Sakai SV201-1 Install guide

SV201 - 1
SHOP MANUAL
3498-64064-0

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, specications 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 modications of the model.

SV201-1 ○
0
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-3. Qualications 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. SV201D-12-001
1-2. SV201T-12-003
1-3. SV201TF-1 2-005
1-4. SV201TB-12-007
2. TABLE OF STANDARD VALUES
2-1. Engine2-009
2-2. Propulsion2-009
2-3. Hydraulic System2-009
2-4. Steering 2-010
2-5. Brakes2-010
2-6. Capacities 2-010
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating 2-011
3-2. Recommended Lubricants2-011
4. TIGHTENING TORQUE CHART2-012

SV201-1 ○
0
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount3-001
1-2. Engine Exterior 3-002
2. CONTROL SYSTEM
2-1. Throttle Control 3-003
2-2. Forward-reverse Control3-004
3. PUMP MOUNT
3-1. Pump Mount3-005
3-1-1. 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
1-2-1. Hydraulic circuit diagram (SV201D-1) 4-003
1-2-2. Hydraulic circuit diagram (SV201T-1, TF-1)4-004
1-2-3. Hydraulic circuit diagram (SV201TB-1)4-005
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping4-006
2-1-1. Propulsion hydraulic piping (Front) 4-006
2-1-2. Propulsion hydraulic piping (Rear)4-007
2-2. Hydraulic Component Specications 4-008
2-2-1. Hydraulic pump assembly (propulsion + vibrator • steering)4-008
2-2-2. Propulsion hydraulic motor (Front) 4-010
2-2-3. Propulsion hydraulic motor (Rear) 4-011
2-2-4. Valve4-012
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-013
3-2. Hydraulic Component Specications 4-014
3-2-1. Vibrator hydraulic motor 4-014
3-2-2. Valve4-015
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping4-016
4-1-1. Steering hydraulic piping (SV201D-1, T-1, TF-1)4-016
4-1-2. Steering hydraulic piping (SV201TB-1) 4-017
4-2. Steering Wheel4-018
4-3. Hydraulic Component Specications 4-019
4-3-1. Orbitrol (SV201D-1, T-1, TF-1) 4-019

SV201-1 ○
0
4-3-2. Orbitrol (SV201TB-1)4-020
4-4. Frame (Center Pin)4-021
5. BLADE SYSTEM
5-1. Blade Hydraulic Piping 4-022
5-2. Hydraulic Component Specications 4-023
5-2-1. Stack valve4-023
5. ELECTRICAL SYSTEM
1. SYSTEM CIRCUIT DIAGRAM
1-1. Electrical Circuit Diagram5-001
2. ELECTRICAL COMPONENTS
2-1. Electrical Component Layout (1)5-002
2-2. Electrical Component Layout (2)5-003
3. ELECTRICAL COMPONENT SPECIFICATIONS
3-1. Fuse Box 5-004
3-2. Combination Meter 5-005
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 ASSY 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 6-018
3. REAR AXLE
3-1. Rear Axle ASSY6-038
3-2. Rear Axle Lubrication 6-039
3-3. Rear Axle Structure6-040
3-3-1. Center housing 6-040
3-3-2. Differential 6-041
3-3-3. Hub reduction gear 6-042
3-3-4. Brake 6-043

SV201-1 ○
0
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
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 (SV201TB-1)
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 Front Propulsion Motor 8-013
9-2. Measurement of Rear Propulsion Motor8-014
10. ADJUSTMENT OF THROTTLE LEVER LINKAGE
10-1. Adjustment8-015

SV201-1 ○
0
11. ADJUSTMENT OF F-R LEVER LINKAGE
11-1. Adjustment8-016
12. BRAKE ADJUSTMENT
12-1. Manually Releasing the Brake8-018
12-2. Adjustment after Manual Release of Brake 8-019
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 Color Code and Number 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9-012
2-2-1. Engine will not start (Starter motor does not run) 1/3 9-012
2-2-1. Engine will not start (Starter motor does not run) 2/3 9-014
2-2-1. Engine will not start (Starter motor does not run) 3/3 9-016
2-2-2. Engine will not start (But starter motor runs) 9-018
2-2-3. Engine does not stop running9-018
2-2-4. No charging9-020
2-2-5. Glow plug is not heated (Engine starting performance is bad in cold
weather)9-020
2-2-6. Starter motor runs even when F-R lever is not at “N” and parking brake is
not applied 9-020
2-3. Propulsion 9-022
2-3-1. Machine moves neither forward nor backward9-022
2-3-2. Brake cannot be released9-024
2-3-3. Brake does not work9-026
2-4. Vibration9-028
2-4-1. No vibration occurs 9-028
2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not
work)9-030

SV201-1 ○
0
2-5. Lighting9-032
2-5-1. Illumination of combination meter does not turn on 9-032
2-5-2. Combination meter warning lamp or indicator lamp is abnormal 9-034
2-5-3. Tachometer reading is abnormal9-036
2-5-4. Hour meter is abnormal 9-036
2-5-5. Temperature meter is abnormal 9-038
2-5-6. Fuel meter is abnormal 9-038
2-5-7. Hydraulic oil lter warning lamp remains ON9-040
2-5-8. Engine oil pressure warning lamp remains ON 9-040
2-5-9. Vibration indicator lamp does not light 9-042
2-5-10. Parking brake indicator lamp does not light9-044
2-5-11. Preheating indicator lamp does not light9-046
2-5-12. Horn does not sound 9-048
2-5-13. Backup buzzer does not sound9-048
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 9-049
3-2. Propulsion System9-050
3-2-1. Machine moves neither forward nor backward 1/2 9-050
3-2-1. Machine moves neither forward nor backward 2/2 9-051
3-2-2. Machine moves in one direction only (forward or backward)9-051
3-2-3. Slow machine speed or small drive force 1/2 9-051
3-2-3. Slow machine speed or small drive force 2/2 9-052
3-2-4. Machine does not stop completely with F-R lever in “N” 9-052
3-2-5. Propulsion system is overheating9-052
3-2-6. Abnormal noise from propulsion system9-053
3-3. Vibrator System9-054
3-3-1. No vibration9-054
3-3-2. Vibrator frequency is too low9-055
3-3-3. Vibrator does not stop9-055
3-3-4. Vibrator system is overheating 9-055
3-3-5. Abnormal noise from vibrator system9-056
3-4. Steering System9-057
3-4-1. Steering wheel is hard to turn9-057
3-4-2. Steering response is slow9-057
3-4-3. Steering wheel backlash or play is large 9-058
3-4-4. Steering system is overheating 9-058
3-4-5. Abnormal noise from steering system 9-058