Sakai Asphalt Roller 774 Service Manual - PDF DOWNLOAD

Sakai Asphalt Roller 774 Service Manual – PDF DOWNLOAD

The Sakai Asphalt Roller 774 Service Manual is a comprehensive guide in PDF format, offering detailed instructions, diagrams, and maintenance procedures for operating and servicing the Sakai 774 Asphalt Roller, facilitating effective maintenance and repair tasks.

FILE DETAILS:

Sakai Asphalt Roller 774 Service Manual – PDF DOWNLOAD

Language : English
Pages : 370
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Sakai Asphalt Roller 774 Service Manual – PDF DOWNLOAD

• This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI roller. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit.
• Safety is everyone’s business and it is one of your primary concerns. Knowing the guidelines presented in this manual will help provide for your safety, for the safety of those around you and for the proper operation and maintenance of the machine. Improper operation is dangerous and can result in injury or death.
• Sakai Heavy Industries cannot foresee all possible circumstances or varying conditions to which the operator, serviceman or machine may be exposed to that might lead to a potential hazard. Therefore, the warnings and cautions listed in this manual and those placed on the machine are not intended to be all inclusive and liability for personal injury or damage to equipment or property cannot be assumed.
• All information, specifications and illustrations in this publication are based on the product information available at the time that the publication was written. The contents may change without prior notice due to modifications of the model.

TABLE OF CONTENTS:

Sakai Asphalt Roller 774 Service Manual – PDF DOWNLOAD

1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words 1-001
1-2. General 1-001
1-3. Qualifications of Operators and Maintenance Personnel 1-002
1-4. Safety Practices and Policies 1-002
1-5. Pre Start Inspection·· 1-003
1-6. Safety Instructions 1-003
1-7. Starting , 1-004
1-8. Operating·· 1-004
1-9. Stopping 1-004
1-10. Maintenance 1-005
1-11. Transporting the Machine 1-007
2. SPECIFICATIONS
1. SPECIFICATION DATA
1-1.SW774 2-001
1-2. SW774ND 2-003
1-3. Common Specifications 2-005
2. TABLE OF STANDARD VALUES
2-1. Engine 2-006
2-2. Propulsion, 2-006
2-3. Hydraulic System 2-006
2-4. Steering· 2-007
2-5. Brakes· 2-007
2-6. Capacities· 2-007
3. FU ELAND LUBRICANTS SPECIFICATION
3-1. Rating 2-008
3-2. Recommended Lubricants 2-008
4. TIGHTENING TORQUE CHART· 2-009
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount 3-001
1-2. Engine Exterior, 3-002
2. FUEL SYSTEM 3-003
3. EXHAUST SYSTEM
3-1. Exhaust System 3-005
3-1-1. DPF ASSY 3-006
3-1-2. SCR ASSY 3-007
3-2. Urea Piping 3-008
3-2-1. DEF pump 3-009
3-2-2. DEF tank 3-010
4. CONTROL SYSTEM
4-1. Forward-reverse Control 3-011
5. PUMP MOUNT
5-1. Pump Mount, 3-012
5-1-1. Installation of pump 3-013
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 (SW774) 4-003
1-2-2. Hydraulic circuit diagram (SW774ND) 4-004
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping 4-005
2-1-1. Propulsion hydraulic piping (1) 4-005
2-1-2. Propulsion hydraulic piping (2) (SW774) 4-006
2-1-3. Propulsion hydraulic piping (2) (SW774ND) 4-007
2-2. Hydraulic Component Specifications 4-008
2-2-1. Hydraulic pump ASSY (propulsion+ vibrator) 4-008
2-2-2. Propulsion hydraulic motor (F) 4-010
2-2-3. Propulsion hydraulic motor (R) 4-012
2-2-4. Parking brake solenoid valve . 4-014
2-2-5. Block (1) 4-015
2-2-6. Block (2) 4-016
2-2-7. Block (3) 4-017
2-3. Description and Operation of Propulsion System 4-019
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-022
3-1-1. Vibrator hydraulic piping (1) 4-022
3-1-2. Vibrator hydraulic piping (2) (SW174) 4-023
3-1-3. Vibrator hydraulic piping (2) (SW174ND) 4-024
3-2. Hydraulic Component Specifications 4-025
3-2-1. Vibrator hydraulic motor (F), (R) (SW174) 4-025
3-2-2. Vibrator hydraulic motor (F), (R) (SW174ND) 4-026
3-2-3. Vibrator solenoid valve (F), (R) 4-027
3-3. Description and Operation of Vibrator System 4-029
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping 4-030
4-2. Steering VVheel 4-031
4-3. Hydraulic Component Specifications 4-032
4-3-1. Steering• charge pump 4-032
4-3-2. Orbitrol 4-033
4-4. Description and Operation of Steering System 4-035
4-4-1. Description and operation of steering system, 4-035
4-4-2. Structure and operation of Orbitrol 0000
“‘”‘””‘””‘””‘””‘”‘””‘””‘””‘””” 4-036
5. 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 5-001
2. SYSTEM CIRCUIT DIAGRAM
2-1 Electrical Circuit Diagram· 5-003
3. ELECTRICAL COMPONENTS
3-1. Wiring Harness Layout (1) 5-004
3-2. Wiring Harness Layout (2) 5-005
3-3. Wiring Harness Layout (3) 0000
“”‘””‘””‘”‘””‘””‘””‘””‘”‘””‘””‘””‘””‘””” 5-006
4. WIRING HARNESSES
4-1. Fuse• Relay Harness 5-007
4-2. Battery Harness 5-009
4-3. ECU Harness 5-011
4-4. ACU Harness 5-013
4-5. Dashboard Harness 5-015
4-6. Air Flow Sensor Harness 5-017
4-7. Engine Harness 5-019
4-8. Stater Switch Harness 5-020
4-9. Head Lamp Harness 5-021
4-10. Member (F) Harness 5-022
4-11. Combination Lamp (F) Harness 5-023
4-12. Combination Lamp (R) Harness 5-024
4-13. F-R Lever Harness 5-025
4-14. F-R Lever Vibration Switch Harness 5-026
4-15. Vibrator Pump Solenoid Harness 5-027
4-16. Water Spray Pump Harness 5-028
4-17. Backup Buzzer Harness 5-029
4-18. Ground Cord 1 5-030
4-19. Ground Cord 2 5-031
4-20. Ground Cord 3 5-032
5. ELECTRICAL COMPONENT SPECIFICATIONS
5-1. Fuse Box (1) 5-033
5-2. Fuse Box (2) 5-034
5-3. Combination Meter, 5-035
6. VIBRATORY DRUM
1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001
2. VIBRATORY DRUM
2-1. Removal and Installation of Vibratory Drum 6-003
2-1-1. Removal of vibratory drum””‘ 6-003
2-1-2. Installation of vibratory drum 6-007
3. VIBRATORY DRUM ASSY (SW774)
3-1. Vibratory Drum ASSY 6-008
3-2. Disassembly and Reassembly of Vibratory Drum 6-009
3-2-1. Disassembly of vibratory drum 6-009
3-2-2. Reassembly of vibratory drum 6-018
4. VIBRATORY DRUM ASSY (SW774ND)
4-1. Vibratory Drum ASSY 6-035
4-2. Disassembly and Reassembly of Vibratory Drum 6-036
4-2-1. Disassembly of vibratory drum 6-036
4-2-2. Reassembly of vibratory drum 6-048
7. BRAKE
1. BRAKE PEDAL 7-001
2. BRAKE SYSTEM
2-1. Description and Operation of Brake Circuit 7-003
8. OPERATOR STATION
1. FLOORBOARD
1-1. Structure of Operator Station 8-001
1-2. Adjustment of Swivel Lock Release Pedal 8-002
9. WATER SPRAY SYSTEM
1. WATER SPRAY PIPING 9-001
1-1. V\/ater Spray Piping (1) 9-001
1-2. V\/ater Spray Piping (2) 9-002
10. INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT
1-1. Safety Precautions for Inspection and Adjustment 10-001
1-2. Preparation for Inspection and Adjustment 10-001
1-3. Precautions for Inspection and Adjustment 10-001
1-4. V\/arm-up 10-001
1-5. Inspection and Adjustment of Engine Related Items 10-001
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement 10-002
2-2. Adjustment 10-003
2-2-1. If pressures on both forward and reverse sides deviate from maximum
circuit pressure range by same value 10-003
2-2-2. If pressure on either forward or reverse side deviates from maximum
circuit pressure range 10-004
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE 10-005
3-1. Measurement 10-005
3-2. Adjustment 10-006
4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1. Measurement 10-007
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1. Measurement 10-008
6. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE
6-1. Measurement 10-009
6-1-1. Measurement of main relief pressure 10-009
6-1-2. Measurement of port relief pressure 10-010
6-2. Adjustment 10-011
6-2-1. Adjustment of main relief pressure 10-011
6-2-2. Adjustment of port relief pressure 10-012
7. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1. Measurement························································································10-013
7-2. Inspection ··························································································10-014
8. ADJUSTMENT OF F-R LEVER
8-1. Adjustment of Linkage············································································ 10-015
8-2. Adjustment of Operating Force ····························································· 10-016
11. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting 11-001
1-2. Important Information for Troubleshooting 11-001
1-3. Before Starting 11-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING
2-1. When Performing Electrical System Fault Diagnosis 11-003
2-1-1. Precautions to take during electrical circuit fault diagnosis 11-003
2-1-2. Inspection procedures using a tester 11-004
2-1-3. Inspection of electrical system 11-009
2-2. Engine Diagnosis Trouble Code 11-011
2-2-1. Description of fault code (SPN, FMI) 11-011
2-2-2. Fault code list (SPN, FM I) 11-012
2-3. Engine 11-021
2-3-1. Engine will not start (Starter motor does not run) 113 11-021
2-3-1. Engine will not start (Starter motor does not run) 2/3 11-023
2-3-1. Engine will not start (Starter motor does not run) 3/3 11-025
2-3-2. Engine will not start (But starter motor runs) 11-025
2-3-3. No charging 11-027
2-3-4. Intake heater is not heated
(Engine starting performance is bad in cold weather) 11-027
2-3-5. Starter motor runs even when F-R lever is not at “N” 11-027
2-3-6. Engine speed cannot be switched 11-029
2-4. Propulsion System 11-031
2-4-1. Machine moves neither forward nor backward 11-031
2-4-2. Brake cannot be released 11-033
2-4-3. Brake does not work 11-035
2-5. Vibration 11-037
2-5-1. No vibration occurs 1/3 11-037
2-5-1. No vibration occurs 2/3 11-039
2-5-1. No vibration occurs 3/3 11-041
2-5-2. Vibration frequency cannot be switched : SW17 4 1/2 11-043
2-5-2. Vibration frequency cannot be switched : SW17 4 2/2 11-045
2-5-3. Vibration does not change
(Remains either low/oscillation or high/normal) 11-047
2-5-4. Vibration mode cannot be switched
(F-R lever vibration switch does not work) 11-049
2-5-5. Vibratory drum cannot be switched 11-051
2-6. V\/ater Spray 11-053
2-6-1. Continuous water spray does not operate 1 /2 11-053
2-6-1. Continuous water spray does not operate 2/2 11-055
2-6-2. Continuous water spray works, but auto water spray does not operate 11-057
2-6-3. Continuous water spray works,
but intermittent water spray does not operate 11-059
2-7. Lighting 11-061
2-7-1. Head lamp, side marker lamp and tail lamp do not light 11-061
2-7-2. Flood lamp does not light 11-063
2-7-3. High-beam of head lamp does not light 11-063
2-7-4. Turn signal lamp does not blink 11-065
2-7-5. Hazard lamp does not light (Turn signal lamp blinks) 11-067
2-7-6. Backup lamp does not light 11-067
2-7-7. Stop lamp does not light 11-069
2-7-8. Illumination of combination meter does not light 11-071
2-7-9. Combination meter warning lamp or indicator lamp is abnormal 11-071
2-7-10. Tachometer reading is abnormal 11-073
2-7-11. Hour meter is abnormal 11-073
2-7-12. Temperature meter is abnormal 11-075
2-7-13. Fuel meter is abnormal 11-075
2-7-14. Hydraulic oil filter warning lamp remains ON 11-077
2-7-15. Charge warning lamp remains ON 11-077
2-7-16. Vibration indicator lamp does not light 11-079
2-7-17. Water spray indicator lamp does not light 11-081
2-7-18. Flood lamp indicator lamp does not light 11-083
2-7-19. Side marker lamp indicator lamp does not light 11-083
2-7-20. Parking brake indicator lamp does not light 11-085
2-7-21 Turn signal indicator lamp does not light 11-087
2-7-22. Horn does not sound 11-089
2-7-23. Backup buzzer does not sound 11-089
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting ······························ 11-090
3-2. Propulsion System················································································· 11-091
3-2-1. Machine moves neither forward nor backward 1/2 ····························· 11-091
3-2-1. Machine moves neither forward nor backward 2/2 11-092
3-2-2. Machine moves in one direction only (forward or backward) 11-092
3-2-3. Slow machine speed or small drive force 1/2 11-092
3-2-3. Slow machine speed or small drive force 2/2 11-093
3-2-4. Machine speed cannot be switched 11-093
3-2-5. Machine does not stop completely with F-R lever in “N” 11-093
3-2-6. Propulsion system is overheating 11-094
3-2-7. Abnormal noise from propulsion system 11-094
3-3. Vibrator System 11-095
3-3-1. No vibration 11-095
3-3-2. Vibration wheel does not switch 11-096
3-3-3. Vibrator frequency is too low 11-096
3-3-4. Vibration mode does not switch 11-097
3-3-5. Vibratory drum does not changeover vibrating 11-097
3-3-6. Vibrator does not stop 11-097
3-3-7. Vibrator system is overheating 11-097
3-3-8. Abnormal noise from vibrator system 11-098
3-4. Steering System 11-099
3-4-1. Steering wheel is hard to turn 11-099
3-4-2. Steering response is slow 11-099
3-4-3. Steering wheel backlash or play is large 11-100
3-4-4. Steering system is overheating 11-100
3-4-5. Abnormal noise from steering system 11-100