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Sakai SW654 Shop Manual
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Sakai SW654 Shop Manual

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SW654
SHOP MANUAL
3498-6559A-1

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Summary of Contents for Sakai SW654

  • Page 1 SW654 SHOP MANUAL 3498-6559A-1...
  • Page 3 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.

  • Page 5: Table Of Contents

    1-10. Maintenance   1-005 1-11. Transporting the Machine   1-007 2. SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW654  2-001 1-2. SW654ND   2-003 1-3. Common Specifications  2-005 2. TABLE OF STANDARD VALUES 2-1. Engine   2-006 2-2.
  • Page 6 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 (SW654)   4-003 ○ 1-2-2. Hydraulic circuit diagram (SW654ND)  4-004 2. PROPULSION HYDRAULIC SYSTEM 2-1.

  • Page 7: Sw654

    6-1. Propulsion Hydraulic Piping   4-022 ○ 6-1-1. Propulsion hydraulic piping (1) (SW654)   4-022 6-1-2. Propulsion hydraulic piping (2) (SW654,SW654ND) (from 30143)  4-023 6-1-3. Propulsion hydraulic piping (2) (SW654B) (from 30143)  4-024 6-2. Hydraulic Component Specifications  4-025 6-2-1.
  • Page 8 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 3. VIBRATORY DRUM ASSEMBLY (SW654) 3-1. Vibratory Drum Assembly 6-008 3-2. Disassembly and Reassembly of Vibratory Drum  6-009 3-2-1.

  • Page 9: Inspection And Adjustment

    5-1. Removal and Installation of Vibratory Drum   6-074 5-1-1. Removal of vibratory drum   6-074 5-1-2. Installation of vibratory drum  6-079 6. VIBRATORY DRUM ASSEMBLY (SW654) (FROM 30143) 6-1. Vibratory Drum Assembly 6-080 6-2. Disassembly and Reassembly of Vibratory Drum  6-081 6-2-1.
  • Page 10 SW654 ○ 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement  9-002 ○ 2-2. Adjustment   9-003 2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value  9-003 2-2-2.

  • Page 11: Troubleshooting

    SW654 ○ 13. ADJUSTMENT OF F-R LEVER AND SHIFT LEVER 13-1. Adjustment of Linkage  9-022 13-2. Adjustment of Operating Force  9-024 13-2-1. Adjustment of F-R lever   9-024 13-2-2. Adjustment of shift lever  9-025 14. MOVABLE WEIGHT ADJUSTMENT (SW654ND)   9-026 14-1.
  • Page 12 2-5-1. No vibration occurs 1/2  1 0-039 2-5-1. No vibration occurs 2/2  1 0-041 2-5-2. Amplitude does not change (Remains either low or high) : SW654  1 0-041 2-5-3. Vibration does not change (Remains normal or oscillation vibration) : SW654ND  1 0-043 2-5-4.
  • Page 13 SW654 ○ 2-7-18. Flood lamp indicator lamp does not light   1 0-079 2-7-19. Side marker lamp indicator lamp does not light 1 0-079 2-7-20. Parking brake indicator lamp does not light   1 0-081 2-7-21. Turn signal indicator lamp does not light   1 0-083 2-7-22.

  • Page 15: Safety

    SAFETY...

  • Page 17: General 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.

  • Page 18: Qualifications Of Operators And Maintenance Personnel

    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.

  • Page 19: Pre Start Inspection

    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.

  • Page 20: Starting

    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. •...

  • Page 21: Maintenance

    • 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...
  • Page 22 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.

  • Page 23: Transporting The Machine

    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.

  • Page 25: Specifications

    SPECIFICATIONS...

  • Page 28: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW654 1480 1480 3100 4300 0559-99086-0-11166-0 Model SAKAI SW654 with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 7,070 kg ( 15,585 lbs. ) Operating weight with ballast N/A kg N/A lbs. )
  • Page 29 SPECIFICATIONS Centrifugal Low amplitude 62 kN ( 13,940 lbf force High amplitude 69 kN ( 15,510 lbf Low amplitude 67 Hz 4,000 vpm Front Frequency High amplitude 50 Hz 3,000 vpm Low amplitude 0.27 mm 0.011 in. Amplitude High amplitude 0.53 mm 0.021 in.

  • Page 30: Sw654Nd

    SPECIFICATIONS 1-2. SW654ND 1480 1480 3100 4300 0559-99086-0-11166-0 Model SAKAI SW654ND with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 7,370 kg ( 16,250 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 7,730 kg ( 17,040 lbs.
  • Page 31 SPECIFICATIONS Centrifugal Normal 68 kN ( 15,285 lbf force Oscillation 124 kN ( 27,875 lbf Normal 49 Hz 2,940 vpm Front Frequency Oscillation 49 Hz 2,940 vpm Normal 0.52 mm 0.020 in. Amplitude Oscillation 0.75 mm 0.030 in. Vibrator system Centrifugal Normal 68 kN...

  • Page 32: Common Specifications

    Rear Front Planetary gear Final drive Rear Planetary gear Power transmission type Hydraulic Vibration system SW654 Single eccentric shaft Vibrator type SW654ND Twin eccentric shaft Dynamic braking through hydrostatic drive system Service brake (F-N-R lever) Brake system Secondary brake...

  • Page 33: Table Of Standard Values

    Pump 0.4 MPa ( 58.0 ) or less Vibration Case pressure Motor 0.2 MPa ( 29.0 ) or less SW654 9.4 L/min ( gal./min ) Drainage SW654ND 6.9 L/min ( gal./min ) (orbitroll relief pressure + Steering oil pressure 18.1 MPa ( 2,625 ±...

  • Page 34: Steering

    Gear box 1.2 L × 2 ( 0.3 gal. × 2 ) Hydraulic oil tank 44 L ( 11.6 gal. SW654 4.0 L × 2 ( 1.1 gal. × 2 ) Vibrator case SW654ND 10.4 L × 2 ( 2.7 gal. × 2 ) Water spray tank 300 L ×...

  • Page 35: Fuel And Lubricants Specification

    SPECIFICATIONS 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable -15 to 30°C 0 to 40°C 15 to 55°C Lubricant classification Standards (5 to 86°F) (32 to 104°F) (59 to 131°F) Cold Moderate Tropical API-CH-4 Engine oil SAE10W-30...

  • Page 36: Tightening Torque Chart

    SPECIFICATIONS 4. TIGHTENING TORQUE CHART N·m (lbf·ft) Strength Classification Nominal Pitch Dia. 10.9 12.9 (3.6) (4.4) (5.8) (5.8) (5.8) (7.2) (9.6) (9.6) 1.25 (13) (17) (23) (23) (29) (36) (44) (44) 1.75 (51) (58) (80) (80) (72) (94) (123) (123) (116) (145) (195)

  • Page 38: Specification Data

    SPECIFICATIONS SW654B 5. SPECIFICATION DATA 5-1. SW654B 1480 1480 3100 4300 0559-99086-0-11166-0 Model SAKAI SW654B with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 7,970 kg ( 17,570 lbs. ) Operating weight with ballast N/A kg N/A lbs. )

  • Page 39: Sw654B

    SW654B SPECIFICATIONS Centrifugal Low amplitude 61 kN ( 13,715 lbf force High amplitude 67 kN ( 15,060 lbf Low amplitude 67 Hz 4,000 vpm Front Frequency High amplitude 50 Hz 3,000 vpm Low amplitude 0.30 mm 0.012 in. Amplitude High amplitude 0.55 mm 0.022 in.

  • Page 40: Common Specifications

    SPECIFICATIONS 5-2. Common Specifications Model KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbocharger Bore × Stroke 94 mm × 120 mm (3.7 in. × 4.72 in.) Displacement 3.331 L ( 203.3 cu.in. Rated speed 2,200 min Rated output...

  • Page 41: Sw654

    Pump 0.4 MPa ( 58.0 ) or less Vibration Case pressure Motor 0.2 MPa ( 29.0 ) or less SW654,SW654B 9.4 L/min ( gal./min ) Drainage SW654ND 6.9 L/min ( gal./min ) (orbitroll relief pressure + Steering oil pressure 18.1 MPa ( 2,625 ±...

  • Page 43: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 45: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount VIEW A DETAIL B DETAIL C 0559-01805-0-10853-A (1) Bracket (9) Bolt : M16×160 (17) Bolt : M12× 60 (2) Bracket (10) Plate (18) Bolt : M16×160 (3) Engine (11) Bolt : M14× 40 P=1.5 (19) Plate (4) Bracket (12) Damper...

  • Page 47: Engine Exterior

    Cooling water outlet Oil drain plug Starter motor VIEW A Intake port Fan belt Turbocharger Thermo unit Cooling water inlet Fan drive pulley Flywheel Camshaft position sensor Oil pan * The actual equipment may differ from that shown above. SW654-03001 3-002...

  • Page 50: Fuel System

    ENGINE AND CONTROLS 2. FUEL SYSTEM 0559-02803-0-10908-A 3-003...
  • Page 51 ENGINE AND CONTROLS Supply pump Common rail Engine VENT Engine Engine (suction) (return) Engine side Check Vehicle side valve Main filter Check Pre-filter valve Fuel pump Separator Fuel tank Fuel tank (suction) (return) Fuel tank Fuel system diagram DETAIL A SECTION B-B 0559-02803-0-10908-A (1) Fuel tank...

  • Page 52: Control System

    ENGINE AND CONTROLS 3. CONTROL SYSTEM 3-1. Throttle Control IDOL SECTION A-A FULL 0559-12805-0-10846-A (1) Lock nut : M6 (7) Potentiometer (2) Stopper bolt (FULL) : M6×60 (8) Nut : M16 (3) Lock nut : M6 (9) Disc spring (Do not apply grease) (4) Stopper bolt (IDOL) : M6×60 (10) Washer (Apply grease*) (5) Throttle lever...

  • Page 53: Forward-Reverse Control

    ENGINE AND CONTROLS 3-2. Forward-reverse Control VIEW B-B VIEW A-A 0559-12804-0-10827-0 (1) F-R lever (L) (4) F-R lever (R) (2) Lever subassembly (5) Control cable (F-R) (3) Shaft subassembly (6) Control cable (shift) 3-006...
  • Page 54 ENGINE AND CONTROLS 2) Lever subassembly SECTION A-A SECTION B-B 0559-12003-0-11017-0 (1) Shift lever (14) Bolt : M12×30 (2) Base (15) Lock nut : M12 (3) Plate (16) Spring (Fill grease*) (4) Rod end (Apply grease*) : M6 (17) Steel ball (5) Lock nut : M6 (18) Washer (Apply grease*)
  • Page 55 ENGINE AND CONTROLS 3) Shaft subassembly SECTION A-A SECTION B-B SECTION C-C 9 10 SECTION D-D SECTION E-E 0559-12004-0-11020-A (1) Arm (14) Steel ball (2) Arm (15) Friction plate (3) Arm (16) Holder (4) Shaft (17) Disc spring (Fill grease*) (5) F-R lever switch (18) Lock nut : M12...

  • Page 56: Pump Mount

    ENGINE AND CONTROLS 4. PUMP MOUNT 4-1. Pump Mount SECTION A-A 0559-36811-0-10839-B (1) Bolt : M10×25 P=1.25 (5) Housing (2) Bolt : M10×30 P=1.25 (6) Flange (3) Pump (7) Hub (4) Bolt : M14×40 (8) Bolt : M12×35 N•m (1) Bolt M10×25 P=1.25 : 69 N·m ( 51 lbf·ft ) (2) Bolt M10×30 P=1.25 : 49 N·m ( 36 lbf·ft ) (8) Bolt M12×35 : 86 N·m ( 63 lbf·ft )

  • Page 57: Installation Of Pump

    ENGINE AND CONTROLS 4-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (3) and hub (7) splines.

  • Page 59: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 62: System Circuit Diagram

    HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits Basic Symbols Pump, Motors and Cylinders DESCRIPTION SYMBOL DESCRIPTION SYMBOL Lines: Hydraulic pumps: Fixed displacement Main working Unidirectional Pilot control Bidirectional Drain or bleed Variable displacement Lines, joining Unidirectional Not connected Bidirectional...
  • Page 63 HYDRAULIC SYSTEMS Valves Methods of Operation DESCRIPTION SYMBOL DESCRIPTION SYMBOL Spring Check valve Manual shut off (On-Off) Manual Pressure compensated Pressure relief Reversing motor Flow control, adjustable Pilot pressure: Internal supply Valve symbols: The basic valve symbol Remote supply one or more squares with lines representing Solenoid: flow paths and flow con-...

  • Page 65: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram 1-2-1. Hydraulic circuit diagram (SW654) Reverse (1/2") (3/8") (3/8") TV2 TMA (1/2") (1/4") (1/2") Propulsion pump Vibrator pump (5/8") Steering charge pump Drum (F) Lo Hi 3.0 MPa PB2 B3 45.0/23.0 cc/rev i=35.00 33.0 MPa 34.5 MPa...

  • Page 67: Hydraulic Circuit Diagram (Sw654Nd)

    HYDRAULIC SYSTEMS 1-2-2. Hydraulic circuit diagram (SW654ND) Reverse (1/2") (3/8") (3/8") TV2 TMA (1/2") (1/4") (1/2") Propulsion pump Vibrator pump (5/8") Steering charge pump Drum (F) Lo Hi 3.0 MPa PB2 B3 45.0/23.0 cc/rev i=35.00 33.0 MPa 34.5 MPa 1.8 MPa 1480 46.0 31.0...

  • Page 69: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM Bypass valve Hose 2-1. Propulsion Hydraulic Piping (PT1 APT) Hydraulic oil 2-1-1. Propulsion hydraulic piping (1) Hose tank (TV2 BV2) Hose SOT) Servo bypass solenoid valve Hose (AT7 Hose (PT3 AVT) TP2 PT4 DETAIL C Pipe assembly 2 Hose Pump assembly...

  • Page 71: Propulsion Hydraulic Piping (2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (2) Propulsion motor (R) Propulsion pump Hose:FB Hose:RA Hose:FA VIEW D Hose:RB VIEW E Hose:RB Hose:RD Hose:RS Hose:RA Hose:RBR SECTION F-F Propulsion motor (F) Hose Hose:FB (TBB BPB) Hose:FD Hose:FB Hose:FS Hose:RD Hose:FB Hose:FD Hose:FS Hose:FD Hose:FA...

  • Page 74: Hydraulic Component Specifications

    1-16 1-15 1-14 1-13 2-14 2-13 2-12 2-15 2-13 2-14 1-12 1-2 1-1 2-11 34.5 MPa 33 MPa 1.9 MPa 32.5 MPa 30 MPa 33 MPa 34.5 MPa 2.4MPa 1-10 1-16 1-14 2-14 2-13 2-2 Hydraulic circuit diagram SW654-04001 4-007...
  • Page 75 (2-13) High pressure gauge port (For port A) : 7/16-20UNF (2-14) Drain port [PT4] : 7/ 8-14UNF (2-15) Cut off valve Specifications • Displacement SW654 (Low amplitude) : 42.0 cm /rev ( 2.6 cu.in./rev ) (High amplitude) : 31.0 cm /rev ( 1.9 cu.in./rev )

  • Page 76: Propulsion Hydraulic Motor

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor VIEW A Flow of oil Propulsion motor (F) : Forward 2 Counterclockwise rotation Propulsion motor (R) : Reverse i=35.00 Propulsion motor (F) : Reverse 5 Clockwise rotation Propulsion motor (R) : Forward Motor ciruit diagram SW652-1-04002 (1) Drain port [FDL] [RDL] :...

  • Page 77: Servo Bypass Solenoid Valve

    HYDRAULIC SYSTEMS 2-2-3. Servo bypass solenoid valve Hydraulic circuit diagram (＋) (−) Connection diagram K-40026 (1) Solenoid (2) O-ring (1B P14) (3) Spool (K) (4) Body (5) Spring (6) Port T : G1/4 (7) Port A [VSA] : G1/4 (8) Port P [VSP] : G1/4 Specifications •...

  • Page 78: Valve Block

    HYDRAULIC SYSTEMS 2-2-4. Valve block VIEW A Hydraulic circuit diagram SW654-04002 (8) Parking brake solenoid valve (1) Port T1 [BT1] : G3/8 (9) Speed change solenoid valve (2) Port T2 : G3/8 (10) Port C1 (3) Port B [BB] : G3/8...

  • Page 79: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping Vibrator pump Hose Propulsion pump Pipe assembly 1 BBB) (PB2 Hose (TBC BCP) Pipe assembly 2 Hose Valve assembly (PA2 BAA) VIEW B Hose TBT) SECTION A-A Hose RVA) (BB1 Valve assembly Valve assembly Hose...

  • Page 81: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor Hydraulic circuit diagram Flow of oil (Low amplitude/Oscillation) 3 Clockwise rotation (High amplitude/Normal) 2 Counterclockwise rotation SW652-1-04005 (1) Drain port 3/ 4-16UNF (2) Port A [FVA][RVA] : 1 1/16-12UN (3) Port B [FVB][RVB] : 1 1/16-12UN (4) Drain port [FVL][RVL] :...

  • Page 82: Valve Assembly

    HYDRAULIC SYSTEMS 3-2-2. Valve assembly Connection diagram Hydraulic circuit diagram SW654-04004 (1) Port B [BBB] : 1 1/16-12UN (10) Solenoid valve a (2) Port CP [BCP] : 9/16-18UNF (11) Flushing valve (3) Port A [BAA] : 1 1/16-12UN (12) Port...

  • Page 83: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM Hydraulic oil filter 4-1. Steering Hydraulic Piping Hose Hose Hose Hose Hose Hose Load solenoid valve (STF SFG) (STF STF) STF) (STF Hose Hose Hose (SFG PG2) Hose Hose SFG) Coupling : DETAIL A Charge pressure gauge port Hose Hose Hose...

  • Page 85: Steering Wheel

    HYDRAULIC SYSTEMS 4-2. Steering Wheel 0559-32802-0-20493-0 (1) Nut : M12 P=1.25 (4) Bolt : M10×30 (2) Steering wheel (5) Orbitrol (3) Column shaft N•m (1) Nut M12 P=1.25 : 54 to 64 N·m ( 40 to 47 lbf·ft ) (4) Bolt M10×30 49 N·m ( 36 lbf·ft ) 4-016...

  • Page 86: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram GW751-04016 (1) Port L [L] : 3/4-16UNF (2) Port R [R] : 3/4-16UNF (3) Port P [P] : 3/4-16UNF (4) Port T [T] : 3/4-16UNF (5) Relief valve Specifications •...

  • Page 87: Load Solenoid Valve

    HYDRAULIC SYSTEMS 4-3-2. Load solenoid valve Hydraulic circuit diagram SW654-04003 (1) Port B : G3/4 (2) Load solenoid valve (3) Port A : G3/4 (4) Port T [LT] : G3/4 [LP] : G3/4 (5) Port P Specifications • Maximum flow 75 L/min 19.8 gal./min...

  • Page 89: System Circuit Diagram (From 30143)

    HYDRAULIC SYSTEMS 5. SYSTEM CIRCUIT DIAGRAM (* : FROM 30143) 5-1. Hydraulic Circuit Diagram (SW654) Reverse (1/2") (3/8") (3/8") TV2 TMA (1/2") (1/4") (1/2") Propulsion pump Vibrator pump (5/8") Steering charge pump Drum (F) PB2 B3 51.0/27.7 cc/rev i=31.353 1.5 MPa 33.0 MPa...

  • Page 91: Hydraulic Circuit Diagram (Sw654Nd)

    HYDRAULIC SYSTEMS 5-2. Hydraulic Circuit Diagram (SW654ND) Reverse (1/2") (3/8") (3/8") TV2 TMA (1/2") (1/4") (1/2") Propulsion pump Vibrator pump (5/8") Steering charge pump Drum (F) PB2 B3 51.0/27.7 cc/rev i=31.353 1.5 MPa Lo Hi 33.0 MPa 34.5 MPa 1.5 MPa 1480 46.0 31.0...

  • Page 93: Hydraulic Circuit Diagram (Sw654B)

    HYDRAULIC SYSTEMS 5-3. Hydraulic Circuit Diagram (SW654B) Reverse (1/2") (3/8") (3/8") TV2 TMA (1/2") (1/4") (1/2") Propulsion pump Vibrator pump (5/8") Steering charge pump Drum (F) PB2 B3 51.0/27.7 cc/rev i=31.353 1.5 MPa Lo Hi 33.0 MPa 34.5 MPa 1.5 MPa 1480 46.0 42.0/31.0...

  • Page 95: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 6. PROPULSION HYDRAULIC SYSTEM Hose Bypass valve 6-1. Propulsion Hydraulic Piping (PT1 APT) Hydraulic oil 6-1-1. Propulsion hydraulic piping (1) (SW654B) Hose tank (TV2 BV2) Hose SOT) Servo bypass solenoid valve Hose (AT7 Hose (PT3 AVT) DETAIL C TP2 PT4 Pipe assembly 2 Hose...

  • Page 97: Propulsion Hydraulic Piping (2) (Sw654,Sw654Nd) (From 30143)

    HYDRAULIC SYSTEMS 6-1-2. Propulsion hydraulic piping (2) (SW654,SW654ND) (* : from 30143) RDA Propulsion motor (R) Propulsion pump Hose:FA Hose:RB Hose:FB VIEW D Hose:RA VIEW E Hose:RA Hose:RD Hose:RS Hose:RB Hose:RBR SECTION F-F Propulsion motor (F) Hose Hose:FA (TBB BPB)

  • Page 99: Propulsion Hydraulic Piping (2) (Sw654B) (From 30143)

    HYDRAULIC SYSTEMS 6-1-3. Propulsion hydraulic piping (2) (SW654B) (* : from 30143) Propulsion motor (R) Propulsion pump Hose:FA Hose:RB Hose VIEW D VIEW E Hose:RA Hose:RD Hose:RS Hose:RB Hose:RBR SECTION F-F Propulsion motor (F) Hose Hose:FA Hose:RD (TBB BPB) Hose:RA Hose:FD Hose:FA Flow divider...

  • Page 102: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 6-2. Hydraulic Component Specifications 6-2-1. Propulsion hydraulic motor (from 30143) Motor ciruit diagram Flow of oil Propulsion motor (F) : Forward 1 Counterclockwise rotation Propulsion motor (R) : Reverse Propulsion motor (F) : Reverse 2 Clockwise rotation Propulsion motor (R) : Forward SW654B-04001...
  • Page 103 HYDRAULIC SYSTEMS (1) Port A [FDA] [RDA] : G3/4 (2) Port B [FDB] [RDB] : G3/4 (3) Parking brake pilot port [FD4] [RD4] : G1/4 [FDX] [RDX] : G1/4 (4) Speed change pilot port (5) High pressure gauge port (For port B) : 7/16-20UNF (6) Manual brake release port : M10...

  • Page 104: Flow Divider (Sw654B)

    HYDRAULIC SYSTEMS 6-2-2. Flow divider (SW654B) Hydraulic circuit diagram SW652-1-04003 (1) Port P [DP] : G1 (2) Block (3) Valve (4) Orifice plug (5) Port A [DA] : G3/4 (6) Port B [DB] : G3/4 Specifications • Maximum flow : 100 L/min ( 26 gal./min ) •...

  • Page 105: Electrical System

    ELECTRICAL SYSTEM...

  • Page 107: Precautions For Work

    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 Wire color...
  • Page 108 ELECTRICAL SYSTEM • Wire color code chart Black/ Black/ Black/ Black/ Black/ Black White stripe Yellow stripe Red stripe Green stripe Blue stripe White/ White/ White/ White/ White/ W White Red stripe Black stripe Blue stripe Yellow stripe Green stripe Red/ Red/ Red/...

  • Page 109: System Circuit Diagram

    ELECTRICAL SYSTEM 2. SYSTEM CIRCuIT DIAGRAM COMBINATION LAMP (F,R) COMBINATION LAMP (R,R) TURN SIGNAL VIBRATION AUTO TURN SIGNAL L07 GR LAMP (R) 21W SWITCH LAMP (R) 21W 2-1. Electrical Circuit Diagram L01 BY L10 GY STOP LAMP SIDE MARKER (R) 21W LAMP (R) 5W TAIL LAMP G06 BR...

  • Page 111: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL CoMPonEnTS Horn (B),(GY) 3-1. Wiring Harness Layout (1) Hydraulic oil filter switch harness Servo bypass solenoid Fuel gauge unit harness (P.5-029) (P.5-030) Combination lamp (F) harness Combination lamp (R,R) Mark F Member (F) harness Hydraulic oil filter switch Load solenoid Sub power Fuel gauge...

  • Page 113: Wiring Harness Layout (2)

    ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (2) Alternator ALT Starter motor STA (B),(RW) Starter switch harness (P.5-019) ECU harness Main harness Mark ST (P.5-013) (P.5-007) Main harness (P.5-007) Mark V Dashboard harness ECU harness (P.5-026) (P.5-013) Engine connector A VIEW H Engine harness Engine connector B (P.5-020)

  • Page 115: Wiring Harness Layout (3)

    ELECTRICAL SYSTEM 3-3. Wiring Harness Layout (3) Lighting switch Lighting Lo-Hi switch 2(WG),3(BY),5(WG),6(Y),7(B) 1(RB),2(Y),3(RW),7(B) Hazard switch ECO lamp Combination meter 1(LY),2(GR),4(LY),5(G) B(Sb),YG(LgR) (P.5-035 ) Parking brake switch Water spray switch (F) Flood lamp switch Water spray timer 1(O),2(BrR),3(GrB),4(LB),5(B) 2(RY),3(RG),5(YR),6(PB),7(B) 1(Gr),2(GrY) Vibration mode change switch Speed change switch...

  • Page 116: Wiring Harnesses

    ELECTRICAL SYSTEM 4. wIRInG HARnESSES Corrugate Corrugate 4-1. Main Harness G03 G04 L YW W YW,50 Corrugate G11 L09 L10 (G/NO) CB104 Dashboard harness SWP-12F BW WR GY F-R lever vibration Corrugate (P.5-026) BR,50 P18 P22 switch harness (L) (Br/COM) CA104 Marking tape Corrugate (P.5-027)
  • Page 117 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B , Upr × 2 Control panel harness (4F), Fuse • relay harness (1)(4M) B , Lwr × 2 Control panel harness (14F), Fuse • relay harness (1)(8M) B , V Control panel harness (4F), Fuse •...

  • Page 118: Fuse • Relay Harness (1)

    ELECTRICAL SYSTEM 4-2. Fuse • Relay Harness (1) Fuse box (2) WB,50 CB104 Fuse box (1) Relay box Fuse relay harness (2) Sub ECU lamp (P.5-011) RY,50 CA104 Liquid spray solenoid Liquid spray relay 7123-2262 58X-2F (option) Tape Corrugate Corrugate Corrugate Corrugate (option)
  • Page 119 ELECTRICAL SYSTEM CONNECTION CONNECTION CONTACT CONTACT SIZE, COLOR SIZE, COLOR POINTS POINTS Diode unit, Main harness (6F) Main harness (8F) Fuse 9 Main harness (8F) Fuse 15 Diode unit, Main harness (6F) Main harness (6F) Relay 5-5 1.25WL Main harness (4F) Fuse 11 Main harness (6F) Relay 1-3, 2-1...

  • Page 120: Fuse • Relay Harness (2)

    ELECTRICAL SYSTEM 4-3. Fuse • Relay Harness (2) Fuse box (2) GrY,200 FASTON F480 B,200 FASTON F480 Relay 7 2WY,200 FASTON F630 2LW,200 FASTON F630 LgB,200 FASTON F480 B,200 FASTON F480 (P09) (P09) (P09) (P09) (P09) (P09) Relay 6 2WY,200 (5WR) (5WR) (5WR)
  • Page 121 ELECTRICAL SYSTEM CONNECTION CONNECTION CONTACT CONTACT SIZE, COLOR SIZE, COLOR POINTS POINTS Diode unit, Main harness (6F) Main harness (8F) Fuse 9 Diode unit, Main harness (6F) Main harness (8F) Fuse 15 Main harness (6F) Relay 5-5 1.25WL Main harness (4F) Fuse 11 Main harness (8F) Fuse 12...

  • Page 122: Ecu Harness

    ELECTRICAL SYSTEM 4-4. ECU Harness Engine connector A Machine side connector Engine side connector TYCO : 42pf 2 wire twist cable MOLEX : 80pf ( gray ) MOLEX : 80pf (blue) Main V37 RW harness SWP-16M V40 V20 (P.5-007) E40 E20 Shield cable ECU(CAN) Shield cable...
  • Page 123 ELECTRICAL SYSTEM SIZE, CONTACT SIZE, CONTACT SIZE, CONTACT CONNECTION CONNECTION CONNECTION COLOR POINTS COLOR POINTS COLOR POINTS ECU(CAN)(service tool), ECU-V13, -V33, ECU-E76, Engine connector A-13 ECU-E01, Engine connector A-4 Fuse • relay harness (1) ECU-E77, Engine connector A-9 ECU-E09, -E29, Engine connector A-7 ECU-V14, Fuse •...

  • Page 124: Control Panel Harness

    ELECTRICAL SYSTEM 4-5. Control Panel Harness Rotatory lamp switch SWP-2F RB4B-SL ACR6 Water spray timer (option) Tape YL YW SWP-2M Liquid spray switch 58X-2F (option) Tape LgR,50 (YG) CB104 58X-2M ECO lamp Sb,50 Corrugate CA104 LY,100 FASTON 187 Corrugate Gr,90 FASTON 187 GR,100 FASTON 187...
  • Page 125 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B , Vibratory drum select switch -2 Lighting switch -2, -5, Main harness (4M) B , Vibratory drum select switch -5 Flood lamp switch -5, Main harness (14M) B , Vibration mode change switch -3 Flood lamp switch -2, Main harness (4M) B , Vibration mode change switch -2, Vibration switch -1, -4...

  • Page 126: Battery Relay Harness

    ELECTRICAL SYSTEM 4-6. Battery Relay Harness 65A (black) 3WL,50 LA308 (NO) Corrugate 5WR,50 LA308 (NO) 65A (black) 5BR,50 LA308 (COM) Fusible link Battery relay Corrugate Corrugate Corrugate 5W,50 LA308 (COM) 65A (black) LgR,50 LA204 Terminal cover Corrugate B,100 LA204 45A (red) Terminal cover DT06-2S...
  • Page 127 ELECTRICAL SYSTEM CONTACT SIZE, COLOR CONNECTION POINTS Battery relay -E, Diode, Fuse relay harness (1) • Fusible link 65A, Battery relay -COM Fusible link 65A, Fuse relay harness (1) • Fusible link 65A, Battery relay -COM Fusible link 65A, Fuse relay harness (1) •...

  • Page 128: Stater Switch Harness

    ELECTRICAL SYSTEM 4-7. Stater Switch Harness LR,80 (ACC) LA105 SWP-6M LgR,80 (BR) LA105 Main harness Starter switch (P.5-007) Corrugate 3BR,80 LA205 5W,80 LA305 58Y-2M GR,50 G(R) CB104 Turn signal G,50 GR(L) CB104 switch Tape LY,50 CB104 P,50 Horn switch CB104 Vinyl tube 1559-09076-0-21156-0 CONTACT...

  • Page 129: Engine Harness

    ELECTRICAL SYSTEM 4-8. Engine Harness Alternator Glow heater Thermo unit LE204 LA104 6189-0443 LA406 28 21 58Y-2M Tape harness Corrugate Corrugate (P.5-013) SWP-3M Tape PB104 LA408 Starter motor 1634-09119-0-21489-0 CONTACT SIZE, COLOR CONNECTION POINTS H , STA H , Glow heater ALT , I ALT , I I , Thermo unit...

  • Page 130: Head Lamp Harness

    ELECTRICAL SYSTEM 4-9. Head Lamp Harness B,50 Head RB3B-SL LA108 lamp (R) Horn GY,50 1.25RW 1.25RB PB104 Member (F) Head harness RB3B-SL lamp (L) Tape Corrugate Corrugate Tape (P.5-022) 1.25RW 1.25RB SWP-4M N Z05 Mihaalu (F) SWP-6F (option) SWP-6M 1559-09093-0-31249-0 CONTACT SIZE, COLOR CONNECTION...

  • Page 131: Member (F) Harness

    ELECTRICAL SYSTEM 4-10. Member (F) Harness 58X-4F 58X-4M L15 L03 GY 2RB Head lamp harness Main harness 3400 (P.5-021) (P.5-007) Corrugate SWP-4F SWP-4M 1559-09094-0-31250-0 CONTACT SIZE, COLOR CONNECTION POINTS Main harness Main harness Main harness Main harness Main harness Main harness Main harness 5-022...

  • Page 132: Combination Lamp (F) Harness

    ELECTRICAL SYSTEM 4-11. Combination Lamp (F) Harness Combination lamp (F,R) Combination lamp (F,L) (Side marker (Turn signal (Ground) (Side marker (Turn signal (Ground) lamp) lamp) lamp) lamp) CB104 CB104 CA104 CB104 CB104 CA104 1250 1300 Main harness SWP-4M Corrugate Corrugate (P.5-007) 1559-09086-0-21196-0 CONTACT...

  • Page 133: Member (R) Harness

    ELECTRICAL SYSTEM 4-12. Member (R) Harness L09 L10 L16 SWP-12M SWP-12F WR GY W GY B Combination lamp 1500 Main harness (R) harness (P.5-007) Corrugate (P.5-025) 58X-2M 58X-2F 1559-09095-0-21251-0 CONTACT SIZE, COLOR CONNECTION POINTS Main harness Main harness Main harness Main harness Main harness Main harness...

  • Page 134: Combination Lamp (R) Harness

    ELECTRICAL SYSTEM 4-13. Combination Lamp (R) Harness Combination W,100 SWP-6F CB104 lamp (R,L) Tape Backup buzzer B,150 LA108 L08 L07 G GR BY * L16 L10 L09 SWP-12M W GY WR N Z04 * Z01 Member (R) GY * harness (P.5-024) Combination SWP-6F...

  • Page 135: Dashboard Harness

    ELECTRICAL SYSTEM 4-14. Dashboard Harness L,50 (Br/COM) F-R lever vibration switch YW,50 (W/NC) (R) harness Tape (P.5-028) W,50 (G/NO) WB,50 O,50 Foot brake switch Tape GY,50 RL,50 Main Vibration AUTO harness SWP-12M switch Tape Corrugate Tape (P.5-007) Br,50 BW,50 F-R lever switch Tape Y,50 LB,50...

  • Page 136: F-R Lever Vibration Switch (L) Harness

    ELECTRICAL SYSTEM 4-15. F-R Lever Vibration Switch (L) Harness Br,55 Br,65 Main harness G,55 G,65 F-R lever vibration switch (L) (P.5-007) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (1), DETAIL F”. (P.5-004) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Main harness, F-R lever vibration switch (L)-1 –...

  • Page 137: F-R Lever Vibration Switch (R) Harness

    ELECTRICAL SYSTEM 4-16. F-R Lever Vibration Switch (R) Harness Br,55 Br,65 Dashboard harness G,55 G,65 F-R lever vibration switch (R) (P.5-026) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (2), DETAIL Q”. (P.5-005) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness, F-R lever vibration switch (R)-1 –...

  • Page 138: Hydraulic Oil Filter Switch Harness

    ELECTRICAL SYSTEM 4-17. Hydraulic Oil Filter Switch Harness Main harness LR,420 CA104 LE105 Hydraulic oil filter switch (P.5-007) Vinyl 1559-09024-0-30391-0 CONTACT SIZE, COLOR CONNECTION POINTS Main harness, Hydraulic oil filter switch 5-029...

  • Page 139: Fuel Gauge Unit Harness

    ELECTRICAL SYSTEM 4-18. Fuel Gauge Unit Harness P,20 CB104 1400 Main harness SWP-3M Fuel gauge unit Corrugate (P.5-007) B,20 CA104 1539-09113-0-20885-A CONTACT SIZE, COLOR CONNECTION POINTS B2 , Fuel gauge unit B2 , Fuel gauge unit 5-030...

  • Page 140: Water Spray Pump Harness

    ELECTRICAL SYSTEM 4-19. Water Spray Pump Harness Water spray 58X-2F pump (F) Main harness 1000 (P.5-007) Corrugate N W05 Water spray 58X-2F pump (R) 1559-09072-0-31152-0 CONTACT SIZE, COLOR CONNECTION POINTS W , FR , RR W , FR W , RR 5-031...

  • Page 141: Cord

    ELECTRICAL SYSTEM 4-20. Cord Y,100 Vinyl tube Control panel harness FASTON 187 (P.5-015) L09,WR L16,W FASTON 187 1559-09087-0-41208-0 CONTACT SIZE, COLOR CONNECTION POINTS – Control panel harness ×2 5-032...

  • Page 142: Electrical Component Specifications

    5A 15A 15A 15A 15A 20A (WL) Battery relay (W) Water spray pump (R) (WR) Water spray pump (F) (WR) Battery relay SW654-05001 Harness color codes : White RY : Red/Yellow stripe : Red RL : Red/Blue stripe WR : White/Red stripe...

  • Page 143: Fuse Box (2)

    ENGINE OVER HEAT lamp ENGINE STOP lamp ENGINE WARNING lamp (GY) Starter relay Sub ECU lamp Load relay Sub ECU SW654-05002 Harness color codes : White WB : White/Black stripe : Red RG : Red/Green stripe : Yellow GY : Green/Yellow stripe...

  • Page 144: Combination Meter

    Engine charge Engine charge warning warning indicator Hydraulic filter indicator Engine oil pressure Glow plug indicator Hydraulic filter Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram Note: The circuit in the dashed box is not mounted. SW654-05003 5-035...

  • Page 145: System Circuit Diagram

    ELECTRICAL SYSTEM 6. SYSTEM CIRCuIT DIAGRAM COMBINATION LAMP (F,R) COMBINATION LAMP (R,R) TURN SIGNAL VIBRATION AUTO TURN SIGNAL L07 GR LAMP (R) 21W SWITCH LAMP (R) 21W 6-1. Electrical Circuit Diagram L01 BY L10 GY STOP LAMP SIDE MARKER (R) 21W LAMP (R) 5W TAIL LAMP G06 BR...

  • Page 147: Wiring Harnesses (From 30136)

    ELECTRICAL SYSTEM 7. wIRInG HARnESSES (* : fRoM 30136) 7-1. Engine Harness Alternator Glow heater Thermo unit LE204 LA104 6189-0443 LA406 28 21 58Y-2M Tape harness Corrugate Corrugate (P.5-013) SWP-3M Tape TYCO : 172320-2 LA408 Starter motor 1634-09119-2-21489-B CONTACT SIZE, COLOR CONNECTION POINTS H , STA...

  • Page 149: Vibratory Drum

    VIBRATORY DRUM...

  • Page 151: Precautions For Disassembly And Reassembly

    VIBRATORY DRUM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.
  • Page 152 VIBRATORY DRUM 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain valve 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.

  • Page 153: Vibratory Drum

    2-1-1. Removal of vibratory drum 1) Securing machine • Hold drum with chocks. • Lock front and rear frames with steering lock bar (1). SW654-06001 2) Removal of mirror assembly • Remove bolts (2). • Remove mirror assembly (3). SW654-06011...
  • Page 154 6 7 8 9 (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter. SW654-06013 2-2) Disconnecting vibrator motor piping • Remove bolts (11). • Remove cover (12). SW654-06014 •...
  • Page 155 Support stand Front axle Rear axle SW652-1-06106 SW654 : 3,360 kg (7,405 lbs.) 3,710 kg (8,180 lbs.) SW654ND : 3,510 kg (7,740 lbs.) 3,860 kg (8,510 lbs.) 5) Removal of cross member 5-1) Remove water spray pipe (16) and electrical harness (17).
  • Page 156 • Damper mounting bolts and nuts must not be stressed during the removal. Front drum assembly Rear drum assembly SW654 : 1,825 kg (4,023 lbs.) 1,820 kg (4,012 lbs.) SW654ND : 2,030 kg (4,475 lbs.) 2,025 kg (4,464 lbs.) SW652-1-06109 7) Removal of plates •...

  • Page 157: Installation Of Vibratory Drum

    VIBRATORY DRUM 2-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. (19) Bolt M16×50 : 265 N·m ( 195 lbf·ft) N•m (23) Bolt M16×50 : 265 N·m ( 195 lbf·ft) (25) Nut M12...

  • Page 159: Vibratory Drum Assembly (Sw654)

    VIBRATORY DRUM 3. VIBRATORY DRUM ASSEMBLY (SW654) (1) Drum 3-1. Vibratory Drum Assembly (2) Housing (3) Bolt : M 8×20 (4) Bolt : M16×45 (5) Vibrator bearing (6) Eccentric shaft (7) Vibrator bearing (8) Bolt : M16×45 (9) Plug (10) Oil seal...

  • Page 161: Disassembly And Reassembly Of Vibratory Drum

    SW654 VIBRATORY DRUM 3-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following Drum vibratory drum disassembly and reassembly procedures assembly are constant with part numbers of vibratory drum assembly shown on page 6-008.
  • Page 162 VIBRATORY DRUM SW654 4) Remove breather (15). • Remove bolts (17). • Remove vibrator motor (21). (21) Vibrator motor : 15 kg (33 lbs.) SW652-1-06004 5) Remove sleeve (19). SW652-1-06005 6) Lift disc subassembly. Disc • Remove bolts (13). subassembly...
  • Page 163 SW654 VIBRATORY DRUM 7) Remove disc subassembly. Disc subassembly : 75 kg (165 lbs.) Disc subassembly SW652-1-06007 8) Remove bolts (8). SW652-1-06008 9) Lift axle shaft (34) using two pulling bolts (M16×45). Pulling bolt SW652-1-06009 6-011...
  • Page 164 VIBRATORY DRUM SW654 WARN ING When installing lifting bolts, screw in the threads fully Lifting bolt before using. 10) Install lifting bolts (M16) to axle shaft (34). SW652-1-06010 11) Remove axle shaft subassembly. Wooden (NOTICE) hammer • In order not to lift eccentric shaft together with axle...
  • Page 165 SW654 VIBRATORY DRUM 13) Install a lifting bolt (M8) to eccentric shaft (6). Lifting bolt SW652-1-06013 W AR N ING Take care not to get your fingers caught in movable Movable weight weights. 14) Remove eccentric shaft (6). (6) Eccentric shaft : 60 g (132 lbs.) (NOTICE) •...
  • Page 166 VIBRATORY DRUM SW654 16) Lift disc subassembly. • Remove bolts (47). Disc subassembly SW652-1-06016 17) Remove disc subassembly. Disc Disc subassembly : 75 kg (165 lbs.) subassembly SW652-1-06017 18) Install lifting bolts (M16) to propulsion motor (46). Lifting bolt •...
  • Page 167 SW654 VIBRATORY DRUM 19) Remove propulsion motor subassembly. Propulsion motor Propulsion motor subassembly : 80 kg (176s lbs.) subassembly SW654-06002 20) Install lifting bolts (M16) to housing (2). • Remove bolts (4). Lifting bolt SW654-06003 21) Remove housing subassembly. Housing subassembly : 50 kg (110 lbs.)
  • Page 168 VIBRATORY DRUM SW654 22) Disassembly of axle shaft subassembly. • Remove bolts (16). • Remove flange (25). Axle shaft subassembly SW652-1-06022 23) Remove bolts (18). • Remove cover (23). • Remove shim (24). SW652-1-06023 24) Put a piece of wooden board on end of axle shaft (34).
  • Page 169 SW654 VIBRATORY DRUM 25) Install lifting bolts (M10) to housing (26). Lifting bolt SW652-1-06025 26) Remove housing subassembly from axle shaft subassembly. Housing Housing subassembly : 20 kg (44 lbs.) subassembly Axle shaft subassembly SW652-1-06026 6-017...

  • Page 170: Reassembly Of Vibratory Drum

    VIBRATORY DRUM SW654 3-2-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality. WARN ING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum.
  • Page 171 SW654 VIBRATORY DRUM 2-3) Apply grease to O-ring (35). • Install O-ring to cover (45). SW654-06005 2-4) Reverse housing subassembly. Housing subassembly Housing subassembly : 50 kg (110 lbs.) • Install cover (45) to housing subassembly with four bolts (3), spring washers and washers.
  • Page 172 VIBRATORY DRUM SW654 4) Lower housing subassembly on mounting surface of drum Housing (1). subassembly Housing subassembly : 50 kg (110 lbs.) (NOTICE) • Take care not to let O-ring to protrude from its groove. SW654-06008 5) Secure housing subassembly with sixteen bolts (4) and washers.
  • Page 173 SW654 VIBRATORY DRUM 7) Reverse propulsion motor subassembly. Lifting bolt Propulsion motor subassembly : 80 kg (176 lbs.) • Install lifting bolts (M16) to propulsion motor (46). SW652-1-06111 8) Lower propulsion motor subassembly on mounting surface of housing (2). Propulsion motor subassembly Propulsion motor subassembly : 80 kg (176 lbs.)
  • Page 174 VIBRATORY DRUM SW654 10) Lift disc subassembly. Disc subassembly Disc subassembly : 75 kg (165 lbs.) SW652-1-06038 11) Lower disc subassembly on mounting surface of propulsion motor (46). Disc subassembly SW652-1-06039 (NOTICE) • The recess of the disc must be parallel with the side of the propulsion motor ports A and B.
  • Page 175 SW654 VIBRATORY DRUM 12) Secure disc subassembly with eleven bolts (47) and washers. Disc subassembly (47) Bolts M16×45 : 265 N·m (195 lbf·ft) N•m SW652-1-06040 W AR N ING Drum subassembly Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
  • Page 176 VIBRATORY DRUM SW654 WARN ING Take care not to get your fingers caught in movable Movable weight weights. 15) Apply a coat of gear oil to eccentric shaft (6) at where bearing will be installed. • Install eccentric shaft. (6) Eccentric shaft : 60 kg (132 lbs.) (NOTICE) •...
  • Page 177 SW654 VIBRATORY DRUM W AR N ING Wear heat resistant gloves when handling heated parts to avoid burns. Axle shaft 17-2) Reverse axle shaft subassembly. subassembly Axle shaft subassembly : 40 kg (88 lbs.) • Heat up roller bearing (11) inner race by using a ring heater or the like.
  • Page 178 VIBRATORY DRUM SW654 17-5) Install lifting bolts (M10) to housing (26). Lifting bolt SW652-1-06049 17-6) Install housing subassembly to axle shaft subassembly. Housing subassembly : 20 kg (44 lbs.) Housing subassembly Axle shaft subassemby SW652-1-06050 17-7) Apply sufficient amount of lithium-based grease to rollers of roller bearing (12) inner race.
  • Page 179 SW654 VIBRATORY DRUM 17-8) Preload adjustment of roller bearing ①  I nstall a shim of about 1 mm (0.04 in.) and secure cover (23) to axle shaft (34) with six bolts (18) and spring washers. Shim SW652-1-06052 ② A gap will remain between end of axle shaft (34) and Shim inside of cover (23).
  • Page 180 VIBRATORY DRUM SW654 ③  R emove bolts (18). • Remove cover (23). • Remove shim. (NOTICE) • Do not turn the housing after the cover is removed. Shim SW652-1-06075 ④  W ithout inserting shim, install cover (23) to axle shaft (34) with six bolts (18) and spring washers.
  • Page 181 SW654 VIBRATORY DRUM ⑥ Remove bolts (18). • Remove cover (23). SW652-1-06074 ⑦  I nstall shim (24) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (23) to axle shaft (34) with six bolts (18) and spring washers.
  • Page 182 VIBRATORY DRUM SW654 17-10) Secure flange (25) to housing (26) with eight bolts (16) and spring washers. (16) Bolts M10×30 : 60 N·m (44 lbf·ft) N•m SW652-1-06057 18) Install lifting bolts to axle shaft (34). Lifting bolt SW652-1-06058 19) Lift axle shaft subassembly.
  • Page 183 SW654 VIBRATORY DRUM 20) Lower axle shaft subassembly on mounting surface of drum slowly. Pipe (NOTICE) • Support the eccentric shaft (6) with a pipe or the like, to prevent tilting of the vibrator bearing inner race during installation. Axle shaft...
  • Page 184 VIBRATORY DRUM SW654 23) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 3 mm (0.04 to 0.12 in.). SW652-1-06063 24) Lift disc subassembly. Disc subassembly Disc subassembly : 75 kg (165 lbs.)
  • Page 185 SW654 VIBRATORY DRUM (NOTICE) • The recess of the disc must face the same direction as the breather mounting hole in the flange. Recess of disc Breather mounting hole SW652-1-06066 26) Secure disc subassembly with sixteen bolts (13) and washers.
  • Page 186 VIBRATORY DRUM SW654 28) Apply molybdenum-based grease to splined portion of sleeve (19). • Fit sleeve to splined portion on eccentric shaft end. SW652-1-06069 29) Apply grease to O-ring (22). • Install O-ring to vibrator motor (21). SW652-1-06070 30) Wind seal tape around threaded portion of breather (15).
  • Page 187 SW654 VIBRATORY DRUM 31) Lay drum assembly with plugs (9-1), (9-2), and level plug Drum assembly (32) positioned as shown right. • Hold with chocks. Drum assembly : 1,455 kg (3,208 lbs.) Chock SW652-1-06001 32) Remove plug (9-1) and level plug (32).
  • Page 189 VIBRATORY DRUM 4. VIBRATORY DRUM ASSEMBLY (SW654ND) (1) Drum (51) Vibrator bearing 4-1. Vibratory Drum Assembly (2) Housing (52) Level plug (3) Cover (53) Bolt : M16×45 11 12 13 14 15 16 17 18 19 23 24 25 26 27 28 29 (4) Bolt : M12×30 (54) O-ring...

  • Page 191: Vibratory Drum Assembly (Sw654Nd)

    SW654ND VIBRATORY DRUM 4-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures Drum are constant with part numbers of vibratory drum assembly assembly shown on page 6-036. 21-1 4-2-1.
  • Page 192 VIBRATORY DRUM SW654ND 4) Remove breather (31). • Remove bolts (33). • Remove vibrator motor (37). (37) Vibrator motor : 15 kg (33 lbs.) SW652ND-1-06004 5) Remove sleeve (35). SW652ND-1-06005 6) Lift disc subassembly. Disc • Remove bolts (29). subassembly SW652ND-1-06006 6-038...
  • Page 193 SW654ND VIBRATORY DRUM 7) Remove disc subassembly. Disc Disc subassembly : 75 kg (165 lbs.) subassembly SW652ND-1-06007 8) Remove bolts (22) and (50). • Remove covers (23) and (47). • Remove bolts (53). SW652ND-1-06008 W AR N ING Lifting bolt When installing lifting bolts, screw in the threads fully before using.
  • Page 194 VIBRATORY DRUM SW654ND 10) Remove axle shaft subassembly. Wooden Axle shaft hammer subassembly Axle shaft subassembly : 205 kg (452 lbs.) (NOTICE) • In order not to lift eccentric shaft together with axle shaft subassembly, tap on the eccentric shaft ends alternately with a wooden hammer during lifting.
  • Page 195 SW654ND VIBRATORY DRUM W AR N ING Movable weight Take care not to get your fingers caught in movable weights. 13) Remove eccentric shaft (8). (8) Eccentric shaft : 70 kg (154 lbs.) (NOTICE) • Put the movable weight at its outmost position. SW652ND-1-06013 14) Install a lifting bolt (M8) to eccentric shaft (59).
  • Page 196 VIBRATORY DRUM SW654ND WARN ING Drum subassembly Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 16) Reverse drum subassembly. Drum subassembly : 1,230 kg (2,712 lbs.) SW652ND-1-06016 17) Lift disc subassembly.
  • Page 197 SW654ND VIBRATORY DRUM 19) Install lifting bolts (M16) to propulsion motor (74). Lifting bolt • Remove bolts (73). SW652ND-1-06019 20) Remove propulsion motor subassembly. Propulsion motor subassembly Propulsion motor subassembly : 80 kg (176 lbs.) SW652ND-1-06020 21) Install lifting bolts (M16) to housing (2). Lifting bolt •...
  • Page 198 VIBRATORY DRUM SW654ND 22) Remove housing subassembly. Housing subassembly Housing subassembly : 160 kg (353 lbs.) SW652ND-1-06022 23) Disassembly of axle shaft subassembly Axle shaft subassembly SW652ND-1-06023 24) Remove bolts (32). • Remove flange (41). SW652ND-1-06024 6-044...
  • Page 199 SW654ND VIBRATORY DRUM 25) Remove bolts (34). • Remove cover (39). • Remove shim (40). SW652ND-1-06025 26) Put a piece of wooden board on end of axle shaft (43). • Set a puller on housing (42). Puller • Remove housing subassembly with roller bearing from Wooder board axle shaft subassembly.
  • Page 200 VIBRATORY DRUM SW654ND 28) Remove housing subassembly from axle shaft subassembly. Housing Axle shaft Housing subassembly : 20 kg (44 lbs.) subassembly subassembly SW652ND-1-06028 29) Remove vibrator bearings (19) and (51) from axle shaft subassembly. Axle shaft subassembly SW652ND-1-06029 6-046...

  • Page 201: Reassembly Of Vibratory Drum

    SW654ND VIBRATORY DRUM 4-2-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality. W AR N ING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum.
  • Page 202 VIBRATORY DRUM SW654ND (NOTICE) • Stop driving in vibrator bearings (5) and (63) when they come to a position slightly protruding from the boss surface of the housing (2) to avoid driving in too 5,63 much. SW652ND-1-06033 2-2) Apply grease to O-rings (6) and (60). •...
  • Page 203 SW654ND VIBRATORY DRUM W AR N ING Lifting bolt When installing lifting bolts, screw in the threads fully before using. 3) Install lifting bolts (M16) to housing (2). SW652ND-1-06036 4) Lift housing subassembly. Housing subassembly : 160 kg (353 lbs.) Housing subassembly •...
  • Page 204 VIBRATORY DRUM SW654ND 6) Drive in two locating pins (7) for housing subassembly and Housing drum (1) temporarily. subassembly SW652ND-1-06039 7) Secure housing subassembly with sixteen bolts (62) and Housing washers. subassembly (62) Bolts M16×45 : 265 N·m (195 lbf·ft) N•m •...
  • Page 205 SW654ND VIBRATORY DRUM 9) Reverse propulsion motor subassembly. Lifting bolt Propulsion motor subassembly : 80 kg (176 lbs.) • Install lifting bolts (M16) to propulsion motor (74). SW652-1-06112 10) Lower propulsion motor subassembly on mounting surface of housing (2). Propulsion motor subassembly Propulsion motor subassembly : 80 kg (176 lbs.) SW652ND-1-06043...
  • Page 206 VIBRATORY DRUM SW654ND 12) Lift disc subassembly. Disc subassembly Disc subassembly : 75 kg (165 lbs.) SW652-1-06038 13) Lower disc subassembly on mounting surface of propulsion motor (74). Disc subassembly SW652ND-1-06046 (NOTICE) • The recess of the disc must be parallel with the side of the propulsion motor which have ports A and B.
  • Page 207 SW654ND VIBRATORY DRUM 14) Secure disc subassembly with eleven bolts (75) and washers. Disc subassembly (75) Bolts M16×45 : 265 N·m (195 lbf·ft) N•m SW652ND-1-06047 W AR N ING Drum subassembly Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
  • Page 208 VIBRATORY DRUM SW654ND WARN ING Lifting bolt Take care not to get your fingers caught in movable weights. 17) Install a lifting bolt (M8) to eccentric shaft (8). Movable (NOTICE) weight • Put the movable weight at its outmost position. SW652ND-1-06050 18) Apply a coat of gear oil to eccentric shaft subassembly at where vibrator bearing (5) will be installed.
  • Page 209 SW654ND VIBRATORY DRUM 20) Heat up gear (56) by using a ring heater or the like. • Drive sunk key (57) into eccentric shaft (59). • Install heated gear. • Install retaining ring (55). (NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
  • Page 210 VIBRATORY DRUM SW654ND 23) Insert eccentric shaft subassembly into vibrator bearing Eccentric (63) while taking care not to tilt vibrator bearing inner race. shaft subassembly (NOTICE) • After inserting the eccentric shaft subassembly into the vibrator bearing, lay the eccentric shaft subassembly against the inner wall of the drum so that it will not fall down.
  • Page 211 SW654ND VIBRATORY DRUM 24-3) Apply a coat of gear oil to axle shaft (43) at where bearing will be press-fitted. • Drive ball bearing (25) into axle shaft. SW652ND-1-06060 24-4) Apply a coat of gear oil to bearing mounting surface of shaft (10).
  • Page 212 VIBRATORY DRUM SW654ND 24-6) Heat up gear (14) by using a ring heater or the like. • Drive sunk key (11) to shaft (10). • Install heated gear. SW652ND-1-06063 24-7) Install collar (13). • Install retaining ring (12). (NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
  • Page 213 SW654ND VIBRATORY DRUM 24-9) Heat up roller bearing (27) inner race by using a ring heater or the like. • Apply a coat of gear oil to axle shaft at where bearing inner race will be press-fitted. • Drive in heated roller bearing inner race. SW652ND-1-06066 24-10) Apply sufficient amount of lithium-based grease to rollers of roller bearing (27) inner race.
  • Page 214 VIBRATORY DRUM SW654ND 24-12) Install lifting bolts (M10) to housing (42). Lifting bolt SW652ND-1-06069 24-13) Install housing subassembly to axle shaft subassembly. Housing Housing subassembly : 20kg (44 lbs.) subassembly Axle shaft subassemby SW652ND-1-06070 24-14) Apply sufficient amount of lithium-based grease to rollers of roller bearing (28) inner race.
  • Page 215 SW654ND VIBRATORY DRUM 24-15) Preload adjustment of roller bearing ①  I nstall a shim of about 1 mm (0.04 in.) and secure cover (39) to axle shaft (43) with six bolts (34) and spring washers. Shim SW652ND-1-06072 ② A gap will remain between end of axle shaft (43) and Shim inside of cover (39).
  • Page 216 VIBRATORY DRUM SW654ND ③  R emove bolts (34). • Remove cover (39). • Remove shim. (NOTICE) Shim • Do not turn the housing after the cover is removed. SW652ND-1-06103 ④ Without inserting shim, install cover (39) to axle shaft (43) with six bolts (34) and spring washers.
  • Page 217 SW654ND VIBRATORY DRUM ⑥ Remove bolts (34). • Remove cover (39). SW652ND-1-06102 ⑦  I nstall shim (40) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (39) to axle shaft (43) with six bolts (34) and spring washers.
  • Page 218 VIBRATORY DRUM SW654ND 24-17) Secure flange (41) to housing (42) with eight bolts (32) and spring washers. (32) Bolts M10×30 : 60 N·m (44 lbf·ft) N•m SW652ND-1-06076 25) Install lifting bolts (M12) to axle shaft subassembly. Lifting bolt Axle shaft subassembly SW652ND-1-06077 26) Lift axle shaft subassembly.
  • Page 219 SW654ND VIBRATORY DRUM 27) Place punch marks on end of eccentric shafts (8) and (59) as shown right. Scribed line Punch Scribed line Punch marks marks Keyway Keyway SW652ND-1-06057 28) Install long guide bolts to end of both eccentric shafts. Axle shaft •...
  • Page 220 VIBRATORY DRUM SW654ND 30) Secure axle shaft subassembly to drum (1) with sixteen bolts (53) and washers. Axle shaft subassembly (53) Bolts M16×45 : 265 N·m (195 lbf·ft) N•m • Drive in locating pins (20) again. SW652ND-1-06081 31) Make sure that punch marks on shaft (10) of eccentric shafts (8) and (59) are as shown right.
  • Page 221 SW654ND VIBRATORY DRUM (NOTICE) • Stop driving in vibrator bearings (19) and (51) when they come to a position slightly protruding from the 19,51 boss surface of axle shaft (43) to avoid driving in too much. SW652ND-1-06084 33) Press fit slightly protruding vibrator bearings (19) and (51) 22,50 23,47 into place by installing covers (23) and (47) with four bolts...
  • Page 222 VIBRATORY DRUM SW654ND 35) Measure dimension “a” from end of eccentric shafts (8) 8,59 and (59) to top of vibrator bearings (19) and (51) by using a depth gauge. 19,51 Depth gauge 8,59 19,51 SW652ND-1-06087 36) Lift eccentric shafts (8) and (59), and measure dimension 8,59 “b”...
  • Page 223 SW654ND VIBRATORY DRUM 38) Apply grease to O-rings (15) and (58). • Install O-rings to covers (23) and (47). 15,58 23,47 SW652ND-1-06090 39) Secure covers (23) and (47) to axle shaft subassembly with four bolts (22), four bolts (50), and washers. (22) and (50) Bolts M12×30 : 110 N·m (81 lbf·ft) N•m SW652ND-1-06091...
  • Page 224 VIBRATORY DRUM SW654ND 41) Lift disc subassembly. Disc subassembly Disc subassembly : 75kg (165 lbs.) SW652-1-06064 42) Lower disc subassembly on mounting surface of housing (42). Disc subassembly SW652ND-1-06094 (NOTICE) • The recess of the disc must face the same direction as the breather mounting hole in the flange.
  • Page 225 SW654ND VIBRATORY DRUM 43) Secure disc subassembly with sixteen bolts (29) and washers. Disc subassembly (29) Bolts M16×45 : 265 N·m (195 lbf·ft) N•m SW652ND-1-06096 44) Drive two spring pins (36) into sleeve (35). SW652ND-1-06097 45) Apply molybdenum-based grease to splined portion of sleeve (35).
  • Page 226 VIBRATORY DRUM SW654ND 46) Apply grease to O-ring (38). • Install O-ring to vibrator motor (37). SW652ND-1-06099 47) Wind seal tape around threaded portion of breather (31). • Install breather. • Secure vibrator motor (37) to flange (41) with two bolts (33) and washers.
  • Page 227 SW654ND VIBRATORY DRUM 49) Remove plug (21-1) and level plug (52). Suppy port • Supply gear oil from oil supply port. 21-1 • Check that oil drips from gauge port. • Quantity of gear oil : 10.4 L (2.7 gal.) •...
  • Page 229 5-1-1. Removal of vibratory drum 1) Securing machine • Hold drum with chocks. • Lock front and rear frames with steering lock bar (1). SW654-06001 2) Removal of mirror assembly • Remove bolts (2). • Remove mirror assembly (3). SW654-06011...
  • Page 230 3) Disconnecting piping 3-1) Disconnecting propulsion motor piping • Remove bolts (4). • Remove cover (5). Chock SW654-06012 • Remove bolts (6). • Remove clamp (7). SW654B-06001 • Disconnect hydraulic hoses (8), (9), (10), (11) and (12) connecting to propulsion motor.
  • Page 231 VIBRATORY DRUM 3-2) Disconnecting vibrator motor piping • Remove bolts (13). • Remove cover (14). SW654-06014 • Remove bolts (15). • Remove clamp (16). SW654-06064 • Disconnect hydraulic hoses (17), (18), and (19) connecting to vibrator motor. 17 18 19...
  • Page 232 Support stand Front axle Rear axle SW652-1-06106 SW654 : 3,360 kg (7,405 lbs.) 3,710 kg (8,180 lbs.) SW654ND : 3,510 kg (7,740 lbs.) 3,860 kg (8,510 lbs.) SW654B : 3,810 kg (8,400 lbs.) 4,160 kg (9,170 lbs.)
  • Page 233 • Damper mounting bolts and nuts must not be stressed during the removal. Front drum assembly Rear drum assembly SW654 : 1,850 kg (4,079 lbs.) 1,825 kg (4,023 lbs.) SW654ND : 2,060 kg (4,541 lbs.) 2,035 kg (4,486 lbs.) SW652-1-06109 SW654B : 2,330 kg (5,137 lbs.) 2,305 kg (5,082 lbs.)
  • Page 234 VIBRATORY DRUM 5-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. (23) Bolt M16×50 : 265 N·m ( 195 lbf·ft) N•m (27) Bolt M16×50 : 265 N·m ( 195 lbf·ft) (29) Nut M12...