Sakai Sw354 Install guide

SW/TW354

SW/TW504

SHOP MANUAL

3498-6446A-1

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.

SW/TW354,SW/TW504 ○

0-001

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. SW354 2-001

1-2. SW354 ROPS2-003

1-3. TW354 2-005

1-4. TW354 ROPS 2-007

1-5. TW504 2-009

1-6. TW504 ROPS 2-011

1-7. Common Specications 2-013

2. TABLE OF STANDARD VALUES

2-1. Engine2-014

2-2. Propulsion2-014

2-3. Hydraulic System2-015

2-4. Steering 2-015

2-5. Brakes2-016

2-6. Capacities 2-016

3. FUEL AND LUBRICANTS SPECIFICATION

3-1. Rating 2-017

3-2. Recommended Lubricants2-017

4. TIGHTENING TORQUE CHART2-018

○

SW/TW354,SW/TW504 ○

0-002

5. SPECIFICATION DATA (SW504)

5-1. SW504 2-019

5-2. SW504 ROPS2-021

5-3. Common Specications 2-023

6. TABLE OF STANDARD VALUES (SW504)

6-1. Engine2-024

6-2. Propulsion2-024

6-3. Hydraulic System2-024

6-4. Steering 2-025

6-5. Brakes2-025

6-6. Capacities 2-025

7. FUEL AND LUBRICANTS SPECIFICATION (SW504)

7-1. Rating 2-026

7-2. Recommended Lubricants2-026

3. ENGINE AND CONTROLS

1. ENGINE

1-1. Engine Mount3-001

2. CONTROL SYSTEM

2-1. Throttle Control 3-002

2-2. Forward-reverse Control3-003

3. PUMP MOUNT

3-1. Pump Mount3-004

3-1-1. Installation of pump  3-005

4. ENGINE (SW504)

4-1. Engine Mount3-006

5. FUEL SYSTEM (SW504) 3-007

6. CONTROL SYSTEM (SW504)

6-1. Throttle Control 3-009

6-2. Forward-reverse Control3-010

7. PUMP MOUNT (SW504)

7-1. Pump Mount3-011

7-1-1. Installation of pump  3-012

4. HYDRAULIC SYSTEMS

1. SYSTEM CIRCUIT DIAGRAM

1-1. Graphic Symbols for Hydraulic Circuits 4-001

○

SW/TW354,SW/TW504 ○

0-003

1-2. Hydraulic Circuit Diagram4-003

1-2-1. Hydraulic circuit diagram (SW354)4-003

1-2-2. Hydraulic circuit diagram (TW354) 4-004

1-2-3. Hydraulic circuit diagram (TW504) 4-005

2. PROPULSION HYDRAULIC SYSTEM

2-1. Propulsion Hydraulic Piping4-006

2-1-1. Propulsion hydraulic piping (F) (SW/TW354)4-006

2-1-2. Propulsion hydraulic piping (F) (TW504) 4-007

2-1-3. Propulsion hydraulic piping (R) (SW354)4-008

2-1-4. Propulsion hydraulic piping (R) (TW354)4-009

2-1-5. Propulsion hydraulic piping (R) (TW504)4-010

2-2. Hydraulic Component Specications 4-011

2-2-1. Propulsion hydraulic pump4-011

2-2-2. Propulsion hydraulic motor (F) (SW/TW354)4-013

2-2-3. Propulsion hydraulic motor (F) (TW504) 4-014

2-2-4. Propulsion hydraulic motor (R) (SW354)4-015

2-2-5. Propulsion hydraulic motor (R) (TW354,504)4-016

2-2-6. Differential lock valve (TW354,504)4-017

3. VIBRATOR HYDRAULIC SYSTEM

3-1. Vibrator Hydraulic Piping 4-018

3-1-1. Vibrator hydraulic piping (SW354) 4-018

3-1-2. Vibrator hydraulic piping (TW354) 4-019

3-1-3. Vibrator hydraulic piping (TW504) 4-020

3-2. Hydraulic Component Specications 4-021

3-2-1. Hydraulic pump assembly (vibrator (F) + steering • charge)4-021

3-2-2. Vibrator hydraulic pump (R) (SW354)4-022

3-2-3. Vibrator hydraulic motor4-023

3-2-4. Cooling fan drive hydraulic motor4-024

3-2-5. Vibrator solenoid valve (F), (R) (SW/TW354) 4-025

3-2-6. Vibrator solenoid valve (TW504)4-026

4. STEERING SYSTEM

4-1. Steering Hydraulic Piping4-027

4-1-1. Steering hydraulic piping (SW/TW354)4-027

4-1-2. Steering hydraulic piping (TW504) 4-028

4-2. Steering Wheel4-029

4-3. Hydraulic Component Specications 4-030

4-3-1. Orbitrol4-030

SW/TW354,SW/TW504 ○

0-004

5. HYDRAULIC CIRCUIT DIAGRAM (SW504)

5-1. Hydraulic Circuit Diagram4-031

6. PROPULSION HYDRAULIC SYSTEM (SW504)

6-1. Propulsion Hydraulic Piping4-032

6-1-1. Propulsion hydraulic piping (F)4-032

6-1-2. Propulsion hydraulic piping (R) 4-033

6-2. Hydraulic Component Specications 4-034

6-2-1. Propulsion hydraulic pump4-034

6-2-2. Propulsion hydraulic motor (R)4-036

7. VIBRATOR HYDRAULIC SYSTEM (SW504)

7-1. Vibrator Hydraulic Piping 4-037

7-2. Hydraulic Component Specications 4-038

7-2-1. Hydraulic pump assembly (vibrator + steering • charge)4-038

7-2-2. Cooling fan drive hydraulic motor4-039

7-2-3. Vibrator solenoid valve assembly4-040

8. STEERING SYSTEM(SW504)

8-1. Steering Hydraulic Piping4-041

8-2. Hydraulic Component Specications 4-042

8-2-1. Orbitrol4-042

5. ELECTRICAL SYSTEM

1. PRECAUTIONS FOR WORK

1-1.Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in

Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses5-001

2. SYSTEM CIRCUIT DIAGRAM

2-1. Electrical Circuit Diagram (SW354)5-003

2-2. Electrical Circuit Diagram (SW354 ROPS)5-004

2-3. Electrical Circuit Diagram (TW354) 5-005

2-4. Electrical Circuit Diagram (TW354 ROPS)5-006

2-5. Electrical Circuit Diagram (TW504) 5-007

2-6. Electrical Circuit Diagram (TW504 ROPS)5-008

3. ELECTRICAL COMPONENTS

3-1. Wiring Harness Layout (SW354) 5-009

3-1-1. Wiring harness layout (1) 5-009

3-1-2. Wiring harness layout (2) 5-010

3-2. Wiring Harness Layout (TW354)5-011

3-2-1. Wiring harness layout (1) 5-011

3-2-2. Wiring harness layout (2) 5-012

○

SW/TW354,SW/TW504 ○

0-005

3-3. Wiring Harness Layout (TW504)5-013

3-3-1. Wiring harness layout (1) 5-013

3-3-2. Wiring harness layout (2) 5-014

4. WIRING HARNESSES

4-1. Engine Harness5-015

4-2. Dashboard Harness5-017

4-3. Frame (F) Harness5-019

4-3-1. Frame (F) harness (SW/TW354)5-019

4-3-2. Frame (F) harness (TW504) 5-021

4-4. Frame (R) Harness 5-023

4-5. Stater Switch Harness5-025

4-6. Control Switch Harness5-026

4-7. Working Switch Harness 5-027

4-7-1. Working switch harness (except ROPS) 5-027

4-7-2. Working switch harness (ROPS)5-028

4-8. Parking Brake Switch Harness 5-029

4-9. Vibration Lo-Hi Change Switch Harness5-030

4-9-1. Short harness (SW/TW354 : except SW354 ROPS)5-030

4-9-2. Vibration Lo-Hi change switch harness (TW504) 5-031

4-10. Vibrator Solenoid (R) Harness5-032

4-10-1. Vibrator solenoid (R) harness (SW354) 5-032

4-10-2. Cap (TW354,504) 5-033

4-11. Hazard Switch Harness 5-034

4-11-1. Cap (except ROPS)5-034

4-11-2. Hazard switch harness (ROPS) 5-035

4-12. Mihaalu Harness5-036

4-13. Liquid Spray Switch Harness (TW354,504) 5-037

4-14. Liquid Spray Pump Harness (TW354,504)5-038

4-15. Short Harness5-039

4-16. Vibratory Drum Select Switch Harness (SW354 ROPS) 5-040

4-17. F-R Lever Vibration Switch (L) Harness5-041

4-18. F-R Lever Vibration Switch (R) Harness 5-042

5. ELECTRICAL COMPONENT SPECIFICATIONS

5-1. Fuse Box (SW354) 5-043

5-2. Fuse Box (TW354) 5-044

5-3. Fuse Box (TW504) 5-045

5-4. Combination Meter 5-046

SW/TW354,SW/TW504 ○

0-006

6. SYSTEM CIRCUIT DIAGRAM (SW504)

6-1. Electrical Circuit Diagram (ROPS)5-047

6-2. Electrical Circuit Diagram (except ROPS) 5-048

7. ELECTRICAL COMPONENTS (SW504)

7-1. Wiring Harness Layout (1)5-049

7-2. Wiring Harness Layout (2)5-050

8. WIRING HARNESSES (SW504)

8-1. Engine Harness5-051

8-2. Dashboard Harness (1)5-053

8-3. Dashboard Harness (2)5-055

8-4. ECU Harness (Vihicle)5-057

8-5. ECU Harness (Engine) 5-059

8-6. Frame (F) Harness5-061

8-7. Frame (R) Harness 5-063

8-8. Stater Switch Harness5-065

8-9. Control Switch Harness5-066

8-10. Working Switch Harness 5-067

8-10-1. Working switch harness (ROPS) 5-067

8-10-2. Working switch harness (except ROPS)5-068

8-11. Vibration Switch Harness 5-069

8-11-1. Vibration switch harness (ROPS)5-069

8-11-2. Vibration Lo-Hi change switch harness (except ROPS)5-070

8-12. Vibrator Solenoid (F) Harness (1) 5-071

8-13. Vibrator Solenoid (F) Harness (2) 5-072

8-14. Vibrator Solenoid (R) Harness (1) 5-073

8-15. Vibrator Solenoid (R) Harness (2) 5-074

8-16. Vibrator Solenoid (R) Harness (3) 5-075

8-17. Vibrator Solenoid (R) Harness (4) 5-076

8-18. Hazard Switch Harness 5-077

8-18-1. Hazard switch harness (ROPS) 5-077

8-18-2. Cap (except ROPS)5-078

8-19. DPF Switch Harness 5-079

8-20. Diagnostic Switch Harness5-080

8-21. Parking Brake Switch Harness5-081

8-22. Mihaalu Harness5-082

8-23. Starter Relay Harness5-083

8-24. F-R Lever Vibration Switch (L) Harness5-084

8-25. F-R Lever Vibration Switch (R) Harness 5-085

8-26. Short Harness5-086

8-27. Cord5-087

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