Sakai SW654 Shop Manual 3498-6559A-0 – PDF DOWNLOAD

Sakai SW654 Shop Manual 3498-6559A-0 – PDF DOWNLOAD

FILE DETAILS:

Sakai SW654 Shop Manual 3498-6559A-0 – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Sakai SW654 Shop Manual 3498-6559A-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. 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
SW654 ○0
0-002
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
SW654 ○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
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
SW654 ○0
0-004
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
SW654 ○0
0-005
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
SW654 ○0
0-006
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
SW654 ○0
0-007
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
SW654 ○0
0-008
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

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