Sakai Soil Roller SV204 Vibrating Roller Shop Manual 3498-6406A-0 - PDF

Sakai Soil Roller SV204 Vibrating Roller Shop Manual 3498-6406A-0 – PDF DOWNLOAD

The Sakai Soil Roller SV204 Vibrating Roller Shop Manual 3498-6406A-0 is a comprehensive guide for maintenance and repairs, facilitating efficient servicing of the SV204 model. Convenient PDF download available.

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Sakai Soil Roller SV204 Vibrating Roller Shop Manual 3498-6406A-0 – PDF DOWNLOAD

Language : English
Pages : 270
Downloadable : Yes
File Type : PDF

DESCRIPTION

Sakai Soil Roller SV204 Vibrating Roller Shop Manual 3498-6406A-0 – 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 SV204 Vibrating Roller Shop Manual 3498-6406A-0 – 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 sv204D 2-001
1-2 SV204T 2-003
1-3 SV204TB 2-005
1-4 SV204TF 2-007
1-5 Common Specifications 2-009
C 2 TABLE OF STANDARD VALUES
2-1 Engine 2-010
2-2 Propulsion 2-010
2-3 Hydraulic System 2-010
2-4 Steering 2-011
2-5 Brakes 2-011
2-6 Capacities 2-011
3 FUEL AND LUBRICANTS SPECIFICATION
3-1 Rating ; 2-012
3-2 Recommended Lubricants 2-012
4 TIGHTENING TORQUE CHART 2-013
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 3-007
4-1-1 Installation of pump 3-008
4 HYDRAULIC SYSTEMS
1 SYSTEM CIRCUIT DIAGRAM
1-1 Graphic Symbols for Hydraulic Circuits
1-2 Hydraulic Circuit Diagram
1-2-1 Hydraulic circuit diagram (SV204D)
1-2-2 Hydraulic circuit diagram (SV204T, TF)
1-2-3 Hydraulic circuit diagram (SV204TB)
2 PROPULSION HYDRAULIC SYSTEM
2-1 Propulsion Hydraulic Piping
2-1-1 Propulsion hydraulic piping (F)
2-1-2 Propulsion hydraulic piping (R)
2-2 Hydraulic Component Specifications
2-2-1 Hydraulic pump ASSY (propulsion + vibrator• steering)
2-2-2 Propulsion hydraulic motor (F)
2-2-3 Propulsion hydraulic motor (R)
2-2-4 Valve
3 VIBRATOR HYDRAULIC SYSTEM
3-1 Vibrator Hydraulic Piping
3-2 Hydraulic Component Specifications
3-2-1 Vibrator hydraulic motor
3-2~2 Vibrator/load solenoid valve
4 STEERING SYSTEM
4-1 Steering Hydraulic Piping
4-1-1 Steering hydraulic piping (SV204D, T, TF)
4-1-2 Steering hydraulic piping (SV204TB)
4-2 Steering Wheel
4-3 Hydraulic Component Specifications 4-019
4-3-1 Orbitrol (SV204D, T, TF) 4-019
4-3-2 Orbitrol (SV204TB) 4-020
5 BLADE SYSTEM
5-1 Blade Hydraulic Piping 4-021
5-2 Hydraulic Component Specifications 4-022
5-2-1 Stack valve 4-022
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) 5-006
4 WIRING HARNESSES
4-1 Frame Harness 5-007
4-2 Dashboard Harness 5-009
4-3 ECU Harness 5-011
4-4 Engine Harness 5-013
4-5 Starter Switch Harness 5-014
4-6 Control Switch Harness 5-015
4-7 ENGINE WARING Lamp Harness 5-016
4-8 DPF Harness 5-017
4-9 F-R Lever Harness•• 5-018
4-10 F-R Lever Vibration Switch Harness 5-019
4-11 Vibrator Solenoid Harness 5-020
4-12 Foot Brake Switch Harness (1) 5-021
4-13 Foot Brake Switch Harness (2) 5-022
4-14 Combination Meter Illumination Harness 5-023
4-15 Short Harness 5-024
5 ELECTRICAL COMPONENT SPECIFICATIONS
5-1 Fuse Box 5-025
5-2 Combination Meter 5-026
6 VIBRATORY DRUM • REAR AXLE
1 PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY
2 VIBRATORY DRUM
2-1 Removal and Installation of Vibratory Drum
2-1-1 Removal of vibratory drum
2-1-2 Installation of vibratory drum
2-2 Vibratory Drum ASSY
2-3 Disassembly and Reassembly of Vibratory Drum
2-3-1 Disassembly of vibratory drum
2-3-2 Reassembly of vibratory drum
3 REAR AXLE
3-1 Rear Axle ASSY
3-2 Rear Axle Lubrication
3-3 Rear Axle Structure
3-3-1 Center housing
3-3-2 Differential
3-3-3 Hub reduction gear
3-3-4 Brake
1 BRAKE PEDAL 7-001
2 BRAKE HYDRAULIC PIPING 7-002
3 BRAKE SYSTEM 7-003
4 HYDRAULIC COMPONENT SPECIFICATIONS
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 INSPECTION OF PROPULSION CIRCUIT PRESSURE
2-1 Measurement 8-002
2-2 Inspection 8-003
3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1 Measurement 8-004
3-2 Adjustment 8-005
4 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
4-1 Measurement 8-006
5 MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE
5-1 Measurement 8-007
6 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
6-1 Measurement 8-008
6-2 Inspection 8-009
7 MEASUREMENT AND INSPECTION OF BLADE CIRCUIT PRESSURE (SV204TB)
7-1 Measurement 8-010
7-2 Inspection 8-011
8 MEASUREMENT OF PROPULSION PUMP CASE PRESSURE
8-1 Measurement 8-012
9 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
9-1 Measurement of Propulsion Motor (F) 8-013
9-2 Measurement of Propulsion Motor (R) 8-014
10 ADJUSTMENT OF THROTTLE LEVER
10-1 Adjustment of Potentiometer 8-015
10-2 Adjustment of Operating Force 8-017
11 ADJUSTMENT OF F-R LEVER LINKAGE
11-1Adjustment 8-018
12 BRAKE ADJUSTMENT
12-1 Manually Releasing the Brake 8-020
12-2 Adjustment after Manual Release of Brake 8-021
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
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 Engine Diagnosis Trouble Code 9-011
2-2-1 Description of diagnostic trouble code (OTC) 9-011
2-2-2 Table of the diagnostic trouble code (OTC) 9-012
2-3 Engine 9-019
2-3-1 Engine will not start (Starter motor does not run) 1/2 9-019
2-3-1 Engine will not start (Starter motor does not run) 2/2 9-021
2-3-2 Engine will not start (But starter motor runs) 9-023
2-3-3 No charging 9-023
2-3-4 Glow plug is not heated
(Engine starting performance is bad in cold weather) 9-025
2-3-5 Starter motor runs even when F-R lever is not at “N” 9-025
2-3-6 Engine speed does not change when operating throttle lever 9-027
2-4 Propulsion 9-029
2-4-1 Machine moves neither forward nor backward 9-029
2-4-2 Brake cannot be released 9-031
2-4-3 Brake does not work 9-033
2-5 Vibration 9-035
2-5-1 No vibration occurs 9-035
2-5-2 Vibration mode cannot be switched
(F-R lever vibration switch does not work) 9-037
2-6 Lighting 9-039
2-6-1 Illumination of combination meter does not light 9-039
2-6-2 Combination meter warning lamp or indicator lamp is abnormal 9-039
2-6-3 Tachometer reading is abnormal 9-041
2-6-4 Hour meter is abnormal 9-041
2-6-5 Temperature meter is abnormal 9-043 (
0-006
2-6-6 Fuel meter is abnormal 9-043
2-6-7 Hydraulic oil filter warning lamp remains ON 9-045
2-6-8 Charge warning lamp remains ON 9-045
2-6-9 Vibration indicator lamp does not light 9-047
2-6-10 Parking brake indicator lamp does not light 9-049
2-6-11 Horn does not sound 9-051
2-6-12 Backup buzzer does not sound 9-051
3 HYDRAULIC SYSTEM TROUBLESHOOTING
3-1 When Performing Hydraulic System Troubleshooting 9-052
3-2 Propulsion System 9-053
3-2-1 Machine moves neither forward nor backward 1/2 9-053
3-2-1 Machine moves neither forward nor backward 2/2 9-054
3-2-2 Machine moves in one direction only (forward or backward) 9-054
3-2-3 Slow machine speed or small drive force 1/2 9-054
3-2-3 Slow machine speed or small drive force 2/2 9-055
3-2-4 Machine does not stop completely with F-R lever in “N” 9-055
3-2-5 Propulsion system is overheating 9-055
3-2-6 Abnormal noise from propulsion system 9-056
3-3 Vibrator System 9-057
3-3-1 No vibration 9-057
3-3-2 Vibrator frequency is too low 9-058
3-3-3 Vibrator does not stop 9-058
3-3-4 Vibrator system is overheating 9-058
3-3-5 Abnormal noise from vibrator system 9-059
3-4 Steering System 9-060
3-4-1 Steering wheel is hard to turn 9-060
3-4-2 Steering response is slow 9-060
3-4-3 Steering wheel backlash or play is large 9-061
3-4-4 Steering system is overheating 9-061
3-4-5 Abnormal noise from steering system 9-061
3-5 Blade (SV204TB) ‘ 9-062
3-5-1 Blade up/down operation not possible 9-062
3-5-2 Blade movement is slow or force is small 9-062
3-5-3 Blade floating operation not possible 9-063
3-5-4 Blade hydraulic system is overheating 9-063
3-5-5 Abnormal noise from blade hydraulic system 9-063
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