Sakai Soil Roller SV540 SHOP MANUAL – PDF DOWNLOAD

Sakai Soil Roller SV540 SHOP MANUAL – PDF DOWNLOAD

The Sakai Soil Roller SV540 Shop Manual is a comprehensive guide for maintenance and repairs, facilitating efficient servicing of the SV540 model. Convenient PDF download available.

FILE DETAILS:

Sakai Soil Roller SV540 SHOP MANUAL – PDF DOWNLOAD

Language : English
Pages : 306
Downloadable : Yes
File Type : PDF

DESCRIPTION

Sakai Soil Roller SV540 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.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Sakai Soil Roller SV540 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. SV540D 2-001
1-2. SV540T 2-003
1-3. SV540TF 2-005
1-4. SV540DF 2-007
1-5. SV640D 2-009
1-6. SV640T 2-011
2. TABLE OF STANDARD VALUES
2-1. Engine 2-013
2-2. Propulsion 2-013
2-3. Hydraulic System 2-013
2-4. Steering 2-014
2-5. Brakes 2-014
2-6. Capacities 2-014
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating 2-015
3-2. Recommended Lubricants 2-015
4. TIGHTENING TORQUE CHART 2-016
SV540 ○0
0-002
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. Forward-reverse Control 3-004
4. PUMP MOUNT
4-1. Pump Mount 3-005
4-1-1. Installation of pump 3-006
4. HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM
1-1. Graphic Symbols for Hydraulic Circuits 4-001
1-2. Hydraulic Circuit Diagram 4-003
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping 4-004
2-1-1. Propulsion hydraulic piping (front) (1) 4-004
2-1-2. Propulsion hydraulic piping (front) (2) 4-005
2-1-3. Propulsion hydraulic piping (rear) 4-006
2-2. Hydraulic Component Specifications 4-007
2-2-1. Hydraulic pump assembly (propulsion + vibrator) 4-007
2-2-2. Propulsion hydraulic motor (front) 4-009
2-2-3. Gear box 4-010
2-2-4. Propulsion hydraulic motor (rear) 4-011
2-2-5. Motor speed change solenoid valve (front) 4-012
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-013
3-2. Hydraulic Component Specifications 4-014
3-2-1. Vibrator hydraulic motor 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. Steering • charge pump 4-018
SV540 ○0
0-003
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
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. Engine Harness 5-007
4-2. Panel Harness (1) 5-009
4-3. Panel Harness (2) 5-011
4-4. Fuse • Relay Harness (1) 5-013
4-5. Fuse • Relay Harness (2) 5-015
4-6. Battery Relay Harness 5-017
4-7. Starter Switch Harness 5-019
4-8. Control Harness 5-020
4-9. Control Switch Harness 5-021
4-10. Motor Rotation Sensor Harness (front) 5-022
4-11. Fuel Unit Harness 5-023
4-12. Diagnostic Switch Harness 5-024
5. ELECTRICAL COMPONENT SPECIFICATIONS
5-1. Fuse Box (1) 5-025
5-2. Fuse Box (2) 5-026
5-3. Combination Meter 5-027
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 6-006
2-2. Vibratory Drum Assembly 6-007
2-3. Disassembly and Reassembly of Vibratory Drum 6-008
2-3-1. Disassembly of vibratory drum 6-008
2-3-2. Reassembly of vibratory drum 6-019
SV540 ○0
0-004
3. REAR AXLE
3-1. Rear Axle (SV540/640D) 6-037
3-2. Rear Axle (SV540/640T, TF, DF) 6-038
3-3. Rear Axle Lubrication 6-039
3-4. Rear Axle Structure 6-040
3-4-1. Center housing 6-040
3-4-2. Differential 6-041
3-4-3. Hub reduction gear 6-042
3-4-4. Brake 6-043
3-4-5. Gear box 6-044
7. 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
4-2. Valve Block 7-005
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 MACHINE HIGH/LOW SPEED CHANGE CIRCUIT
PRESSURE
4-1. Measurement of Propulsion Motor (front) 8-007
4-2. Measurement of Propulsion Motor (rear) 8-008
SV540 ○0
0-005
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1. Measurement 8-009
6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE
6-1. Measurement 8-010
6-2. Inspection 8-011
7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT
PRESSURE 8-012
7-1. Measurement 8-013
7-2. Adjustment 8-014
8. MEASUREMENT OF VIBRATOR HIGH/LOW CHANGE CIRCUIT PRESSURE
8-1. Measurement 8-015
9. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
9-1. Measurement 8-016
9-2. Inspection 8-017
10. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
10-1. Measurement of Propulsion Pump Case Pressure 8-018
10-2. Measurement of Vibrator Pump Case Pressure 8-019
11. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
11-1. Measurement of Propulsion Motor (front) 8-020
11-2. Measurement of Propulsion Motor (rear) 8-021
12. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
12-1. Measurement 8-022
13. ADJUSTMENT OF F-R LEVER LINKAGE
13-1. Adjustment 8-023
14. BRAKE ADJUSTMENT
14-1. Manually Releasing the Brake 8-024
14-2. Adjustment after Manual Release of Brake 8-025
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
SV540 ○0
0-006
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
2-3. Error Codes 9-022
2-4. Engine 9-025
2-4-1. Engine will not start (Starter motor does not run) 1/4 9-025
2-4-1. Engine will not start (Starter motor does not run) 2/4 9-027
2-4-1. Engine will not start (Starter motor does not run) 3/4 9-029
2-4-1. Engine will not start (Starter motor does not run) 4/4 9-031
2-4-2. Engine will not start (But starter motor runs) 9-033
2-4-3. No charging 9-035
2-4-4. Grid heater does not work
(Engine starting performance is bad in cold weather) 9-035
2-4-5. Starter motor runs even when F-R lever is not at “N” and
parking brake is not applied 9-037
2-4-6. Engine speed cannot be switched 9-037
2-5. Propulsion 9-039
2-5-1. Machine moves neither forward nor backward 9-039
2-5-2. Machine speed cannot be changed 1/5 9-041
2-5-2. Machine speed cannot be changed 2/5 9-043
2-5-2. Machine speed cannot be changed 3/5 9-045
2-5-2. Machine speed cannot be changed 4/5 9-047
2-5-2. Machine speed cannot be changed 5/5 9-049
2-5-3. Brake cannot be released 9-051
2-5-4. Brake does not work 9-053
2-6. Vibration 9-055
2-6-1. No vibration occurs 1/3 9-055
2-6-1. No vibration occurs 2/3 9-057
2-6-1. No vibration occurs 3/3 9-059
2-6-2. Amplitude does not change (Remains either low or high) 1/3 9-061
2-6-2. Amplitude does not change (Remains either low or high) 2/3 9-063
2-6-2. Amplitude does not change (Remains either low or high) 3/3 9-065
2-6-3. Vibration mode cannot be switched
(F-R lever vibration switch does not work) 9-067
2-6-4. Vibrator force is low in ECO mode 9-069
2-7. Lighting 9-071
2-7-1. Combination meter warning lamp or indicator lamp is abnormal 9-071
SV540 ○0
0-007
2-7-2. Tachometer reading is abnormal 9-073
2-7-3. Hour meter is abnormal 9-073
2-7-4. Temperature meter is abnormal 9-075
2-7-5. Fuel meter is abnormal 9-075
2-7-6. Hydraulic oil filter warning lamp remains ON 9-077
2-7-7. Engine oil pressure warning lamp remains ON 9-079
2-7-8. Vibration indicator lamp does not light 9-081
2-7-9. Parking brake indicator lamp does not light 9-083
2-7-10. ECO mode indicator lamp does not light 9-085
2-7-11. Horn does not sound 9-087
2-7-12. Backup buzzer does not sound 9-087
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 9-088
3-2. Propulsion System 9-089
3-2-1. Machine moves neither forward nor backward 1/2 9-089
3-2-1. Machine moves neither forward nor backward 2/2 9-090
3-2-2. Machine moves in one direction only (forward or backward) 9-090
3-2-3. Slow machine speed or small drive force 1/2 9-090
3-2-3. Slow machine speed or small drive force 2/2 9-091
3-2-4. Machine speed cannot be switched 9-091
3-2-5. Machine does not stop completely with F-R lever in “N” 9-091
3-2-6. Propulsion system is overheating 9-092
3-2-7. Abnormal noise from propulsion system 9-092
3-3. Vibrator System 9-093
3-3-1. No vibration 9-093
3-3-2. Vibrator frequency is too low 9-094
3-3-3. Amplitude does not switch between high and low 9-094
3-3-4. Vibrator does not stop 9-095
3-3-5. Vibrator system is overheating 9-095
3-3-6. Abnormal noise from vibrator system 9-095
3-4. Steering System 9-096
3-4-1. Steering wheel is hard to turn 9-096
3-4-2. Steering response is slow 9-096
3-4-3. Steering wheel backlash or play is large 9-097
3-4-4. Steering system is overheating 9-097
3-4-5. Abnormal noise from steering system 9-097