Sakai Asphalt Roller SW354 TW354 TW504 Service Manual PDF

Sakai Asphalt Roller SW354 TW354 TW504 Service Manual – PDF DOWNLOAD

The Sakai Asphalt Roller SW354 TW354 TW504 Service Manual PDF provides comprehensive instructions for maintenance, repair, and operation of Sakai asphalt rollers. It’s a vital resource for ensuring optimal performance and longevity of these machines.

FILE DETAILS:

Sakai Asphalt Roller SW354 TW354 TW504 Service Manual – PDF DOWNLOAD

Language : English
Pages : 334
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Sakai Asphalt Roller SW354 TW354 TW504 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 SW354 TW354 TW504 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. SW354 2-001
1-2. SW354 ROPS 2-003
1-3. TW354 2-005
1-4. TW354 ROPS 2-007
1-5. TW504 2-009
1-6. TW504 ROPS 2-011
1-7. Common Specifications 2-013
2. TABLE OF STANDARD VALUES 2-014
2-1. Engine 2-014
2-2. Propulsion 2-014
2-3. Hydraulic System 2-015
2-4. Steering 2-015
2-5. Brakes 2-016
2-6. Capacities 2-016
3. FUEL AND LUBRICANTS SPECIFICATION 2-017
3-1. Rating 2-017
3-2. Recommended Lubricants 2-017
4. TIGHTENING TORQUE CHART 2-018
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount 3-001
2. CONTROL SYSTEM
2-1. Throttle Control 3-002
2-2. Forward-reverse Control 3-003
3. PUMP MOUNT
3-1. Pump Mount 3-004
3-1-1. Installation of pump 3-005
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 (SW354) 4-003
1-2-2. Hydraulic circuit diagram (TW354) 4-004
1-2-3. Hydraulic circuit diagram (TW504) 4-005
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping 4-006
2-1-1. Propulsion hydraulic piping (F) (SW/TW354) 4-006
2-1-2. Propulsion hydraulic piping (F) (TW504) 4-007
2-1-3. Propulsion hydraulic piping (R) (SW354) 4-008
2-1-4. Propulsion hydraulic piping (R) (TW354) 4-009
2-1-5. Propulsion hydraulic piping (R) (TW504) 4-010
2-2. Hydraulic Component Specifications 4-011
2-2-1. Propulsion hydraulic pump 4-011
2-2-2. Propulsion hydraulic motor (F) (SW/TW354) 4-013
2-2-3. Propulsion hydraulic motor (F) (TW504) 4-014
2-2-4. Propulsion hydraulic motor (R) (SW354) 4-015
2-2-5. Propulsion hydraulic motor (R) (TW354,504) 4-016
2-2-6. Differential lock valve (TW354,504) 4-017
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-018
3-1-1. Vibrator hydraulic piping (SW354) 4-018
3-1-2. Vibrator hydraulic piping (TW354) 4-019
3-1-3. Vibrator hydraulic piping (TW504) 4-020
3-2. Hydraulic Component Specifications 4-021
3-2-1. Hydraulic pump assembly (vibrator (F) + steering • charge) 4-021
3-2-2. Vibrator hydraulic pump (R) (SW354) 4-022
3-2-3. Vibrator hydraulic motor 4-023
3-2-4. Cooling fan drive hydraulic motor 4-024
3-2-5. Vibrator solenoid valve (F), (R) (SW/TW354) 4-025
3-2-6. Vibrator solenoid valve (TW504) 4-026
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping 4-027
4-1-1. Steering hydraulic piping (SW/TW354) 4-027
4-1-2. Steering hydraulic piping (TW504) 4-028
4-2. Steering Wheel 4-029
4-3. Hydraulic Component Specifications 4-030
4-3-1. Orbitrol 4-030
5. ELECTRICAL SYSTEM
1. Precautions for wor k
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 (SW354) 5-003
2-2. Electrical Circuit Diagram (SW354 ROPS) 5-004
2-3. Electrical Circuit Diagram (TW354) 5-005
2-4. Electrical Circuit Diagram (TW354 ROPS) 5-006
2-5. Electrical Circuit Diagram (TW504) 5-007
2-6. Electrical Circuit Diagram (TW504 ROPS) 5-008
3. ELECTRICAL COMPONENTS
3-1. Wiring Harness Layout (SW354) 5-009
3-1-1. Wiring harness layout (1) 5-009
3-1-2. Wiring harness layout (2) 5-010
3-2. Wiring Harness Layout (TW354) 5-011
3-2-1. Wiring harness layout (1) 5-011
3-2-2. Wiring harness layout (2) 5-012
3-3. Wiring Harness Layout (TW504) 5-013
3-3-1. Wiring harness layout (1) 5-013
3-3-2. Wiring harness layout (2) 5-014
4. WIRING HARNESSES
4-1. Engine Harness 5-015
4-2. Dashboard Harness 5-017
4-3. Frame (F) Harness 5-019
4-3-1. Frame (F) harness (SW/TW354) 5-019
4-3-2. Frame (F) harness (TW504) 5-021
4-4. Frame (R) Harness 5-023
4-5. Stater Switch Harness 5-025
4-6. Control Switch Harness 5-026
4-7. Working Switch Harness 5-027
4-7-1. Working switch harness (except ROPS) 5-027
4-7-2. Working switch harness (ROPS) 5-028
4-8. Parking Brake Switch Harness 5-029
4-9. Vibration Lo-Hi Change Switch Harness 5-030
4-9-1. Short harness (SW/TW354 : except SW354 ROPS) 5-030
4-9-2. Vibration Lo-Hi change switch harness (TW504) 5-031
4-10. Vibrator Solenoid (R) Harness 5-032
4-10-1. Vibrator solenoid (R) harness (SW354) 5-032
4-10-2. Cap (TW354,504) 5-033
4-11. Hazard Switch Harness 5-034
4-11-1. Cap (except ROPS) 5-034
4-11-2. Hazard switch harness (ROPS) 5-035
4-12. Mihaalu Harness 5-036
4-13. Liquid Spray Switch Harness (TW354,504) 5-037
4-14. Liquid Spray Pump Harness (TW354,504) 5-038
4-15. Short Harness 5-039
4-16. Vibratory Drum Select Switch Harness (SW354 ROPS) 5-040
4-17. F-R Lever Vibration Switch (L) Harness 5-041
4-18. F-R Lever Vibration Switch (R) Harness 5-042
5. ELECTRICAL COMPONENT SPECIFICATIONS
5-1. Fuse Box (SW354) 5-043
5-2. Fuse Box (TW354) 5-044
5-3. Fuse Box (TW504) 5-045
5-4. Combination Meter 5-046
6. VIBRATORY DRUM • REAR WHEEL
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 6-006
3. VIBRATORY DRUM ASSEMBLY
3-1. Vibratory Drum Assembly (SW/TW354) 6-007
3-2. Vibratory Drum Assembly (TW504) 6-008
3-3. Disassembly and Reassembly of Vibratory Drum 6-009
3-3-1. Disassembly of vibratory drum 6-009
3-3-2. Reassembly of vibratory drum 6-020
4. REAR AXLE
4-1. Rear Axle Assembly (TW types) 6-039
4-2. Removal and Installation of Rear Axle (TW types) 6-040
4-2-1. Removal of rear axle 6-041
4-2-2. Installation of rear axle 6-044
7. BRAKE
1. BRAKE PEDAL 7-001
2. BRAKE SYSTEM
2-1. Brake System (SW354) 7-002
2-2. Brake System (TW354, 504) 7-003
8. WATER SPRAY SYSTEM
1. WATER SPRAY PIPING
1-1. Water Spray Piping (SW354) 8-001
1-2. Water Spray Piping (TW354, 504) 8-002
2. LIQUID SPRAY SYSTEM
2-1. Liquid Spray Piping (TW354,504) 8-003
9. INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT
1-1. Safety Precautions for Inspection and Adjustment 9-001
1-2. Preparation for Inspection and Adjustment 9-001
1-3. Precautions for Inspection and Adjustment 9-001
1-4. Warm-up 9-001
1-5. Inspection and Adjustment of Engine Related Items 9-001
2. MEASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement 9-002
2-2. Inspection 9-003
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1. Measurement 9-004
3-2. Adjustment 9-005
4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE
4-1. Measurement 9-006
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1. Measurement 9-007
5-1-1. SW types: front and rear, TW types: front 9-007
5-1-2. TW types: rear 9-008
6. MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE
6-1. Measurement 9-009
7. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1. Measurement 9-010
7-2. Inspection 9-011
8. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
8-1. Measurement of Propulsion Pump Case Pressure 9-012
9. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
9-1. Measurement 9-013
9-1-1. SW types: front and rear, TW types: front 9-013
9-1-2. TW types: rear 9-014
10. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (EXCEPT TW504)
10-1. Measurement 9-015
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (TW504)
11-1. Measurement 9-016
12. ADJUSTMENT OF THROTTLE LEVER
12-1. Adjustment of Linkage 9-017
12-2. Adjustment of Operating Force 9-018
13. ADJUSTMENT OF F-R LEVER
13-1. Adjustment of Linkage 9-019
13-2. Adjustment of Operating Force 9-020
14. PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE
(REPLACEMENT STANDARD)
14-1. Measurement 9-021
10. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting 10-001
1-2. Important Information for Troubleshooting 10-001
1-3. Before Starting 10-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING
2-1. When Performing Electrical System Fault Diagnosis 10-003
2-1-1. Precautions to take during electrical circuit fault diagnosis 10-003
2-1-2. Inspection procedures using a tester 10-004
2-1-3. Inspection of electrical system 10-009
2-2. Engine 10-012
2-2-1. Engine will not start (Starter motor does not run) 1/3 10-012
2-2-1. Engine will not start (Starter motor does not run) 2/3 10-014
2-2-1. Engine will not start (Starter motor does not run) 3/3 10-016
2-2-2. Engine will not start (But starter motor runs) 10-016
2-2-3. Engine does not stop running 10-018
2-2-4. No charging 10-018
2-2-5. Glow plugs is not heated
(Engine starting performance is bad in cold weather) 10-018
2-2-6. Starter motor runs even when F-R lever is not at “N” 10-020
2-3. Propulsion 10-022
2-3-1. Machine moves neither forward nor backward 10-022
2-3-2. Machine speed cannot be changed 10-024
2-3-3. Brake cannot be released 10-026
2-3-4. Brake does not work 10-028
2-4. Vibration 10-030
2-4-1. No vibration occurs 1/2 10-030
2-4-1. No vibration occurs 2/2 10-032
2-4-2. Vibration mode cannot be switched
(F-R lever vibration switch does not work) 10-034
2-4-3. Vibratory drum cannot be switched (SW354 ROPS) 10-036
2-4-4. Amplitude does not change (Remains either low or high) (TW504) 10-038
2-5. Water Spray 10-040
2-5-1. Continuous water spray does not operate 10-040
2-5-2. Continuous water spray works, but auto water spray does not operate 10-042
2-5-3. Liquid cannot be sprayed (TW354, 504) 10-044
2-6. Lighting 10-046
2-6-1. Head lamp and tail lamp do not light 10-046
2-6-2. Flood lamp does not light 10-046
2-6-3. Turn signal lamp does not blink 10-048
2-6-4. Hazard lamp does not light (Turn signal blinks) (ROPS type) 10-050
2-6-5. Stop lamp does not light 10-052
2-6-6. Illumination of combination meter does not light 10-054
2-6-7. Combination meter warning lamp or indicator lamp is abnormal 10-054
2-6-8. Tachometer reading is abnormal 10-056
2-6-9. Hour meter is abnormal 10-056
2-6-10. Temperature meter is abnormal 10-058
2-6-11. Fuel meter is abnormal 10-058
2-6-12. Hydraulic oil filter warning lamp remains ON 10-060
2-6-13. Charge warning lamp remains ON 10-060
2-6-14. Engine oil pressure warning lamp remains ON 10-062
2-6-15. Vibration indicator lamp does not light 10-064
2-6-16. Water spray indicator lamp does not light 10-066
2-6-17. Liquid spray indicator lamp does not light (TW354, 504) 10-066
2-6-18. Flood lamp indicator lamp does not light 10-068
2-6-19. Parking brake indicator lamp does not light 10-068
2-6-20. Turn signal indicator lamp does not light 10-070
2-6-21. Horn does not sound 10-072
2-6-22. Backup buzzer does not sound 10-072
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 10-073
3-2. Propulsion System 10-074
3-2-1. Machine moves neither forward nor backward 1/2 10-074
3-2-1. Machine moves neither forward nor backward 2/2 10-075
3-2-2. Machine moves in one direction only (forward or backward) 10-075
3-2-3. Slow machine speed or small drive force 1/2 10-075
3-2-3. Slow machine speed or small drive force 2/2 10-076
3-2-4. Machine speed cannot be switched 10-076
3-2-5. Machine does not stop completely with F-R lever in “N” 10-076
3-2-6. Driving not possible with differential locked (TW354, 504) 10-077
3-2-7. Propulsion system is overheating 10-077
3-2-8. Abnormal noise from propulsion system 10-077
3-3. Vibrator System 10-078
3-3-1. No vibration 10-078
3-3-2. Vibrator frequency is too low 10-079
3-3-3. Vibratory drum does not changeover vibrating (SW354 ROPS) 10-079
3-3-4. Vibration mode does not switch (TW504) 10-079
3-3-5. Vibrator does not stop 10-079
3-3-6. Vibrator system is overheating 10-080
3-3-7. Abnormal noise from vibrator system 10-080
3-4. Steering System 10-081
3-4-1. Steering wheel is hard to turn 10-081
3-4-2. Steering response is slow 10-081
3-4-3. Steering wheel backlash or play is large 10-082
3-4-4. Steering system is overheating 10-082
3-4-5. Abnormal noise from steering system 10-082
3-5. Cooling System 10-083
3-5-1. Cooling fan does not rotate 10-083
3-5-2. Cooling system is overheating 10-083