$Vv510-1 SHOP MANUAL SAKAI| 7 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.Lea CONTENTS 1. SAFETY 1. GENERAL SAFETY encase steno : 4-001 111 Understanding the Safely Symbols an Signl Words 1-001 1-2. Goneral ~ sn 1-8. Qualifications of Operators and Maintenance Personnel. « oo 14, Safety Practices and Policies 41-5. Pre Start Inspection 4-6. Safely Instructions 1-001 1-002 1-002 1-003 1-003 4-7. Startingr sores 41-8. Operating 1-9. Stopping =~ 1-004 1-10. Maintenance 4-005 1-11, Transporting the Machine ~ 1-007 SPECIFICATIONS 1, SPECIFICATION DATA a eae 4-4, SV510D-I1 oe 2-001 1-2, SVS10T- 2-003 1-3, Sv510T8-T evens 2.005, 1-4, SVS10TF-IT 2.007 1-5, SVS10TFB-IL 2-009 2. TABLE OF STANDARD VALUES 2.011 2:4. Engine 2.011 2:2, Drive device 2011 2.8. Hydraulic devices 2.012 2:4. Steering devices: 2.012 2.5. Brakes 2.013 2.6. Oil and grease capacity’ os 2.013 8. FUEL AND LUBRICANTS SPECIFICATION ~ 2014 S41. Rating + 2.014 3-2, Recommended lubricants sce 2-014 4, TIGHTENING TORQUE CHART =~ ree co 2015 ENGINE AND CONTROLS — 4, ENGINE 8-001 4-4. Engine mount 3-0012, CONTROL SYSTEM: 3-002 241, Throttle control ++ 3-002 2.2, Forward-reverse control 3-003 8, PUMP MOUNT + 3-004 8-1, Pump mount (SVB1OD/T/TF- IL) +-1sesesssoe - : 3-004 3-2, Pump attachment (SV51OD/17TF- 1) 3.005; 3-8. Pump mount (SV510TB/TFB- 1) 3-007 3-4, Pump attachment (SVS10TS/TBF- II) 3-008 4. HYDRAULIC SYSTEMS 1, SYSTEM CIRCUIT DIAGRAM ~~ 4001 1-1. Graphic symbols for hydraulic sree 4-001 4-2, Hydraulic circuit diagram (SVB 1OD/T/TF- M1) 4-008 1-8. Hydraulic circuit diagram (SVS10TB/TFB-I1) “ 4-004 2, PROPULSION HYDRAULIC SYSTEM serene 4-005 2-1. Propulsion hydraulic piping (1) (ron 4-005 ; 2.2, Propulsion hydraulic piping (2) (rear) 4-006 2.8. Hydraulic equipment specifications 4007 2-3-1. Propulsion pump (propulsion, vibrator, steering/chargo) (SVETOD/TITF-Il) sservsne 4-007 2-8-2. Propulsion pump (aropuion, var, slestingicarg) (8V51OTEFB-I}) 4-008 2-8-8, Propulsion hydraulic motor front se serene 4-008 2.6.4, Internal structure of propulsion hydraulic motor (Kron!) eve A010 2.8-5, Propulsion hydraulic motor (rear) ~ + eon 2-8-6, Different! lock valve 4012 2.8-7. Manifold (or diferenial lock valve) 4.013 2.8.8, Flow dividing valve 4014 2.8.9, Internal structure of flow dividing valvo 4015 3, VIBRATOR HYDRAULIC SYSTEM S 4016 341. Vibrator hydraulic piping 4016 3.2, Hydraulle equipment spoctications seen “4017 8-244. Vibrator hydlraulle motor" soe ene 4ON7 4, STEERING SYSTEM seen 4018 4-1. Steering hydraulic piping (SVS10D/1/7F- 1) 4.018 42, Storing hyrautc ppng (SVS1OTB/TFB-I}) vanes 4-919 4-8. Frame (conter pin) se 4-020 44, Slooring wheel so 4021 44-1, Stooting valve (Orbito}) 4-022 TF nnmmua —$- a[I 45, Stooring oyinder-~ 4454. ltemal stu of storing yin ~ 5. BLADE + 5-1. Blade hysraule piping (SVS1OTB/TFB-I1) 5.2. Hydraule equipment specifications: 52-1, Control valve - 7 5-2-2. Internal structure of cylinder a eemenerrrrar ty 4.024 4-028 4.025 4.026 5-2-8, Flow dividing valve ~ rreesanen vee 4.028 5. ELECTRICAL SYSTEM 1, GENERAL SYSTEM CIRCUIT DIAGRAM + 5-001 41-4, Electrical wiring diagram 5-001 2, ELECTRICAL COMPONENTS ~ rs 5-002 2:1, Electrical component layout (1) sree sees 8.002 2:2, Electrical component layout (2) . 5-008 23, Battery layout : z 5-004 8. ELECTRICAL COMPONENT SPECIFICATIONS ~~" se 5-005 3-1, Fuse box 8:2, Engine stop system 3-21, Engine stopper unalone and operon 8-8, Diode unit ssserr senescence 5-007 5-009 6. VIBRATORY DRUM - REAR AXLE 1, PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001 2. VIBRATORY DRUM ese reenter yt 6-008 2 |. Removal and installation of vibratory drum 2-1-4, Romoval of vibratory drum 2-4-2. Insiallation of vibratory drum 2:2, Vibratory drum assembly ~ 2.3, Disassembly and reassembly of vibratory drum 2-3-1, Disassembly of vibratory drum ~~ 6-007 24.2. Rossaomby of vray doen ~ e014 S.AKLE © : even 6-022 944, Rear axle cee rvenenernee sees 6022 8-2, Rear axle lubrication 6-023 8-3. Rear axle structure: 6-024 33+. Gearbox 6-024 8-3-2, Conter housing ee 6-025 3-8-8, Differential rss esee 6-0267 9-3-4, Hub reduction gear 6-027 348-5, Braker-rvssese 6-028 7. BRAKES 1. BRAKE SYSTEM 7-001 1-1. Brake pedal 7-001 1-2, Brake circuit configuration 7-002 1-3. Brake piping 7-008 ‘14, Brake solenoid valve - 7-004 2, BRAKE STRUCTURE 7-005 3, BRAKE ADJUSTMENT 7-008 341. Brake clearance adjustment: 7-006 93-2, Manually releasing the brake 7-007 8. INSPECTION AND ADJUSTMENT J.INSPECTION AND ADJUSTMENT ree BOOT ‘+4. Inspection and Adjusiment « 8-001 4-4-1, Safety precautions for inspection and adjustment: 8-001 1-1-2. Preparation for inspection and adjustment 8-002 1-1-3, Precaution fo npeoton ond euciment 8-002 1-1-4, Warmup ~ 8-002 2, MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 8-003, 244, Measurement 8-003 22. Acjusiment 8.004 8, MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE <----0 8-005 S+1, Measurement 8-005 3:2. Adjustment ee 8-006 4, MEASUREMENT OF VEHICLE HIGH/LOW-SPEED CHANGE CIRCUIT PRESSURE 4-1. Measurement ~ en 5, MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE. ~ 6-1, Measurement 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE “8-009 6-1. Measurement 8-009 6-2, Inspection ~ 8-010 ‘7. MEASUREMENT AND INSPECTION OF VIBRATION CHARGE CIRCUIT PRESSURE ++ Bott a —p— ans ol7-1, Measurement ott 7-2. Inspection ~ 8.012 8, MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE =: 8-013 8-1, Measurement 8.013 82. Inspection 8-014 9, ADJUSTMENT OF THROTTLE LEVER LINKAGE ~ 8015 941. Agjusiment se 8-015 10, ADJUSTMENT OF FORWARD-REVERSE LEVER LINKAGE e016 10-4. Adjustment rosea e016 9, TROUBLESHOOTING 1. TROUBLESHOOTING 1+. Safety precautions for troubleshooting ~ 1-2. Important information for troubleshooting 1-9. Before starting a troubleshooting session 4-4. Wire color code +--+ 2. FAULT DIAGNOSIS OF ELECTRICAL SYSTEM ~ 8-008 2-4. When performing electrical system fault diagnosis, s--s-s-r-rvesesnseeeinees 6003 Precautions to take during electric circut fault diagnosis 9-003 Inspection of electrical system sera 9-003 2-2. Engino seve 9-007 2-2-1. Engine Will Not Start (Starter Motor Doss No! Run) 9-007 Engine Will Not Start (But Starter Motor Runs) 9-009 3, Engine Does Not Stop Running 9-009 4, No Charging: veetercentntsauanean e011 ‘5. Glow Plug Is Not Heated (Engine Starting Performance Is Bad) 9-011 22-6. Starter Motor Runs Even Without Forward/Revorse Lever In Neutral 9-011 2-8. Propulsion evenness seven mo 9013 2-3-1. Vehicle Moves Neither Forward Nor Backward -=~-~ z 9-018 2.3.2. Differential Lock Does Not Function . cones 9.013, 28-3, Dragging Of The Roll Ocours During Driving When The Differential Is Locked 9.013 2-5-4, Vehicle Speed (Gear) Does Not Change 9-015 2:8-5. Brake Does Not Release ~ 8017 2-8-6, Brake Does Not Operate. ~ 9017 2-4, Vibrator seat 2-019 2r4-4. No Vibration Occurs s-svressrsesesesnea sess 9-019 2-4-2. Amplitude Does Not Change (Remains Either Low or High) =~ 9-019 2-4-3. Vibrator Control Is Continously Engaged Or a b- se nol |