Sakai SV400D-2 Install guide

SV400-2
SHOP MANUAL
0404-99027-0-31649-B

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.

CONTENTS
1. SAFETY
1. GENERAL SAFETY 1-001
1-1. Understanding the Safety Symbols and Signal 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 1-003
1-8. Operating 1-003
1-9. Stopping 1-004
1-10. Maintenance 1-004
1-11. Transporting the Machine 1-006
2. SPECIFICATIONS
1. SPECIFICATION DATA 2-001
1-1. SV400D-2 2-001
1-2. SV400T-2 2-003
1-3. SV400TB-2 2-005
1-4. SV400TF-2 2-007
1-5. SV400FB-2 2-009
2. SPECIFICATIONS AND SETTING 2-011
2-1. Engine 2-011
2-2. Propulsion 2-011
2-3. Hydraulic Devices 2-012
2-4. Steering Devices 2-012
2-5. Brakes 2-013
2-6. Oil and Grease Capacity 2-013
3. FUEL AND LUBRICANTS SPECIFICATION 2-014
3-1. Rating 2-014
3-2. Recommended Lubricants 2-014
4. TIGHTENING TORQUE CHART 2-015
3. ENGINE AND CONTROLS
1. ENGINE 3-001
1-1. Engine Mount 3-001

1-2. Engine Exterior 3-002
1-3. Cooling System 3-003
2. CONTROL SYSTEM 3-004
2-1. Throttle Control 3-004
2-2. Forward-reverse Control 3-005
3. PUMP MOUNT 3-006
3-1. Pump Mount 3-006
3-2. Pump Attachment 3-007
4. HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM 4-001
1-1. Graphic Symbols for Hydraulic 4-001
1-2. Hydraulic Circuit Diagram (SV400D/T/TF-2) 4-003
1-3. Hydraulic Circuit Diagram (SV400TB/FB-2) 4-004
2. PROPULSION HYDRAULIC SYSTEM 4-005
2-1. Propulsion Hydraulic Piping (1) (Front) 4-005
2-2. Propulsion Hydraulic Piping (2) (Rear) 4-006
2-3. Hydraulic Equipment Specications 4-007
2-3-1. Propulsion pump (propulsion, vibrator, steering/charge) (SV400D/T/TF-2) 4-007
2-3-2. Propulsion pump (propulsion, vibrator, steering/charge) (SV400TB/FB-2) 4-009
2-3-3. Propulsion hydraulic motor (front) 4-011
2-3-4. Internal structure of propulsion hydraulic motor (front) 4-012
2-3-5. Propulsion hydraulic motor (rear) 4-013
2-3-6. Block 4-014
3. VIBRATOR HYDRAULIC SYSTEM 4-015
3-1. Vibrator Hydraulic Piping 4-015
3-2. Hydraulic Equipment Specications 4-016
3-2-1. Vibrator hydraulic motor 4-016
4. STEERING SYSTEM 4-017
4-1. Steering Hydraulic Piping (SV400D/T/TF-2) 4-017
4-2. Steering Hydraulic Piping (SV400TB/FB-2) 4-018
4-3. Frame (Center Pin) 4-019
4-4. Steering Wheel 4-020
4-4-1. Steering valve (Orbitrol) 4-021
4-5. Steering Cylinder 4-022
4-5-1. Internal structure of steering cylinder 4-023
5. BLADE (SV400TB/FB-2) 4-024
5-1. Blade Hydraulic Piping 4-024
5-2. Hydraulic Equipment Specications 4-025
5-2-1. Control valve 4-025

5-2-2. Internal structure of cylinder 4-026
5-2-3. Flow dividing valve 4-027
5. ELECTRICAL SYSTEM
1. GENERAL SYSTEM CIRCUIT 5-001
1-1. Electrical Wiring Diagram 5-001
2. ELECTRICAL COMPONENTS 5-002
2-1. Electrical Component Layout (1) 5-002
2-2. Electrical Component Layout (2) 5-003
2-3. Battery Layout 5-004
3. ELECTRICAL COMPONENT SPECIFICATIONS 5-005
3-1. Fuse Box 5-005
3-2. Diode Unit 5-006
6. VIBRATORY DRUM • REAR AXLE
1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY  6-001
2. VIBRATORY DRUM 6-002
2-1. Removal and Installation of Vibratory Drum 6-002
2-1-1. Removal of vibratory drum 6-002
2-1-2. Installation of vibratory drum 6-005
2-2. Vibratory Drum Assembly 6-006
2-3. Disassembly and Reassembly of Vibratory Drum 6-007
2-3-1. Disassembly of vibratory drum 6-007
2-3-2. Reassembly of vibratory drum 6-013
3. AXLE 6-021
3-1. Rear Axle 6-021
3-2. Rear Axle Lubrication 6-022
3-3. Rear Axle Structure 6-023
3-3-1. Center housing 6-023
3-3-2. Differential 6-024
3-3-3. Hub reduction gear 6-025
3-3-4. Brake 6-026
7. BRAKES
1. BRAKE SYSTEM 7-001
1-1. Brake Pedal 7-001
1-2. Brake Circuit Conguration 7-002
1-2-1. Brake ON condition 7-002
1-2-2. Brake OFF condition 7-003
1-3. Brake Piping 7-004

1-4. Brake Solenoid  7-005
2. BRAKE STRUCTURE 7-006
3. BRAKE ADJUSTMENT 7-007
3-1. Brake Clearance Adjustment 7-007
3-2. Manually Releasing the Brake 7-008
8. INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT 8-001
1-1. Inspection and Adjustment 8-001
1-1-1. Safety precautions for inspection and adjustment 8-001
1-1-2. Preparation for inspection and adjustment 8-002
1-1-3. Precautions for inspection and adjustment 8-002
1-1-4. Warm-up 8-002
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 8-003
2-1. Measurement 8-003
2-2. Adjustment 8-004
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE
CIRCUIT PRESSURE 8-005
3-1. Measurement 8-005
3-2. Adjustment 8-006
4. MEASUREMENT OF VEHICLE HIGH/LOW-SPEED CHANGE CIRCUIT
PRESSURE 8-007
4-1. Measurement 8-007
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 8-008
5-1. Measurement 8-008
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 8-011
7-1. Measurement 8-012
7-2. Inspection 8-013
8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-014
8-1. Measurement 8-014
8-2. Inspection 8-015
9. ADJUSTMENT OF THROTTLE LEVER LINKAGE 8-016
9-1. Adjustment 8-016
10. ADJUSTMENT OF FORWARD-REVERSE LEVER LINKAGE 8-017
10-1. Adjustment 8-017

9. TROUBLESHOOTING
1. TROUBLESHOOTING 9-001
1-1. Safety Precautions for Troubleshooting 9-001
1-2. Important Information for Troubleshooting  9-002
1-3. Before Starting a Troubleshooting Session  9-002
1-4. Wire Color Code  9-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING 9-003
2-1. When Performing Electrical System Fault Diagnosis  9-003
2-1-1. Precautions to take during electric circuit fault diagnosis  9-003
2-1-2. Inspection of electrical system  9-003
2-2. Engine 9-007
2-2-1. Engine will not start (starter motor does not run) 9-007
2-2-2. Engine will not start (but starter motor runs) 9-011
2-2-3. Engine does not stop running 9-011
2-2-4. No charging 9-011
2-2-5. Starter motor runs even without forward/reverse lever in neutral 9-011
2-2-6. Starting engine is difcult 9-013
2-3. Propulsion 9-015
2-3-1. Vehicle speed does not change 9-015
2-3-2. Brake does not release 9-015
2-3-3. Brake does not operate 9-019
2-3-4. Vehicle moves neither forward nor backward 9-021
2-4. Vibrator 9-025
2-4-1. No vibration occurs 9-025
2-4-2. Amplitude does not change (remains either low or high) 9-025
2-4-3. Vibrator control is continuously engaged or does not change
when the forward/reverse lever is operated 9-027
2-5. Lighting and Accessories 9-029
2-5-1. Combination meter monitor lamps do not light 9-029
2-5-2. Tachometer reading is abnormal 9-029
2-5-3. Hour meter is abnormal 9-031
2-5-4. Temperature gauge is abnormal 9-031
2-5-5. Fuel gauge is abnormal 9-031
2-5-6. Hydraulic oil lter warning lamp remains ON 9-033
2-5-7. Oil pressure warning lamp remains ON 9-033
2-5-8. Vibrator operation indicator lamp does not turn ON 9-033
2-5-9. Parking brake indicator lamp does not light 9-035
2-5-10. Horn does not sound 9-035
2-5-11. Backup buzzer does not beep 9-037
2-5-12. Engine warning lamp remains ON 9-037

3. HYDRAULIC SYSTEM TROUBLESHOOTING  9-038
3-1. When Performing Hydraulic System Troubleshooting 9-038
3-2. Propulsion 9-039
3-2-1. Vehicle moves neither forward nor backward 9-039
3-2-2. Vehicle moves in one direction only (forward or backward) 9-040
3-2-3. Slow vehicle speed or small drive force 9-040
3-2-4. Vehicle speed does not change 9-041
3-2-5. Vehicle does not stop completely with forward/reverse lever
in neutral position 9-041
3-2-6. Propulsion system is overheating 9-042
3-2-7. Abnormal noise from propulsion system 9-042
3-3. Vibrator 9-043
3-3-1. No vibration 9-043
3-3-2. Vibrator frequency is too low 9-044
3-3-3. Vibrator L-H does not switch 9-044
3-3-4. Vibrator does not stop 9-044
3-3-5. Vibrator system is overheating 9-045
3-3-6. Abnormal noise from vibrator system 9-045
3-4. Steering 9-046
3-4-1. Steering wheel is hard to turn 9-046
3-4-2. Steering response is slow 9-046
3-4-3. Steering wheel backlash or play is large 9-047
3-4-4. Steering system is overheating 9-047
3-4-5. Abnormal noise from steering system 9-047
3-5. Blade (SV400TB/FB-2) 9-048
3-5-1. Blade up/down operation not possible 9-048
3-5-2. Blade movement is slow or force is small 9-048
3-5-3. Blade oating operation not possible 9-049
3-5-4. Blade hydraulic system is overheating 9-049
3-5-5. Abnormal noise from blade hydraulic system 9-049