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User Manuals: Sakai SW504 Drum Vibratory Roller
Manuals and User Guides for Sakai SW504 Drum Vibratory Roller. We have
1
Sakai SW504 Drum Vibratory Roller manual available for free PDF download: Shop Manual
Sakai SW504 Shop Manual (480 pages)
Brand:
Sakai
| Category:
Construction Equipment
| Size: 30 MB
Table of Contents
Table of Contents
5
Safety
17
General Safety
19
Understanding the Safety Symbols and Words
19
General
19
Qualifications of Operators and Maintenance Personnel
20
Safety Practices and Policies
20
Pre Start Inspection
21
Safety Instructions
21
Starting
22
Operating
22
Stopping
22
Maintenance
23
Transporting the Machine
25
Specifications
27
Specification Data
30
Sw354
31
Sw354 Rops
32
Tw354
34
Tw354 Rops
36
Tw504
38
Tw504 Rops
40
Common Specifications
42
Table of Standard Values
43
Engine
43
Propulsion
43
Hydraulic System
44
Steering
44
Brakes
45
Capacities
45
Fuel and Lubricants Specification
46
Rating
46
Recommended Lubricants
46
Tightening Torque Chart
47
Specification Data (Sw504)
48
Sw504
49
Sw504 Rops
50
Common Specifications
52
Table of Standard Values (Sw504)
53
Engine
53
Propulsion
53
Hydraulic System
53
Steering
54
Brakes
54
Capacities
54
Fuel and Lubricants Specification (Sw504)
55
Rating
55
Recommended Lubricants
55
Engine and Controls
57
Engine
59
Engine Mount
59
Control System
60
Throttle Control
60
Forward-Reverse Control
61
Pump Mount
62
Installation of Pump
63
Engine (Sw504)
65
Engine Mount
65
Fuel System (Sw504)
66
Control System (Sw504)
68
Throttle Control
68
Forward-Reverse Control
69
Pump Mount (Sw504)
70
Pump Mount
70
Installation of Pump
71
Hydraulic Systems
73
System Circuit Diagram
76
Graphic Symbols for Hydraulic Circuits
76
Hydraulic Circuit Diagram
79
Hydraulic Circuit Diagram (SW354)
79
Hydraulic Circuit Diagram (TW354)
81
Hydraulic Circuit Diagram (TW504)
83
Propulsion Hydraulic System
85
Propulsion Hydraulic Piping
85
Propulsion Hydraulic Piping (F) (SW/TW354)
85
Propulsion Hydraulic Piping (F) (TW504)
87
Propulsion Hydraulic Piping (R) (SW354)
89
Propulsion Hydraulic Piping (R) (TW354)
91
Propulsion Hydraulic Piping (R) (TW504)
93
Hydraulic Component Specifications
96
Propulsion Hydraulic Pump
96
Propulsion Hydraulic Motor (F) (SW/TW354)
98
Propulsion Hydraulic Motor (F) (TW504)
99
Propulsion Hydraulic Motor (R) (SW354)
100
Propulsion Hydraulic Motor (R) (TW354,504)
101
Differential Lock Valve (TW354,504)
102
Vibrator Hydraulic System
103
Vibrator Hydraulic Piping
103
Vibrator Hydraulic Piping (SW354)
103
Vibrator Hydraulic Piping (TW354)
105
Vibrator Hydraulic Piping (TW504)
107
Hydraulic Component Specifications
109
Hydraulic Pump Assembly (Vibrator (F) + Steering • Charge)
109
Vibrator Hydraulic Pump (R) (SW354)
110
Vibrator Hydraulic Motor
111
Cooling Fan Drive Hydraulic Motor
112
Vibrator Solenoid Valve (F), (R) (SW/TW354)
113
Vibrator Solenoid Valve (TW504)
114
Steering System
115
Steering Hydraulic Piping
115
Steering Hydraulic Piping (SW/TW354)
115
Steering Hydraulic Piping (TW504)
117
Steering Wheel
119
Orbitrol
119
Hydraulic Circuit Diagram (Sw504)
120
Hydraulic Circuit Diagram
121
Propulsion Hydraulic System (Sw504)
123
Propulsion Hydraulic Piping
123
Propulsion Hydraulic Piping (F)
123
Propulsion Hydraulic Piping (R)
125
Hydraulic Component Specifications
128
Propulsion Hydraulic Pump
128
Propulsion Hydraulic Motor (R)
130
Vibrator Hydraulic System (Sw504)
131
Vibrator Hydraulic Piping
131
Hydraulic Component Specifications
133
Hydraulic Pump Assembly (Vibrator + Steering • Charge)
133
Cooling Fan Drive Hydraulic Motor
134
Vibrator Solenoid Valve Assembly
135
Steering System (Sw504)
137
Steering Hydraulic Piping
137
Hydraulic Component Specifications
139
Orbitrol
139
Electrical System
141
Precautions for Work
143
Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses
143
System Circuit Diagram
145
Electrical Circuit Diagram (SW354)
145
Electrical Circuit Diagram (SW354 ROPS)
147
Electrical Circuit Diagram (TW354)
149
Electrical Circuit Diagram (TW354 ROPS)
151
Electrical Circuit Diagram (TW504)
153
Electrical Circuit Diagram (TW504 ROPS)
155
Electrical Components
157
Wiring Harness Layout (SW354)
157
Wiring Harness Layout (1)
157
Wiring Harness Layout (2)
159
Wiring Harness Layout (TW354)
161
Wiring Harness Layout (1)
161
Wiring Harness Layout (2)
163
Wiring Harness Layout (TW504)
165
Wiring Harness Layout (1)
165
Engine Harness
165
Dashboard Harness
167
Frame (F) Harness
172
Frame (F) Harness (SW/TW354)
172
Frame (F) Harness (TW504)
174
Frame (R) Harness
176
Stater Switch Harness
179
Working Switch Harness (Except ROPS)
181
Working Switch Harness (ROPS)
182
Parking Brake Switch Harness
183
Vibration Lo-Hi Change Switch Harness
184
Short Harness (SW/TW354 : Except SW354 ROPS)
184
Vibration Lo-Hi Change Switch Harness (TW504)
185
Vibrator Solenoid (R) Harness
186
Vibrator Solenoid (R) Harness (SW354)
186
Cap (TW354,504)
187
Hazard Switch Harness
188
Cap (Except ROPS)
188
Hazard Switch Harness (ROPS)
189
Mihaalu Harness
190
Liquid Spray Switch Harness (TW354,504)
191
Liquid Spray Pump Harness (TW354,504)
192
Short Harness
193
Vibratory Drum Select Switch Harness (SW354 ROPS)
194
F-R Lever Vibration Switch (L) Harness
195
F-R Lever Vibration Switch (R) Harness
196
Electrical Component Specifications
197
Fuse Box (SW354)
197
Fuse Box (TW354)
198
Fuse Box (TW504)
199
Combination Meter
200
System Circuit Diagram (Sw504)
201
Electrical Circuit Diagram (ROPS)
201
Electrical Circuit Diagram (Except ROPS)
203
Electrical Components (Sw504)
205
Wiring Harness Layout (1)
205
Wiring Harness Layout (2)
207
Wiring Harnesses (Sw504)
208
Engine Harness
208
Dashboard Harness (1)
210
Dashboard Harness (2)
212
ECU Harness (Vihicle)
214
ECU Harness (Engine)
216
Frame (F) Harness
218
Frame (R) Harness
220
Stater Switch Harness
222
Control Switch Harness
223
Working Switch Harness
224
Working Switch Harness (ROPS)
224
Working Switch Harness (Except ROPS)
225
Vibration Switch Harness
226
Vibration Switch Harness (ROPS)
226
Vibration Lo-Hi Change Switch Harness (Except ROPS)
227
Vibrator Solenoid (F) Harness (1)
228
Vibrator Solenoid (F) Harness (2)
229
Vibrator Solenoid (R) Harness (1)
230
Vibrator Solenoid (R) Harness (2)
231
Vibrator Solenoid (R) Harness (3)
233
Vibrator Solenoid (R) Harness (4)
233
Hazard Switch Harness
234
Hazard Switch Harness (ROPS)
234
Cap (Except ROPS)
235
DPF Switch Harness
236
Diagnostic Switch Harness
237
Parking Brake Switch Harness
238
Mihaalu Harness
239
Starter Relay Harness
240
F-R Lever Vibration Switch (L) Harness
241
F-R Lever Vibration Switch (R) Harness
242
Short Harness
243
Cord
244
Electrical Component Specifications (Sw504)
245
Fuse Box
245
Combination Meter
246
Vibratory Drum • Rear Wheel
247
Precautions for Disassembly and Reassembly
249
Vibratory Drum
251
Removal and Installation of Vibratory Drum
251
Removal of Vibratory Drum
251
Installation of Vibratory Drum
254
Vibratory Drum Assembly
255
Vibratory Drum Assembly (TW504)
257
Disassembly and Reassembly of Vibratory Drum
259
Disassembly of Vibratory Drum
259
Reassembly of Vibratory Drum
270
Rear Axle
289
Rear Axle Assembly (TW Types)
289
Removal and Installation of Rear Axle (TW Types)
290
Removal of Rear Axle
291
Installation of Rear Axle
294
Vibratory Drum (Sw504)
295
Removal and Installation of Vibratory Drum
295
Disassembly and Reassembly of Vibratory Drum
295
Brake
297
Brake Pedal
299
Brake System
300
Brake System (TW354, 504)
301
Water Spray System
303
Water Spray Piping
305
Water Spray Piping (TW354,504)
307
Liquid Spray System
309
Liquid Spray Piping (TW354,504)
309
Inspection and Adjustment
311
Safety Precautions for Inspection and Adjustment
313
Preparation for Inspection and Adjustment
313
Precautions for Inspection and Adjustment
313
Warm-Up
313
Inspection and Adjustment of Engine Related Items
313
Measurement and Inspection of Propulsion Circuit Pressure
314
Measurement
314
Inspection
315
Measurement and Adjustment of Propulsion Charge Circuit Pressure
316
Measurement
316
Adjustment
317
Measurement of Machine High/Low Speed Change Circuit Pressure
318
Measurement
318
Measurement of Parking Brake Release Pressure
319
Measurement
319
SW Types: Front and Rear, TW Types: Front
319
TW Types: Rear
320
Measurement of Vibrator Circuit Pressure
321
Measurement
321
Measurement and Inspection of Steering Circuit Pressure
322
Measurement
322
Inspection
323
Measurement of Hydraulic Pump Case Pressure
324
Measurement of Propulsion Pump Case Pressure
324
Measurement of Propulsion Motor Case Pressure
325
Measurement
325
SW Types: Front and Rear, TW Types: Front
325
TW Types: Rear
326
Measurement of Vibrator Motor Case Pressure (Except Tw504)
327
Measurement
327
Measurement of Vibrator Motor Case Pressure (Tw504)
328
Measurement
328
Adjustment of Throttle Lever
329
Adjustment of Linkage
329
Adjustment of Operating Force
330
Adjustment of F-R Lever
331
Adjustment of Linkage
331
Adjustment of Operating Force
332
Measurement and Inspection of Propulsion Circuit Pressure (Sw504)
334
Inspection
335
Measurement and Adjustment of Propulsion Charge Circuit Pressure (Sw504)
336
Measurement
336
Adjustment
337
Measurement of Machine High/Low Speed Change Circuit
338
Measurement
338
Measurement of Vibrator Circuit Pressure (Sw504)
339
Measurement
339
Measurement and Inspection of Steering Circuit Pressure
340
Measurement
340
Inspection
341
Measurement of Hydraulic Pump Case Pressure (Sw504)
342
Measurement of Propulsion Pump Case Pressure
342
Adjustment of Throttle Lever (Sw504)
343
Adjustment of Potentiometer
343
Adjustment of Operating Force
344
Adjustment of F-R Lever (Sw504)
345
Adjustment of Linkage
345
Troubleshooting
347
Safety Precautions for Troubleshooting
349
Important Information for Troubleshooting
349
Before Starting
350
Electrical System Troubleshooting
351
When Performing Electrical System Fault Diagnosis
351
Precautions to Take During Electrical Circuit Fault Diagnosis
351
Inspection Procedures Using a Tester
352
Inspection of Electrical System
357
Engine
361
Engine will Not Start (Starter Motor Does Not Run) 1/3
365
Engine will Not Start (but Starter Motor Runs)
365
Engine Does Not Stop Running
367
No Charging
367
Glow Plugs Is Not Heated
367
Starter Motor Runs Even When F-R Lever Is Not at "N
369
Propulsion
371
Machine Moves Neither Forward nor Backward
371
Machine Speed Cannot be Changed
373
Brake Cannot be Released
375
Brake Does Not Work
377
Vibration
378
No Vibration Occurs 1/2
379
No Vibration Occurs 2/2
381
Vibration Mode Cannot be Switched
383
Vibratory Drum Cannot be Switched (SW354 ROPS)
385
Amplitude Does Not Change (Remains Either Low or High) (TW504)
387
Water Spray
389
Continuous Water Spray Does Not Operate
389
Continuous Water Spray Works, but Auto Water Spray Does Not Operate
391
Liquid Cannot be Sprayed (TW354, 504)
393
Lighting
394
Head Lamp and Tail Lamp Do Not Light
395
Flood Lamp Does Not Light
395
Turn Signal Lamp Does Not Blink
397
Hazard Lamp Does Not Light (Turn Signal Blinks) (ROPS Type)
399
Stop Lamp Does Not Light
401
Illumination of Combination Meter Does Not Light
403
Combination Meter Warning Lamp or Indicator Lamp Is Abnormal
403
Tachometer Reading Is Abnormal
405
Hour Meter Is Abnormal
405
Temperature Meter Is Abnormal
407
Fuel Meter Is Abnormal
407
Hydraulic Oil Filter Warning Lamp Remains on
409
Charge Warning Lamp Remains on
409
Engine Oil Pressure Warning Lamp Remains on
411
Vibration Indicator Lamp Does Not Light
413
Water Spray Indicator Lamp Does Not Light
415
Liquid Spray Indicator Lamp Does Not Light (TW354, 504)
415
Flood Lamp Indicator Lamp Does Not Light
417
Parking Brake Indicator Lamp Does Not Light
417
Turn Signal Indicator Lamp Does Not Light
419
Horn Does Not Sound
421
Backup Buzzer Does Not Sound
421
Hydraulic System Troubleshooting
422
When Performing Hydraulic System Troubleshooting
422
Propulsion System
423
Machine Moves Neither Forward nor Backward 1/2
423
Machine Moves Neither Forward nor Backward 2/2
424
Machine Moves in One Direction Only (Forward or Backward)
424
Slow Machine Speed or Small Drive Force 1/2
424
Slow Machine Speed or Small Drive Force 2/2
425
Machine Speed Cannot be Switched
425
Machine Does Not Stop Completely with F-R Lever in "N
425
Driving Not Possible with Differential Locked (TW354, 504)
426
Propulsion System Is Overheating
426
Abnormal Noise from Propulsion System
426
Vibrator System
427
No Vibration
427
Vibrator Frequency Is too Low
428
Vibratory Drum Does Not Changeover Vibrating (SW354 ROPS)
428
Vibration Mode Does Not Switch (TW504)
428
Vibrator Does Not Stop
428
Vibrator System Is Overheating
429
Abnormal Noise from Vibrator System
429
Steering System
430
Steering Wheel Is Hard to Turn
430
Steering Response Is Slow
430
Steering Wheel Backlash or Play Is Large
431
Steering System Is Overheating
431
Abnormal Noise from Steering System
431
Cooling System
432
Cooling Fan Does Not Rotate
432
Cooling System Is Overheating
432
Electrical System Troubleshooting (Sw504)
433
Engine Diagnosis Trouble Code
433
Description of Diagnostic Trouble Code (SPN, FMI)
433
Table of the Diagnostic Trouble Code (DTC)
434
Engine
441
Engine will Not Start (Starter Motor Does Not Run) 1/3
441
Engine will Not Start (Starter Motor Does Not Run) 2/3
443
Engine will Not Start (Starter Motor Does Not Run) 3/3
445
Engine will Not Start (but Starter Motor Runs)
445
Glow Plugs Is Not Heated
447
Engine Speed Does Not Change When Operating Throttle Lever
449
Propulsion
451
Vibration
452
No Vibration Occurs 1/3
453
No Vibration Occurs 2/3
455
No Vibration Occurs 3/3
457
Vibratory Drum Cannot be Switched (ROPS)
459
Water Spray
461
Lighting
462
Illumination of Combination Meter Does Not Light
463
Combination Meter Warning Lamp or Indicator Lamp Is Abnormal
465
Tachometer Reading Is Abnormal
465
Hour Meter Is Abnormal
467
Fuel Meter Is Abnormal
467
Hydraulic Oil Filter Warning Lamp Remains on
469
Charge Warning Lamp Remains on
469
Vibration Indicator Lamp Does Not Light
471
Water Spray Indicator Lamp Does Not Light
473
Flood Lamp Indicator Lamp Does Not Light
475
Parking Brake Indicator Lamp Does Not Light
475
Turn Signal Indicator Lamp Does Not Light
477
Hydraulic System Troubleshooting (Sw504)
478
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