Sakai Asphalt Roller SW654 Service Manual – PDF DOWNLOAD

Sakai Asphalt Roller SW654 Service Manual – PDF DOWNLOAD 

The Sakai Asphalt Roller SW654 Service Manual PDF offers comprehensive guidance for maintenance, repair, and troubleshooting of the SW654 model. It includes detailed instructions, diagrams, and specifications for efficient servicing.

FILE DETAILS:

Sakai Asphalt Roller SW654 Service Manual – PDF DOWNLOAD 

Language : English
Pages : 338
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Sakai Asphalt Roller SW654 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 SW654 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. 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. 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. FUEL AND 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. CONTROL SYSTEM
3-1. Throttle Control 3-005
3-2. Forward-reverse Control 3-006
4. PUMP MOUNT
4-1. Pump Mount 3-009
4-1-1. Installation of pump 3-010
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. Propulsion Hydraulic Piping 4-005
2-1-1. Propulsion hydraulic piping (1) 4-005
2-1-2. Propulsion hydraulic piping (2) 4-006
2-2. Hydraulic Component Specifications 4-007
2-2-1. Hydraulic pump assembly
(propulsion + vibrator + steering • charge + load) 4-007
2-2-2. Propulsion hydraulic motor 4-009
2-2-3. Servo bypass solenoid valve 4-010
2-2-4. Valve block 4-011
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-012
3-2. Hydraulic Component Specifications 4-013
3-2-1. Vibrator hydraulic motor 4-013
3-2-2. Valve assembly 4-014
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping 4-015
4-2. Steering Wheel 4-016
4-3. Hydraulic Component Specifications 4-017
4-3-1. Orbitrol 4-017
4-3-2. Load solenoid valve 4-018
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 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) 5-006
4. WIRING HARNESSES
4-1. Main Harness 5-007
4-2. Fuse • Relay Harness (1) 5-009
4-3. Fuse • Relay Harness (2) 5-011
4-4. ECU Harness 5-013
4-5. Control Panel Harness 5-015
4-6. Battery Relay Harness 5-017
4-7. Stater Switch Harness 5-019
4-8. Engine 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. Member (R) Harness 5-024
4-13. Combination Lamp (R) Harness 5-025
4-14. Dashboard Harness 5-026
4-15. F-R Lever Vibration Switch (L) Harness 5-027
4-16. F-R Lever Vibration Switch (R) Harness 5-028
4-17. Hydraulic Oil Filter Switch Harness 5-029
4-18. Fuel Gauge Unit Harness 5-030
4-19. Water Spray Pump Harness 5-031
4-20. Cord 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 ASSEMBLY (SW654)
3-1. Vibratory Drum Assembly 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 ASSEMBLY (SW654ND)
4-1. Vibratory Drum Assembly 6-036
4-2. Disassembly and Reassembly of Vibratory Drum 6-037
4-2-1. Disassembly of vibratory drum 6-037
4-2-2. Reassembly of vibratory drum 6-047
7. BRAKE
1. BRAKE PEDAL 7-001
2. BRAKE SYSTEM 7-002
8. WATER SPRAY SYSTEM
1. WATER SPRAY PIPING
1-1. Water Spray Piping (1) 8-001
1-2. Water Spray Piping (2) 8-002
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 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. If pressure on either forward or reverse side deviates from maximum
circuit pressure range 9-004
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION/ VIBRATOR CHARGE
CIRCUIT PRESSURE 9-005
3-1. Measurement 9-005
3-2. Adjustment 9-006
4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT
PRESSURE 9-007
4-1. Measurement 9-007
5. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
5-1. Measurement 9-008
6. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 9-009
6-1. Measurement 9-009
7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE
7-1. Measurement 9-010
7-2. Adjustment 9-011
7-2-1. If pressures on both Low amplitude/Oscillation and High amplitude/
Normal sides deviate from maximum circuit pressure range by same
value 9-011
7-2-2. If pressure on either Low amplitude/Oscillation or High amplitude/
Normal side deviates from maximum circuit pressure range 9-012
8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
8-1. Measurement 9-013
8-2. Inspection 9-014
9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
9-1. Measurement of Propulsion Pump Case Pressure 9-015
9-2. Measurement of Vibrator Pump Case Pressure 9-016
10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
10-1. Measurement 9-017
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
11-1. Measurement 9-018
12. ADJUSTMENT OF THROTTLE LEVER
12-1. Adjustment of Potentiometer 9-019
12-2. Adjustment of Operating Force 9-021
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. Adjustment 9-026
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 Diagnosis Trouble Code 10-011
2-2-1. Description of diagnostic trouble code (DTC) 10-011
2-2-2. Table of the diagnostic trouble code (DTC) 10-012
2-3. Engine 10-019
2-3-1. Engine will not start (Starter motor does not run) 1/3 10-019
2-3-1. Engine will not start (Starter motor does not run) 2/3 10-021
2-3-1. Engine will not start (Starter motor does not run) 3/3 10-023
2-3-2. Engine will not start (But starter motor runs) 10-025
2-3-3. No charging 10-025
2-3-4. Glow heater is not heated
(Engine starting performance is bad in cold weather) 10-027
2-3-5. Starter motor runs even when F-R lever is not at “N” 10-027
2-3-6. Engine speed does not change when operating throttle lever 10-029
2-4. Propulsion System 10-031
2-4-1. Machine moves neither forward nor backward 10-031
2-4-2. Machine speed cannot be changed 10-033
2-4-3. Brake cannot be released 10-035
2-4-4. Brake does not work 10-037
2-5. Vibration 10-039
2-5-1. No vibration occurs 1/2 10-039
2-5-1. No vibration occurs 2/2 10-041
2-5-2. Amplitude does not change (Remains either low or high)
: SW654 10-041
2-5-3. Vibration does not change (Remains normal or oscillation vibration)
: SW654ND 10-043
2-5-4. Vibration mode cannot be switched
(F-R lever vibration switch does not work) 10-045
2-5-5. Vibratory drum cannot be switched 10-047
2-6. Water Spray 10-049
2-6-1. Continuous water spray does not operate 1/2 10-049
2-6-1. Continuous water spray does not operate 2/2 10-051
2-6-2. Continuous water spray works, but auto water spray does not operate 10-053
2-6-3. Continuous water spray works, but intermittent water spray does not
operate 10-055
2-7. Lighting 10-057
2-7-1. Head lamp, side marker lamp and tail lamp do not light 10-057
2-7-2. Flood lamp does not light 10-059
2-7-3. High-beam of head lamp does not light 10-059
2-7-4. Turn signal lamp does not blink 10-061
2-7-5. Hazard lamp does not light (Turn signal blinks) 10-063
2-7-6. Backup lamp does not light 10-063
2-7-7. Stop lamp does not light 10-065
2-7-8. Illumination of combination meter does not light 10-067
2-7-9. Combination meter warning lamp or indicator lamp is abnormal 10-067
2-7-10. Tachometer reading is abnormal 10-069
2-7-11. Hour meter is abnormal 10-069
2-7-12. Temperature meter is abnormal 10-071
2-7-13. Fuel meter is abnormal 10-071
2-7-14. Hydraulic oil filter warning lamp remains ON 10-073
2-7-15. Charge warning lamp remains ON 10-073
2-7-16. Vibration indicator lamp does not light 10-075
2-7-17. Water spray indicator lamp does not light 10-077
2-7-18. Flood lamp indicator lamp does not light 10-079
2-7-19. Side marker lamp indicator lamp does not light 10-079
2-7-20. Parking brake indicator lamp does not light 10-081
2-7-21. Turn signal indicator lamp does not light 10-083
2-7-22. Horn does not sound 10-085
2-7-23. Backup buzzer does not sound 10-085
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 10-086
3-2. Propulsion System 10-087
3-2-1. Machine moves neither forward nor backward 1/2 10-087
3-2-1. Machine moves neither forward nor backward 2/2 10-088
3-2-2. Machine moves in one direction only (forward or backward) 10-088
3-2-3. Slow machine speed or small drive force 1/2 10-088
3-2-3. Slow machine speed or small drive force 2/2 10-089
3-2-4. Machine speed cannot be switched 10-089
3-2-5. Machine does not stop completely with F-R lever in “N” 10-089
3-2-6. Propulsion system is overheating 10-090
3-2-7. Abnormal noise from propulsion system 10-090
3-3. Vibrator System 10-091
3-3-1. No vibration 1/2 10-091
3-3-1. No vibration 2/2 10-092
3-3-2. Vibrator frequency is too low 10-092
3-3-3. Vibration mode does not switch 10-093
3-3-4. Vibratory drum does not changeover vibrating 10-093
3-3-5. Vibrator does not stop 10-093
3-3-6. Vibrator system is overheating 10-093
3-3-7. Abnormal noise from vibrator system 10-094
3-4. Steering System 10-095
3-4-1. Steering wheel is hard to turn 10-095
3-4-2. Steering response is slow 10-095
3-4-3. Steering wheel backlash or play is large 10-096
3-4-4. Steering system is overheating 10-096
3-4-5. Abnormal noise from steering system 10-096