Sakai SV540 Series Manuals

Manuals and User Guides for Sakai SV540 Series. We have 2 Sakai SV540 Series manuals available for free PDF download: Shop Manual, Operating & Maintenance Instructions

Sakai SV540 Series Shop Manual

Sakai SV540 Series Shop Manual (306 pages)

Brand: Sakai | Category: Construction Equipment | Size: 45 MB

Table of Contents

Table of Contents
5
Safety

13
- General Safety
  15
  - Understanding the Safety Symbols and Words
    15
  - General
    15
    
    Qualifications of Operators and Maintenance Personnel
    16
    
    Safety Practices and Policies
    16
  - Pre Start Inspection
    17
  - Safety Instructions
    17
    
    Operating
    18
    
    Starting
    18
  - Stopping
    18
  - Maintenance
    19
    
    Transporting the Machine
    21
Specifications

23
- Specification Data
  26
- Sv540D
  26
  - Sv540T
    28
  - Sv540Tf
    30
  - Sv540Df
    32
  - Sv640D
    34
    
    Sv640T
    36
    
    Engine
    38
    
    Table of Standard Values
    38
  - Propulsion
    38
  - Hydraulic System
    38
    
    Steering
    39
  - Brakes
    39
  - Capacities
    39
    
    Fuel and Lubricants Specification
    40
  - Rating
    40
    
    Recommended Lubricants
    40
    
    Tightening Torque Chart
    41
Engine and Controls

43
- Engine
  45
  - Engine Mount
    45
  - Engine Exterior
    47
    
    Fuel System
    49
    
    Control System
    50
    
    Forward-Reverse Control
    50
    
    Pump Mount
    51
    
    Installation of Pump
    52
Hydraulic Systems

53
Electrical System

85
- PRECAUTIONS for Work
  87
- Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses
  87
- Electrical Equipment Installation
  88
- System Circuit Diagram
  89
- Electrical Circuit Diagram
  89
- Electrical Components
  91
  - Battery Layout
    91
    
    Wiring Harness Layout (1)
    93
  - Wiring Harness Layout (2)
    95
    
    Engine Harness
    95
  - Panel Harness (1)
    95
    
    Fuse • Relay Harness (1)
    95
    
    Panel Harness (2)
    95
  - Fuse • Relay Harness (2)
    95
    
    Battery Relay Harness
    106
    
    Starter Switch Harness
    109
    
    Control Harness
    110
    
    Control Switch Harness
    111
    
    Motor Rotation Sensor Harness (Front)
    112
  - Fuel Unit Harness
    113
    
    Diagnostic Switch Harness
    114
    
    Electrical Component Specifications
    115
  - Fuse Box (1)
    115
    
    Fuse Box (2)
    116
    
    Combination Meter
    117
Vibratory Drum • Rear Axle

119
- Precautions for Disassembly and Reassembly
  121
- Vibratory Drum
  123
- Removal and Installation of Vibratory Drum
  123
  - Removal of Vibratory Drum
    123
  - Installation of Vibratory Drum
    126
  - Vibratory Drum Assembly
    127
  - Disassembly and Reassembly of Vibratory Drum
    129
  - Disassembly of Vibratory Drum
    129
  - Reassembly of Vibratory Drum
    140
- Rear Axle
  159
  - Rear Axle (SV540/640D)
    159
  - Rear Axle (SV540/640T, TF, DF)
    161
    
    Rear Axle Lubrication
    163
  - Rear Axle Structure
    164
  - Center Housing
    164
    
    Differential
    165
    
    Hub Reduction Gear
    166
    
    Brake
    167
    
    Gear Box
    168
Brake

169
- Brake Pedal
  171
- Brake Hydraulic Piping
  173
  - Brake System
    175
  - Hydraulic Component Specifications
    176
  - Brake Solenoid Valve
    176
  - Valve Block
    177
Inspection and Adjustment

179
- Safety Precautions for Inspection and Adjustment
  181
- Preparation for Inspection and Adjustment
  181
  - Precautions for Inspection and Adjustment
    181
    
    Inspection and Adjustment of Engine Related Items
    181
    
    Warm-Up
    181
    
    Measurement
    182
    
    Measurement and Adjustment of Propulsion Circuit Pressure
    182
    
    Adjustment
    183
    
    Measurement and Adjustment of Propulsion Charge Circuit
    184
  - Pressure
    185
  - Measurement
    185
  - Adjustment
    186
  - MEASUREMENT of MACHINE High/Low SPEED CHANGE CIRCUIT PRESSURE
    187
  - Measurement of Propulsion Motor (Front)
    187
  - Measurement of Propulsion Motor (Rear)
    188
    
    Measurement
    189
    
    Measurement of Parking Brake Release Pressure
    189
    
    Measurement and Inspection of Vibrator Circuit Pressure
    190
  - Measurement
    190
- Inspection
  191
  - Measurement and Adjustment of Vibrator Charge Circuit
    192
  - Pressure
    193
    
    Measurement
    193
    
    Adjustment
    194
    
    MEASUREMENT of VIBRATOR High/Low CHANGE CIRCUIT PRESSURE
    195
  - Measurement
    195
    
    Measurement
    196
    
    Measurement and Inspection of Steering Circuit Pressure
    196
    
    Inspection
    197
    
    Measurement of Hydraulic Pump Case Pressure
    198
    
    Measurement of Propulsion Pump Case Pressure
    198
    
    Measurement of Vibrator Pump Case Pressure
    199
  - Measurement of Propulsion Motor Case Pressure
    200
  - Measurement of Propulsion Motor (Front)
    200
  - Measurement of Propulsion Motor (Rear)
    201
  - Measurement of Vibrator Motor Case Pressure
    202
    
    Measurement
    202
    
    Adjustment
    203
    
    Adjustment of F-R Lever Linkage
    203
  - Brake Adjustment
    204
  - Manually Releasing the Brake
    204
  - Adjustment after Manual Release of Brake
    205
Troubleshooting

207
- Safety Precautions for Troubleshooting
  209
  - Important Information for Troubleshooting
    209
    
    Before Starting
    210
    
    Wire Number and Color Code
    210
    
    Electrical System Troubleshooting
    211
    
    Precautions to Take During Electrical Circuit Fault Diagnosis
    211
    
    When Performing Electrical System Fault Diagnosis
    211
    
    Inspection Procedures Using a Tester
    212
    
    Inspection of Electrical System
    217
- Fault Codes
  219
  - Fault Detection
    219
  - Fault Lamps
    219
- Flash out of Fault Codes
  220
  - Fault Code List
    221
  - Error Codes
    230
- Engine
  233
- Engine will Not Start (Starter Motor Does Not Run) 1/4
  233
- Engine will Not Start (Starter Motor Does Not Run) 2/4
  235
- Engine will Not Start (Starter Motor Does Not Run) 3/4
  237
  - Engine will Not Start (Starter Motor Does Not Run) 4/4
    239
  - Engine will Not Start (but Starter Motor Runs)
    241
- No Charging
  243
  - Grid Heater Does Not Work
    243
  - Engine Speed Cannot be Switched
    245
- Propulsion
  247
- Machine Moves Neither Forward nor Backward
  247
- Machine Speed Cannot be Changed 1/5
  249
- Machine Speed Cannot be Changed 2/5
  251
- Machine Speed Cannot be Changed 3/5
  253
- Machine Speed Cannot be Changed 4/5
  255
- Machine Speed Cannot be Changed 5/5
  257
  - Brake Cannot be Released
    259
- Brake Does Not Work
  261
- Vibration
  263
- No Vibration Occurs 1/3
  263
- No Vibration Occurs 2/3
  265
- No Vibration Occurs 3/3
  267
- Amplitude Does Not Change (Remains Either Low or High) 1/3
  269
- Amplitude Does Not Change (Remains Either Low or High) 2/3
  271
- Amplitude Does Not Change (Remains Either Low or High) 3/3
  273
  - Vibration Mode Cannot be Switched
    275
  - Vibrator Force Is Low in ECO Mode
    277
- Lighting
  279
- Combination Meter Warning Lamp or Indicator Lamp Is Abnormal
  279
- Tachometer Reading Is Abnormal
  281
- Hour Meter Is Abnormal
  281
- Temperature Meter Is Abnormal
  283
- Fuel Meter Is Abnormal
  283
- Hydraulic Oil Filter Warning Lamp Remains on
  285
- Engine Oil Pressure Warning Lamp Remains on
  287
- Vibration Indicator Lamp Does Not Light
  289
- Parking Brake Indicator Lamp Does Not Light
  291
- ECO Mode Indicator Lamp Does Not Light
  293
- Horn Does Not Sound
  295
- Backup Buzzer Does Not Sound
  295
- Hydraulic System Troubleshooting
  296
- When Performing Hydraulic System Troubleshooting
  296
- Propulsion System
  297
- Machine Moves Neither Forward nor Backward 1/2
  297
- Machine Moves Neither Forward nor Backward 2/2
  298
- Machine Moves in One Direction Only (Forward or Backward)
  298
- Slow Machine Speed or Small Drive Force 1/2
  298
- Slow Machine Speed or Small Drive Force 2/2
  299
- Machine Speed Cannot be Switched
  299
- Machine Does Not Stop Completely with F-R Lever in "N
  299
- Propulsion System Is Overheating
  300
- Abnormal Noise from Propulsion System
  300
- Vibrator System
  301
- No Vibration
  301
- Vibrator Frequency Is too Low
  302
- Amplitude Does Not Switch between High and Low
  302
- Vibrator Does Not Stop
  303
- Vibrator System Is Overheating
  303
- Abnormal Noise from Vibrator System
  303
- Steering System
  304
- Steering Wheel Is Hard to Turn
  304
- Steering Response Is Slow
  304
- Steering Wheel Backlash or Play Is Large
  305
- Steering System Is Overheating
  305
- Abnormal Noise from Steering System
  305

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Sakai SV540 Series Operating & Maintenance Instructions

Sakai SV540 Series Operating & Maintenance Instructions (108 pages)

Brand: Sakai | Category: Construction Equipment | Size: 9 MB

Table of Contents

Table of Contents
3
Machine and Engine Identification Numbers
6
Safety Notices
7
1 Basic Safety Precautions

9
- General Precautions
  9
- Preparation for Safe Operation
  13
- Before Starting the Engine
  14
- After Starting the Engine
  16
- During Operation
  17
- Loading and Unloading
  21
- Transportation
  21
- Handling the Battery
  22
- Towing
  23
- Before Servicing
  24
- During Servicing
  26
- Safety Decals
  29
2 Operation

31
- Instruments and Controls
  31
  - Operator's Station
    31
  - Gauges, Indicator Lamps and Warning Lamps
    32
  - Switches
    36
  - Operating Levers / Pedals
    40
  - Unloader Valve
    41
  - Fuse Box
    42
- Handling and Adjustments
  43
- Operation
  47
  - Before-Starting Inspection
    47
  - Starting the Engine
    48
  - After Starting the Engine
    49
  - Traveling
    50
  - Stopping / Parking
    52
  - Stopping the Engine
    53
  - Check after Stopping the Engine
    53
- Vibratory Operation
  54
- Precautions for Work
  56
  - Compaction Operation
    56
  - When Going Downhill
    56
  - On a Slope
    56
- Applicable Jobs
  57
- After Operation
  58
- Loading and Unloading
  58
  - Use of a Trailer Equipped with a Winch
    59
  - Self-Propelling
    59
- After Loading the Machine
  60
- Transportation
  60
- Operation in Cold Weather
  60
  - Fuel Oil and Grease
    60
  - Coolant
    61
  - Battery
    62
- When the Cold Season Is over
  63
- For a Long Storage Period
  63
- During the Storage Period
  64
- When the Battery Has Discharged
  64
  - Connection and Disconnection of Booster Cables
    65
3 Periodic Maintenance

67
- Precautions
  67
  - Lifting the Machine by Hoist
    70
- Walk-Around Checking
  71
  - Tire Inflation Pressure Check
    72
  - Checking for External Injury to a Tire
    72
- Periodic Maintenance Points
  73
- Maintenance Procedure
  75
  - Every 10 Service Hours or Daily
    75
  - Every 50 Service Hours
    78
  - Every 250 Service Hours
    80
  - Every 500 Service Hours
    83
  - Every 1000 Service Hours
    86
  - As Required
    88
- Consumable Parts
  93
- Fluid and Lubricant Capacities
  95
- Electric Wiring Diagram
  97
4 Specifications

100

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