Sakai Roller SV412 Vibrating Roller Shop Manual – PDF DOWNLOAD

Sakai Roller SV412 Vibrating Roller Shop Manual – p –  PDF DOWNLOAD

The Sakai SV412 Vibrating Roller Shop Manual is vital for maintenance. Covering SV412 series rollers, it facilitates efficient servicing and repairs.

FILE DETAILS:

Sakai Roller SV412 Vibrating Roller Shop Manual –  PDF DOWNLOAD

Language : English
Pages : 320
Downloadable : Yes
File Type : PDF

DESCRIPTION

Sakai Roller SV412 Vibrating Roller Shop Manual –  PDF DOWNLOAD

Introduction

• 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

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TABLE OF CONTENTS:

Sakai Soil Roller SV412 Vibrating Roller Shop 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 SV412D 2-001
1-2 SV412T 2-003
1-3 SV412TF 2-005
1-4 SV412TB 2-007
1-5 SV412FB 2-009
2 TABLE OF STANDARD VALUES
2-1 Engine 2-011
2-2 Propulsion 2-011
2-3 Hydraulic Systems 2-011
2-4 Steering 2-012
2-5 Brakes 2-012
2-6 Capacities 2-012
3 FUEL AND LUBRICANTS SPECIFICATION
3-1 Rating 2-013
3-2 Recommended Lubricants 2-013
4 TIGHTENING TORQUE CHART 2-014
SV412 ○0
3 ENGINE AND CONTROLS
1 ENGINE
1-1 Engine Mount 3-001
1-2 Engine Exterior 3-002
2 CONTROL SYSTEM
2-1 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 (SV412D, T, TF) 4-003
1-2-2 Hydraulic circuit diagram (SV412TB, FB) 4-004
2 PROPULSION HYDRAULIC SYSTEM
2-1 Propulsion Hydraulic Piping 4-005
2-1-1 Propulsion hydraulic piping (Front) 4-005
2-1-2 Propulsion hydraulic piping (Rear) 4-006
2-2 Hydraulic Component Specifications 4-007
2-2-1 Hydraulic pump assembly (propulsion + vibrator • steering)
(SV412D, T, TF) 4-007
2-2-2 Hydraulic pump assembly (propulsion + vibrator • steering)
(SV412TB, TF) 4-009
2-2-3 Propulsion hydraulic motor (Front) 4-011
2-2-4 Propulsion hydraulic motor (Rear) 4-012
2-2-5 Servo bypass solenoid valve 4-013
3 VIBRATOR HYDRAULIC SYSTEM
3-1 Vibrator Hydraulic Piping 4-014
3-2 Hydraulic Component Specification 4-015
3-2-1 Vibrator hydraulic motor 4-015
4 STEERING SYSTEM
4-1 Steering Hydraulic Piping 4-016
4-1-1 Steering hydraulic piping (SV412D, T, TF) 4-016
4-1-2 Steering hydraulic piping (SV412TB, FB) 4-017
4-2 Steering Wheel 4-018
4-3 Hydraulic Component Specifications 4-019
SV412 ○0
4-3-1 Orbitrol 4-019
4-3-2 Valve (SV412TB, FB) 4-020
4-4 Frame (Center Pin) 4-021
5 BLADE SYSTEM (SV412TB, FB)
5-1 Blade Hydraulic Piping 4-022
5-2 Hydraulic Component Specification 4-023
5-2-1 Valve 4-023
6 HIGH TORQUE TYPE ONLY
6-1 Hydraulic Circuit Diagram (SV412D, T, TF) 4-024
6-2 Hydraulic Circuit Diagram (SV412TB, FB) 4-025
6-3 Propulsion Hydraulic Piping (Front) 4-026
6-4 Propulsion Hydraulic Piping (Rear) 4-027
6-5 Propulsion Hydraulic Motor (Front) 4-028
6-6 Gear Box 4-029
6-7 Propulsion Hydraulic Motor (Rear) 4-031
5 ELECTRICAL SYSTEM
1 Precautions for wor k
1-1 W ire Numbers, Wire Sizes, Wire Colors and Connectors Shown in
Electrical Circuit Diagrams, Wiring Harness Layout and Wiring Harnesses 5-001
1-2 Electrical Equipment Installation 5-002
2 SYSTEM CIRCUIT DIAGRAM
2-1 Electrical Circuit Diagram 5-003
3 ELECTRICAL COMPONENTS
3-1 Battery Layout 5-004
3-2 Wiring Harness Layout (1) 5-005
3-3 Wiring Harness Layout (2) 5-006
4 WIRING HARNESSES
4-1 Main Frame Harness 5-007
4-2 Engine Harness 5-009
4-3 Dashboard Harness 5-011
4-4 Starter Switch Harness 5-013
4-5 Throttle Switch Harness 5-014
4-6 Vibrator Solenoid Harness 5-015
4-7 Hydraulic Oil Filter Harness 5-016
4-8 Speed Change Switch Harness 5-017
4-9 Starter Relay Harness 5-018
4-10 Speed Change Solenoid Harness 5-019
4-11 Vibration Select Switch Harness 5-020
SV412 ○0
4-12 Parking Brake Switch Harness 5-021
4-13 Diagnostic Switch Harness 5-022
5 ELECTRICAL COMPONENT SPECIFICATIONS
5-1 Fuse Box 5-023
5-2 Combination Meter 5-024
6 HIGH TORQUE TYPE ONLY
6-1 Electrical Circuit Diagram 5-025
6-2 Wiring Harness Layout 5-026
6-3 Travel Mode Select Switch Harness 5-027
6-4 Front Motor Solenoid Harness 5-028
6 VIBRATORY DRUM • REAR AXLE
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
2-2 Vibratory Drum Assembly 6-008
2-3 Disassembly and Reassembly of Vibratory Drum 6-009
2-3-1 Disassembly of vibratory drum 6-009
2-3-2 Reassembly of vibratory drum 6-015
3 AXLE
3-1 Rear Axle (SV412D) 6-023
3-2 Rear Axle (SV412T, TF, TB, FB) 6-024
3-3 Rear Axle Lubrication 6-025
3-4 Rear Axle Structure 6-026
3-4-1 Center housing 6-026
3-4-2 Differential 6-027
3-4-3 Hub reduction gear 6-028
3-4-4 Brake 6-029
4 HIGH TORQUE TYPE ONLY
4-1 Vibratory Drum Assembly 6-030
4-2 Disassembly and Reassembly of Vibratory Drum 6-031
4-2-1 Disassembly of vibratory drum 6-031
4-2-2 Reassembly of vibratory drum 6-037
SV412 ○0
7 BRAKE
1 BRAKE SYSTEM
1-1 Brake Pedal 7-001
2 BRAKE HYDRAULIC PIPING 7-002
3 BRAKE SYSTEM 7-003
4 HYDRAULIC COMPONENT SPECIFICATION
4-1 Brake Solenoid Valve 7-004
8 INSPECTION AND ADJUSTMENT
1 INSPECTION AND ADJUSTMENT
1-1 Safety Precautions for Inspection and Adjustment 8-001
1-2 Preparation for Inspection and Adjustment 8-001
1-3 Precautions for Inspection and Adjustment 8-001
1-4 Warm-up 8-001
1-5 Inspection and Adjustment of Engine Related Items 8-001
2 MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1 Measurement 8-002
2-2 Adjustment 8-003
3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE 8-004
3-1 Measurement 8-005
3-2 Adjustment 8-006
4 MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1 Measurement 8-007
5 MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE
5-1 Measurement 8-008
6 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
6-1 Measurement 8-009
7 MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE
7-1 Measurement 8-010
7-2 Inspection 8-011
8 MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT
PRESSURE 8-012
8-1 Measurement 8-013
8-2 Adjustment 8-014
9 MEASUREMENT OF VIBRATOR HIGH/LOW CHANGE CIRCUIT PRESSURE
9-1 Measurement 8-015
SV412 ○0
10 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
10-1 Measurement 8-016
10-2 Inspection 8-017
11 MEASUREMENT AND INSPECTION OF BLADE CIRCUIT PRESSURE (SV412TB, FB)
11-1 Measurement 8-018
11-2 Inspection 8-019
12 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
12-1 Measurement 8-020
13 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
13-1 Measurement of Front Propulsion Motor 8-021
13-2 Measurement of Rear Propulsion Motor 8-022
14 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
14-1 Measurement 8-023
15 ADJUSTMENT OF F-R LEVER LINKAGE
15-1 Adjustment 8-024
16 BRAKE ADJUSTMENT
16-1 Manually Releasing the Brake 8-025
16-2 Adjustment after Manual Release of Brake 8-026
16-3 Brake Clearance Adjustment 8-027
17 HIGH TORQUE TYPE ONLY
17-1 Measurement of Propulsion Motor Case Pressure 8-028
17-1-1 Measurement of front propulsion motor 8-028
9 TROUBLESHOOTING
1 TROUBLESHOOTING
1-1 Safety Precautions for Troubleshooting 9-001
1-2 Important Information for Troubleshooting 9-001
1-3 Before Starting 9-002
1-4 Wire Number and Color Code 9-002
2 ELECTRICAL SYSTEM TROUBLESHOOTING
2-1 When Performing Electrical System Fault Diagnosis 9-003
2-1-1 Precautions to take during electrical circuit fault diagnosis 9-003
2-1-2 Inspection procedures using a tester 9-004
2-1-3 Inspection of electrical system 9-009
2-2 Fault Codes 9-011
2-2-1 Fault detection 9-011
2-2-2 Fault lamps 9-011
2-2-3 Flash out of fault codes 9-012
2-2-4 Fault code list 9-013
SV412 ○0
2-3 Engine 9-024
2-3-1 Engine will not start (Starter motor does not run) 1/3 9-024
2-3-1 Engine will not start (Starter motor does not run) 2/3 9-026
2-3-1 Engine will not start (Starter motor does not run) 3/3 9-028
2-3-2 Engine will not start (But starter motor runs) 9-030
2-3-3 No charging 9-032
2-3-4 Grid heater does not work (Engine starting performance is bad in cold
weather) 9-032
2-3-5 Starter motor runs even when F-R lever is not at “N” and parking brake is
not applied 9-034
2-3-6 Engine speed cannot be switched 9-034
2-4 Propulsion 9-036
2-4-1 Machine moves neither forward nor backward 1/2 9-036
2-4-1 Machine moves neither forward nor backward 2/2 9-038
2-4-2 Machine speed cannot be changed 9-040
2-4-3 Brake cannot be released 1/2 9-042
2-4-3 Brake cannot be released 2/2 9-044
2-4-4 Brake does not work 9-046
2-5 Vibration 9-048
2-5-1 No vibration occurs 9-048
2-5-2 Amplitude does not change (Remains either Low or High) 9-050
2-5-3 Vibration mode cannot be switched (F-R lever vibration switch does
not work) 9-052
2-6 Lighting 9-054
2-6-1 Illumination of combination meter does not turn on 9-054
2-6-2 Combination meter warning lamp or indicator lamp is abnormal 9-056
2-6-3 Tachometer reading is abnormal 9-058
2-6-4 Hour meter is abnormal 9-058
2-6-5 Temperature meter is abnormal 9-060
2-6-6 Fuel meter is abnormal 9-060
2-6-7 Hydraulic oil filter warning lamp remains ON 9-062
2-6-8 Engine oil pressure warning lamp remains ON 9-064
2-6-9 Vibration indicator lamp does not light 9-066
2-6-10 Parking brake indicator lamp does not light 9-068
2-6-11 Horn does not sound 9-070
2-6-12 Backup buzzer does not sound 9-070
3 HYDRAULIC SYSTEM TROUBLESHOOTING
3-1 When Performing Hydraulic System Troubleshooting 9-071
SV412 ○0
3-2 Propulsion System 9-072
3-2-1 Machine moves neither forward nor backward 1/2 9-072
3-2-1 Machine moves neither forward nor backward 2/2 9-073
3-2-2 Machine moves in one direction only (forward or backward) 9-073
3-2-3 Slow machine speed or small drive force 1/2 9-073
3-2-3 Slow machine speed or small drive force 2/2 9-074
3-2-4 Machine speed cannot be switched 9-074
3-2-5 Machine does not stop completely with F-R lever in “N” 9-074
3-2-6 Propulsion system is overheating 9-075
3-2-7 Abnormal noise from propulsion system 9-075
3-3 Vibrator System 9-076
3-3-1 No vibration 9-076
3-3-2 Vibrator frequency is too low 9-077
3-3-3 Amplitude does not switch between high and low 9-077
3-3-4 Vibrator does not stop 9-078
3-3-5 Vibrator system is overheating 9-078
3-3-6 Abnormal noise from vibrator system 9-078
3-4 Steering System 9-079
3-4-1 Steering wheel is hard to turn 9-079
3-4-2 Steering response is slow 9-079
3-4-3 Steering wheel backlash or play is large 9-080
3-4-4 Steering system is overheating 9-080
3-4-5 Abnormal noise from steering system 9-080
3-5 Blade (SV412TB, FB) 9-081
3-5-1 Blade up/down operation not possible 9-081
3-5-2 Blade movement is slow or force is small 9-081
3-5-3 Blade floating operation not possible 9-082
3-5-4 Blade hydraulic system is overheating 9-082
3-5-5 Abnormal noise from blade hydraulic system 9-082
4 HIGH TORQUE TYPE ONLY
4-1 Electrical System Troubleshooting (Propulsion) 9-084
4-1-1 Travel mode cannot be changed 1/2 9-084
4-1-1 Travel mode cannot be changed 2/2 9-086
4-2 Hydraulic System Troubleshooting (Propulsion) 9-087
4-2-1 Machine moves neither forward nor backward 1/2 9-087
4-2-1 Machine moves neither forward nor backward 2/2 9-088
4-2-2 Travel mode cannot be switched 9-088
4-2-3 Propulsion system is overheating 9-089
4-2-4 Abnormal noise from propulsion system 9-089