational
range.
559 Injector metering rail 1 pressure Possibly hard to start, low power or engine
(Orange) • Data valid but below normal operation range. smoke. Engine could possibly not start.
584 Starter relay driver circuit Either the engine will not start or the engine will
(Orange) • Voltage above normal or shorted to high not have starter lockout protection.
source.
585 Starter relay driver circuit The engine will not have starter lockout
(Orange) • Voltage below normal or shorted to low protection.
source.
595 Turbocharger 1 speed No effect on engine performance.
599 Auxiliary commanded dual output shutdown Engine will shutdown.
(Red) • Special instructions.
649 Change lubricating oil and filter Maintenance reminder only.
(Orange/ • Condition exists.
Blinking)
9-017
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
687 Turbocharger 1 speed Engine power derate. The ECM uses an
(Orange) • Data valid but below normal operating range. estimated turbocharger speed.
689 Engine crankshaft speed/position Engine power derate.
691 Turbocharger 1 compression intake temperature Engine power derate.
(Orange) circuit
source.
692 Turbocharger 1 compression intake temperature Engine power derate.
(Orange) circuit
source.
731 Engine speed/position camshaft and crankshaft Engine will run derated.
(Orange) misalignment Hard start and rough idle possible.
• Mechanical system not responding or out of
adjustment.
778 Engine camshaft speed/position sensor Engine can run rough. Possibly poor starting
(Orange) • Data erratic, intermittent or incorrect. capability. Engine runs using primary engine
position sensor.
1117 Power supply lost with starter switch ON Possible no noticeable performance effects,
(None) • Data erratic, intermittent or incorrect. engine dying or hard starting. Fault information,
trip information and maintenance monitor data
can be inaccurate.
(Orange) circuit Limp home power only.
source.
(Orange) circuit Limp home power only.
source.
1242 Accelerator pedal or lever position sensor 1 The engine will only idle.
(Red) • Data erratic, intermittent or incorrect.
1515 SAE J1939 multiplexed accelerator pedal or The engine will only idle.
(Red) lever sensor system
• Received network data in error.
1539 Auxiliary pressure sensor input 1 circuit None on performance.
source.
1621 Auxiliary pressure sensor input 1 circuit None on performance.
source.
1695 Sensor supply 5 Severe derate in power output of the engine.
(Orange) • Voltage above normal or shorted to high Limp home power only.
source.
1696 Sensor supply 5 Severe derate in power output of the engine.
(Orange) • Voltage below normal or shorted to low Limp home power only.
source.
1843 Crankcase pressure circuit No engine protection for high crankcase
(Orange) • Voltage above normal or shorted to high pressure.
source.
9-018
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
1844 Crankcase pressure circuit No engine protection for high crankcase
(Orange) • Voltage below normal or shorted to low pressure.
source.
1896 EGR valve controller EGR valve actuation will be disabled.
(Orange) • Out of calibration
1898 VGT actuator controller Low intake manifold pressure. The VGT will be
(Orange) • Out of calibration in the open position.
(Orange) • Data valid but above normal operation range higher injection pressure (especially at idle
• Most severe level. or light load) or possible power interruption
associated with dump valve reset.
1938 ECU power output supply voltage 1 None on performance.
(Orange) • Data valid but below normal operating range.
1961 EGR valve control circuit over temperature EGR valve operation will be disabled.
• Least severe level.
(Orange/ • Data valid but above normal operating range.
2182 Engine brake actuator driver 1 circuit Engine brake on cylinders 1, 2 and 3 can not be
(Orange) • Voltage above normal or shorted to high activated.
source.
2183 Engine brake actuator driver 1 circuit Engine brake on cylinders 1, 2 and 3 can not be
(Orange) • Voltage below normal or shorted to low activated.
source.
2185 Sensor supply 4 circuit Engine will only idle.
source.
2186 Sensor supply 4 circuit Engine will only idle.
source.
2195 Auxiliary equipment sensor input 3 engine Engine may shutdown.
(Red) protection critical
• Special instructions.
2272 EGR valve position circuit EGR valve actuation will be disabled.
source.
2288 Turbocharger 1 speed Engine power derate to lower the turbocharger
(None) • Data valid but above normal operating range. speed.
2311 Electronic fuel injection control valve circuit Possible low power.
(Orange) • Condition exists.
2321 Engine crankshaft speed/position Engine may exhibit misfire as control switches
(None) • Data erratic, intermittent or incorrect. from the primary to the backup speed sensor.
Engine power is reduced while the engine
operates on the backup speed sensor.
2322 Engine camshaft speed/position sensor None on performance.
(None) • Data erratic, intermittent or incorrect.
9-019
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
2349 EGR valve control circuit EGR valve actuation will be disabled.
(Orange) • Current above normal or grounded circuit.
(Orange) • Mechanical system not responding or out of
adjustment.
2363 Engine brake actuator driver output 2 circuit Engine brake on cylinders 4, 5 and 6 can not be
(Orange) • Voltage below normal or shorted to low activated.
source.
2367 Engine brake actuator driver output 2 circuit Engine brake on cylinders 4, 5 and 6 can not be
(Orange) • Voltage above normal or shorted to high activated.
source.
2372 Fuel filter differential pressure Engine can possibly have low power.
2373 Exhaust gas pressure sensor circuit None on performance.
source.
2374 Exhaust gas pressure sensor circuit None on performance.
source.
2375 Exhaust gas recirculation temperature sensor EGR valve actuation will be disabled.
(Orange) circuit
source.
2376 Exhaust gas recirculation temperature sensor EGR valve actuation will be disabled.
(Orange) circuit
source.
2377 Fan control circuit The fan may stay on continuously or not run at
(Orange) • Voltage above normal or shorted to high all.
source.
2448 Coolant level None on performance.
(Orange/ • Data valid but below normal operating range.
2554 Exhaust gas pressure The ECM will estimate the exhaust gas
(Orange) • Data erratic, intermittent or incorrect. pressure.
2555 Engine intake air heater 1 circuit The intake air heats may be ON or OFF at all
(Orange) • Voltage above normal or shorted to high the time.
source.
2556 Engine intake air heater 1 circuit The intake air heats may be ON or OFF at all
(Orange) • Voltage below normal or shorted to low the time.
source.
2557 Auxiliary PWM driver #1 Can not control transmission.
source.
2558 Auxiliary PWM driver #1 Can not control transmission.
source.
9-020
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
2646 Engine coolant temperature EGR valve actuation will be disabled.
(Orange) • Condition exists.
2765 Engine injector bank 1 barcodes None on performance.
(None) • Out of calibration.
2961 Exhaust gas recirculation temperature Slight fueling derate to bring EGR temperature
(None) • Data valid but above normal operating range. under the maximum limit.
2973 Intake manifold 1 pressure Engine power derate.
3186 Tachograph output shaft speed None on performance.
(Orange) • Abnormal update rate.
3213 Tachograph output shaft speed None on performance.
(Orange) • Received network data in error.
3326 SAE J1939 multiplexed accelerator pedal or Engine will only idle.
(Red) lever sensor system
• Abnormal update rate.
3328 Transmission output shaft speed None on performance.
3418 Transmission output shaft speed None on performance.
3525 Wheel-based vehicle speed None on performance.
3526 Wheel-based vehicle speed None on performance.
(Red) • Received network data in error.
(Red) • Abnormal update rate.
3616 Engine VGT nozzle position Engine power may be derated.
(None) • Mechanical system not responding or out of
adjustment.
3697 Engine control module calibration memory Engine may not start.
(Red) • Bad intelligent device or component.
3724 Battery 1 voltage EGR valve actuation will be disabled.
(Orange) • Data valid but below normal operating range.
3727 High pressure common rail fuel pressure relief Possible low power or power interruption
(None) valve associated with relief valve reset.
• Mechanical system not responding or out of
adjustment.
3737 Engine starter mode overcrank protection Starter operation is prohibited until the starter
(None) • Condition exists. motor has adequately cooled.
3741 High pressure common rail fuel pressure relief Engine may run rough, may stop running, may
(Orange) valve not start or may be difficult to start.
• Data valid but above normal operational
range.
3765 Auxiliary temperature sensor input 2 circuit None on performance.
source.
9-021
TROUBLESHOOTING
Fault code
Reason Effect
(Lamp)
3766 Auxiliary temperature sensor input 2 circuit None on performance.
source.
(NOTICE)
• For details, refer to “Service information” of engine manufacturer.
9-022
TROUBLESHOOTING
Fig.: 2-3-1
REVERSE FORWARD
THROTTLE SWITCH
CENTER MIDDLE 1-3,4-6
RIGHT HAND FULL 1-3,4-5
6
30 RY 4
5 97 RW
30 1.25RY
F-R LEVER
25 2BW
SWITCH 3 93 WG
94 BW 1
12 R
NC NO COM
2
R B
THROTTLE
13 W
12 R
SWITCH
10
2
7
9
5
6
1
36 LgR NO COM 12 R
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FOOT BRAKE SWITCH
(WHEN NOT DEPRESS)
TO SEVRO
BYPASS RELAY (R5) FUSE BOX
23 3RG
16 2W
3 5R
36 LgR 1 3 37 BrW
2 67 BrY
TO 38 GR 92 WL 㨒
4 X B 93 WG
COMBINATION 5
㨏
METER 㨑
91 LW
PARKING BRAKE 97 RW
X B
SWITCH
㨍㨎
THROTTLE
13 W
RELAY (R9)
26 2Lg 20 2LgR 25 2BW F.L. 45A

23 3RG 75 3G
3 5 3 5
13 W X B X B 67 BrY 3 5R F.L. 65A 76 5WR
1 2 2 1
INTERLOCK PARKING INTERLOCK 61 8W F.L. 45A 74 8WY
RELAY (R1) RELAY (R2)
61 8W F.L. 45A 74 8WY
C 4 5BY 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
B R 1 R 2 A CC B R C
STARTER
SWITCH HEAT 18 2RW
28 1.25LgW
16 2W
3 5
OFF 107 LgY 108 GB
ON 1 2
STARTER LOCKOUT
ST RELAY (R8)
STARTER SWITCH
28 1.25LgW 62 1.25WB
3 5
36 LgR X B
14 5R 15 5RB
1 2
3 5
ENGINE STOP 18 2RW X 2B
RELAY (R7)
1 2
STARTER
RELAY
AV30
78 3WB 86 3WL 86 3WL
30A
FUSE
ENGINE ECM.(CM2250) NO COM

J3(60PIN)
78 WB 79 B
1 (+) BATTERY BATTERY (-) 21
24 BR
AV60
78 WB 79 B
2 (+) BATTERY BATTERY (-) 22 14 5R
79 B BR
78 WB
78 WB 79 B 50 15 5RB BATTERY
12 (+) BATTERY BATTERY (-) 32 30 RELAY
28 LgW 88 GY
8 STOP LAMP E
X 2B
89 Y G
16 WARNING LAMP
90 YG STARTER MOTOR
FUSE
62 1.25WB 98 BL 79 3B AV60
5A 3 KEY SW. SIGNAL
AV20
92 WL
ISC 2 SW (MID) 38
91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE 94 BW 61 8W
SW AND TEMP SENSOR RETURN 19 +
HARNESS 62 WB CYLINDER
133 GL DIAGNOSTIC 59 BLOCK
107 LgY
134 BrR STARTER LOCKOUT 15 AV20 95D31R
108 GB
FUEL OUTPUT RETURN 1 (-) 13
7 WG -
LAMP
BATTERY
IGNITION
PHASE
GROUND
SENSOR INTAKE AIR HEATER (+) 4

AV60
14 DUAL OUTPUT A (+)
FOR OIL PRESS.
130 BR B
C 43 OEM SENSOR (SIGNAL RETURN) BATTERY
B 131 LgR
SENSOR 44 COOLANT LEVEL (SIGNAL) ALTERNATOR
132 RW
A 52 SENSOR SUPPLY (POWER) FUSE
AV30 AV30
17 CAN A (+) 250A
B 5 3
GRID HEATER 7 WG 108 GB
18 CAN A (-) 1 2
GRID HEATER
RELAY
SV412-09001
9-023
TROUBLESHOOTING
2-3. Engine
Check following items before troubleshooting.
• No blown fuses and power is applied up to fuses.
• Check any ground circuit which belongs to components to be checked.
• Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine
manufacturer.
2-3-1. Engine will not start (Starter motor does not run) 1/3
• F-R lever must be in “N”.
• Parking brake switch must be applied.
• Foot brake switch must be ON (Brake pedal is not depressed).
Reference Fig.: 2-3-1
Check point Check/Cause Action
1. Battery • Measure battery voltage or specific gravity. Charge or replace
Standard voltage : 12 V or more battery.
Standard gravity : 1.26 or more
• If value is below standard, battery capacity is insufficient.
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) When starter switch is ON, measure voltage between Replace starter motor.
starter motor terminal 30 and chassis ground.
Standard voltage : 12 V or more
(2) When starter switch is START, measure voltage
between starter motor terminal 50 and chassis ground.
• If starter motor does not run even though above items (1)
and (2) are OK, starter motor is faulty.
4. Battery Relay (1) When starter switch is OFF, measure voltage between Replace battery relay.
battery relay primary terminal COM and chassis ground.
(2) When starter switch is ON, measure voltage between
battery relay coil terminal BR inlet wire BR and coil
ground terminal E.
battery relay secondary terminal NO and chassis ground.
• If above items (1) and (2) are OK and item (3) is NG,
battery relay is faulty.
5. Starter Lockout Relay (1) When starter switch is ON, measure voltage between starter Replace starter lockout
(R8) lockout relay terminal 1 inlet wire LgY and chassis ground. relay (R8).
between starter lockout relay terminal 3 inlet wire W
and chassis ground.
between starter lockout relay terminal 5 outlet wire RW
and chassis ground.
starter lockout relay is faulty.
9-024
TROUBLESHOOTING
Fig.: 2-3-1
REVERSE FORWARD
THROTTLE SWITCH
6
30 RY 4
5 97 RW
30 1.25RY
F-R LEVER
25 2BW
SWITCH 3 93 WG
94 BW 1
12 R
NC NO COM
2
R B
THROTTLE
13 W
12 R
SWITCH
10
2
7
9
5
6
1
36 LgR NO COM 12 R
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FOOT BRAKE SWITCH
(WHEN NOT DEPRESS)
TO SEVRO
23 3RG
16 2W
3 5R
36 LgR 1 3 37 BrW
2 67 BrY
TO 38 GR 92 WL 㨒
4 X B 93 WG
COMBINATION 5
㨏
METER 㨑
91 LW
PARKING BRAKE 97 RW
X B
SWITCH
㨍㨎
THROTTLE
13 W
RELAY (R9)
26 2Lg 20 2LgR 25 2BW F.L. 45A

23 3RG 75 3G
3 5 3 5
13 W X B X B 67 BrY 3 5R F.L. 65A 76 5WR
1 2 2 1
61 8W F.L. 45A 74 8WY
C 4 5BY 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH HEAT 18 2RW
28 1.25LgW
16 2W
3 5
OFF 107 LgY 108 GB
ON 1 2
STARTER LOCKOUT
ST RELAY (R8)
STARTER SWITCH
28 1.25LgW 62 1.25WB
3 5
36 LgR X B
14 5R 15 5RB
1 2
3 5
RELAY (R7)
1 2
STARTER
RELAY
AV30
78 3WB 86 3WL 86 3WL
30A
FUSE

J3(60PIN)
78 WB 79 B
24 BR
AV60
78 WB 79 B
79 B BR
78 WB
28 LgW 88 GY
8 STOP LAMP E
X 2B
89 Y G
16 WARNING LAMP
90 YG STARTER MOTOR
FUSE
62 1.25WB 98 BL 79 3B AV60
5A 3 KEY SW. SIGNAL
AV20
92 WL
ISC 2 SW (MID) 38
91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE 94 BW 61 8W
107 LgY
108 GB
7 WG -
LAMP
BATTERY
IGNITION
PHASE
GROUND

AV60
FOR OIL PRESS.
130 BR B
B 131 LgR
132 RW
AV30 AV30
17 CAN A (+) 250A
B 5 3
18 CAN A (-) 1 2
GRID HEATER
RELAY
SV412-09001
9-025
TROUBLESHOOTING
6. Starter Relay (1) When starter switch is START, measure voltage Replace starter relay.
between starter relay terminal 1 inlet wire RW and
chassis ground.
starter relay terminal 5 inlet wire RB and chassis
ground.
between starter relay terminal 3 outlet wire R and
chassis ground.
starter relay is faulty.
7. F-R Lever Switch (1) When starter switch is ON, measure voltage between Replace F-R lever
F-R lever switch terminal COM inlet wire R and chassis switch.
ground.
F-R lever switch terminal NC outlet wire W and chassis
ground.
• If above item (1) is OK and item (2) is NG, F-R lever
switch is faulty.
8. Foot Brake Switch (1) When starter switch is ON, measure voltage between Replace foot brake
foot brake switch terminal COM inlet wire R and chassis switch.
ground.
foot brake switch terminal NO outlet wire LgR and
chassis ground.
• If above item (1) is OK and item (2) is NG, foot brake
switch is faulty
9. Parking Brake Switch (1) When starter switch is ON, measure voltage between Replace parking brake
parking brake switch terminal 1 inlet wire LgR and switch.
chassis ground.
parking brake switch terminal 2 outlet wire BrY and
chassis ground.
• If above item (1) is OK and item (2) is NG, parking brake
switch is faulty.
9-026
TROUBLESHOOTING
Fig.: 2-3-1
REVERSE FORWARD
THROTTLE SWITCH
6
30 RY 4
5 97 RW
30 1.25RY
F-R LEVER
25 2BW
SWITCH 3 93 WG
94 BW 1
12 R
NC NO COM
2
R B
THROTTLE
13 W
12 R
SWITCH
10
2
7
9
5
6
1
36 LgR NO COM 12 R
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FOOT BRAKE SWITCH
(WHEN NOT DEPRESS)
TO SEVRO
23 3RG
16 2W
3 5R
36 LgR 1 3 37 BrW
2 67 BrY
TO 38 GR 92 WL 㨒
4 X B 93 WG
COMBINATION 5
㨏
METER 㨑
91 LW
PARKING BRAKE 97 RW
X B
SWITCH
㨍㨎
THROTTLE
13 W
RELAY (R9)
26 2Lg 20 2LgR 25 2BW F.L. 45A

23 3RG 75 3G
3 5 3 5
13 W X B X B 67 BrY 3 5R F.L. 65A 76 5WR
1 2 2 1
61 8W F.L. 45A 74 8WY
C 4 5BY 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH HEAT 18 2RW
28 1.25LgW
16 2W
3 5
OFF 107 LgY 108 GB
ON 1 2
STARTER LOCKOUT
ST RELAY (R8)
STARTER SWITCH
28 1.25LgW 62 1.25WB
3 5
36 LgR X B
14 5R 15 5RB
1 2
3 5
RELAY (R7)
1 2
STARTER
RELAY
AV30
78 3WB 86 3WL 86 3WL
30A
FUSE

J3(60PIN)
78 WB 79 B
24 BR
AV60
78 WB 79 B
79 B BR
78 WB
28 LgW 88 GY
8 STOP LAMP E
X 2B
89 Y G
16 WARNING LAMP
90 YG STARTER MOTOR
FUSE
62 1.25WB 98 BL 79 3B AV60
5A 3 KEY SW. SIGNAL
AV20
92 WL
ISC 2 SW (MID) 38
91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE 94 BW 61 8W
107 LgY
108 GB
7 WG -
LAMP
BATTERY
IGNITION
PHASE
GROUND

AV60
FOR OIL PRESS.
130 BR B
B 131 LgR
132 RW
AV30 AV30
17 CAN A (+) 250A
B 5 3
18 CAN A (-) 1 2
GRID HEATER
RELAY
SV412-09001
9-027
TROUBLESHOOTING
10. Interlock Relay (R1) (1) When starter switch is ON, measure voltage between Replace interlock relay
interlock relay terminal 1 inlet wire W and chassis (R1).
ground.
between interlock relay terminal 3 inlet wire Lg and
chassis ground.
between interlock relay terminal 5 outlet wire LgR and
chassis ground.
interlock relay is faulty.
11. P
arking Interlock (1) When starter switch is ON, measure voltage between Replace parking interlock
Relay (R2) parking interlock relay terminal 1 inlet wire BrY and relay (R2).
chassis ground.
between parking interlock relay terminal 3 inlet wire LgR
and chassis ground.
between parking interlock relay terminal 5 outlet wire
BW and chassis ground.
parking interlock relay is faulty.
12. Engine Stop Relay (1) When starter switch is ON, measure voltage between Replace engine stop
(R7) engine stop relay terminal 1 inlet wire LgR and chassis relay (R7).
ground.
engine stop relay terminal 3 inlet wire LgW and chassis
ground.
engine stop relay terminal 5 outlet wire WB and chassis
ground.
engine stop relay is faulty.
13. Harness Connecting • Measure resistance of harness connecting between Repair or replace
Between Terminals terminals. harness.
Standard resistance : 10 Ω or less
• If resistance is abnormal, harness is faulty.
9-028
TROUBLESHOOTING
Fig.: 2-3-2
8 7
4 3 1
6 5
SV412-09013
(1) Fuel from supply tank (6) Common rail fuel return
(2) Water/fuel separator filter (remote or engine mounted) (7) Fuel rail pressure relief valve
(3) Priming pump (remote or engine mounted) (8) Fuel return from injectors
(4) Fuel supply to gear pump (9) Fuel return to tank
(5) Fuel pump fuel return
9-029
TROUBLESHOOTING
2-3-2. Engine will not start (But starter motor runs)

• In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not
supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate.
• Check that fuel is supplied to inlet of fuel gear pump.
1. Fuel Tank • Check that fuel tank is filled with diesel oil. Fill tank with fuel.
• If quantity is low, fuel is not delivered to fuel system.
• Check that there is no water has entered fuel tank. Drain water from tank.
• If water has entered tank, engine does not start.
• Check that quality of diesel oil is sufficient. Replace fuel in tank with
• If oil does not meet standard, engine may fail. an appropriate one.
2. Water/ • Check that water does not cover water-in-fuel (WIF) Drain water.
Fuel Separator Filter/ sensor in contaminant collection bowl.
Fuel Filter • If water covers the sensor, engine may not start.
(Pressure Side) • Check filter for clogging. • Replace filter.
• Insufficient supply of proper fuel due to clogging of filter. • Bleed filter.
(NOTICE)
• Air bleeding should be performed whenever filter is
replaced.
3. Fuel Gear Pump • Disconnect hose connecting to fuel gear pump and check • Replace fuel gear
that fuel flows out of pump. pump.
• If fuel does not flow out of pump, it is not delivered to fuel • Bleed pump.
system.
(NOTICE)
• Air bleeding should be performed whenever fuel gear
pump is replaced.
4. Hoses Connecting • Check hoses for fuel leakage and clogging. Replace hose.
Between Parts • Hose failure due to deterioration.
(NOTICE)
• Air bleeding should be performed whenever fuel hose
is replaced.
9-030
TROUBLESHOOTING
Fig.: 2-3-1
REVERSE FORWARD
THROTTLE SWITCH
6
30 RY 4
5 97 RW
30 1.25RY
F-R LEVER
25 2BW
SWITCH 3 93 WG
94 BW 1
12 R
NC NO COM
2
R B
THROTTLE
13 W
12 R
SWITCH
10
2
7
9
5
6
1
36 LgR NO COM 12 R
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FOOT BRAKE SWITCH
(WHEN NOT DEPRESS)
TO SEVRO
23 3RG
16 2W
3 5R
36 LgR 1 3 37 BrW
2 67 BrY
TO 38 GR 92 WL 㨒
4 X B 93 WG
COMBINATION 5
㨏
METER 㨑
91 LW
PARKING BRAKE 97 RW
X B
SWITCH
㨍㨎
THROTTLE
13 W
RELAY (R9)
26 2Lg 20 2LgR 25 2BW F.L. 45A

23 3RG 75 3G
3 5 3 5
13 W X B X B 67 BrY 3 5R F.L. 65A 76 5WR
1 2 2 1
61 8W F.L. 45A 74 8WY
C 4 5BY 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH HEAT 18 2RW
28 1.25LgW
16 2W
3 5
OFF 107 LgY 108 GB
ON 1 2
STARTER LOCKOUT
ST RELAY (R8)
STARTER SWITCH
28 1.25LgW 62 1.25WB
3 5
36 LgR X B
14 5R 15 5RB
1 2
3 5
RELAY (R7)
1 2
STARTER
RELAY
AV30
78 3WB 86 3WL 86 3WL
30A
FUSE

J3(60PIN)
78 WB 79 B
24 BR
AV60
78 WB 79 B
79 B BR
78 WB
28 LgW 88 GY
8 STOP LAMP E
X 2B
89 Y G
16 WARNING LAMP
90 YG STARTER MOTOR
FUSE
62 1.25WB 98 BL 79 3B AV60
5A 3 KEY SW. SIGNAL
AV20
92 WL
ISC 2 SW (MID) 38
91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE 94 BW 61 8W
107 LgY
108 GB
7 WG -
LAMP
BATTERY
IGNITION
PHASE
GROUND

AV60
FOR OIL PRESS.
130 BR B
B 131 LgR
132 RW
AV30 AV30
17 CAN A (+) 250A
B 5 3
18 CAN A (-) 1 2
GRID HEATER
RELAY
SV412-09001
9-031
TROUBLESHOOTING
2-3-3. No charging
1. Alternator • After starting engine, measure voltage between alternator Replace alternator or
terminal BATTERY wire W 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.
2-3-4. Grid heater does not work (Engine starting performance is bad in cold weather)
Reference Fig. : 2-3-1
1. Grid Heater • When starter switch is ON, measure voltage between grid Replace grid heater.
heater inlet wire and chassis ground.
• If voltage is normal, grid heater is faulty.
2. Grid Heater Relay (1) When starter switch is ON, measure voltage between Replace grid heater
grid heater relay terminal 2 inlet wire GB and chassis relay.
ground.
grid heater relay terminal 3 inlet wire and chassis
ground.
grid heater relay terminal 5 outlet wire and chassis
ground.
• If above items (1) and (2) are OK and item (3) is NG, grid
heater relay is faulty.
(NOTICE)
• If any abnormality is found in shielded twisted wires,
repair is not approved. Be sure to replace them.
9-032
TROUBLESHOOTING
Fig.: 2-3-1
REVERSE FORWARD
THROTTLE SWITCH
6
30 RY 4
5 97 RW
30 1.25RY
F-R LEVER
25 2BW
SWITCH 3 93 WG
94 BW 1
12 R
NC NO COM
2
R B
THROTTLE
13 W
12 R
SWITCH
10
2
7
9
5
6
1
36 LgR NO COM 12 R
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FOOT BRAKE SWITCH
(WHEN NOT DEPRESS)
TO SEVRO
23 3RG
16 2W
3 5R
36 LgR 1 3 37 BrW
2 67 BrY
TO 38 GR 92 WL 㨒
4 X B 93 WG
COMBINATION 5
㨏
METER 㨑
91 LW
PARKING BRAKE 97 RW
X B
SWITCH
㨍㨎
THROTTLE
13 W
RELAY (R9)
26 2Lg 20 2LgR 25 2BW F.L. 45A

23 3RG 75 3G
3 5 3 5
13 W X B X B 67 BrY 3 5R F.L. 65A 76 5WR
1 2 2 1
61 8W F.L. 45A 74 8WY
C 4 5BY 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH HEAT 18 2RW
28 1.25LgW
16 2W
3 5
OFF 107 LgY 108 GB
ON 1 2
STARTER LOCKOUT
ST RELAY (R8)
STARTER SWITCH
28 1.25LgW 62 1.25WB
3 5
36 LgR X B
14 5R 15 5RB
1 2
3 5
RELAY (R7)
1 2
STARTER
RELAY
AV30
78 3WB 86 3WL 86 3WL
30A
FUSE

J3(60PIN)
78 WB 79 B
24 BR
AV60
78 WB 79 B
79 B BR
78 WB
28 LgW 88 GY
8 STOP LAMP E
X 2B
89 Y G
16 WARNING LAMP
90 YG STARTER MOTOR
FUSE
62 1.25WB 98 BL 79 3B AV60
5A 3 KEY SW. SIGNAL
AV20
92 WL
ISC 2 SW (MID) 38
91 LW 61 8W
ISC 1 SW (FULL) 39
ENGINE 94 BW 61 8W
107 LgY
108 GB
7 WG -
LAMP
BATTERY
IGNITION
PHASE
GROUND

AV60
FOR OIL PRESS.
130 BR B
B 131 LgR
132 RW
AV30 AV30
17 CAN A (+) 250A
B 5 3
18 CAN A (-) 1 2
GRID HEATER
RELAY
SV412-09001
9-033
TROUBLESHOOTING
2-3-5. Starter motor runs even when F-R lever is not at “N” and parking brake is not
applied
1. F-R Lever Switch • When starter switch is OFF and F-R lever is “F” or “R”, Replace F-R lever
check continuity between F-R lever switch terminal COM switch.
and terminal NC.
There is no continuity in normal condition.
• If there is continuity, F-R lever switch is faulty.
2. Parking Brake Switch • When starter switch is OFF and parking brake switch is Replace parking brake
released position, check continuity between parking brake switch.
switch terminal 1 and 2.
• If there is continuity, parking brake switch is faulty.
2-3-6. Engine speed cannot be switched

1. Throttle Switch (1) When throttle switch is “IDLE”, check continuity between Replace throttle switch.
throttle switch terminals 1 and 2, 4 and 6.
There is continuity in normal condition.
(2) When throttle switch is “MID”, check continuity between
throttle switch terminals 1 and 3, 4 and 6.
(3) When throttle switch is “FULL”, check continuity
between throttle switch terminals 1 and 3, 4 and 5.
• If above item (1), (2) or (3) is NG, throttle switch is faulty.
2. Throttle Relay (R9) (1) When starter switch is ON and throttle switch is “FULL”, Replace throttle relay
measure voltage between throttle relay terminal b inlet (R9).
wire RW and chassis ground.
(2) When starter switch is ON and throttle switch is “FULL”,
measure voltage between throttle relay terminal e outlet
wire LW and chassis ground.
There is electricity in normal condition.
(3) When starter switch is ON and throttle switch is “MID”,
measure voltage between throttle relay terminal f outlet
wire WL and chassis ground.
There is electricity in normal condition.
• If above item (1) is OK and item (2) or (3) is NG, throttle
relay is faulty.
9-034
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
TO 38 GR 4 TO PARKING PARKING
COMBINATION 5 X B INTERLOCK BRAKE
METER RELAY (R2) SOLENOID
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
RELAY (R5) NC NO COM
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
NEUTRAL HOLDING 13 W
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SPEED CHANGE SPEED CHANGE
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH
STARTER SWITCH NO COM

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
TO STARTER MOTOR AV60
B
SV412-09002
9-035
TROUBLESHOOTING
2-4. Propulsion
2-4-1. Machine moves neither forward nor backward 1/2

• Parking brake switch must be released.
1. Servo Bypass Solenoid • Disconnect harness and measure resistance of coil. Replace servo bypass
Standard resistance : 12.3 ± 1.2 Ω solenoid.
• If measured resistance is abnormal, servo bypass
solenoid is faulty.
2. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake
• If measured resistance is abnormal, parking brake
solenoid is faulty.
3.Servo Bypass Relay (1) When starter switch is ON, measure voltage between Replace servo bypass
(R5) servo bypass relay terminal 1 inlet wire BrW and relay (R5).
chassis ground.
servo bypass terminal 3 inlet wire GW and chassis
ground.
servo bypass relay terminal 5 outlet wire LY and chassis
ground.
servo bypass is faulty.
4.Propulsion Pump (1) When starter switch is ON and F-R lever is “F” or “R”, Replace propulsion
Neutral Holding Relay measure voltage between propulsion pump neutral pump neutral holding
(R6) holding relay terminal 1 inlet wire LY and chassis relay (R6).
ground.
(2) When starter switch is ON and F-R lever is “F” or “R”,
measure voltage between propulsion pump neutral
holding relay terminal 3 inlet wire R and chassis ground.
measure voltage between propulsion pump neutral holding
relay terminal 5 outlet wire GW and chassis ground.
propulsion pump neutral holding relay is faulty.
9-036
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09002
9-037
TROUBLESHOOTING

5. Diode Unit (1) When starter switch is ON and F-R lever is “N”, Replace diode unit.
measure voltage between diode unit terminal I inlet wire
W and chassis ground.
(2) When starter switch is ON and F-R lever is “N”,
measure voltage between diode unit terminal H outlet
wire GW and chassis ground.
• If above item (1) is OK and item (2) is NG, diode unit is
faulty.
6. F-R Lever Switch (1) When starter switch is ON, measure voltage between Replace F-R lever
F-R lever switch terminal COM inlet wire R and chassis switch.
ground.
(2) When starter switch is ON and F-R lever is “N”,
measure voltage between F-R lever switch terminal NC
outlet wire W and chassis ground.
switch is faulty.
ground.
chassis ground.
switch is faulty.
chassis ground.
parking brake switch terminal 3 outlet wire BrW and
chassis ground.
switch is faulty.
9-038
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09002
9-039
TROUBLESHOOTING
2-4-2. Machine speed cannot be changed

• Speed change switch must be “ ”.
1. Speed Change • Disconnect harness and measure resistance of coil. Replace speed change
Solenoid Standard resistance : 5.1 Ω solenoid.
• If measured resistance is abnormal, speed change
solenoid is faulty.
2. Speed Change Switch (1) When starter switch is ON, measure voltage between Replace speed change
speed change switch terminal 1 inlet wire L and chassis switch.
ground.
speed change switch terminal 2 outlet wire LW and
chassis ground.
• If above item (1) is OK and (2) is NG, speed change
switch is faulty.
9-040
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09002
9-041
TROUBLESHOOTING
2-4-3. Brake cannot be released 1/2

Standard voltage : 12.3 ± 1.2 Ω solenoid.
solenoid is faulty.
2. Servo Bypass Relay (1) When starter switch is ON, measure voltage between Replace servo bypass
chassis ground.
servo bypass terminal 3 inlet wire GW and chassis
ground.
servo bypass relay terminal 5 outlet wire LY and chassis
ground.
servo bypass is faulty.
3. Propulsion Pump (1) When starter switch is ON, measure voltage between Replace propulsion
Neutral Holding Relay propulsion pump neutral holding relay terminal 1 inlet pump neutral holding
(R6) wire LY and chassis ground. relay (R6).
holding relay terminal 3 inlet wire R and chassis ground.
holding relay terminal 5 outlet wire GW and chassis
ground.
propulsion pump neutral holding relay is faulty.
ground.
chassis ground.
switch is faulty.
9-042
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09002
9-043
TROUBLESHOOTING
2-4-3. Brake cannot be released 2/2

chassis ground.
parking brake switch terminal 3 outlet wire BrW and
chassis ground.
switch is faulty.
9-044
TROUBLESHOOTING
Fig.: 2-4-1
36 LgR NO COM 12 R
FOOT BRAKE SWITCH

(WHEN NOT DEPRESS)
3 37 BrW 66 LY X B
36 LgR 1 SOL
2 REVERSE FORWARD
PARKING BRAKE
SWITCH
65 GW 66 LY 66 LY X B
SOL
3 5
1 SOLENOID
2
F-R LEVER
SERVO BYPASS
SWITCH
R B DIODE UNIT
F G H
13 W
12 R
A E B C D I
65 GW 12 R
5 3 A B C D
66 LY X B
E F G H I
1 2
PROPULSION PUMP
RELAY (R6)
65 GW 65 GW
3
39 L
X B 50 LW 2
SOL 1
12 R
39 L
SOLENOID SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09002
9-045
TROUBLESHOOTING
2-4-4. Brake does not work

• Foot brake switch must be OFF (Brake pedal is depressed).
solenoid is faulty.
2. Parking Brake Switch • When starter switch is ON, measure voltage between Replace parking brake
parking brake switch terminal 3 outlet wire BrW and switch.
chassis ground.
There is no electricity in normal condition.
• If electricity flows, parking brake switch is faulty.
3. Foot Brake Switch • When starter switch is ON, measure voltage between foot Replace foot brake
brake switch terminal NO outlet wire LgR and chassis switch.
ground.
• If electricity flows, foot brake switch is faulty.
4. Servo Bypass Relay (1) When starter switch is ON, measure voltage between Replace servo bypass
chassis ground.
servo bypass terminal 5 outlet wire LY and chassis
ground.
• If above item (1) is OK and item (2) is NG, servo bypass
is faulty.
5. Propulsion Pump (1) When starter switch is ON, measure voltage between Replace propulsion
Neutral Holding Relay propulsion pump neutral holding relay terminal 1 inlet pump neutral holding
(R6) wire LY and chassis ground. relay (R6).
holding relay terminal 5 outlet wire GW and chassis
ground.
• If above item (1) is OK and item (2) is NG, propulsion
pump neutral holding relay is faulty.
9-046
TROUBLESHOOTING
Fig.: 2-5-1
DIODE UNIT
F G H
A E B C D I
A B C D
E F G H I
TO 31 Br
THROTTLE SWITCH COMBINATION
METER
9 YR
CENTER 10 YB
MIDDLE 1-3,4-6
6 HIGH
30 RY 4 3 81 RG RG 6
97 RW 1 Y 11 Y 4
5 97 RW 1 5 9 YR a X B
TO 2 11 Y 2
3 93 WG
30 1.25RY
TO 94 BW 1 THROTTLE F-R LEVER 3

VIBRATION MODE 1 SOL
ENGINE 2 RELAY (R9) VIBRATION 2 10 YB X B
CHANGE SWITCH
ECM SWITCH
THROTTLE VIBRATION b
SWITCH 11 Y SELECT LOW
SWITCH
VIBRATOR
SOLENOID
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX
TO
23 3RG
3 5R
ENGINE TO
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
HEAT
OFF
ON
76 5WR
77 5BW
74 8WY
74 8WY
ST
75 3G
STARTER SWITCH
C 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH
NO COM
TO GRID HEATER AV60
RELAY
AV60
24 BR BR
BATTERY +
RELAY
E
X 2B
95D31R
BATTERY
-
AV60 AV60
TO
STARTER AV60
MOTOR B
SV412-09003
9-047
TROUBLESHOOTING
2-5. Vibration
• Throttle switch must be “FULL”.
2-5-1. No vibration occurs

• Vibration mode change switch must be “CONT” (continuous mode).
• Vibration select switch must not be “ ”.
1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace vibrator
Standard resistance : 5.1 Ω solenoid.
• If resistance is abnormal, vibrator solenoid is faulty.
2. Vibration Select Switch (1) When starter switch is ON, measure voltage between Replace vibration select
vibration select switch terminal 1 inlet wire Y, terminal 4 switch.
inlet wire Y and chassis ground.
(2) When starter switch is ON and vibration select switch is
“ ”, measure voltage between vibration select
switch terminal 2 outlet wire YB and chassis ground.
switch terminal 5 outlet wire YR and chassis ground.
• If above item (1) is OK and item (2) or (3) is NG, vibration
select switch is faulty.
3. Throttle Switch (1) When starter switch is ON, measure voltage between Replace throttle switch.
throttle switch terminal 4 inlet wire RY and chassis
ground.
throttle switch terminal 5 outlet wire RW and chassis
ground.
• If above item (1) is OK and item (2) is NG, throttle switch
is faulty.
4. Vibration Mode Change (1) When starter switch is ON, measure voltage between Replace vibration mode
Switch vibration mode change switch terminal 1 inlet wire RW change switch.
and chassis ground.
vibration mode change switch terminal 2 outlet wire Y
and chassis ground.
• If above item (1) is OK and item (2) is NG, vibration mode
change switch is faulty.
5. Harness Connecting •M easure resistance of harness connecting between Repair or replace
9-048
TROUBLESHOOTING
Fig.: 2-5-1
DIODE UNIT
F G H
A E B C D I
A B C D
E F G H I
TO 31 Br
METER
9 YR
CENTER 10 YB
MIDDLE 1-3,4-6
6 HIGH
30 RY 4 3 81 RG RG 6
97 RW 1 Y 11 Y 4
5 97 RW 1 5 9 YR a X B
TO 2 11 Y 2
3 93 WG
30 1.25RY

CHANGE SWITCH
ECM SWITCH
SWITCH
VIBRATOR
SOLENOID
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX
TO
23 3RG
3 5R
ENGINE TO
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
HEAT
OFF
ON
76 5WR
77 5BW
74 8WY
74 8WY
ST
75 3G
STARTER SWITCH
C 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH
NO COM
TO GRID HEATER AV60
RELAY
AV60
24 BR BR
BATTERY +
RELAY
E
X 2B
95D31R
BATTERY
-
AV60 AV60
TO
STARTER AV60
MOTOR B
SV412-09003
9-049
TROUBLESHOOTING
2-5-2. Amplitude does not change (Remains either Low or High)

• Vibration mode change switch must be “CONT” (continuous mode).
1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace vibrator
• If resistance is abnormal, vibrator solenoid is faulty.
2. Vibration Select Switch (1) When starter switch is ON, measure voltage between Replace vibration select
vibration select switch terminal 1 inlet wire Y, terminal 4 switch.
inlet wire Y and chassis ground.
switch terminal 2 outlet wire YB and chassis ground.
switch terminal 5 outlet wire YR and chassis ground.
• If above item (1) is OK and item (2) or (3) is NG, vibration
select switch is faulty.
9-050
TROUBLESHOOTING
Fig.: 2-5-1
DIODE UNIT
F G H
A E B C D I
A B C D
E F G H I
TO 31 Br
METER
9 YR
CENTER 10 YB
MIDDLE 1-3,4-6
6 HIGH
30 RY 4 3 81 RG RG 6
97 RW 1 Y 11 Y 4
5 97 RW 1 5 9 YR a X B
TO 2 11 Y 2
3 93 WG
30 1.25RY

CHANGE SWITCH
ECM SWITCH
SWITCH
VIBRATOR
SOLENOID
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
FUSE BOX
TO
23 3RG
3 5R
ENGINE TO
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
HEAT
OFF
ON
76 5WR
77 5BW
74 8WY
74 8WY
ST
75 3G
STARTER SWITCH
C 4 5BY F.L. 65A 77 5BW

B
24 BR
BR
ACC
STARTER
SWITCH
NO COM
TO GRID HEATER AV60
RELAY
AV60
24 BR BR
BATTERY +
RELAY
E
X 2B
95D31R
BATTERY
-
AV60 AV60
TO
STARTER AV60
MOTOR B
SV412-09003
9-051
TROUBLESHOOTING
2-5-3. Vibration mode cannot be switched (F-R lever vibration switch does not work)
• Vibration mode change switch to “ ” (manual mode).
• Vibration select switch must not be “ ”.
1. F-R Lever Vibration (1) When starter switch is ON, measure voltage between Replace F-R lever
Switch F-R lever vibration switch terminal 1 inlet wire RG and vibration switch.
chassis ground.
(2) When starter switch is ON and F-R lever vibration
switch is pressed once, measure voltage between
F-R lever vibration switch terminal 2 outlet wire Y and
chassis ground.
vibration switch is faulty.
2. Vibration Mode Change (1) When starter switch is ON, measure voltage between Replace vibration mode
Switch vibration mode change switch terminal 1 inlet wire RW change switch.
and chassis ground.
vibration mode change switch terminal 3 outlet wire RG
and chassis ground.
• If above item (1) is OK and item (2) is NG, vibration mode
change switch is faulty.
9-052
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
COMBINATION METER SET
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
110 PULSE/REV SET(NO.5)
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
WR GL LR YL BrW GR GW G OPEN OPEN
LW Br LB L W GY RB GB
OG LgY WB OW FUSE BOX
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B
6 YB LAMP CHECK TO GRID

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
Battery (+12V) Power 5V -
excitation power CYLINDER
circuit supply
Movement Tachometer
AV60
BLOCK
Starter switch (ACC) ALTERNATOR
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

(square wave) LCD Hour meter J3(60PIN)
78 WB
78 WB
EEPROM 2 (+) BATTERY BATTERY (-) 22
78 WB
Fuel sensor 11 (+) BATTERY BATTERY (-) 31
78 WB
Coolant temp. sensor 12 (+) BATTERY BATTERY (-) 32
28 LgW 88 GY
REV. ratio SEL.1 8 STOP LAMP
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
REV. ratio SEL.3 6 WAIT TO START LAMP
CPU
REV. ratio SEL.4 FUSE

interface
Output
98 BL
Illumination LED 5A 3 KEY SW. SIGNAL
12V Side marker lamp ENGINE ISC 2 SW (MID) 38
Water spray
indicator HARNESS
Combination meter ISC 1 SW (FULL) 39
ilumination Liquid spray 133 GL
indicator SW AND TEMP SENSOR RETURN 19
Turn signal (right)
Side marker lamp 134 BrR
Turn signal (left) indicator DIAGNOSTIC 59
Flood lamp indicator FUEL SENSOR STARTER LOCKOUT 15
Vibrator 108 GB
Vibration indicator
Output interface
Liquid spray 8 YL X B OUTPUT RETURN 1 (-) 13

(left) 7 WG
Water spray 3 5 INTAKE AIR HEATER (+) 4
Input interface
Turn signal indicator 108 GB 109 RB

(right) 14 DUAL OUTPUT A (+)
Flood lamp Parking brake 1 2
FOR OIL PRESS.
indicator ENGINE OIL
Preheating TO GRID
Engine oil pressure PRESSURE RELAY (R10)
Parking brake warning indicator 130 BR HEATER
Charge warning C 43 OEM SENSOR (SIGNAL RETURN) RELAY
Charge warning indicator 131 LgR
Hydraulic oil filter B
Engine oil pressure SENSOR 44 COOLANT LEVEL (SIGNAL)
warning indicator 132 RW
warning
Preheating indicator A 52 SENSOR SUPPLY (POWER)
warning
17 CAN A (+)
Lamp check
Coolant temp. SEL.1 18 CAN A (-)

Coolant temp. SEL.2
Note: The circuit in the dashed box is not mounted. SV412-09004
9-053
TROUBLESHOOTING
2-6. Lighting
• No blown fuse and power is applied up to fuses.
• When measuring voltage and current without disconnecting connectors, refer to “measuring voltage and current
following using tester” (P. 9-006 to P. 9-008).
2-6-1. Illumination of combination meter does not turn on

1. Harness • Measure resistance between fuse box terminal 3 wire RY Repair or replace
and combination meter connector terminal wire No. 42 harness.
wire RY.
2. Combination Meter (1) When starter switch is ON, measure voltage between Replace combination
(Combination meter combination meter terminal wires and ground terminal meter.
illumination) wire.
• Battery terminal wire No. 70 inlet wire WR and ground
terminal wire B
• Starter switch terminal wire No. 35 inlet wire YW and
ground terminal wire B
combination meter illumination terminal wire No. 42 inlet
wire RY and chassis ground.
• If above items (1) and (2) are OK and combination meter
illumination does not turn on, combination meter is faulty.
9-054
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
circuit supply
Movement Tachometer
AV60
BLOCK
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

78 WB
78 WB
78 WB
78 WB
28 LgW 88 GY
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
CPU

interface
Output
98 BL
Water spray
indicator HARNESS
Turn signal (right)
Vibrator 108 GB
Vibration indicator
Output interface

(left) 7 WG
Input interface

FOR OIL PRESS.
Preheating TO GRID
warning
warning
17 CAN A (+)
Lamp check

Coolant temp. SEL.2
9-055
TROUBLESHOOTING
2-6-2. Combination meter warning lamp or indicator lamp is abnormal

1. Harness • Disconnect connectors between combination meter and Repair or replace
lamp check relay. harness.
• Measure resistance between terminals and chassis
ground.
• Combination meter connector terminal wire No. 32 wire
BY and chassis ground
• Lamp check relay terminal 3 wire BY and chassis
ground
Standard resistance: 100 kΩ or more
2. Lamp Check Relay (1) When starter switch is ON, measure voltage between Repair or replace lamp
(R4) lamp check relay terminal 2 outlet wire LgB and chassis check relay (R4) or
ground. alternator.
lamp check relay terminal 5 outlet wire B and chassis
ground.
(3) After starting engine, measure voltage between lamp
check relay terminal wires and chassis ground.
• Lamp check relay terminal 2 inlet wire LgB and
chassis ground
• Lamp check relay terminal 5 outlet wire B and chassis
ground
• If above item (1) is OK and item (2) is NG, lamp check
relay is faulty.
alternator is faulty.
(Lamp check) combination meter terminal wires and ground terminal meter.
wire.
terminal wire B
(2) When starter switch is ON, check that parking brake
indicator lamp, hydraulic oil filter warning lamp, engine
oil pressure warning lamp and electrical charge warning
lamp illuminate and then go out after starting engine.
• If above item (1) is OK and the item (2) is NG,
combination meter is faulty.
(NOTICE)
• Since engine cannot start unless parking brake
switch is applied and F-R lever is “N”, parking brake
indicator lamp does not go out even after starting
engine.
9-056
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
circuit supply
Movement Tachometer
AV60
BLOCK
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

78 WB
78 WB
78 WB
78 WB
28 LgW 88 GY
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
CPU

interface
Output
98 BL
Water spray
indicator HARNESS
Turn signal (right)
Vibrator 108 GB
Vibration indicator
Output interface

(left) 7 WG
Input interface

FOR OIL PRESS.
Preheating TO GRID
warning
warning
17 CAN A (+)
Lamp check

Coolant temp. SEL.2
9-057
TROUBLESHOOTING
2-6-3. Tachometer reading is abnormal

1. Combination Meter (1) When starter switch is ON, measure voltage between Replace tachometer
(Tachometer) combination meter terminal wires and ground terminal sensor or combination
wire. meter.
terminal wire B
(2) C heck that combination meter terminal B wires (rev.
ratio 1 and 3) are grounded.
(3) S tart engine and measure pulse between combination
meter rev. pulse input. 1 terminal wire No. 21 inlet wire
YG and chassis ground.
Standard pulse : 110 pulses/rotation of engine
• If above items (1) and (2) are OK and pulse 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.
2-6-4. Hour meter is abnormal

1. C
ombination Meter • When starter switch is ON, measure voltage between Replace combination
(Hour meter) combination meter terminal wires and ground terminal meter.
wire.
terminal wire B
• If no abnormality is found, combination meter is faulty.
9-058
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
circuit supply
Movement Tachometer
AV60
BLOCK
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

78 WB
78 WB
78 WB
78 WB
28 LgW 88 GY
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
CPU

interface
Output
98 BL
Water spray
indicator HARNESS
Turn signal (right)
Vibrator 108 GB
Vibration indicator
Output interface

(left) 7 WG
Input interface

FOR OIL PRESS.
Preheating TO GRID
warning
warning
17 CAN A (+)
Lamp check

Coolant temp. SEL.2
9-059
TROUBLESHOOTING
2-6-5. Temperature meter is abnormal

1. Thermo Unit •D isconnect harness and measure resistance of thermo Replace thermo unit.
unit.
Standard resistance :
164.6 Ω [(at unit temperature of 50°C (122°F)]
26.44 Ω [(at unit temperature of 103°C (217°F)]
• If resistance is abnormal, thermo unit is faulty.
2. Combination Meter • When starter switch is ON, measure voltage between Replace combination
(Temperature meter) combination meter terminal wires and ground terminal meter.
wire.
terminal wire B
2-6-6. Fuel meter is abnormal

1. Fuel Unit • Disconnect harness and measure resistance of fuel unit. Replace fuel unit.
Standard resistance :
13.5 Ω (with float in “F”)
80.0 Ω (with float in “E”)
• If resistance is abnormal, fuel unit is faulty.
2. Combination Meter • When starter switch is ON, measure voltage between Replace combination
(Fuel meter) combination meter terminal wires and ground terminal meter.
wire.
terminal wire B
9-060
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
circuit supply
Movement Tachometer
AV60
BLOCK
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

78 WB
78 WB
78 WB
78 WB
28 LgW 88 GY
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
CPU

interface
Output
98 BL
Water spray
indicator HARNESS
Turn signal (right)
Vibrator 108 GB
Vibration indicator
Output interface

(left) 7 WG
Input interface

FOR OIL PRESS.
Preheating TO GRID
warning
warning
17 CAN A (+)
Lamp check

Coolant temp. SEL.2
9-061
TROUBLESHOOTING
2-6-7. Hydraulic oil filter warning lamp remains ON

1. Harness • Disconnect connectors between hydraulic oil filter switch Repair or replace
1, 2 and combination meter. harness.
• Measure resistance between terminal and chassis
ground.
• Hydraulic oil filter switch 1 or 2 terminal wire Y and
chassis ground.
Y and chassis ground.
Standard resistance : 100 kΩ or more
2. Hydraulic Oil Filter • When starter switch is OFF, check continuity between Replace hydraulic oil
Switch 1 or 2 hydraulic oil filter switch 1 or 2 inlet terminal and chassis filter switch 1 or 2.
ground.
• If there is continuity, hydraulic oil filter switch 1 or 2 is
faulty.
(Hydraulic oil filter combination meter terminal wires and ground terminal meter.
warning indicator lamp) wire.
• Battery terminal inlet wire No. 70 inlet wire WR and
ground terminal wire B.
• Starter switch terminal inlet wire No. 35 inlet wire YW
and ground terminal wire B.
combination meter hydraulic oil filter warning terminal
outlet wire Y and chassis ground.
• If above items (1) and (2) are OK and no abnormality
is found in hydraulic oil filter switch 1 or 2 but hydraulic
oil filter warning lamp remains on after starting engine,
combination meter is faulty.
9-062
TROUBLESHOOTING
Fig.: 2-6-1
42 RY 42 RY
COMBINATION METER
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
LAMP CHECK
35 YW
FLOOD LAMP
PREHEATING
FUEL METER
42 RY
VIBRATOR
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN

10
2
7
9
5
6
1
TEMP. 50-103͠ SET(NO.0)
TEMP.CURVE SEL.
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
R P O B Y YR YW 1 2
23 3RG
3 5R
35 YW
FUSE
70 WR 4 BY
5A
4 BY
35 YW
X B
X B
C 4 5BY
X B
HEAT B
F.L. 45A 23 3RG
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
42 RY OFF 24 BR
BR
8 YL ACC
ON
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
STARTER
32 BY
ST
28 1.25LgW
SWITCH
70 WR
STARTER SWITCH
77 5BW
74 8WY
21 YG
75 3G
32 BY X B
3 5
X B 29 LgB 28 LgW
2 1 NO COM
X B

RELAY (R4) HEATER
HYDRAULIC OIL RELAY
AV60
FILTER SWITCH 1
86 3WL
22 Y 24 BR BR
6 YB
B BATTERY
21 YG
17 YR
RELAY TO
X B
8 YL
E STARTER
X 2B
22 Y MOTOR
TACHO B THERMO
METER UNIT
HYDRAULIC OIL
AV60
SENSOR
AV60
29 LgB
61 8W
61 8W
62 WB
FILTER SWITCH 2
X B
FUEL UNIT B AV20

+
LAMP
BATTERY
IGNITION
PHASE
GROUND
95D31R
12V
circuit supply
Movement Tachometer
AV60
BLOCK
12V Input
interface B
BATTERY
CAN interface
Movement Fuel meter

78 3WB 86 3WL
30A
FUSE
Temperature
Movement meter
REV. pulse input.1
Frequency divider
(pickup)
ENGINE ECM.(CM2250)
selector
REV. pulse input.2

78 WB
78 WB
78 WB
78 WB
28 LgW 88 GY
89 Y
16 WARNING LAMP
Input interface
62 1.25WB
REV. ratio SEL.2

90 YG
CPU

interface
Output
98 BL
Water spray
indicator HARNESS
Turn signal (right)
Vibrator 108 GB
Vibration indicator
Output interface

(left) 7 WG
Input interface

FOR OIL PRESS.
Preheating TO GRID
warning
warning
17 CAN A (+)
Lamp check

Coolant temp. SEL.2
9-063
TROUBLESHOOTING
2-6-8. Engine oil pressure warning lamp remains ON

• Check whether engine check lamps show no fault code.
1. Harness • Disconnect connectors between engine ECM, engine oil Repair or replace
pressure relay (R10) and combination meter. harness.
• Measure resistance between terminals and chassis
ground.
• Engine ECM output return (-) terminal 13 wire GB and
chassis ground.
• Engine oil pressure relay (R10) terminal 1 wire GB and
chassis ground.
• Engine ECM dual output A (+) for oil press terminal 14
wire RB and chassis ground.
• Engine oil pressure relay (R10) terminal 2 wire RB and
chassis ground.
YL and chassis ground.
• Engine oil pressure relay (R10) terminal 3 wire YL and
chassis ground.
(NOTICE)
• If any abnormality is found in shielded twisted wires,
repair is not approved. Be sure to replace them.
2. Engine Oil Pressure (1) When starter switch is ON, measure voltage between Replace engine oil
Relay (R10) engine oil pressure relay (R10) terminal 2 outlet wire pressure relay (R10).
RB and chassis ground.
engine oil pressure relay (R10) terminal 5 outlet wire B
and chassis ground.
• If above item (1) is OK and item (2) is NG, engine oil
pressure relay (R10) is faulty.
(Engine oil pressure combination meter terminal wires and ground terminal meter.
warning indicator lamp) wire.
• Battery terminal inlet wire No. 70 inlet wire WR and
ground terminal wire B.
• Starter switch terminal inlet wire No. 35 inlet wire YW
and ground terminal wire B.
combination meter engine oil pressure warning terminal
outlet wire No. 8 wire YL and chassis ground.
• If above items (1) and (2) are OK and no fault code is
shown but engine oil pressure warning lamp remains on
after starting engine, combination meter is faulty.
9-064
TROUBLESHOOTING
Fig.: 2-6-2
DIODE UNIT
F G H
42 RY
A E B C D I
COMBINATION METER
A B C D
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
E F G H I
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2 31 Br
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
9 YR
LAMP CHECK
FLOOD LAMP
PREHEATING
FUEL METER
VIBRATOR
10 YB
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN HIGH

(ENGINE:110 PULSE/REV) RG 6
Y 11 Y 4
1 5 9 YR a X B
TEMP. 50-103͠ SET(NO.0) 2
TEMP.CURVE SEL. F-R LEVER 3
1 SOL
R P O B Y YR YW 1 2 VIBRATION 2 10 YB X B
WR GL LR YL BrW GR GW G OPEN OPEN SWITCH
VIBRATION b
LW Br LB L W GY RB GB SELECT LOW
SWITCH
OG LgY WB OW VIBRATOR
11 Y SOLENOID
31 Br 81 RG
35 YW
X B
THROTTLE SWITCH
X B

X B

42 RY CENTER MIDDLE 1-3,4-6
70 WR RIGHT HAND FULL 1-3,4-5
6
38 GR
30 RY 4 3 81 RG
X B
5 97 RW 97 RW 1
2 11 Y
30 1.25RY
TO
TO 3 93 WG
35 YW
94 BW 1 THROTTLE
42 RY
VIBRATION MODE
ENGINE 2 RELAY (R9) CHANGE SWITCH
ECM
THROTTLE
SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
TO SERVO
37 BrW 3 TO FOOT
BYPASS 1 36 LgR
RELAY (R5) 2 BRAKE
67 BrY 5 4 38 GR SWITCH
TO PARKING
INTERLOCK FUSE BOX
X B
23 3RG
RELAY (R2) PARKING BRAKE

3 5R
SWITCH
FUSE
70 WR 4 BY
5A
12V
excitation power
circuit supply
Movement Tachometer
4 BY
Starter switch (ACC) Input

12V
interface TO TO
ENGINE ALTERNATOR
CAN interface
Movement Fuel meter ECM

C 4 5BY
B
F.L. 45A 23 3RG
Temperature 24 BR
4 5BY
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
Movement meter BR
REV. pulse input.1
Frequency divider
ACC
(pickup)
selector
STARTER
F.L. 65A
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
REV. pulse input.2 SWITCH

77 5BW
77 5BW
74 8WY
75 3G
EEPROM
Fuel sensor
HEAT
Coolant temp. sensor OFF
REV. ratio SEL.1 ON NO COM
TO GRID AV60
Input interface
REV. ratio SEL.2 ST HEATER

REV. ratio SEL.3
CPU
RELAY
STARTER SWITCH
REV. ratio SEL.4
interface
24 BR BR
Output
Illumination LED
BATTERY
12V Side marker lamp
Water spray RELAY
Combination meter indicator E
X 2B
ilumination Liquid spray

indicator
Turn signal (right)
Side marker lamp
Turn signal (left) indicator
Flood lamp indicator
AV60
Vibrator
Vibration indicator
Output interface

(left) +
Water spray
Input interface

(right)
Flood lamp Parking brake 95D31R
indicator
Preheating
Engine oil pressure
Charge warning -
Charge warning indicator AV60 AV60
Engine oil pressure warning indicator TO STARTER MOTOR
warning AV60
warning
Lamp check
BATTERY
Coolant temp. SEL.1
Coolant temp. SEL.2
9-065
TROUBLESHOOTING
2-6-9. Vibration indicator lamp does not light

• Check that vibrator can be operated.
1. Harness (1) M easure resistance between vibration select switch Repair or replace
terminal 5 wire YR and diode unit terminal E wire YR. harness.
(2) M easure resistance between vibration select switch
terminal 2 wire YB and diode unit terminal A wire YB.
(3) M easure resistance between diode unit terminal F wire
Br and combination meter connector terminal wire No.
31 wire Br.
• If above item (1), (2) or (3) is NG, harness is faulty.
2. Diode Unit (1) When starter switch is ON and vibration select switch is Replace diode unit.
“ ”, measure voltage between diode unit terminal A
inlet wire YB and chassis ground.
“ ”, measure voltage between diode unit terminal E
inlet wire YR and chassis ground.
diode unit terminal F outlet wire Br and chassis ground.
diode unit is faulty.
(Vibration indicator combination meter terminal wires and ground terminal meter.
lamp) wire.
terminal wire B
(2) When starter switch is ON, vibration mode change
switch is “CONT” and vibration select switch is “ ”
or “ ”, measure voltage between combination meter
vibration terminal wire No. 31 inlet wire Br and chassis
ground.
• If above items (1) and (2) are OK and vibration indicator
lamp does not light, combination meter is faulty.
9-066
TROUBLESHOOTING
Fig.: 2-6-2
DIODE UNIT
F G H
42 RY
A E B C D I
COMBINATION METER
A B C D
BrW
LgY

OG
GR
GB
GY
LW
RB
YR
GL
E F G H I
LR
LB
SIDE MARKER LAMP YL

Br
CHARGE WARNING W
R
B

L
REV. RATIO SEL.2 31 Br
REV. RATIO SEL.4
REV. RATIO SEL.3
REV. RATIO SEL.1

TURN SIGNAL(R)
PARKING BRAKE
TURN SIGNAL(L)
BATTERY 12V(+)
WATER SPRAY
LIQUID SPRAY
9 YR
LAMP CHECK
FLOOD LAMP
PREHEATING
FUEL METER
VIBRATOR
10 YB
REV RATIO SEL.
1 2 3 4
GND
GND OPEN GND OPEN HIGH

(ENGINE:110 PULSE/REV) RG 6
Y 11 Y 4
1 5 9 YR a X B
TEMP. 50-103͠ SET(NO.0) 2
TEMP.CURVE SEL. F-R LEVER 3
1 SOL
R P O B Y YR YW 1 2 VIBRATION 2 10 YB X B
WR GL LR YL BrW GR GW G OPEN OPEN SWITCH
VIBRATION b
LW Br LB L W GY RB GB SELECT LOW
SWITCH
OG LgY WB OW VIBRATOR
11 Y SOLENOID
31 Br 81 RG
35 YW
X B
THROTTLE SWITCH
X B

X B

42 RY CENTER MIDDLE 1-3,4-6
70 WR RIGHT HAND FULL 1-3,4-5
6
38 GR
30 RY 4 3 81 RG
X B
5 97 RW 97 RW 1
2 11 Y
30 1.25RY
TO
TO 3 93 WG
35 YW
94 BW 1 THROTTLE
42 RY
VIBRATION MODE
ENGINE 2 RELAY (R9) CHANGE SWITCH
ECM
THROTTLE
SWITCH
10
2
7
9
5
6
1
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
TO SERVO
37 BrW 3 TO FOOT
BYPASS 1 36 LgR
RELAY (R5) 2 BRAKE
67 BrY 5 4 38 GR SWITCH
TO PARKING
INTERLOCK FUSE BOX
X B
23 3RG
RELAY (R2) PARKING BRAKE

3 5R
SWITCH
FUSE
70 WR 4 BY
5A
12V
excitation power
circuit supply
Movement Tachometer
4 BY
Starter switch (ACC) Input

12V
interface TO TO
ENGINE ALTERNATOR
CAN interface
Movement Fuel meter ECM

C 4 5BY
B
F.L. 45A 23 3RG
Temperature 24 BR
4 5BY
4 5BY
74 8WY F.L. 45A 61 8W
61 8W
3 5R
Movement meter BR
REV. pulse input.1
Frequency divider
ACC
(pickup)
selector
STARTER
F.L. 65A
F.L. 65A
76 5WR F.L. 65A
F.L. 45A
REV. pulse input.2 SWITCH

77 5BW
77 5BW
74 8WY
75 3G
EEPROM
Fuel sensor
HEAT
Coolant temp. sensor OFF
REV. ratio SEL.1 ON NO COM
TO GRID AV60
Input interface
REV. ratio SEL.2 ST HEATER

REV. ratio SEL.3
CPU
RELAY
STARTER SWITCH
REV. ratio SEL.4
interface
24 BR BR
Output
Illumination LED
BATTERY
12V Side marker lamp
Water spray RELAY
Combination meter indicator E
X 2B
ilumination Liquid spray

indicator
Turn signal (right)
Side marker lamp
Turn signal (left) indicator
Flood lamp indicator
AV60
Vibrator
Vibration indicator
Output interface

(left) +
Water spray
Input interface

(right)
Flood lamp Parking brake 95D31R
indicator
Preheating
Engine oil pressure
Charge warning -
Charge warning indicator AV60 AV60
Engine oil pressure warning indicator TO STARTER MOTOR
warning AV60
warning
Lamp check
BATTERY
Coolant temp. SEL.1
Coolant temp. SEL.2
9-067
TROUBLESHOOTING
2-6-10. Parking brake indicator lamp does not light

1. Harness • Measure resistance between parking brake switch Repair or replace
terminal 4 wire GR and combination meter connector harness.
terminal wire No. 38 wire GR.
2. Parking Brake Switch •W hen parking brake is applied, check continuity between Replace parking brake
parking brake switch terminal 4 and 5. switch.
• If there is no continuity, parking brake switch is faulty.
(Parking brake combination meter terminal wires and ground terminal meter.
indicator lamp) wire.
terminal wire B
(2) When starter switch is ON and parking brake is applied,
measure voltage between combination meter parking
brake terminal wire No. 38 outlet wire GR and chassis
ground.
• If above items (1) and (2) are OK and parking brake
indicator lamp does not light, combination meter is faulty.
9-068
TROUBLESHOOTING
Fig.: 2-6-3
REVERSE FORWARD
BACKUP
BUZZER
SWITCH
N
C
N
O
W
C
O
2 GB
M
2 GB
B
X B
BACKUP BUZZER
12 R
HORN
X B 34 LgW 34 LgW 30 1.25RY

5 3
33 Lg 30 RY 30 1.25RY
2 1
12 R
HORN
RELAY (R3)
33 Lg
10
2
7
9
5
6
1
B
20A
20A
20A
20A
20A
HORN SWITCH
15A
15A
15A
15A
15A
FUSE BOX TO
23 3RG
ENGINE TO
3 5R
ECM ALTERNATOR
23 3RG
4 5BY
61 8W
61 8W
3 5R
F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
76 5WR
77 5BW
74 8WY
74 8WY
75 3G

B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
AV60
24 BR BR
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09006
9-069
TROUBLESHOOTING
2-6-11. Horn does not sound

1. Horn •D isconnect horn and directly connect battery positive Replace horn.
terminal to horn terminal wire LgW side and negative
terminal to horn terminal wire B side.
• If horn does not sound, horn is faulty.
2. Horn Relay (1) When starter switch is ON and horn switch is pressed, Replace horn relay (R3).
(R3) measure voltage between horn relay terminal 2 outlet
wire Lg and chassis ground.
(2) When starter switch is ON and horn switch is pressed,
measure voltage between horn relay terminal 5 outlet
wire LgW and chassis ground.
• If above item (1) is OK and item (2) is NG, horn relay is
faulty.
3. Horn Switch • When horn switch is OFF, measure resistance between Replace horn switch.
horn switch terminals.
• If resistance is abnormal, horn switch is faulty.
2-6-12. Backup buzzer does not sound

1. Backup Buzzer •D isconnect backup buzzer and directly connect battery Replace backup buzzer.
positive terminal to backup buzzer terminal wire GB 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) When starter switch is ON, measure voltage between Replace backup buzzer
backup buzzer switch terminal COM inlet wire R and switch.
chassis ground.
(2) When starter switch is ON and F-R lever is “R”,
measure voltage between backup buzzer switch
terminal NO outlet wire GB and chassis ground.
• If above item (1) is OK and item (2) is NG, backup buzzer
switch is faulty.
3. Harness Connecting • M easure resistance of harness connecting between Repair or replace
9-070
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.
9-071
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.

Check point Cause Check/Action
1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained.
Hydraulic Oil Tank
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 Propulsion pump does not discharge oil • Measure charge pressure.
Pressure because charge pressure is low. • If low, check and adjust charge relief valve
or replace it if necessary.
Insufficient charge pump discharge. Repair charge pump or replace it if
necessary.
Charge pressure decreases due to internal • When solenoid is energized, check if oil
leakage of solenoid valve connecting oil flows in return circuit to tank.
supply circuit with charge circuit. • If oil is flowing, repair solenoid valve or
• Parking brake solenoid valve replace it if necessary.
• Speed change solenoid valve
5. Servo Bypass If spool of servo bypass solenoid valve • Measure pressure in servo cylinder
Solenoid Valve is stuck, pressure in both sides of servo chambers.
cylinder chamber is equalized. This causes • If pressure is equal in both chambers,
propulsion pump unable to discharge oil. repair servo bypass solenoid valve or
6. Suction Filter for Charge pump flow is reduced due to Clean suction filter or replace it if necessary.
Charge Pump clogged filter.
7. Propulsion Circuit Circuit does not obtain required pressure • Measure propulsion circuit pressure.
Pressure because setting pressure of high pressure • If low, check and adjust multifunction valve
relief is low. or replace it if necessary.
8. Propulsion Motor Propulsion circuit pressure is not held in If pressure in propulsion motor case is not
propulsion motor case. within allowable range, 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.
9-072
TROUBLESHOOTING

9. Propulsion Pump Discharge flow rate is insufficient due to • Measure discharge flow rate of propulsion
efficiency degradation of propulsion pump. 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 If pressure in propulsion pump case is not
propulsion pump case. within allowable range, repair propulsion
pump or replace it if necessary.
10. Parking Brake Brake remains applied because spool of Repair parking brake solenoid valve or
Solenoid Valve parking brake solenoid valve does not shift. replace it if necessary.
11. B
rake Inlet Brake cannot be released because brake • Measure brake release pressure.
Pressure inlet pressure is low. • If low, repair or replace propulsion motor.
12. Rear Axle Sticking of disc brakes causes brakes to • Replace disc brakes.
remain applied.
13. Flange Drive torque is not transmitted to pump due Replace flange.
to faulty flange.
3-2-2. Machine moves in one direction only (forward or backward)

2. Multifunction Valve Low circuit pressure due to incorrect high • Interchange two multifunction valves.
pressure relief setting or internal leakage of • If faulty condition is accordingly reversed,
multifunction valve. check and adjust multifunction valve or
3-2-3. Slow machine speed or small drive force 1/2

1. Bypass Valve Bypass valve is slightly open. Close bypass valve completely.
3. Charge Circuit Stroke of propulsion pump swash plate • Measure charge pressure.
Pressure is small because charge pressure is low, • If low, check and adjust charge relief valve
decreasing discharge rate of propulsion or replace it if necessary.
pump.
necessary.
4. Suction Filter for Flow rate of charge pump decreases as Clean suction filter or replace it if necessary.
Charge Pump well as charge pressure decreases due to
clogged filter.
9-073
TROUBLESHOOTING
3-2-3. Slow machine speed or small drive force 2/2

5. Propulsion Motor Propulsion motor inlet pressure is low. • Measure propulsion motor inlet pressure.
• If low, check and adjust multifunction valve
Propulsion circuit pressure is not held in If pressure in propulsion motor case is not
Output of propulsion motor decreases and • Measure drain quantity from propulsion
number of revolutions decreases due to motor.
internal leakage of propulsion motor. • If drain quantity is larger than standard
if necessary.
if necessary.
3-2-4. Machine speed cannot be switched

1. Speed Change Machine speed does not change because Repair speed change solenoid valve or
Solenoid Valve spool of speed change solenoid valve does replace it if necessary.
not change.
2. Rear Propulsion Faulty rear propulsion motor swash plate Repair propulsion motor or replace it if
Motor Swash Plate stroke cylinder. necessary.
Stroke Cylinder
3-2-5. Machine does not stop completely with F-R lever in “N”
1. F-R lever Linkage F-R lever linkage is faulty. Check and adjust F-R lever linkage or
2. Servo Control Servo control valve neutral position Check and adjust servo control valve or
Valve adjustment failure. replace it if necessary.
3. Servo Cylinder Faulty servo cylinder or faulty pump swash Repair propulsion pump or replace it if
plate setting. necessary.
9-074
TROUBLESHOOTING
3-2-6. Propulsion system is overheating

Hydraulic Oil Tank
2. Oil Cooler Cooling efficiency is reduced due to clogged Clean oil cooler fins.
oil cooler fins.
3. Flushing Valve Hydraulic oil in propulsion closed circuit is Repair flushing valve or replace it if
(only rear insufficiently cooled due to flushing valve necessary.
propulsion motor) shuttle spool sticking.
Hydraulic oil in propulsion closed circuit is Check dust or damage in flushing relief
insufficiently cooled because flushing valve valve and replace it if necessary.
relief setting pressure is excessively high.
Hydraulic oil in propulsion closed circuit is Clean flushing relief valve or replace it if
insufficiently cooled due to flushing valve necessary.
relief valve poppet sticking.
4. Propulsion Circuit If circuit pressure setting is excessively low, • Measure propulsion circuit pressure.
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 • Measure propulsion circuit pressure.
opens, causing temperature of hydraulic oil • If high, decrease propulsion load.
in circuit to rise.
5. Suction Filter for Load of charge pump increases due to Clean suction filter or replace it if necessary.
Charge Pump clogged filter, causing temperature of
6. Hydraulic Oil Filter 1 Charge circuit pressure increases due to Clean hydraulic oil filter 1 or replace it if
clogged filter. necessary.
3-2-7. Abnormal noise from propulsion system

1. Axle Bearings Axle bearings supporting front and rear Replace axle bearings.
drums are damaged.
2. Reduction gear Reduction gear of front motor is damaged. Replace reduction gear.
(front motor)
3. Rear Axle Rear axle gear is damaged. Replace rear axle gear.
4. Hydraulic Hose Vibrator sound of hydraulic hose is Tighten bolts of loose hydraulic hose clamp
Clamp generated because clamp securing to specified torque.
hydraulic hose is loose.
5. Suction Filter for Cavitation is occurring in charge pump due Clean suction filter or replace it if necessary.
Charge Pump to clogged filter.
6. Charge Circuit If charge pressure is low, brake cannot be • Measure charge pressure.
Pressure released completely, which causes brake • If low, check and adjust charge relief valve
drag. or replace it if necessary.
7. Propulsion Motor Internal bearing of propulsion motor is Repair propulsion motor or replace it if
damaged. necessary.
9-075
TROUBLESHOOTING
3-3. Vibrator System

If a problem occurs in the vibrator systems such as the vibrator pump, vibrator motor and vibrator solenoid valve,
(NOTICE)
hydraulic circuit.
3-3-1. No vibration
Hydraulic Oil Tank
2. Charge Circuit Vibrator pump does not discharge oil due to • Measure charge pressure.
Pressure low charge pressure. • If low, check and adjust charge relief valve
necessary.
3. Vibrator Solenoid Vibrator pump cannot discharge oil because Repair vibrator solenoid valve or replace
Valve spool of vibrator solenoid valve does not them if necessary.
shift.
Charge Pump clogged filler.
5. Vibrator Circuit Circuit does not obtain required pressure • Measure vibrator circuit pressure.
Pressure because setting pressure of high pressure • If low, check and clean high pressure relief
check relief is low. valve or replace it if necessary.
6. Vibrator Motor Vibrator circuit pressure is not held in If pressure in vibrator motor case is not
vibrator motor case. within allowable range, repair vibrator motor
Internal leakage of vibrator motor. • Measure drain quantity from vibrator motor.
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 • Measure discharge flow rate of vibrator
pump due to reduced efficiency of vibrator pump with flow meter.
pump. • If discharge flow rate is not within specified
range, repair vibrator pump or replace it if
necessary.
Insufficient pump discharge due to wear of Replace vibrator pump.
vibrator pump drive shaft spline.
Vibrator circuit pressure is not held in If pressure in vibrator pump case is not
vibrator pump case. within allowable range, repair vibrator pump
9-076
TROUBLESHOOTING
3-3-2. Vibrator frequency is too low

Hydraulic Oil Tank
2. Charge Circuit Stroke of vibrator pump swash plate is small • Measure charge pressure.
Pressure because charge pressure is low, decreasing • If low, check and adjust charge relief valve
discharge rate of vibrator pump. or replace it if necessary.
necessary.
3. Suction Filter for Flow rate of charge pump decreases as Clean suction filter or replace it if necessary.
Charge Pump well as charge pressure decreases due to
clogged filter.
4. Vibrator Motor Vibrator motor inlet pressure is low. • Measure vibrator motor inlet pressure.
• If low, check and clean high pressure relief
valve or replace it if necessary.
Vibrator circuit pressure is not held in If pressure in vibrator motor case is not
vibrator motor case. within allowable range, repair vibrator motor
Decrease in vibrator motor rpm due to • Measure drain quantity from vibrator motor.
internal leakage in vibrator motor. • If drain quantity is larger than standard
value, repair vibrator motor or replace it if
necessary.
5. Vibrator Pump Insufficient discharge rate from vibrator • Measure discharge flow rate of vibrator
pump due to reduced efficiency of vibrator pump with flow meter.
pump. • If discharge flow rate is not within specified
range, repair vibrator pump or replace it if
necessary.
Insufficient pump discharge due to wear of Replace vibrator pump.
vibrator pump drive shaft spline.
Vibrator circuit pressure is not held in If pressure in vibrator pump case is not
vibrator pump case. within allowable range, repair vibrator pump
3-3-3. Amplitude does not switch between high and low

1. Vibrator Solenoid Vibrator solenoid valve spool shifts only in Repair vibrator solenoid valve or replace it if
Valve one direction. necessary.
9-077
TROUBLESHOOTING
3-3-4. Vibrator does not stop

1. Vibrator Solenoid Vibrator solenoid valve spool does not Repair vibrator solenoid valve or replace it if
Valve return to neutral position. necessary.
2. Vibrator Pump Vibrator pump swash place does not return Repair vibrator pump or replace it if
to neutral position. necessary.
3-3-5. Vibrator system is overheating

Hydraulic Oil Tank
oil cooler fins.
3. Vibrator Circuit If circuit pressure setting is excessively low, • Measure vibrator circuit pressure.
Pressure relief valve opens, causing temperature of • If low, check and clean relief valve or
hydraulic oil in circuit to rise. replace it if necessary.
If load is excessively heavy, relief valve • Measure vibrator circuit pressure.
opens, causing temperature of hydraulic oil • If high, decrease vibration load.
in circuit to rise.
3-3-6. Abnormal noise from vibrator system

1. Vibrator Bearings Vibrator bearings supporting eccentric shaft Replace vibrator bearings.
are damaged.
4. Vibrator Motor Internal bearing of vibrator motor is Repair vibrator motor or replace it if
damaged. necessary.
9-078
TROUBLESHOOTING
3-4. Steering System

If a problem occurs in the steering systems such as the steering pump and orbitrol, determine the cause and carry
out action as required, according to the following general troubleshooting items.
(NOTICE)
hydraulic circuit.
3-4-1. Steering wheel is hard to turn

Hydraulic Oil Tank
2. Orbitrol Relief valve is open or setting pressure is • Measure steering circuit pressure.
low. • If low, check and clean relief valve or
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 Check and clean orbitrol or replace it if
contaminated or clearance is incorrect. necessary.
3. Steering Circuit Pressure in return circuit from orbitrol Clean hydraulic oil filter 1 or replace it if
Pressure increases due to clogged charging hydraulic necessary.
oil filter 1.
4. Steering Cylinder Cylinder thrust decreases due to internal Repair steering cylinder or replace it if
leakage of steering cylinder. necessary.
5. Suction Filter for Charge pump discharge rate decreases due Clean suction filter or replace it if necessary.
Steering • Charge to clogged filter.
Pump
6. Steering • Charge Discharging pressure is insufficient due to • Measure steering circuit pressure.
Pump efficiency degradation of charge pump. • If low, replace charge pump.
7. Steering Column Column shaft and orbitrol shaft center are Align column shaft with orbitrol shaft center
misaligned. 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

Hydraulic Oil Tank
2. Orbitrol Oil is bypassing because relief valve is • Measure steering circuit pressure.
open. • If low, check and clean relief valve or
3. Steering Cylinder Internal leakage of steering cylinder. Repair steering cylinder or replace it if
necessary.
4. Suction Filter for Charge pump discharge rate decreases due Clean suction filter or replace it if necessary.
Pump
5. Steering • Charge Discharging pressure is insufficient due to • Measure steering circuit pressure.
Pump efficiency degradation of charge pump. • If low, replace charge pump.
9-079
TROUBLESHOOTING
3-4-3. Steering wheel backlash or play is large

1. Steering Column Spline of column shaft or orbitrol is worn. Replace column shaft or orbitrol.
Column shaft bearings are worn. Replace column shaft bearings.
2. Steering Wheel Serration (spline) of wheel or column shaft Replace wheel or column shaft.
is worn.
3-4-4. Steering system is overheating

Hydraulic Oil Tank
oil cooler fins.
3. Steering Circuit If circuit pressure setting is excessively low, • Measure steering circuit pressure.
Pressure relief valve is open, causing temperature of • If low, replace relief valve.
If load is excessively heavy, relief valve is • Measure steering circuit pressure.
open, causing temperature of hydraulic oil • If high, decrease steering load.
in circuit to rise.
4. Suction Filter for Load of steering pump increases due Clean suction filter or replace it if necessary.
Steering • Charge to clogged filter, causing temperature of
Pump hydraulic oil in circuit to rise.
3-4-5. Abnormal noise from steering system

1. Oil Level of Pump suction pressure is high because oil Fill tank until correct oil level is obtained.
Hydraulic Oil Tank level of hydraulic oil tank is low, causing
cavitation in steering circuit system.
2. Steering Circuit Cavitation is caused by air in circuit. Bleed circuit.
Pump
9-080
TROUBLESHOOTING
3-5. Blade (SV412TB, FB)

If a problem occurs in the blade control system, determine the cause and carry out action as required, according to
the following general troubleshooting items.
(NOTICE)
hydraulic circuit.
3-5-1. Blade up/down operation not possible

Hydraulic Oil Tank
2. Flow Dividing Valve Oil flow is not divided because spool is stuck Clean spool or replace it if necessary.
(Steering Blade) for on one side, interrupting hydraulic circuit.
Separation
3. Blade Circuit Circuit does not obtain required pressure • Measure blade circuit pressure.
Pressure because setting pressure of stack valve • If low, inspect stack valve relief valve or
relief valve is low. replace it if necessary.
4. Stack Valve Blade cylinder does not operate because If stack valve lever does not move, check
stack valve spool does not change. and clean spool, or replace stack valve.
5. Blade Cylinder Cylinder thrust decreases due to internal Repair blade cylinder or replace it if
leakage of blade cylinder. necessary.
6. Suction Filter for Steering pump discharge rate decreases Clean suction filter or replace it if necessary.
Steering • Charge due to clogged filter.
Pump
7. Steering • Charge Discharging pressure is insufficient due to • Measure the steering circuit pressure.
Pump efficiency degradation of steering pump. • If low, replace steering pump.
3-5-2. Blade movement is slow or force is small

Hydraulic Oil Tank
2. Stack Valve Oil bypassing because relief valve is open. • Measure blade circuit pressure.
• If low, inspect relief valve or replace it if
necessary.
3. Blade Cylinder Internal leakage of blade cylinder Repair blade cylinder or replace it if
necessary.
4. Suction Filter for Steering pump discharge rate decreases Clean suction filter or replace it if necessary.
Steering • Charge due to clogged filter.
Pump
5. Steering • Charge Discharge rate is insufficient due to • Measure the steering circuit pressure.
Pump efficiency degradation of steering pump. • If low, replace steering pump.
9-081
TROUBLESHOOTING
3-5-3. Blade floating operation not possible

Stack Valve Blade floating operation is not possible If stack valve lever does not move, check
because stack valve spool does not change. and clean spool, or replace stack valve.
3-5-4. Blade hydraulic system is overheating

Hydraulic Oil Tank
2. Blade Circuit If circuit pressure setting is excessively low, • Measure blade circuit pressure.
Setting Pressure relief valve is open, causing temperature of • If low, replace relief valve.
If load is excessively heavy, relief valve is • Measure blade circuit pressure.
open, causing temperature of hydraulic oil in • If high, decrease blade load.
circuit to rise.
3. S
uction Filter for Load of steering pump increases due Clean suction filter or replace it if necessary.
Steering • Charge to clogged filter, causing temperature of
Pump hydraulic oil in circuit to rise.
3-5-5. Abnormal noise from blade hydraulic system

1. Oil Level of Pump suction pressure is high because oil Fill tank until the correct oil level is obtained.
Hydraulic Oil Tank level of hydraulic oil tank is low, causing
cavitation in the blade system circuit.
2. Blade Circuit Cavitation is caused by air in circuit. Bleed circuit.
Clamp generated because clamp securing hydraulic to specified torque.
hose is loose.
4. S
uction Filter for Cavitation results at steering pump due to Clean suction filter or replace it if necessary.
Steering • Charge clogged filter.
Pump
9-082
TROUBLESHOOTING
Fig.: 4-1-1

39 L
LEFT HAND 1-2,4-6
CENTER 1-3,4-6
10
2
7
9
5
6
1
RIGHT HAND 1-3,4-5
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
2 51 G
1
3 53 WG 53 WR X B
SOL FUSE BOX
5 TO
39 L 4
23 3RG
FRONT MOTOR ENGINE TO
6 52 LR
3 5R
59 LW
SOLENOID ECM ALTERNATOR

TRAVEL MODE
SELECT SWITCH
23 3RG
52 LR X B
4 5BY
50 LW 50 LW
61 8W
61 8W
3 5R
SOL

51 G X B REAR MOTOR
SOLENOID

F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
TRAVEL MODE
RELAY (R11)
76 5WR
77 5BW
74 8WY
74 8WY
75 3G
B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
24 BR BR AV60
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09014
9-083
TROUBLESHOOTING

4-1. Electrical System Troubleshooting (Propulsion)
4-1-1. Travel mode cannot be changed 1/2
1. Front Motor Solenoid • Disconnect harness and measure resistance of coil. Replace front motor
• If measured resistance is abnormal, front motor solenoid
is faulty.
2. Rear Motor Solenoid • Disconnect harness and measure resistance of coil. Replace rear motor
• If measured resistance is abnormal, rear motor solenoid
is faulty.
3. Travel Mode Relay (1) When starter switch is ON and travel mode select Replace travel mode
(R11) switch is “ ”, measure voltage between travel mode relay (R11).
relay terminal 1 inlet wire G and chassis ground.
(2) When starter switch is ON and travel mode select
switch is “ ”, measure voltage between travel mode
relay terminal 3 inlet wire LR and chassis ground.
relay terminal 5 outlet wire LW and chassis ground.
travel mode relay is faulty.
9-084
TROUBLESHOOTING
Fig.: 4-1-1

39 L
LEFT HAND 1-2,4-6
CENTER 1-3,4-6
10
2
7
9
5
6
1
RIGHT HAND 1-3,4-5
20A
20A
20A
20A
20A
15A
15A
15A
15A
15A
2 51 G
1
3 53 WG 53 WR X B
SOL FUSE BOX
5 TO
39 L 4
23 3RG
FRONT MOTOR ENGINE TO
6 52 LR
3 5R
59 LW
SOLENOID ECM ALTERNATOR

TRAVEL MODE
SELECT SWITCH
23 3RG
52 LR X B
4 5BY
50 LW 50 LW
61 8W
61 8W
3 5R
SOL

51 G X B REAR MOTOR
SOLENOID

F.L. 65A
F.L. 65A
F.L. 45A
F.L. 45A
F.L. 45A
TRAVEL MODE
RELAY (R11)
76 5WR
77 5BW
74 8WY
74 8WY
75 3G
B
HEAT
24 BR
OFF BR
ACC
ON
STARTER
ST SWITCH

TO GRID HEATER
RELAY
24 BR BR AV60
BATTERY
RELAY
E
X 2B
AV60
95D31R
BATTERY
-
AV60 AV60
B
SV412-09014
9-085
TROUBLESHOOTING
4-1-1. Travel mode cannot be changed 2/2

4. Travel Mode Select (1) W
hen starter switch is ON, measure voltage between Replace travel mode
Switch travel mode select switch terminal 1, 4 inlet wire L and select switch.
chasiss ground.
select switch terminal wires and chassis ground.
• Travel mode select switch terminal 2 outlet wire G and
chasiss ground.
• Travel mode select switch terminal 6 outlet wire LR
and chasiss ground.
(3) W hen starter switch is ON and travel mode select
switch is “ ”, measure voltage between travel
mode select switch terminal wires and chassis ground.
• Travel mode select switch terminal 3 outlet wire WG
and chasiss ground.
• Travel mode select switch terminal 6 outlet wire LR
and chasiss ground.
(4) W hen starter switch is ON and travel mode select
select switch terminal wires and chassis ground.
• Travel mode select switch terminal 3 outlet wire WG
and chasiss ground.
• Travel mode select switch terminal 5 outlet wire LW
and chasiss ground.
• If above item (1) is OK and item (2), (3) or (4) is NG,
travel mode select switch is faulty.
9-086
TROUBLESHOOTING
4-2. Hydraulic System Troubleshooting (Propulsion)

If a problem occurs in the propulsion systems such as the propulsion pump, propulsion motor and brakes,
(NOTICE)
hydraulic circuit.

Hydraulic Oil Tank
2. Bypass Valve Bypass valve is open. Close bypass valve.
4. Charge Circuit Propulsion pump does not discharge oil • Measure charge pressure.
Pressure because charge pressure is low. • If low, check and adjust charge relief valve
necessary.
• Rear motor solenoid valve
5. Servo Bypass If spool of servo bypass solenoid valve • Measure pressure in servo cylinder
Solenoid Valve is stuck, pressure in both sides of servo chambers.
cylinder chamber is equalized. This causes • If pressure is equal in both chambers,
propulsion pump unable to discharge oil. repair servo bypass solenoid valve or
Charge Pump clogged filter.
7. Propulsion Circuit Circuit does not obtain required pressure • Measure propulsion circuit pressure.
Pressure because setting pressure of high pressure • If low, check and adjust multifunction valve
relief is low. or replace it if necessary.
8. Propulsion Motor Propulsion circuit pressure is not held in If pressure in propulsion motor case is not
Internal leakage of propulsion motor. • Measure drain quantity from propulsion
motor.
if necessary.
9-087
TROUBLESHOOTING

if necessary.
10. Parking Brake Brake remains applied because spool of Repair parking brake solenoid valve or
Solenoid Valve parking brake solenoid valve does not shift. replace it if necessary.
11. B
rake Inlet Brake cannot be released because brake • Measure brake release pressure.
Pressure inlet pressure is low. • If low, repair or replace propulsion motor.
12. Rear Axle Sticking of disc brakes causes brakes to • Replace disc brakes.
remain applied.
13. Flange Drive torque is not transmitted to pump due Replace flange.
to faulty flange.
4-2-2. Travel mode cannot be switched

1. Front Motor Travel mode does not change because Repair front motor solenoid valve or replace
Solenoid Valve spool of front motor solenoid valve does not it if necessary.
change.
2. Rear Motor Travel mode does not change because Repair rear motor solenoid valve or replace
Solenoid Valve spool of rear motor solenoid valve does not it if necessary.
change.
3. Propulsion Motor Faulty propulsion motor swash plate stroke Repair propulsion motor or replace it if
Swash Plate cylinder. necessary.
Stroke Cylinder
9-088
TROUBLESHOOTING
4-2-3. Propulsion system is overheating

Hydraulic Oil Tank
oil cooler fins.
3. Flushing Valve Hydraulic oil in propulsion closed circuit is Repair flushing valve or replace it if
shuttle spool sticking.
Hydraulic oil in propulsion closed circuit is Check dust or damage in flushing relief
insufficiently cooled because flushing valve valve and replace it if necessary.
relief setting pressure is excessively high.
Hydraulic oil in propulsion closed circuit is Clean flushing relief valve or replace it if
relief valve poppet sticking.
4. Propulsion Circuit If circuit pressure setting is excessively low, • Measure propulsion circuit pressure.
Pressure relief valve opens, causing temperature of • If low, increase relief setting pressure.
If load is excessively heavy, relief valve • Measure propulsion circuit pressure.
opens, causing temperature of hydraulic oil • If high, decrease propulsion load.
in circuit to rise.
4-2-4. Abnormal noise from propulsion system

1. Axle Bearings Axle bearings supporting front and rear Replace axle bearings.
drums are damaged.
2. Gear Box Reduction gear of gear box is damaged. Replace reduction gear.
(Front motor)
3. Rear Axle Rear axle gear is damaged. Replace rear axle gear.
6. Charge Circuit If charge pressure is low, brake cannot be • Measure charge pressure.
Pressure released completely, which causes brake • If low, check and adjust charge relief valve
drag. or replace it if necessary.
7. Propulsion Motor Internal bearing of propulsion motor is Repair propulsion motor or replace it if
damaged. necessary.
9-089
SAKAI HEAVY INDUSTRIES, LTD.
Head office: Seiwa Bldg., 4-8, Shibadaimon 1-chome,

Minato-ku, Tokyo, Japan
Telephone: +81-3-3434-3401
Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan

Telephone: +81-480-52-1111
Copyright © 2013 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Printed in Japan 2013.05.50 ○
0 H.S
0404-99053-0-32048-0

SV412 Shop Manual

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SV412

Sakai Heavy Industries cannot foresee all possible circumstances or varying

All information, specifications and illustrations in this publication are based on

3. ENGINE AND CONTROLS

4-12. Parking Brake Switch Harness

6. VIBRATORY DRUM • REAR AXLE

8. INSPECTION AND ADJUSTMENT

10. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE

3-2. Propulsion System

DANGER: Indicates an imminently hazardous situation or condition which if not avoided

WARNING: Indicates a potentially hazardous situation or condition which if not avoided

CAUTION: Indicates a potentially hazardous situation or condition which if not avoided

(NOTICE): Indicates important information about operation or maintenance of the

★: Indicates standard value to judge whether measured value is good or not.

1-3. Qualifications of Operators and Maintenance Personnel

1-4. Safety Practices and Policies

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

1-5. Pre Start Inspection

1-6. Safety Instructions

1-11. Transporting the Machine

1700 920 2650 1410

CUMMINS QSB3.3 Diesel Engine

1700 935 2650 1415

CUMMINS QSB3.3 Diesel Engine

1700 935 2650 1415

CUMMINS QSB3.3 Diesel Engine

1700 1265 2650 1415

CUMMINS QSB3.3 Diesel Engine

1700 1260 2650 1415

CUMMINS QSB3.3 Diesel Engine

2. TABLE OF STANDARD VALUES

2-3. Hydraulic Systems

Motor drainage 6.3 L/min ( 1.7 gal./min )

(orbitroll relief pressure +

Clearance between brake pedal and 169 mm (6.7 in.)

4.5 mm (0.18 in.)

3. FUEL AND LUBRICANTS SPECIFICATION

Engine oil API grade CH-4 SAE10W-30 SAE15W-40 SAE15W-40 MIL-L-2104B

Gear oil API grade GL4 SAE80W-90 SAE90 SAE140 MIL-L-2105

ISO-VG32 ISO-VG46 ISO-VG68

Grease Lithium type extreme pressure NLGI-2

Fuel Diesel oil ASTM D975-2D

3-2. Recommended Lubricants

4. TIGHTENING TORQUE CHART

Nominal Strength Classification

12 1.75 69 (51) 78 (58) 108 (80) 108 (80)

16 1.5 167 (123) 206 (152) 284 (209) 284 (209)

(1) Bracket (7) Stopper (13) Plate

1-2. Engine Exterior

Flywheel housing Flywheel Crankcase breather

(1) Bolt : M10× 25 (6) Housing

(1) Bolt M10× 25 : 59 N·m ( 44 lbf·ft )

3-1-1. Installation of pump 1

★ Specified dimension a: 9 mm (0.35 in.) 4

(9) Bolt M12×35 : 86 N·m (63 lbf·ft)

⑤ Secure housing (6) to engine flywheel housing with twelve

⑥ Engage hub (4) with flange (5).

(7) Bolt M14×45 : 167 N·m (123 lbf·ft)

1. SYSTEM CIRCUIT DIAGRAM

Basic Symbols Pump, Motors and Cylinders

Pilot control Unidirectional

Drain or bleed Bidirectional

Valves Methods of Operation

Check valve Spring

10. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE

DANGER: Indicates an imminently hazardous situation or condition which if not avoided

WARNING: Indicates a potentially hazardous situation or condition which if not avoided

CAUTION: Indicates a potentially hazardous situation or condition which if not avoided

(NOTICE): Indicates important information about operation or maintenance of the

★: Indicates standard value to judge whether measured value is good or not.

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

⑤ Secure housing (6) to engine flywheel housing with twelve

⑥ Engage hub (4) with flange (5).