Table of Contents

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PREFACE
Generally, rollers tend to come large-sized and find their applications in
dangerous fields such as rough terrain, steep slopes or slippery areas. Faulty
rollers may risk a grave accident.
For purpose-built rollers to negotiate problem terrain with the ultimate in
performance maintained free from failure over the longest possible period of
time, adequate handling and regular preventive maintenance recommended
are of prime importance. If a trouble developes, it should be effectively
corrected with proper safety measures taken.
This service manual is intended to serve as a guide particularly for
maintenance personnel to perform quality service by gaining working
knowledge of and reliable maintenance techniques for machines in question.
Included in this literature are descriptions of SPECIFICATIONS, STRUCTURE
& OPERATION, INSPECTION & ADJUSTEMNT, FAULT DIAGNOSIS and
DISASSEMBLY & ASSEMBLY. Systematic explanations are being given to
each of these five cathegories in this sequence.
Rollers principally concern qualitative factors as represented by 'compaction
density', to say nothing of quantitative elements like 'productivity'.
SPECIFICATIONS section includes performance data of major significance
e.g. 'vibratory frequency' to be checked when servicing machines in question.
For reasonable maintenance services, it is a precondition to know the vital
portions of machines in question and how they work. Referring to relevant
electric wiring and hydraulic circuit diagrams, STRUCTURE & OPERATION
instructs location of key units and function of systems into which the key units
are assembled.

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Summary of Contents for Sakai SW352

  • Page 1 PREFACE Generally, rollers tend to come large-sized and find their applications in dangerous fields such as rough terrain, steep slopes or slippery areas. Faulty rollers may risk a grave accident. For purpose-built rollers to negotiate problem terrain with the ultimate in performance maintained free from failure over the longest possible period of time, adequate handling and regular preventive maintenance recommended are of prime importance.
  • Page 2 Adjustment practice to restore a faulty machine to the normal operating state involves measurement procedure which compares measured figures with the standard values. INSPECTION & ADJUSTMENT specifies conditions to measurement and standard values. Safety precautions are also given where necessary. Illustrations included indicate important points like gauge connection location.
  • Page 3: Table Of Contents

    CONTENTS SPECIFICATIONS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1-001 STRUCTURE AND OPERATION・...
  • Page 5: Specifications

    SPECIFICATIONS...
  • Page 7 1-1. SW352 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・...
  • Page 8 SPECIFICATIONS 1.External Views and Specification Data 1-1. SW352 1200 2000 1200 2675 TW5021001 Model SW352 Vibrating power: Frequency 55 Hz Weight: Centrifugal force 20.6 kN (4,630 lbs) Gross weight 2,940 kg (6,485 lbs) Gradability 21 degrees Empty weight 2,740 kg (6,045 lbs) Rolling width 1,200 mm (47”)
  • Page 9 SPECIFICATIONS 1-2. TW352 1200 2000 2675 TW5021002 Model TW352 Vibrating power: Frequency 55 Hz Weight: Centrifugal force 20.6 kN (4,630 lbs) Gross weight 2,640 kg (5,820 lbs) Gradability 21 degrees Empty weight 2,440 kg (5,380 lbs) Rolling width 1,200 mm (47”) Dimention: Minimum turning radius 3.8 m (150”)
  • Page 10 SPECIFICATIONS 1-3. SW502 1300 2300 1300 3100 TW5021003 Model SW502 Vibrating power: High Frequency 55 Hz 55 Hz Weight: Centrifugal force 26.5 kN (5,955 lbs) 34.3 kN (7,710 lbs) Gross weight 4,090 kg (9,020 lbs) Gradability 21 degrees Empty weight 3,780 kg (8,335 lbs) Rolling width 1,300 mm (51”)
  • Page 11 SPECIFICATIONS 1-4. TW502 1300 2300 3105 TW5021004 Model TW502 Vibrating power: High Frequency 55 Hz 55 Hz Weight: Centrifugal force 26.5 kN (5,955 lbs) 34.3 kN (7,710 lbs) Gross weight 3,540 kg (7,800 lbs) Gradability 21 degrees Empty weight 3,230 kg (7,120 lbs) Rolling width 1,300 mm (51”) Dimension:...
  • Page 12 MEMO...
  • Page 13: Structure And Operation

    STRUCTURE AND OPERATION...
  • Page 15 2-1-3. Front vibrator pump assembly and steering/charge pump assembly · · · · · · · 2-013 2-1-4. Hydraulic circuit diagram (SW352) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-014 2-1-5.
  • Page 16 6-3. Electric wiring diagram (SW352) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·...
  • Page 17: Location Of Engine-Related Units

    Location of Engine-related Units 1. Location of Engine-related Units 1-1. Engine mount TW5022001 1. Engine mount (front) 2. Engine mount (rear) ★ Above illustrations show the engine mount of TW502. 2-003...
  • Page 18: Intake System

    Location of Engine-related Units 1-2. Intake system TW5022003 1. Intake hose 2. Air cleaner 3. Intake hose ★ Above illustrations represent the intake items of SW352, TW352. 2-004...
  • Page 19 Location of Engine-related Units 1-3. Intake system TW5022002 1. Intake hose 4. Intake hose 2. Air cleaner 5. Intake hose 3. Intake pipe ★ Above illustrations are the intake items of TW502. 2-005...
  • Page 20: Exhaust System

    Location of Engine-related Units 1-4. Exhaust system TW5022005 1. Exhaust pipe 2. Muffler 3. Exhaust pipe ★ Above drawings ilustrate the exhaust items of SW352, TW352. 2-006...
  • Page 21 Location of Engine-related Units 1-5. Exhaust system TW5022004 1. Exhaust pipe 2. Muffler 3. Exhaust pipe ★ Above figures represent the exhaust items of TW502. 2-007...
  • Page 22: Cooling Piping And Radiator

    Location of Engine-related Units 1-6. Cooling piping and radiator TW5022057 1. Radiator 5. Sub tank 2. Radiator fan motor 6. Pipe 3. Radiator fan 7. Hose 4. Radiator inlet hose 8. Radiator outlet hose 2-008...
  • Page 23: Fuel Piping And Fuel Tank

    Location of Engine-related Units 1-7. Fuel piping and fuel tank TW5022006 1. Fuel tank 5. Hose (injection pump to fuel tank) 2. Hose (fuel tank to filter) 6. Fuel filter 3. Hose (filter to fuel pump) 7. Fuel pump 4. Hose (fuel pump to injection pump) 2-009...
  • Page 24: Fuel Controls

    Location of Engine-related Units 1-8. Fuel controls VIEW A TW5022007 1. Throttle lever 2. Knob 3. Throttle cable 2-010...
  • Page 25: Description And Operation Of Hydraulic System

    ★ Both pumps have the same shape but different displacement. VIEW A SW5022008 1. Port A (forward travel) 10. Control lever Technical data (SW352, TW352) 2. Port B (reversing) 11. Case drain port ・Model PVM28-608 3. Multi-function valve (port A) 12.
  • Page 26: Rear Vibrator Pump Assembly (Sw352, Sw502)

    Description and Operation of Hydraulic system 2-1-2. Rear vibrator pump assembly (SW352, SW502) VIEW A SW5022009 1. Inlet port Technical data 2. Outlet port ・Model YP15A13A ・Displacement: 12.87 cm /rev (0.8 cu.in/rev) ・Pressure setting: 12.7 MPa (130 kgf/cm 2-012...
  • Page 27 2. Outlet port (No.1 pump: Front vibrator) ・Model: DDG1A15·12 3. Outlet port (No.2 pump: Steering/charge) ・Displacement: 15 cm /rev (0.9 cu.in/rev) ・Pressure setting: 12.7 MPa (130 kgf/cm (SW352, TW352) 14.4 MPa (147 kgf/cm (SW502, TW502) Technical data (No.2 pump) ・Displacement: 12.5 cm /rev (0.8 cu.in/rev) ・Pressure setting: 3.5 MPa (138 kgf/cm...
  • Page 28: Hydraulic Circuit Diagram (Sw352)

    Description and Operation of Hydraulic System 2-1-4. Hydraulic circuit diagram (SW352) 2-014...
  • Page 29: Hydraulic Circuit Diagram (Sw502)

    Description and Operation of Hydraulic System 2-1-5. Hydraulic circuit diagram (SW502) 2-015...
  • Page 30: Hydraulic Circuit Diagram (Tw352)

    Description and Operation of Hydraulic System 2-1-6. Hydraulic circuit diagram (TW352) 2-016...
  • Page 31: Hydraulic Circuit Diagram (Tw502)

    Description and Operation of Hydraulic System 2-1-7. Hydraulic circuit diagram (TW502) 2-017...
  • Page 32: Propulsion Line

    Description and Operation of Hydraulic System 2-2. Propulsion line 2-2-1. Hydraulic piping (front) VIEW A TW5022015 1. Propulsion pump 8. Charge hose 2. Propulsion motor (front) 9. Drain hose (pump) 3. High pressure hose (forward travel) 10. Oil cooler outlet hose 4.
  • Page 33: Hydraulic Piping (Rear)

    Description and Operation of Hydraulic System 2-2-2. Hydraulic piping (rear) TW5022016 1. Rear propulsion motor 2. High pressure hose (forward travel) 3. High pressure hose (reversing) 4. Rear motor drain hose 5. Brake release hose 6. Bypass valve ★ Above illustrations represent the hydraulic piping of SW502. 2-019...
  • Page 34 Description and Operation of Hydraulic System 2-2-3. Hydraulic piping (rear) VIEW A TW5022017 1. Front propulsion motor (L.H.) 7. High pressure hose (forward travel) 2. High pressure hose (forward travel) 8. High pressure hose (reversing) 3. High pressure hose (reversing) 9.
  • Page 35: Propulsion Motor (Cam Motor) Assembly (Front)

    2-2-4. Propulsion motor (cam motor) assembly (front) ★ Both motors have the same shape with different displacement. TW5022018 1. Port B (forward travel) Technical data (front of SW352, TW352) 2. Port A (reversing) ・Model DCM0280-536 3. Drain port ・Max. displacement: 465 cm /rev (28.4 cu.in/rev)
  • Page 36: Propulsion Motor (Cam Motor) Assembly (Rear)

    1. Port A (forward and reversing) 2. Port B (forward and reversing) 3. Drain port 4. Brake release port (imergency release) 5. Brake release port Technical data (rear of SW352) Technical data (rear of SW502) ・Model: DCM0280-541 ・Model: DCM0560-549 ・Displacement: 465 cm /rev (28.4 cu.in/rev)
  • Page 37: Description And Operation Of Cam Motor

    Description and Operation of Hydraulic System 2-2-6. Description and operation of cam motor Construction of cam motor ・The cam motor is made up of output flange (1), housing (2), cam ring (4), end cap (5), brake housing (6), brake cover (9), cylinder block (10), distributor (11), speed selector valve (12) and flushing valve (13), etc.
  • Page 38 Description and Operation of Hydraulic System Font propulsion motor (cam motor fitted :High main pressure with speed selector valve) :Low main pressure Operation ★ It is assumed that oil is fed into port A of the motor. Selection of low speed ★...
  • Page 39 Description and Operation of Hydraulic System Selection of High speed :Main high pressure ★ Spool operating pilot pressure: 1.0-4.9 :Main low pressure MPa (10-50 kgf/cm :Charge pressure ・Two of three ports lead to distributor (11) with speed selector valve (12) moved in the direction shown by arrow.
  • Page 40 Description and Operation of Hydraulic System Rear propulsion motor (cam motor with :High main pressure speed selector valve not fitted) Operation :Low main pressure ★ It is assumed oil is fed into port A of motor. ・Pump flow into port A of end cap (5) is distributed to six ports of distributor (11) which lead to port A.
  • Page 41: Rear Axle Assembly (Tw352, Tw502)

    Description and Operation of Hydraulic System 2-2-7. Rear axle assembly (TW352, TW502) ★ Wide tire version TW5022027 1. Hub bolt 4. Disc wheel 2. Hub nut 5. Disc 3. Tire 6. Propulsion motor 2-027...
  • Page 42: Propulsion Controls

    Description and Operation of Hydraulic System 2-2-8. Propulsion controls SECTION A-A TW5022028 1. Forward-reverse (F-R) lever 5. Interlock switch 2. Vibrator on-off switch 6. Reverse alarm switch 3. Shaft 7. Control lever 4. Control cable 2-028...
  • Page 43: Propulsion Circuit Diagram (Sw352, Sw502)

    Description and Operation of Hydraulic System 2-2-9. Propulsion circuit diagram (SW352, SW502) 1. Engine 2. Coupling 3. Propulsion pump a. Control valve b. Servo piston c. Multi-function valve d. Charge relief valve e. Brake release solenoid valve f. Speed selector solenoid valve 4.
  • Page 44: Propulsion Circuit Diagram (Tw352, Tw502)

    Description and Operation of Hydraulic System 2-2-10. Propulsion circuit diagram (TW352, TW502) 1. Engine 2. Coupling 3. Propulsion pump a. Control valve b. Servo piston c. Multi-function valve d. Charge relief valve e. Brake release solenoid valve f. Speed selector solenoid valve 4.
  • Page 45: Description And Operation Of Propulsion System

    ‘High speed’. Rear propulsion motor ・The rear propulsion motor (SW352, TW352, SW502, TW502) uses a fixed displacement radial piston motor (cam motor). Choice of two speeds in the front motor varies the amount of oil flowing into the rear motor.
  • Page 46 (1) and (2), while component parts of assemblies are shown by small letters like (a) and (b). SW352, SW502 ★ The front and rear motors connect together in parallel in their hydraulic circuit.
  • Page 47 Description and Operation of Hydraulic System TW352, TW502 ・The propulsion system is a combination of a propulsion pump and three propulsion motors (cam motors). The front and rear motors connect with each other in parallel in their hydraulic circuit. ・Moving the forward-reverse lever forward makes servo piston (b) of control valve (a) function to tilt the pump swashplate in the forward drive...
  • Page 48 Description and Operation of Hydraulic System Speed selection * See hydraulic circuit diagrams on pages 2-032 and 2-033. ・When speed selector solenoid valve (f) becomes energized, oil from the charge circuit is fed into the speed selection port of front propulsion motor (cam motor) (5) to actuate speed selector valve (g). ・With valve (g) actuated, oil that has been fed into six of twelve ports of distributor (11) while the machine is running at ‘Low speed’...
  • Page 49 Description and Operation of Hydraulic System Circuit protection against excessive pressure ・Multi-function valve (c) fitted in the propulsion pump relieves the circuit pressure if it exceeds the setting of the valve, preventing damage to the circuit. Charge circuit ・The propulsion ciruit is of a closed loop circuit.
  • Page 50: Vibrating System

    Description and Operation of Hydraulic System 2-3. Vibrating system 2-3-1. Hydraulic piping (SW352) VIEW A TW5022033 1. Front vibrator pump & 5. High pressure hose 9. Front check valve steering/charge pump 6. Return hose 10. Rear vibrator on-off solenoid 2. Suction hose 7.
  • Page 51: Hydraulic Piping (Sw502)

    Description and Operation of Hydraulic System 2-3-2. Hydraulic piping (SW502) TW5022034 1. Front vibrator pump & 5. High pressure hose (high amp.) 9. Rear vibrator pump steering/charge pump 6. High pressure hose (low amp.) 10. Rear pump outlet hose 2. Suction hose 7.
  • Page 52: Hydraulic Piping (Tw352)

    Description and Operation of Hydraulic system 2-3-3. Hydraulic piping (TW352) VIEW A TW5022035 1. Vibrator pump & 5. High pressure hose steering/charge pump 6. Return hose 2. Suction hose 7. Drain hose 3. Pump outlet hose 8. Vibrator on-off solenoid valve 4.
  • Page 53: Hydraulic Piping (Tw502)

    Description and Operation of Hydraulic system 2-3-4. Hydraulic piping (TW502) TW5022036 1. Vibrator pump & 5. High pressure hose (high amp.) steering/charge pump 6. High pressure hose (low amp.) 2. Suction hose 7. Drain hose 3. Pump outlet hose 8. Amplitude selector solenoid 4.
  • Page 54: Vibrator Motor Assembly

    2-3-5. Vibrator motor assembly TW5022037 1. Port A (inlet/outlet port) Technical data 2. Port B (inlet/outlet port) ・Model: SNM2/11 3. Drain port ・Displacement: 10.8 cm /rev (0.7 cu.in/rev) ・Pressure setting: 12.7 MPa (130 kgf/cm (SW352, TW352) 14.4 MPa (141 kgf/cm (SW502, TW502) 2-040...
  • Page 55: Radiator Fan Motor Assembly

    Description and Operation of Hydraulic system 2-3-6. Radiator fan motor assembly VIEW A TW5022038 1. Inlet port Technical data 2. Outlet port ・Model: WM09A1C 3. Pressure relief valve ・Displacement: 14.0 cm /rev (0.9 cu.in/rev) ・Pressure setting: 5.0 MPa (51 kgf/cm 2-041...
  • Page 56: Vibrator (Sw352, Tw352)

    Description and Operation of Hydraulic system 2-3-7. Vibrator (SW352, TW352) 8 9 10 11 13 12 TW5022039 1. Side plate 9. Disc 17. O-ring 25. O-ring 2. Propulsion motor 10. Shim 18. Breather 26. O-ring 3. Shockmount 11. O-ring 19. Taper roller bearing 27.
  • Page 57: Vibrator (Sw502, Tw502)

    Description and Operation of Hydraulic system 2-3-8. Vibrator (SW502, TW502) Counterclockwise rotation-High amp. Clockwise rotation-Low amp. TW5022040 SECTION A-A 1. Side plate 9. Disc 17. O-ring 25. Shaft 2. Propulsion motor 10. Shim 18. Breather 26. Fixed weight 3. Shockmount 11.
  • Page 58: Vibrator Circuit Diagram (Sw352, Tw352)

    Description and Operation of Hydraulic system 2-3-9. Vibrator circuit diagram (SW352, TW352) Rear vibrator of SW352 TW5022041 1. Engine 8. Radiator fan motor 2. Vibrator pump (with check valve and relief valve) 3. Suction filter 9. Oil cooler 4. Vibrator on-off solenoid valve 10.
  • Page 59: Vibrator Circuit Diagram (Sw502, Tw502)

    Description and Operation of Hydraulic system 2-3-10. Vibrator circuit diagram (SW502, TW502) Rear vibrator of SW502 TW5022042 1. Engine 8. Oil cooler 2. Front vibrator pump 9. Rear vibrator pump 3. Suction filter 10. Amplitude selector solenoid valve 4. Amplitude selector solenoid valve (with pressure relief valve) (with pressure relief valve) 11.
  • Page 60: Description And Operation Of Vibrating System

    Vibrator motor ・Same type as the vibrator pump. Operation SW352, TW352 (front vibrator) * See hydraulic circuit diagrams on page 2-044. ・Vibrator pump (2) feeds oil all the time that the engine is running. When the vibrator is not in use, oil is fed to radiator fan motor (8) via vibrator on-off solenoid valve (4) to drive it and then exhausted to the tank either through the oil cooler or directly.
  • Page 61 Description and Operation of Hydraulic system SW352 (rear vibrator) * See hydraulic circuit diagrams on page 2-044. ・Being a gear pump, rear vibrator pmp (2) discharges oil as long as it is driven. When the vibrator is not in use, it is unloaded by vibrator on-off solenoid valve (11).
  • Page 62: Steering System

    Description and Operation of Hydraulic system 2-4. Steering system 2-4-1. Hydraulic piping TW5022043 7. High pressure hose (left turn) 1. Steering/charge pump 8. Steering valve (Orbitrol) 2. Suction hose 3. Pump outlet hose (1) 9. Steering cylinder 4. Charge circuit hose (1) 10.
  • Page 63: Steering Valve (Orbitrol)

    ・Valve system: Open center non-load reaction 5. Spring 15. O-ring ・Displacement: 100 cm /rev (6.1 cu.in/rev) 6. Cross pin 16. Bush (SW352, TW352) 7. Drive 17. Check valve 160 cm /rev (9.8 cu.in/rev) 8. Distributor plate 18. Ball (SW502, TW502) 9.
  • Page 64: Steering Cylinder Assembly

    Description and Operation of Hydraulic system 2-4-3. Steering cylinder assembly SW5002040 1. Cylinder 5. Nut 9. O-ring 2. Piston rod 6. Seal 10. Spherical bearing 3. End cap 7. Dust seal 11. Lock ring 4. Piston 8. U-ring 2-050...
  • Page 65: Steering Circuit Diagram

    Description and Operation of Hydraulic system 2-4-4. Steering circuit diagram TW5022045 1. Engine 6. Suction filter 2. Coupling 7. Steering valve (Orbitrol) 3. Propulsion pump a. Relief valve 4. Steering/charge pump 8. Steering cylinder 5. Line filter 2-051...
  • Page 66: Description And Operation Of Steering Circuit

    Description and Operation of Hydraulic system 2-4-5. Description and operation of steering circuit Description ・The steering system consists of steering/ charge pump (4), line filter (5), steering valve (Orbitrol) (7) and steering cylinder (8). The steering mechanism is of an articulated type in which the machine frame is articulated at its center.
  • Page 67: Brake System

    Brake System 3. Brake System 3-1. Brake pedal SECTION A-A TW5022047 1. Brake pedal 2. Brake pedal switch 3. F-R lever rod (centering rod) 4. F-R lever rod (centering rod) 5. Spring 2-053...
  • Page 68: Description And Operation Of Parking Brake (Negative Brake) Circuit

    Brake System 3-2. Description and operation of parking brake (negative brake) circuit Description Parking brake switch set to RELEASE ・Consists of brake pedal (1), foot brake switch (2), position. centering rods (3), (4), parking brake switch (5), ・The contact points of parking brake switch (5) F-R lever (6), brake release solenoid valve (7), close the circuit to the brake release solenoid parking brakes (negative brakes) (8), (9), (10)
  • Page 69: Sprinkler

    Sprinkler 4. Sprinkler 4-1. Sprinkler piping TW5022049 1. Sprinkler tank 6. Hose (pump to rear pipe) 2. Sprinkler pump 7. Hose (pump to front pipe) 3. Sprinkler filter 8. Sprinkler pipe (rear) 4. Hose (tank to filter) 9. Sprinkler pipe (front) 5.
  • Page 70: Liquid Sprayer

    Liquid Sprayer 5. Liquid Sprayer 5-1. Liquid sprayer piping SECTION A-A TW5022050 1. Liquid tank 6. Hose (pump to pipe) 2. Liquid filter 7. Hose (pipe to pump) 3. Hose (tank to filter) 8. Liquid pipe 4. Hose (filter to pump) 9.
  • Page 71: Electric System

    Electric System 6. Electric System 6-1. Location of instrument panel and key units VIEW A VIEW B VIEW C TW5022051 1. Fuse box 8. Vibrator relay 15. Turn signal lamp 2. Control box 9. Glow lamp timer 16. Battery 3. Horn relay 10.
  • Page 72: Location Of Key Units

    Electric System 6-2. Location of key units DETAIL A TW5022052 1. Engine oil pressure switch 6. Amplitude selector solenoid 10. Glow plug 2. Fuel unit valve (rear) 11.Tachometer sensor 3. Alternator 7. Brake release solenoid valve 12. Engine stop solenoid 4.
  • Page 73: Electric Wiring Diagram (Sw352)

    Electric System 6-3. Electric wiring diagram (SW352) FLOOD LAMP HEAD LAMP 25W TURN SIGNAL LAMP (R) HEAD LAMP 25W STOP LAMP 10W TAIL LAMP/PARKING LAMP 12W BACK-UP LAMP TURN SIGNAL LAMP(R) WATER SPRAY PARKING BRAKE SPEED CHANGE F/R LEVER SW.(R)
  • Page 74: Electric Wiring Diagram (Tw352)

    Electric System 6-4. Electric wiring diagram (TW352) FLOOD LAMP HEAD LAMP LIQUID 25W TURN SIGNAL LAMP (R) HEAD LAMP SPRAY 25W STOP LAMP SWITCH 10W TAIL LAMP/PARKING LAMP 2BrR 2BrW BrW R 12W BACK-UP LAMP TURN SIGNAL LAMP(R) LIQUID WATER SPRAY F/R LEVER SW.(R) SPRAY MOTOR...
  • Page 75: Electric Wiring Diagram (Sw502)

    Electric System 6-5. Electric wiring diagram (SW502) FLOOD LAMP HEAD LAMP 25W TURN SIGNAL LAMP (R) HEAD LAMP 25W STOP LAMP 10W TAIL LAMP/PARKING LAMP 12W BACK-UP LAMP TURN SIGNAL LAMP(R) WATER SPRAY PARKING BRAKE SPEED CHANGE F/R LEVER SW.(R) MOTOR HORN BACK-UP...
  • Page 76: Electric Wiring Diagram (Tw502)

    Electric System 6-6. Electric wiring diagram (TW502) FLOOD LAMP HEAD LAMP LIQUID 25W TURN SIGNAL LAMP (R) HEAD LAMP SPRAY 25W STOP LAMP SWITCH 10W TAIL LAMP/PARKING LAMP 2BrR 2BrW BrW R 12W BACK-UP LAMP TURN SIGNAL LAMP(R) LIQUID WATER SPRAY F/R LEVER SW.(R) SPRAY MOTOR...
  • Page 77: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...
  • Page 79 1-1. SW352, TW352 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・...
  • Page 80 Standard Value Chart 1. Standard Value Chart 1-1. SW352, TW352 Standard value Permissible Item Measuring conditions Unit for new machine range 950 ± 25 • Coolant temp. Low idle ← : Displayed on gauge 2450 ± 50 Engine Speed High idle ←...
  • Page 81 Standard Value Chart 1-2. SW502, TW502 Standard value Permissible Item Measuring conditions Unit for new machine range 950 ± 25 • Coolant temp. Low idle ← : Displayed on gauge 2450 ± 50 Engine Speed High idle ← • Hydraulic oil working (rpm) temperature : 50 ±...
  • Page 82 Inspection and Adjustment 2. Inspection and Adjustment 2-1. Measurement and adjustment of pressure in propulsion main circuit 1. Measurement ・Hydraulic oil temperature: 50 ± 5 °C Park the machine on level ground. Stop the engine. Block the wheels. Make certain that the parking brake func- tions correctly.
  • Page 83 Inspection and Adjustment 2-2. Measuremment and adjustment of propulsion charge circuit pressure 1. Measurement ・Hydraulic oil temperature: 50 ± 5 °C 1, 2 (opposite side) Position the machine on level ground. Stop the engine and chock the wheels. ★ Because oil is supplied from the steering/charge pump, make sure, prior to measurement, that the steering system works correctly.
  • Page 84 Inspection and Adjustment 2-3. Measurement of propulsion motor speed selecting pressure 1. Measurement ・Hydraulic oil temperature: 50 ± 5 °C Position the machine on level surface. Stop the engine and place chock blocks in front and rear of wheels. ★ Prior to measurement, check that the steering system works correctly, since oil is fed from the steering/charge pump.
  • Page 85 Inspection and Adjustment 2-4. Measurement of brake release pressure 1. Measurement ・Hydraulic oil temperature: 50 ± 5 °C Park the machine on level surface. Stop the engine and block the wheels. ★ Make certain that, prior to measuement, the steering system functions correctly, as oil is supplied from the steering circuit.
  • Page 86 ・Hydraulic oil temperature: 50 ± 5 °C Position the machine on level surface. Stop the engine and block the wheels. SW352, TW352 1) Disconnect hose (1) at the high pressure inlet port of the front vibrator motor. Fit adapter t.
  • Page 87 Inspection and Adjustment SW502, TW502 1) Disconnect hose (1) from the front propulsion motor at the high pressure inlet port for low amplitude or hose (2) at the high pressure inlet port for high amplitude. Fit adapter t. ★ TW502 has the front vibrator alone. 2) Install a 0-24.5 MPa (0-250 kgf/cm pressure gauge to adapter y.
  • Page 88 Inspection and Adjustment 2-6. Measurement and adjustment of steering circuit pressure 1. Measurement ・Hydraulic oil temperature: 50 ± 5 °C Position the machine on level ground. Stop the engine. Chock the wheels. ★ Because the return line of the steering cir- cuit makes the pressure source of the propulsion charge circuit, ensure before measurement, that the steering system...
  • Page 89 3) Start the engine. Slacken lock nut (4) and adjust stop bolt (5) until correct low idle revolution is obtained. ・Low idle: 950 ± 50 rpm for SW352, TW352 950 ± 50 rpm for SW502, TW502 4) With throttle lever (1) moved to the full throttle position, loosen locknut (7) and adjust stop bolt (8) so that governor lever (3) makes contact with stopper (6) on the full throttle side.
  • Page 90 Inspection and Adjustment 2-8. Adjustment of F-R lever linkage stroke Park the machine on level ground. Stop the engine. Chock the wheels. ★ When the propulsion pump or F-R lever linkage has been renewed or if the F-R lever fails to move smoothly, adjust the F-R lever stroke as instructed below: 1.
  • Page 91: Fault Diagnosis

    FAULT DIAGNOSIS...
  • Page 93 FAULT DIAGNOSIS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4-002 1.
  • Page 94 Precautions for Fault Diagnosis 1. Precautions for Fault Diagnosis Park the machine on level ground. Make sure that the safety pins are engaged, wheels chocked and parking brake applied. When working with other workmates, use hand signals authorized, and keep people not concerned away from the work area.
  • Page 95 How to Make a Fault Diagnosis 2. How to Make a Fault Diagnosis Office and repair shop (Maker’s side) Site (Customer’s side) Procedure 1. Confirmation of trouble 1) Make inquiries about the following items upon request of repair from customer. Customer Work site •...
  • Page 96 How to Use Fault Diagnosis Flow Chart 3. How to Use Fault Diagnosis Flow Chart 1. Fault diagnosis code numbers 1) Electric system: E-01 to E-09 2) Hydraulic and mechanical systems: H-01 to H-09 2. How to use the fault diagnosis flow chart Example q E-10 Headlamps do not work w ★...
  • Page 97 How to Use Fault Diagnosis Flow Chart ・As a result of checking, if YES line or NO line directly goes to the description in the CAUSE column, take necessary action as indicated in the REMEDY column. ・Under each box (□) are standard value and condition necessary for diagnosis procedure. If the result gives an affirmative answer to the question adressed in the box or agrees with the value indicated under the box, then go to YES line.
  • Page 98 Precautions for Fault Diagnosis of Electric System 4. Precautions for Fault Diagnosis of Electric System 1. When disconnecting or connecting connectors or harnesses, cut the power supply. 2. Before making a diagnosis, check the connectors or harnesses for poor connection. ★...
  • Page 99 Fault Diagnosis of Electric System (Mode E) 5. Fault Diagnosis of Electric System (Mode E) E-01 Engine does not start ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4-202 E-02 Engine does not stop ・...
  • Page 100 Fault Diagnosis of Electric System (Mode E) E-01 Engine does not start ★ Set the F-R lever to the neutral position. ★ Check for burnt fuse first. ★ For voltage measurement, turn the starter switch ON. a) Starter motor does not operate. (1/2) Is stated voltage present at starter terminal S that...
  • Page 101 Fault Diagnosis of Electric System (Mode E) Possible cause Remedy Starter faulty. Renew. Wire from interlock relay terminal to starter terminal S Repair or renew not connected or incorrectly wire. connected. Interlock relay faulty. Renew. Is stated voltage present at interlock relay coil that carries wire GY? F-R lever interlock switch...
  • Page 102 Fault Diagnosis of Electric System (Mode E) Possible cause Remedy Starter switch faulty Renew. (between B and BR) Is specified voltage  fed to starter switch  Wire WR or W from battery Repair or renew terminal B that  relay terminal COM to starter wire. carries wire WR? switch terminal B not connected Renew fuse.  Is specified voltage  or incorrctly connected. fed to battery relay  • 10〜14V terminal COM that  Cable from battery plus (+) carries wire W? terminal to battery relay terminal Repair or renew COM not connected or incorrectly cable.  • 10〜14V connected. Electric wiring diagram for modes E-01 and E-02 Battery AV60 Battery relay...
  • Page 103 Fault Diagnosis of Electric System (Mode E) b) Engine stop solenoid does not operate (Starter runs.). Possible cause Remedy Engine stop solenoid earth wire Repair or renew. faulty. Is resistance of engine stop solenoid as specified? Is specified voltage Engine stop solenoid faulty. Renew.
  • Page 104 • Turn starter switch to HEAT. Electric wiring diagram for mode E-03 Glow lamp timer Combination meter 3 4 5 6 Glow indicator lamp Fuse From battery relay Starter switch Glow plugs * SW352, TW352 and TW502 have three glow plugs. 4-206...
  • Page 105 Fault Diagnosis of Electric System (Mode E) E-04 No charging (charge indicator lamp on monitor display comes on) ★ Check that fuse is not damaged. ★ Measure the voltage with the starter switch ON. Possible cause Remedy Regulator faulty. Renew. Does specified voltage appear at alternator terminal IG...
  • Page 106 E-06 Vibrator does not work ★ Ensure that fuse is not damaged first. ★ Measure the voltage with the starter switch ON. SW352, TW352 a) Vibrator does not operate with on-off switch on top of F-R lever actuated. ★ Make a diagnosis with MANUAL mode selected.
  • Page 107 Fault Diagnosis of Electric System (Mode E) Possible cause Remedy To “A” on page 4-208 Is resistance of F-R lever earth wire as specified? F-R lever switch earth wire not Repair or renew connected or incorrectly wire. • About 1 Ω Is stated voltage connected.
  • Page 108 Fault Diagnosis of Electric System (Mode E) SW502, TW502 a) Vibrator does not operate with on-off switch on top of F-R lever actuated. ★ Make a diagnosis with MANUAL mode and LOW amplitude or High amplitude selected. Is resistance of wire RW from vibration mode selector switch terminal 2 to vibrator...
  • Page 109 Fault Diagnosis of Electric System (Mode E) Possible cause Remedy To “A” on page 4-210 Is resistance of F-R lever earth wire as specified ? Earth wire not connected or Repair or renew incorrectly connected. wire. • About 1 Ω Is stated voltage •...
  • Page 110 Fault Diagnosis of Electric System (Mode E) b) Vibrator does not operate with AUTO mode but works by operation of F-R lever switch. ★ Make a diagnosis with AUTO mode selected. Possible cause Remedy To “A” Is resistance of wire BrY from vibration mode selector switch terminal 5 to vibrator...
  • Page 111 To starter motor Vibration mode selector switch Fuse Vibrator On-Off solenoid (rear drum) * Above figure illustrates diagram of SW352. TW352 has front vibrating unit only. Electric wiring diagram for mode E-6 (SW502, TW502) Combination meter Fuse Vibrator indicator lamp Vibrator indicator lamp relay...
  • Page 112 Fault Diagnosis of Electric System (Mode E) E-07 Sprinkler does not operate ★ Check for burnt fuse first. ★ Measure the voltage with starter switch ON. Possible cause Remedy Renew. Sprinkler motor faulty. Is resistance of sprinkler earth wire as specified? Repair or renew Sprinkler motor earth wire not wire.
  • Page 113 Fault Diagnosis of Electric System (Mode E) E-08 Low-High speed range selection is not available ★ Check for burnt fuse first. ★ Measure voltage with starter switch ON. Possible cause Remedy Hydraulic system faulty. (See H-03.) Is resistance of solenoid earth wire as specified? Solenoid earth wire not connected Repair or renew...
  • Page 114 Fault Diagnosis of Electric System (Mode E) E-09 Parking brake is not released ★ Check for burnt fuse first. ★ Measure the voltage with the starter switch ON. ★ Make a diagnosis with the parking brake switch in the RELEASE position, and the brake pedal not depressed.
  • Page 115 Fault Diagnosis of Electric System (Mode E) Electric wiring diagram for mode E-09 Brake pedal switch Parking brake switch Fuse Parking brake solenoid Stoplamp Combination meter Parking brake indicator lmap Brake lamp relay 4-217...
  • Page 116 MEMO...
  • Page 117 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) 6. Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-01 Not Propelled ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 4-404 H-02 Speed not Gained or Low Traction ・...
  • Page 118 Amplitude selector solenoid valve Pressure relief valve Vibrator Front motor Front vibrator Rear motor* Rear vibrator* Steering/charge pump Steering valve (Orbitrol) Steering Steering cylinder Steering mechanism Coupling Others F-R lever linkage Engine Diagnosis code H-01a H-01b H-02a H-02b H-03 * For SW352, SW502 4-402...
  • Page 119 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) Vibrator Steering Low vibration Inoperative (SW/TW352) Inoperative (SW/TW502) Parking brake Poor parking intensity not released brake function a) Front and b) Either front a) Front and b) Either front Either front Not achieved Heavy or slow rear or rear...
  • Page 120 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-01 Not propelled ★ Make a diagnosis on electric systems first. If they are normal, then use the following procedures. ★ Check the oil level in the hydraulic tank first. a) Propelled in neither direction Possible cause Remedy (neither forward nor backward).
  • Page 121 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) b) Machine travels in one direction alone, either forward or in reverse. Possible cause Remedy Multi-function valve faulty. (Foreign matter is present or Renew. valve is defective.) Is fault condition reversed if multi- function valves are Renew exchanged with...
  • Page 122 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-02 Speed not Gained or Low Traction a) Speed gained in neither direction (neither forward nor backward). ★ Make sure that the unloader valve stays closed. Possible cause Remedy Propulsion pump performance degraded.
  • Page 123 ★ Make a diagnosis of electric systems first. If they are normal, then use procedures as instructed bellow: Possible cause Remedy SW352, TW352 a) Vibrator inoperative at both High and Low amplitudes. Vibrator on-off solenoid valve Repair or renew. faulty.
  • Page 124 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-05 Low Vibration Intensity ★ Inspect electric systems first. If normal then use procedure as described below. ★ Low vibration intensity either in front or rear drum. Possible cause Remedy Vibrator pump performance Renew vibrator In both drums degraded.
  • Page 125 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-07 Heavy or Slow Steering Possible cause Remedy Steering mechanism faulty. Repair. Is pressure as specified when steering cylinder Steering valve (Orbitrol) relief Renew steering piston reaches end setting lowered. valve. of stroke? Is steering cylinder *See Standard...
  • Page 126 Fault Diagnosis of Hydraulic and Mechanical Systems (Mode H) H-09 Poor Parking Brake Function ★ Make a diagnosis of electric systems first. If they are normal, then use the flow chart below: Possible cause Remedy Negative brake faulty. Repair or renew. Is brake release pressure lower than 1.6MPa?
  • Page 127: Disassembly And Assembly

    DISASSEMBLY AND ASSEMBLY...
  • Page 129 DISASSEMBLY AND ASSEMBLY ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 5-003 Precautions for Work 1.
  • Page 130 10-2. Installation of propulsion/vibration/steering/charge pump assembly ・ ・ ・ ・ ・ ・ ・ ・ 5-125 11. Removal and Installation of Vibrator Pump Assembly (SW352, SW502) 11-1. Removal of vibrator pump assembly・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 5-126 11-2.
  • Page 131 Precautions for Work Precautions for Work ★ When removing, disassemblig, assembling and installing the units, follow the general precautions as described below: 1. Precautions for removal • The coolant which contains an untifreeze should be treated carefully and must not be drained carelessly on the ground.
  • Page 132 MEMO...
  • Page 133 Removal and Installation of Alternator Assembly 1. Removal and Installation of Alternator Assembly 1-1. Removal of alternator assembly Disconnect the negative (–) cable from the battery. 1. Engine hood 1) Open the engine hood. 2) Remove the fan belt cover. 2.
  • Page 134 Removal and Installation of Starter Assembly 2. Removal and Installation of Starter Assembly 2-1. Removal of starter assembly Disconnect the negative (–) cable from the battery. 1. Engine hood Open the left hand access cover of front frame. 2. Electric wiring of starter Disconnect connector (1) and feed wire (2) from the starter.
  • Page 135 Removal and Installation of Radiator/Oil Cooler Assembly 3. Removal and Installation of Radiator/Oil Cooler Assembly 3-1. Removal of radiator/oil cooler assembly 1. Engine hood 1) Open the engine hood. 2) Open the right hand side cover of front frame. 3) Remove the rear cover of front frame. 2.
  • Page 136 Removal and Installation of Engine and Propulsion/Vibration/Steering/Charge Pump Assembly 4. Removal and Installation of Engine and Propulsion/Vibration/Steering/Charge Pump Assembly 4-1. Removal of engine and propulsion/vibrator/steering/charge pump assembly Disconnect the battery negative (–) cable. 1. Removal of engine hood 1) Remove the damper inside the hood. 2) Lift the hood and remove the hinge and anti-fall arm.
  • Page 137 Disconnect hydraulic hoses (27)–(28) at the vibrator/steering/charge pump. ★ Blank the open ends of hoses and elbos. TW5025012 10. Vibrator pump hose (SW352, SW502) Disconnect vibrator pump hoses (27), (28) on the engine side. ★ Blank the open ends of hoses and elbos.
  • Page 138 Removal and Installation of Engine and Propulsion/Vibration/Steering/Charge Pump Assembly 11. Engine oil drain hose and earth wire 1) Drain engine oil from the engine. 2) Disconnect drain hose (29) at the frame. 3) Disconnect earth wire (30) at the frame. TW5025014 12.
  • Page 139 Removal and Installation of Engine and Propulsion/Vibration/Steering/Charge Pump Assembly 4-2. Installation of engine and propulsion/vibration/steering/charge pump assembly ★ For installation, reverse the removal sequence. * Adjust the F-R lever linkage referring to “Adjustment of F-R lever linkage stroke”, page 3-109. * Adjust the linkage referring to “Throttle linkage adjustment”, page 3-108.
  • Page 140 Removal and Installation of Coupling 5. Removal and Installation of Coupling 5-1. Removal of coupling 1. Propulsion/vibrator/steering/charge pump assembly Remove the assembly referring to “Removal of propulsion/vibrator/steering/charge pump asembly”. 2. Flywheel cover 1) With a jack, support the engine flywheel housing from below.
  • Page 141 Removal and Installation of Front Drum Assembly 6. Removal and Installation of Front Drum Assembly 6-1. Removal of front drum assembly ★ Remove the rear drum of SW352 and SW502 using the same procedure. 1. Scraper blade Latch the scraper blades off the drum.
  • Page 142 Removal and Installation of Front Drum Assembly 3) On a hoist, lift and hold front frame (11). Place a wooden block under the front frame and disengage the hoist hook. TW5025023 4) Lift the drum assembly (14) off the machine. 5) On a hoist, lift side plate (12), take off twelve retaining bolts (15), and separate plate (12) from shockmounts.
  • Page 143 Removal and Installation of Front Drum Assembly 6-2. Instllation of front drum assembly ★ Install in the reverse order of removal. [*1] Tightening torque of bolts: 265 N·m (27 kgf·m) [*2] Tightening torque of nuts: 108 N·m (11 kgf·m) ★ Add oil to the hydraulic tank to the specified level for compensation of a leak during removal.
  • Page 144 Disassembly and Assembly of Front Drum Assembly 7. Disassembly and Assembly of Front Drum Assembly 7-1. Disassembly of front drum assembly Preparation Remove front drum assembly referring to “Removal of front drum assembly”, page 5-109. Drain oil from the vibrator case. 1.
  • Page 145 Disassembly and Assembly of Front Drum Assembly 4) With a puller, pull off disk (8) from axle shaft (9). ★ The bearing inner race is removed together with the disc. TW5025029 4. Axle shaft 1) Remove eight fixing bolts from axle shaft (9).
  • Page 146 Disassembly and Assembly of Front Drum Assembly 7. Holder & vibrator shaft Lifting bolt 1) Remove eight fastening bolts (19). 2) Screw pull bolts into the holes of holder (20) and separate it from the drum. 3) Using lifting bolts and shuckles, lift off holder (20).
  • Page 147 Disassembly and Assembly of Front Drum Assembly 7-2. Assembly of front drum assembly ★ Thoroughly clean the parts and remove burrs etc. 1. Holder & vibrator shaft 1) On a hoist, stand the drum on the floor with propulsion motor up. * See “Disassembly of front drum assembly”, page 5-112.
  • Page 148 Disassembly and Assembly of Front Drum Assembly 3. Disc 1) Using lifting bolts, install disc (16) to propulsion motor assembly. Tighten six securing bolts (15). ・Tightening torque: 343 N·m (35 kgf·m) 2) Install elbos (10)–(14). TW5025031 4. Vibrator shaft end float ★...
  • Page 149 (disc drag). ・Disc drag: 64 N·m (6.5 ± 0.3 kgf·m) TW5025080 (SW352, TW352) 45 N·m (4.5 ± 0.3 kgf·m) (SW502, TW502) SW/TW502 If the drag is lower than specified, increase shim thickness.
  • Page 150 Disassembly and Assembly of Front Drum Assembly 5) Fit cover (5) and tighten six fixing bolts (4). ・Tightening torque: 108 N·m (11 kgf·m) TW5025027 7. Sleeve Fit sleeve (3) to the vibrator shaft TW5025026 8. Vibrator motor assembly Install propoulsion motor assembly (1) to sleeve (3).
  • Page 151 Removal and Installation of Center Pin Assembly 8. Removal and Installation of Center Pin Assembly 8-1. Removal of center pin assembly Disconnect battery negative (–) cable. 1. Hydraulic hose 1) Remove the floor board by the operator’s seat. 2) Remove seven hoses (1)–(3). Blank the open ends of hoses and ★...
  • Page 152 Removal and Installation of Center Pin Assembly 5. Steering cylinder rod Remove the lock plate bolt, pull off pin (8) and disconnect the rod (9) from the front frame. TW5025046 6. Front frame & drum assembly 1) Using a jack, support the rear frame from below.
  • Page 153 Removal and Installation of Center Pin Assembly 8-2. Installation of center pin assembly ★ Reverse the removal procedure. [*1] [*2] Torque setting of bolts: 265 N·m (27 kgf·m) ★ Add oil to the tank to the specified level for compensation of a leak. ★...
  • Page 154 Removal and Installation of Rear Propulsion Motor Assembly and Wheels (TW352, TW502) 9. Removal and Installation of Rear Propulsion Motor Assembly and Wheels (TW352, TW502) 9-1. Removal of rear propulsion motor assembly and wheels ★ For a fork lift to operate, secure enough spaces on the left and right sides of the machine.
  • Page 155 Removal and Installation of Rear Propulsion Motor Assembly and Wheels (TW352, TW502) 6. Removal and installation of wheels 1) Remove six hub nuts (10) from wheel (3). [*1] 2) On a hoist, lift off wheel (3). TW5025054 3) Turn the wheel assembly upside down and remove six hub nuts (10).
  • Page 156 Removal and Installation of Rear Propulsion Motor Assembly and Wheels (TW352, TW502) 9-2. Installation of rear propulsion motor assembly and wheels ★ Install by reversing the removal sequence. [*1] Torque setting of bolts: 186 N·m (19 kgf·m) [*2] Torque setting of bolts: 265 N·m (27 kgf·m) [*3] Torque setting of bolts: 167 N·m (17 kgf·m) ★...
  • Page 157 Removal and Installation of Propulsion/Vibration/Steering/Charge Pump Assembly (SW352, SW502) 10. Removal and Installation of Propulsion/Vibration/ Steering/Charge Pump Assembly (SW352, SW502) 10-1. Removal of propulsion/vibration/steering/charge pump assembly Remove the assembly referring to steps 7 ★ to 9 in “Removal of engine and propulsion/ vibration/steering/charge pump assembly”,...
  • Page 158 Removal and Installation of Vibrator Pump Assembly (SW352, SW502) 11. Removal and Installation of Vibrator Pump Assembly (SW352, SW502) 11-1. Removal of vibrator pump assembly 1. Hydraulic oil Drain half an amount of hydraulic oil from the pump. 2. Hydraulic hose Disconnect vibrator hoses (1) and (2) at the engine.
  • Page 159 Removal and Installation of Vibrator Motor Assembly 12. Removal and Installation of Vibrator Motor Assembly 12-1. Removal of vibrator motor assembly 1. Hydraulic hose Disconnect hoses (2)–(4). ★ Blank the open ends of hoses and elbos. 2. Vibrator motor ass’y Remove two fixing bolts and remove vibrator motor assembly (1).
  • Page 160 Disassembly and Assembly of Propulsion Motor Negative Brake 13. Disassembly and Assembly of Propulsion Motor Negative Brake 13-1. Disassembly of propulsion motor negative brake 1. Brake cover Slacken eight socket head cap screws (2) fastening brake cover (1). * Loosen the screws evenly, since brake spring (3) attempts to lift brake cover (1).
  • Page 161 Disassembly and Assembly of Propulsion Motor Negative Brake 4. Brake piston Brake piston will be lifted with the forced brake release screw (5) (socket head cap screw) screwed into the brake release port. Screw and washer for forced brake releasing DCM0280 DCM0560 Screw...
  • Page 162 Disassembly and Assembly of Propulsion Motor Negative Brake 6. Brake disc Take off the brake shim, separate discs (7) Wire and friction discs (8). Use a wire with a bent end to make the work easy. Remove four to five pieces of separate discs (7) and friction discs (8), then the brake shaft will be pulled off.
  • Page 163 Disassembly and Assembly of Propulsion Motor Negative Brake 2. Brake shim After assembling separate discs (7) and friction discs (8), proceed to the installation of brake shims (9). Principally, original shims (9) that have been removed should be used, but if the stroke of brake piston (“Inspection after replacement”, page 5-134) is not to specification, increase or decrease shim (9)
  • Page 164 Disassembly and Assembly of Propulsion Motor Negative Brake 3. Steel ball Assemble brake shaft spring (10) and steel ball (11) into the cam motor. If the brake is assembled into the cam motor with the cam motor positioned horizontally (brake is fitted from the side), apply a slightly high viscous grease to steel ball (11) to prevent falling free.
  • Page 165 Disassembly and Assembly of Propulsion Motor Negative Brake 4. Brake piston Assemble the small O-ring and big O-ring to brake piston (12). Assemble brake piston (12) into the brake housing. Drive the brake piston fully home by tapping it with a soft-faced hammer.
  • Page 166 Disassembly and Assembly of Propulsion Motor Negative Brake Inspection after replacement (Measurement of brake piston stroke) ・The brake stroke mentioned below is the value for new brake discs, which differs from the stroke specified under “Replacement standard” for used discs, page 5-136. 1.
  • Page 167 Disassembly and Assembly of Propulsion Motor Negative Brake 3. Installation of plug Screw socket head plug (13) with the O-ring into the forced brake release port. Torque setting of forced brake release port plug DCM0280 DCM0560 Plug size G1/4 G3/8 Width across flats 6 mm (0.24 in) 8 mm (0.32 in)
  • Page 168 Disassembly and Assembly of Propulsion Motor Negative Brake Measurement of brake piston stroke (replacement standard) 1. Plug removal Remove the socket head plug (14) with O-ring from the brake release port. TW5025070 2. Brake release bolt Screw the brake release socket head screw into the brake release port.
  • Page 169 Disassembly and Assembly of Propulsion Motor Negative Brake Spare parts list It is recommended to renew O-rings when replacing friction discs and separate discs. Drawing No. (Daikin No./Standard nominal size) Item Qt’y DCM0280 DCM0560 Friction disc SP1988 SP2090 Separate disc 1733585 1733704 Brake shim set...
  • Page 170 Removal and Installation of Steering Cylinder Assembly 14. Removal and Installation of Steering Cylinder Assembly 14-1. Removal of steering cylinder assembly * Engage the steering lock bar securely for safe work in the articulated area of the machine. 1. Cylinder rod Pull pin (1) and remove cylinder rod (2) from bracket (3).
  • Page 171 Removal and Installation of Steering Cylinder Assembly 14-2. Installation of steering cylinder assembly ★ For installation, reverse the removal procedure. ★ Fit spacer between the rod and bracket on top and bottom locations. ★ Add oil to the specified level. ★...
  • Page 172 Disassembly and Assembly of Steerig Cylinder Assembly 15. Disassembly and Assembly of Steerig Cylinder Assembly 15-1. Disassembly of steering cylinder assembly Preparation Remove the steering cylinder assembly using the procedure in “Removal of steering cylinder assembly”, page 138. 1. Piston-piston rod assembly 1) Loosen end cap (2) and pull off the assem- bly from cylinder (3).
  • Page 173 Disassembly and Assembly of Steerig Cylinder Assembly 15-2. Assembly of steering cylinder assembly ★ Thoroughly clean the component parts. Remove burrs etc. ★ When assembling, apply a coat of engine oil to the running surfaces. 1. Cylinder head 1) Install O-ring (13) to end cap (2). 2) Fit dust seal (12) and U-ring (10) to end cap (2).
  • Page 174 Removal and Installation of Steering Wheel 16. Removal and Installation of Steering Wheel 16-1. Removal of steering wheel 1. Contact plate Remove horn cap (1) from the steering wheel and remove contact plate (2), lock spring (3) and spring (4). SV5005213 2.
  • Page 175 Removal and installation of Orbitrol 17. Removal and installation of Orbitrol 17-1. Removal of Orbitrol 1. Cover Remove the cover under the instrument panel. 2. Orbitrol 1) Disconnect four hoses (2). Before disconnection, label the hoses ★ for correct reconnection. Plug the open ends of the hoses and ★...
  • Page 176 No. 98084-0 Head office: 1-4-8, Shiba-Daimon, Minato-ku Tokyo, Japan Telephone: Tokyo(03) 3431-9971 Facsimile: (03) 3431-6212 Printed in Japan 2006.7.100 0 C.D...

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