Sakai SV510-III Install guide

SV510-
SHOP MANUAL
3498-6412A-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, specifications 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.

SV510- ○
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. SV510D-Ⅲ2-001
1-2. SV510T-Ⅲ2-003
1-3. SV510TF-Ⅲ 2-005
2. TABLE OF STANDARD VALUES
2-1. Engine2-007
2-2. Propulsion2-007
2-3. Hydraulic System2-007
2-4. Steering 2-008
2-5. Brakes2-008
2-6. Capacities 2-008
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating 2-009
3-2. Recommended Lubricants2-009
4. TIGHTENING TORQUE CHART2-010
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount3-001
1-2. Engine Exterior 3-002

SV510- ○
0
2. CONTROL SYSTEM
2-1. 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
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping4-004
2-1-1. Propulsion hydraulic piping (front type 1) 4-004
2-1-2. Propulsion hydraulic piping (front type 2) 4-005
2-1-3. Propulsion hydraulic piping (rear)4-006
2-2. Hydraulic Component Specications 4-007
2-2-1. Hydraulic pump assembly (propulsion + vibrator + steering)4-007
2-2-2. Gear box4-009
2-2-3. Propulsion hydraulic motor (front)4-011
2-2-4. Propulsion hydraulic motor (rear) 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
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping4-015
4-2. Steering Wheel4-016
4-3. Hydraulic Component Specications 4-017
4-3-1. Orbitrol4-017
4-4. Frame (Center Pin)4-018
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

SV510- ○
0
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 Assembly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 6-020
3. REAR AXLE
3-1. Rear Axle Assembly6-037
3-1-1. Rear axle assembly (type 1) 6-037
3-1-2. Rear axle assembly (type 2) 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 (type 1) 6-043
3-3-5. Brake (type 2) 6-044
3-3-6. Gearbox6-045
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

SV510- ○
0
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement8-002
2-2. Adjustment8-003
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1. Measurement8-004
3-2. Adjustment8-005
4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT
PRESSURE
4-1. Measurement8-006
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1. Measurement8-007
6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE
6-1. Measurement8-008
6-2. Inspection 8-009
7. MEASUREMENT AND INSPECTION OF VIBRATOR CHARGE CIRCUIT
PRESSURE8-010
7-1. Measurement8-011
7-2. Inspection 8-012
8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
8-1. Measurement8-013
8-2. Inspection 8-014
9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
9-1. Measurement of Propulsion Pump Case Pressure 8-015
9-2. Measurement of Vibrator Pump Case Pressure8-016
10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
10-1. Measurement 8-017
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
11-1. Measurement 8-018
12. ADJUSTMENT OF F-R LEVER LINKAGE
12-1. Adjustment8-019
13. BRAKE ADJUSTMENT
13-1. Manually Releasing the Brake8-020
13-2. Adjustment after Manual Release of Brake 8-021
13-3. Brake Clearance Adjustment (Type 1 only)8-022
9. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting 9-001

SV510- ○
0
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. Fault Codes9-011
2-2-1. Description of fault codes9-011
2-2-2. Reading procedures of fault codes9-012
2-2-3. Fault code list9-013
2-3. Error Codes9-021
2-3-1. Description of error codes 9-021
2-3-2. Error code list9-021
2-4. Engine9-023
2-4-1. Engine will not start (Starter motor does not run) 1/29-023
2-4-1. Engine will not start (Starter motor does not run) 2/29-025
2-4-2. Engine will not start (But starter motor runs) 9-027
2-4-3. No charging9-029
2-4-4. Engine speed cannot be switched 9-029
2-4-5. Starter motor runs even when F-R lever is not at neutral position 9-031
2-5. Propulsion9-033
2-5-1. Machine moves neither forward nor backward9-033
2-5-2. Machine speed cannot be changed9-035
2-5-3. Traction control does not work 1/39-037
2-5-3. Traction control does not work 2/39-039
2-5-3. Traction control does not work 3/39-041
2-5-4. Brake does not work9-043
2-6. Vibration9-045
2-6-1. No vibration occurs9-045
2-6-2. Amplitude does not change (Remains either Low or High)9-047
2-6-3. Vibration mode cannot be switched (F-R lever vibration switch
does not work)9-049
2-7. Lighting9-051
2-7-1. Illumination of combination meter does not turn on 9-051
2-7-2. Combination meter warning lamp or indicator lamp is abnormal 9-053
2-7-3. Tachometer reading is abnormal9-055
2-7-4. Hour meter is abnormal9-055

SV510- ○
0
2-7-5. Temperature meter is abnormal 9-057
2-7-6. Fuel meter is abnormal 9-057
2-7-7. Hydraulic oil lter warning lamp remains ON9-057
2-7-8. Oil pressure warning lamp remains ON9-059
2-7-9. Vibration indicator lamp does not light 9-061
2-7-10. Parking brake indicator lamp does not light9-063
2-7-11. Horn does not sound 9-065
2-7-12. Backup buzzer does not sound9-065
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 9-066
3-2. Propulsion System9-067
3-2-1. Machine moves neither forward nor backward 1/2 9-067
3-2-1. Machine moves neither forward nor backward 2/2 9-068
3-2-2. Machine moves in one direction only (forward or backward)9-068
3-2-3. Slow machine speed or small drive force 1/2 9-068
3-2-3. Slow machine speed or small drive force 2/2 9-069
3-2-4. Machine speed cannot be switched9-069
3-2-5. Machine does not stop completely with F-R lever in neutral position 9-069
3-2-6. Propulsion system is overheating9-070
3-2-7. Abnormal noise from propulsion system9-070
3-3. Vibrator System9-071
3-3-1. No vibration9-071
3-3-2. Vibrator frequency is too low9-072
3-3-3. Amplitude does not switch between high and low9-072
3-3-4. Vibrator does not stop9-072
3-3-5. Vibrator system is overheating9-073
3-3-6. Abnormal noise from vibrator system9-073
3-4. Steering System9-074
3-4-1. Steering wheel is hard to turn9-074
3-4-2. Steering response is slow 9-074
3-4-3. Steering wheel backlash or play is large 9-075
3-4-4. Steering system is overheating 9-075
3-4-5. Abnormal noise from steering system 9-075

SAFETY

1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol.
DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and
CAUTION are displayed, become alert. Your safety or those around you may be involved.
NOTICE is used to provide important information that is not hazard related.
DANGER: Indicates an imminently hazardous situation or condition which if not avoided
can result in serious personal injury or death.
WARNING: Indicates a potentially hazardous situation or condition which if not avoided
can result in serious personal injury or death.
CAUTION: Indicates a potentially hazardous situation or condition which if not avoided
may result in moderate personal injury or damage to the machine or
personal property.
(NOTICE): Indicates important information about operation or maintenance of the
machine that may cause damage, breakdown, or shortened service life of
the machine if you fail to observe or important point to maintain of quality in
maintenance works.
: Indicates standard value to judge whether measured value is good or not.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
N•m
In the assembly operation, tightening torque in locations that require particular
attention.
1-2. General
• Operators and maintenance personnel must be alert to recognize and avoid potential
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
• The machine must only be used for its intended purpose as described in the Operator’s
Manual. It must be operated by safety-conscious persons who are fully aware of the risks
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
★

1-002
SAFETY
• The machine is designed specically for the compaction of asphalt or soil road construction
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
• Operating the machine within the limits of its designated use also involves compliance with
the inspection and maintenance requirements contained in the Operation and Maintenance
Manual.
1-3. Qualications of Operators and Maintenance Personnel
• Work on the machine must be performed by qualified personnel only. Individual
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
• Define the operator’s responsibilities; the operator should have authority to refuse
instructions that are contrary to safety.
• Do not allow persons being trained to operate or perform maintenance on the machine
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies
• Keep the manuals in the container provided on the machine. Manuals must always be
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
and protective equipment and trafc or jobsite regulations.
• Machine operating instructions should also be supplemented with detailed instructions
pertaining to the specic jobsite or work location.
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
• Wear close tting garments and always tie back and secure long hair, also avoid wearing
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.

1-003
SAFETY
• Observe all safety instructions and warnings attached to the machine.
• Make sure all safety instructions and warnings on the machine are complete and perfectly
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position and the parking
brake is applied.
• Never make any modifications to the machine which might affect safety without the
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection
• Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly
performed. Repair or replace any malfunctioning, broken or missing parts before using the
machine. Refer to the maintenance schedule in the Operator’s Manual.
• Check that all instructions and safety stickers are in place and readable.
• Never ll the fuel tank with the engine running or while near an open ame or while smoking.
• Always clean up any spilled fuel.
• Check for any warning tags placed on the machine, do not operate the machine until all
repairs have been made and warning tags have been removed by authorized personnel.
• Check the seat belt for wear or damage; inspect the belt hardware and fabric. Replace
if hardware is damaged or the belt is frayed or nicked or stitching is loose. Check that
mounting hardware is tight.
• Clean the steps and operating platform of dirt and foreign matter to reduce danger of
slipping.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed, gradeability, steering
and braking.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions
• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
• Operate the machine only if all protective and safety devices are in place and fully
functional.
• Always use the hand rails and steps to get on and off your machine maintaining 3-point
contact (using both hands).

1-004
SAFETY
1-7. Starting
• Start the machine only from the driver’s seat and always wear the seat belt.
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
• Check that braking, steering, signals and lights are fully functional before starting work or
traveling with the machine.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Never climb on and off the machine while it is in motion.
• Always remain seated with the seat belt fastened when traveling, compacting or loading or
unloading the machine.
• Use caution and be very observant when operating in close quarters and congested areas.
• Obey all traffic regulations when working on public roads and make sure machine is
compatible with these regulations.
• Never carry passengers.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
• Do not work close to edges or in the vicinity of overhanging banks or on grades that could
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
(travel control) lever in low speed range when climbing or descending hills or steep grades.
• Make sure there is sufcient clearance when crossing underpasses, bridges and tunnels or
when passing under overhead power lines.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
• Always switch on the lighting system (if equipped) during poor visibility conditions and after
dark.
• Do not attempt to control the compactor travel speed with the throttle control. Maintain
engine speed at the full operating RPM.
• Do not run the engine in a closed building for an extended period of time. Exhaust fumes
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground. If this is not possible,
always park at a right angle to the slope and block the drums or tires.
• Do not leave the operator’s platform with the engine running. Always move the travel lever
to neutral position and apply the parking brake then turn the starter switch to OFF.
• Lock all lockable compartments.

1-005
SAFETY
• Park behind a safe barrier, use proper ags, and warning devices, especially when parking
in areas of heavy trafc.
1-10. Maintenance
• In any performing any work concerning the operation, adjustment or modification of the
machine or it’s safety devices or any work related to maintenance, inspection or repair,
always follow the start-up and shut-down procedures in the Operator’s Manual and the
Maintenance Manual.
• Ensure that the maintenance area is safe and secure.
• If the machine is shut down for maintenance or repair work
it must be secured against inadvertent starting by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground
with the drums or tires blocked to prevent inadvertent
movement.
• Immediately after the engine has stopped, the exhaust
system, engine, radiator coolant, engine oil, hydraulic uid
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
or draining oil or changing lters can cause serious burns.
Wait until the machine has cooled down.
• Use care when attaching and securing lifting tackle to
individual parts and large assemblies being removed
or repositioned for repair purposes to avoid the risk of
accident. Use lifting devices that are in perfect condition and
of sufficient lifting capacity. Never stand under suspended
loads.
• Always use the proper tools and workshop equipment in
good condition when performing maintenance or repairs on
the machine.
• Always use specially designed safety ladders and working
platforms when working above floor level. Never use
machine parts as a climbing aid.
• Keep all steps, handles, handrails, platforms and ladders free from mud, dirt, grease, ice or
snow.
• Clean the machine, especially threaded connections of any traces of oil or fuel before
carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free
cleaning rags.
• Examine all fuel, lubricant and hydraulic fluid lines and connectors for leaks, loose
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Whenever possible, avoid servicing or maintenance when the engine is running unless the
drums or tires are adequately blocked, the articulation lock bar is in the locked position and
the parking brake is applied.

1-006
SAFETY
• Never ll the fuel tank with the engine running, while near an open ame or while smoking.
Always clean up any spilled fuel.
• Ensure safe operation, optimum performance of the machine and its warranty by using only
genuine SAKAI replacement parts.
• Use only the specied uids and lubricants. Substitute only products known to be equivalent
from reputable manufacturers.
• Disconnect the battery cables when working on the electrical system
or when welding on the compactor.
• Be sure the battery area is well ventilated (clear of fumes) should it be
necessary to connect a jumper cable or battery charger. Fumes can
ignite from a spark and may explode.
• Be sure battery charger is OFF when making connections if charging is required.
• Use only original fuses with the specified rating. Switch off the machine immediately if
trouble occurs in the electrical system.
• Work on the electrical system may only be carried out by a qualified electrician or by a
specially trained person according to electrical engineering principles.
• Inspect the electrical equipment of the machine at regular intervals. Defects such as loose
connections or burnt or scorched wires must be repaired or replaced immediately.
• Do not weld, flame cut or perform grinding on the machine unless expressly authorized,
as there may be a risk of fire or explosion. Disconnect the battery when welding on the
machine.
• Clean the machine and its surrounding from dust or other ammable substances and make
sure the area is adequately ventilated before beginning welding, ame cutting or grinding
operations.
• Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of
chang, cracking, brittleness, deformation, blistering, tting separation, leakage, corrosion
or other damage which may affect their function or strength.
• Do not work on hydraulic system while the engine is running and the system is under
pressure. The hydraulic system remains pressurized even after the engine has stopped.
• Do not disconnect hydraulic hoses or ttings until the pressure has been properly relieved.
• Wait until the systems and uid have cooled down before disconnecting.
• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece
of cardboard and always wear gloves and safety glasses.
• Get immediate medical attention if uid has been injected under your skin. Fluid penetration
from a pin hole leak can cause severe injury or death.
• Ensure that hydraulic lines and hoses are routed and fitted properly. Ensure that no
connections are interchanged. All ttings, lengths and specications of hoses must comply
with the technical requirements.

1-007
SAFETY
• Observe all product safety regulations when handling fuel, oils, grease, engine coolant and
other chemical substances. Be careful especially when these items are hot as there is a risk
of burning or scalding.
• Operate internal combustion engines and fuel operated heating systems
only in adequately ventilated premises. Before starting the engine in an
enclosed area, make sure there is sufcient ventilation.
1-11. Transporting the Machine
• Use only suitable and approved trailers and haul vehicles and lifting equipment of sufcient
capacity.
• Entrust to experienced personnel the fastening and lifting of loads and instructing of crane
operators.
• Only experienced persons familiar with the operation of the machine may load and unload
the machine.
• Use ramps or a loading dock when loading or unloading the machine. Ramps must be the
proper strength, low angle and the proper height and width.
• Block the drums or tires (front and rear) of the hauling vehicle when loading and unloading
the compactor. Ensure that the haul vehicle is on level ground and approach the loading
ramps squarely to make sure that the compactor does not slide off the edge of the ramp.
• Keep the deck clear of mud, oil, ice or snow or other materials that can make the deck
slippery.
• Position the compactor on the trailer or transport vehicle centered from side to side, and
apply the brake. Shut off the engine and lock all lockable compartments.
• Block the drums or tires and lock the articulation lock bar. Chain the machine down properly
using the appropriate tackle.
• Know the overall height of the compactor and hauling vehicle. Observe height and weight
regulations and be sure you can pass safely at overhead obstructions.
• Obey all trafc regulations and be sure that the proper clearance ags, lights and warning
signs including “Slow Moving Vehicle” emblem are displayed when traveling on public roads.
• Know the approximate stopping distance at any given speed.
• Drive Safely. Never turn corners at excessive speeds.