Sakai SWTW354 TW504 Shop Manual 3498-6446A-0  – PDF DOWNLOAD

Sakai SWTW354 TW504 Shop Manual 3498-6446A-0  – PDF DOWNLOAD

FILE DETAILS:

Sakai SWTW354 TW504 Shop Manual 3498-6446A-0  – PDF DOWNLOAD

Language : English
Pages :334
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sakai SWTW354 TW504 Shop Manual 3498-6446A-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 SW354 2-001
1-2 SW354 ROPS 2-003
1-3 TW354 2-005
1-4 TW354 ROPS 2-007
1-5 TW504 2-009
1-6 TW504 ROPS 2-011
1-7 Common Specifications 2-013
2 TABLE OF STANDARD VALUES 2-014
2-1 Engine 2-014
2-2 Propulsion 2-014
2-3 Hydraulic System 2-015
2-4 Steering 2-015
2-5 Brakes 2-016
2-6 Capacities 2-016
3 FUEL AND LUBRICANTS SPECIFICATION 2-017
3-1 Rating 2-017
3-2 Recommended Lubricants 2-017
4 TIGHTENING TORQUE CHART 2-018
SW/TW354,TW504 ○0
0-002
3 ENGINE AND CONTROLS
1 ENGINE
1-1 Engine Mount 3-001
2 CONTROL SYSTEM
2-1 Throttle Control 3-002
2-2 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 (SW354) 4-003
1-2-2 Hydraulic circuit diagram (TW354) 4-004
1-2-3 Hydraulic circuit diagram (TW504) 4-005
2 PROPULSION HYDRAULIC SYSTEM
2-1 Propulsion Hydraulic Piping 4-006
2-1-1 Propulsion hydraulic piping (F) (SW/TW354) 4-006
2-1-2 Propulsion hydraulic piping (F) (TW504) 4-007
2-1-3 Propulsion hydraulic piping (R) (SW354) 4-008
2-1-4 Propulsion hydraulic piping (R) (TW354) 4-009
2-1-5 Propulsion hydraulic piping (R) (TW504) 4-010
2-2 Hydraulic Component Specifications 4-011
2-2-1 Propulsion hydraulic pump 4-011
2-2-2 Propulsion hydraulic motor (F) (SW/TW354) 4-013
2-2-3 Propulsion hydraulic motor (F) (TW504) 4-014
2-2-4 Propulsion hydraulic motor (R) (SW354) 4-015
2-2-5 Propulsion hydraulic motor (R) (TW354,504) 4-016
2-2-6 Differential lock valve (TW354,504) 4-017
3 VIBRATOR HYDRAULIC SYSTEM
3-1 Vibrator Hydraulic Piping 4-018
3-1-1 Vibrator hydraulic piping (SW354) 4-018
3-1-2 Vibrator hydraulic piping (TW354) 4-019
3-1-3 Vibrator hydraulic piping (TW504) 4-020
3-2 Hydraulic Component Specifications 4-021
3-2-1 Hydraulic pump assembly (vibrator (F) + steering • charge) 4-021
3-2-2 Vibrator hydraulic pump (R) (SW354) 4-022
SW/TW354,TW504 ○0
0-003
3-2-3 Vibrator hydraulic motor 4-023
3-2-4 Cooling fan drive hydraulic motor 4-024
3-2-5 Vibrator solenoid valve (F), (R) (SW/TW354) 4-025
3-2-6 Vibrator solenoid valve (TW504) 4-026
4 STEERING SYSTEM
4-1 Steering Hydraulic Piping 4-027
4-1-1 Steering hydraulic piping (SW/TW354) 4-027
4-1-2 Steering hydraulic piping (TW504) 4-028
4-2 Steering Wheel 4-029
4-3 Hydraulic Component Specifications 4-030
4-3-1 Orbitrol 4-030
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 (SW354) 5-003
2-2 Electrical Circuit Diagram (SW354 ROPS) 5-004
2-3 Electrical Circuit Diagram (TW354) 5-005
2-4 Electrical Circuit Diagram (TW354 ROPS) 5-006
2-5 Electrical Circuit Diagram (TW504) 5-007
2-6 Electrical Circuit Diagram (TW504 ROPS) 5-008
3 ELECTRICAL COMPONENTS
3-1 Wiring Harness Layout (SW354) 5-009
3-1-1 Wiring harness layout (1) 5-009
3-1-2 Wiring harness layout (2) 5-010
3-2 Wiring Harness Layout (TW354) 5-011
3-2-1 Wiring harness layout (1) 5-011
3-2-2 Wiring harness layout (2) 5-012
3-3 Wiring Harness Layout (TW504) 5-013
3-3-1 Wiring harness layout (1) 5-013
3-3-2 Wiring harness layout (2) 5-014
4 WIRING HARNESSES
4-1 Engine Harness 5-015
4-2 Dashboard Harness 5-017
4-3 Frame (F) Harness 5-019
4-3-1 Frame (F) harness (SW/TW354) 5-019
4-3-2 Frame (F) harness (TW504) 5-021
SW/TW354,TW504 ○0
0-004
4-4 Frame (R) Harness 5-023
4-5 Stater Switch Harness 5-025
4-6 Control Switch Harness 5-026
4-7 Working Switch Harness 5-027
4-7-1 Working switch harness (except ROPS) 5-027
4-7-2 Working switch harness (ROPS) 5-028
4-8 Parking Brake Switch Harness 5-029
4-9 Vibration Lo-Hi Change Switch Harness 5-030
4-9-1 Short harness (SW/TW354 : except SW354 ROPS) 5-030
4-9-2 Vibration Lo-Hi change switch harness (TW504) 5-031
4-10 Vibrator Solenoid (R) Harness 5-032
4-10-1 Vibrator solenoid (R) harness (SW354) 5-032
4-10-2 Cap (TW354,504) 5-033
4-11 Hazard Switch Harness 5-034
4-11-1 Cap (except ROPS) 5-034
4-11-2 Hazard switch harness (ROPS) 5-035
4-12 Mihaalu Harness 5-036
4-13 Liquid Spray Switch Harness (TW354,504) 5-037
4-14 Liquid Spray Pump Harness (TW354,504) 5-038
4-15 Short Harness 5-039
4-16 Vibratory Drum Select Switch Harness (SW354 ROPS) 5-040
4-17 F-R Lever Vibration Switch (L) Harness 5-041
4-18 F-R Lever Vibration Switch (R) Harness 5-042
5 ELECTRICAL COMPONENT SPECIFICATIONS
5-1 Fuse Box (SW354) 5-043
5-2 Fuse Box (TW354) 5-044
5-3 Fuse Box (TW504) 5-045
5-4 Combination Meter 5-046
6 VIBRATORY DRUM • REAR WHEEL
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
3 VIBRATORY DRUM ASSEMBLY
3-1 Vibratory Drum Assembly (SW/TW354) 6-007
3-2 Vibratory Drum Assembly (TW504) 6-008
SW/TW354,TW504 ○0
0-005
3-3 Disassembly and Reassembly of Vibratory Drum 6-009
3-3-1 Disassembly of vibratory drum 6-009
3-3-2 Reassembly of vibratory drum 6-020
4 REAR AXLE
4-1 Rear Axle Assembly (TW types) 6-039
4-2 Removal and Installation of Rear Axle (TW types) 6-040
4-2-1 Removal of rear axle 6-041
4-2-2 Installation of rear axle 6-044
7 BRAKE
1 BRAKE PEDAL 7-001
2 BRAKE SYSTEM
2-1 Brake System (SW354) 7-002
2-2 Brake System (TW354, 504) 7-003
8 WATER SPRAY SYSTEM
1 WATER SPRAY PIPING
1-1 Water Spray Piping (SW354) 8-001
1-2 Water Spray Piping (TW354, 504) 8-002
2 LIQUID SPRAY SYSTEM
2-1 Liquid Spray Piping (TW354,504) 8-003
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 INSPECTION OF PROPULSION CIRCUIT PRESSURE
2-1 Measurement 9-002
2-2 Inspection 9-003
3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1 Measurement 9-004
3-2 Adjustment 9-005
4 MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE
4-1 Measurement 9-006
SW/TW354,TW504 ○0
0-006
5 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1 Measurement 9-007
5-1-1 SW types: front and rear, TW types: front 9-007
5-1-2 TW types: rear 9-008
6 MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE
6-1 Measurement 9-009
7 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1 Measurement 9-010
7-2 Inspection 9-011
8 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
8-1 Measurement of Propulsion Pump Case Pressure 9-012
9 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
9-1 Measurement 9-013
9-1-1 SW types: front and rear, TW types: front 9-013
9-1-2 TW types: rear 9-014
10 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (EXCEPT TW504)
10-1 Measurement 9-015
11 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (TW504)
11-1 Measurement 9-016
12 ADJUSTMENT OF THROTTLE LEVER
12-1 Adjustment of Linkage 9-017
12-2 Adjustment of Operating Force 9-018
13 ADJUSTMENT OF F-R LEVER
13-1 Adjustment of Linkage 9-019
13-2 Adjustment of Operating Force 9-020
14 PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE
(REPLACEMENT STANDARD)
14-1 Measurement 9-021
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
SW/TW354,TW504 ○0
0-007
2-2 Engine 10-012
2-2-1 Engine will not start (Starter motor does not run) 1/3 10-012
2-2-1 Engine will not start (Starter motor does not run) 2/3 10-014
2-2-1 Engine will not start (Starter motor does not run) 3/3 10-016
2-2-2 Engine will not start (But starter motor runs) 10-016
2-2-3 Engine does not stop running 10-018
2-2-4 No charging 10-018
2-2-5 Glow plugs is not heated
(Engine starting performance is bad in cold weather) 10-018
2-2-6 Starter motor runs even when F-R lever is not at “N” 10-020
2-3 Propulsion 10-022
2-3-1 Machine moves neither forward nor backward 10-022
2-3-2 Machine speed cannot be changed 10-024
2-3-3 Brake cannot be released 10-026
2-3-4 Brake does not work 10-028
2-4 Vibration 10-030
2-4-1 No vibration occurs 1/2 10-030
2-4-1 No vibration occurs 2/2 10-032
2-4-2 Vibration mode cannot be switched
(F-R lever vibration switch does not work) 10-034
2-4-3 Vibratory drum cannot be switched (SW354 ROPS) 10-036
2-4-4 Amplitude does not change (Remains either low or high) (TW504) 10-038
2-5 Water Spray 10-040
2-5-1 Continuous water spray does not operate 10-040
2-5-2 Continuous water spray works, but auto water spray does not operate 10-042
2-5-3 Liquid cannot be sprayed (TW354, 504) 10-044
2-6 Lighting 10-046
2-6-1 Head lamp and tail lamp do not light 10-046
2-6-2 Flood lamp does not light 10-046
2-6-3 Turn signal lamp does not blink 10-048
2-6-4 Hazard lamp does not light (Turn signal blinks) (ROPS type) 10-050
2-6-5 Stop lamp does not light 10-052
2-6-6 Illumination of combination meter does not light 10-054
2-6-7 Combination meter warning lamp or indicator lamp is abnormal 10-054
2-6-8 Tachometer reading is abnormal 10-056
2-6-9 Hour meter is abnormal 10-056
2-6-10 Temperature meter is abnormal 10-058
2-6-11 Fuel meter is abnormal 10-058
2-6-12 Hydraulic oil filter warning lamp remains ON 10-060
SW/TW354,TW504 ○0
0-008
2-6-13 Charge warning lamp remains ON 10-060
2-6-14 Engine oil pressure warning lamp remains ON 10-062
2-6-15 Vibration indicator lamp does not light 10-064
2-6-16 Water spray indicator lamp does not light 10-066
2-6-17 Liquid spray indicator lamp does not light (TW354, 504) 10-066
2-6-18 Flood lamp indicator lamp does not light 10-068
2-6-19 Parking brake indicator lamp does not light 10-068
2-6-20 Turn signal indicator lamp does not light 10-070
2-6-21 Horn does not sound 10-072
2-6-22 Backup buzzer does not sound 10-072
3 HYDRAULIC SYSTEM TROUBLESHOOTING
3-1 When Performing Hydraulic System Troubleshooting 10-073
3-2 Propulsion System 10-074
3-2-1 Machine moves neither forward nor backward 1/2 10-074
3-2-1 Machine moves neither forward nor backward 2/2 10-075
3-2-2 Machine moves in one direction only (forward or backward) 10-075
3-2-3 Slow machine speed or small drive force 1/2 10-075
3-2-3 Slow machine speed or small drive force 2/2 10-076
3-2-4 Machine speed cannot be switched 10-076
3-2-5 Machine does not stop completely with F-R lever in “N” 10-076
3-2-6 Driving not possible with differential locked (TW354, 504) 10-077
3-2-7 Propulsion system is overheating 10-077
3-2-8 Abnormal noise from propulsion system 10-077
3-3 Vibrator System 10-078
3-3-1 No vibration 10-078
3-3-2 Vibrator frequency is too low 10-079
3-3-3 Vibratory drum does not changeover vibrating (SW354 ROPS) 10-079
3-3-4 Vibration mode does not switch (TW504) 10-079
3-3-5 Vibrator does not stop 10-079
3-3-6 Vibrator system is overheating 10-080
3-3-7 Abnormal noise from vibrator system 10-080
3-4 Steering System 10-081
3-4-1 Steering wheel is hard to turn 10-081
3-4-2 Steering response is slow 10-081
3-4-3 Steering wheel backlash or play is large 10-082
3-4-4 Steering system is overheating 10-082
3-4-5 Abnormal noise from steering system 10-082
3-5 Cooling System 10-083
3-5-1 Cooling fan does not rotate 10-083
3-5-2 Cooling system is overheating 10-083

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