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