Sakai TW504 - User Manual

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SW/TW354

SW/TW504

SHOP MANUAL

3498-6446A-1

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Table of Contents5
Safety17
General Safety19
Understanding the Safety Symbols and Words19
General19
Qualifications of Operators and Maintenance Personnel20
Safety Practices and Policies20
Pre Start Inspection21
Safety Instructions21
Starting22
Operating22
Stopping22
Maintenance23
Transporting the Machine25
Specifications27
Specification Data30
Sw35431
Sw354 Rops32
Tw35434
Tw354 Rops36
Tw50438
Tw504 Rops40
Common Specifications42
Table of Standard Values43
Engine43
Propulsion43
Hydraulic System44
Steering44
Brakes45
Capacities45
Fuel and Lubricants Specification46
Rating46
Recommended Lubricants46
Tightening Torque Chart47
Specification Data (Sw504)48
Sw50449
Sw504 Rops50
Common Specifications52
Table of Standard Values (Sw504)53
Engine53
Propulsion53
Hydraulic System53
Steering54
Brakes54
Capacities54
Fuel and Lubricants Specification (Sw504)55
Rating55
Recommended Lubricants55
Engine and Controls57
Engine59
Engine Mount59
Control System60
Throttle Control60
Forward-Reverse Control61
Pump Mount62
Installation of Pump63
Engine (Sw504)65
Engine Mount65
Fuel System (Sw504)66
Control System (Sw504)68
Throttle Control68
Forward-Reverse Control69
Pump Mount (Sw504)70
Pump Mount70
Installation of Pump71
Hydraulic Systems73
System Circuit Diagram76
Graphic Symbols for Hydraulic Circuits76
Hydraulic Circuit Diagram79
Hydraulic Circuit Diagram (SW354)79
Hydraulic Circuit Diagram (TW354)81
Hydraulic Circuit Diagram (TW504)83
Propulsion Hydraulic System85
Propulsion Hydraulic Piping85
Propulsion Hydraulic Piping (F) (SW/TW354)85
Propulsion Hydraulic Piping (F) (TW504)87
Propulsion Hydraulic Piping (R) (SW354)89
Propulsion Hydraulic Piping (R) (TW354)91
Propulsion Hydraulic Piping (R) (TW504)93
Hydraulic Component Specifications96
Propulsion Hydraulic Pump96
Propulsion Hydraulic Motor (F) (SW/TW354)98
Propulsion Hydraulic Motor (F) (TW504)99
Propulsion Hydraulic Motor (R) (SW354)100
Propulsion Hydraulic Motor (R) (TW354,504)101
Differential Lock Valve (TW354,504)102
Vibrator Hydraulic System103
Vibrator Hydraulic Piping103
Vibrator Hydraulic Piping (SW354)103
Vibrator Hydraulic Piping (TW354)105
Vibrator Hydraulic Piping (TW504)107
Hydraulic Component Specifications109
Hydraulic Pump Assembly (Vibrator (F) + Steering • Charge)109
Vibrator Hydraulic Pump (R) (SW354)110
Vibrator Hydraulic Motor111
Cooling Fan Drive Hydraulic Motor112
Vibrator Solenoid Valve (F), (R) (SW/TW354)113
Vibrator Solenoid Valve (TW504)114
Steering System115
Steering Hydraulic Piping115
Steering Hydraulic Piping (SW/TW354)115
Steering Hydraulic Piping (TW504)117
Steering Wheel119
Orbitrol119
Hydraulic Circuit Diagram (Sw504)120
Hydraulic Circuit Diagram121
Propulsion Hydraulic System (Sw504)123
Propulsion Hydraulic Piping123
Propulsion Hydraulic Piping (F)123
Propulsion Hydraulic Piping (R)125
Hydraulic Component Specifications128
Propulsion Hydraulic Pump128
Propulsion Hydraulic Motor (R)130
Vibrator Hydraulic System (Sw504)131
Vibrator Hydraulic Piping131
Hydraulic Component Specifications133
Hydraulic Pump Assembly (Vibrator + Steering • Charge)133
Cooling Fan Drive Hydraulic Motor134
Vibrator Solenoid Valve Assembly135
Steering System (Sw504)137
Steering Hydraulic Piping137
Hydraulic Component Specifications139
Orbitrol139
Electrical System141
Precautions for Work143
Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses143
System Circuit Diagram145
Electrical Circuit Diagram (SW354)145
Electrical Circuit Diagram (SW354 ROPS)147
Electrical Circuit Diagram (TW354)149
Electrical Circuit Diagram (TW354 ROPS)151
Electrical Circuit Diagram (TW504)153
Electrical Circuit Diagram (TW504 ROPS)155
Electrical Components157
Wiring Harness Layout (SW354)157
Wiring Harness Layout (1)157
Wiring Harness Layout (2)159
Wiring Harness Layout (TW354)161
Wiring Harness Layout (1)161
Wiring Harness Layout (2)163
Wiring Harness Layout (TW504)165
Wiring Harness Layout (1)165
Engine Harness165
Dashboard Harness167
Frame (F) Harness172
Frame (F) Harness (SW/TW354)172
Frame (F) Harness (TW504)174
Frame (R) Harness176
Stater Switch Harness179
Working Switch Harness (Except ROPS)181
Working Switch Harness (ROPS)182
Parking Brake Switch Harness183
Vibration Lo-Hi Change Switch Harness184
Short Harness (SW/TW354 : Except SW354 ROPS)184
Vibration Lo-Hi Change Switch Harness (TW504)185
Vibrator Solenoid (R) Harness186
Vibrator Solenoid (R) Harness (SW354)186
Cap (TW354,504)187
Hazard Switch Harness188
Cap (Except ROPS)188
Hazard Switch Harness (ROPS)189
Mihaalu Harness190
Liquid Spray Switch Harness (TW354,504)191
Liquid Spray Pump Harness (TW354,504)192
Short Harness193
Vibratory Drum Select Switch Harness (SW354 ROPS)194
F-R Lever Vibration Switch (L) Harness195
F-R Lever Vibration Switch (R) Harness196
Electrical Component Specifications197
Fuse Box (SW354)197
Fuse Box (TW354)198
Fuse Box (TW504)199
Combination Meter200
System Circuit Diagram (Sw504)201
Electrical Circuit Diagram (ROPS)201
Electrical Circuit Diagram (Except ROPS)203
Electrical Components (Sw504)205
Wiring Harness Layout (1)205
Wiring Harness Layout (2)207
Wiring Harnesses (Sw504)208
Engine Harness208
Dashboard Harness (1)210
Dashboard Harness (2)212
ECU Harness (Vihicle)214
ECU Harness (Engine)216
Frame (F) Harness218
Frame (R) Harness220
Stater Switch Harness222
Control Switch Harness223
Working Switch Harness224
Working Switch Harness (ROPS)224
Working Switch Harness (Except ROPS)225
Vibration Switch Harness226
Vibration Switch Harness (ROPS)226
Vibration Lo-Hi Change Switch Harness (Except ROPS)227
Vibrator Solenoid (F) Harness (1)228
Vibrator Solenoid (F) Harness (2)229
Vibrator Solenoid (R) Harness (1)230
Vibrator Solenoid (R) Harness (2)231
Vibrator Solenoid (R) Harness (3)233
Vibrator Solenoid (R) Harness (4)233
Hazard Switch Harness234
Hazard Switch Harness (ROPS)234
Cap (Except ROPS)235
DPF Switch Harness236
Diagnostic Switch Harness237
Parking Brake Switch Harness238
Mihaalu Harness239
Starter Relay Harness240
F-R Lever Vibration Switch (L) Harness241
F-R Lever Vibration Switch (R) Harness242
Short Harness243
Cord244
Electrical Component Specifications (Sw504)245
Fuse Box245
Combination Meter246
Vibratory Drum • Rear Wheel247
Precautions for Disassembly and Reassembly249
Vibratory Drum251
Removal and Installation of Vibratory Drum251
Removal of Vibratory Drum251
Installation of Vibratory Drum254
Vibratory Drum Assembly255
Vibratory Drum Assembly (TW504)257
Disassembly and Reassembly of Vibratory Drum259
Disassembly of Vibratory Drum259
Reassembly of Vibratory Drum270
Rear Axle289
Rear Axle Assembly (TW Types)289
Removal and Installation of Rear Axle (TW Types)290
Removal of Rear Axle291
Installation of Rear Axle294
Vibratory Drum (Sw504)295
Removal and Installation of Vibratory Drum295
Disassembly and Reassembly of Vibratory Drum295
Brake297
Brake Pedal299
Brake System300
Brake System (TW354, 504)301
Water Spray System303
Water Spray Piping305
Water Spray Piping (TW354,504)307
Liquid Spray System309
Liquid Spray Piping (TW354,504)309
Inspection and Adjustment311
Safety Precautions for Inspection and Adjustment313
Preparation for Inspection and Adjustment313
Precautions for Inspection and Adjustment313
Warm-Up313
Inspection and Adjustment of Engine Related Items313
Measurement and Inspection of Propulsion Circuit Pressure314
Measurement314
Inspection315
Measurement and Adjustment of Propulsion Charge Circuit Pressure316
Measurement316
Adjustment317
Measurement of Machine High/Low Speed Change Circuit Pressure318
Measurement318
Measurement of Parking Brake Release Pressure319
Measurement319
SW Types: Front and Rear, TW Types: Front319
TW Types: Rear320
Measurement of Vibrator Circuit Pressure321
Measurement321
Measurement and Inspection of Steering Circuit Pressure322
Measurement322
Inspection323
Measurement of Hydraulic Pump Case Pressure324
Measurement of Propulsion Pump Case Pressure324
Measurement of Propulsion Motor Case Pressure325
Measurement325
SW Types: Front and Rear, TW Types: Front325
TW Types: Rear326
Measurement of Vibrator Motor Case Pressure (Except Tw504)327
Measurement327
Measurement of Vibrator Motor Case Pressure (Tw504)328
Measurement328
Adjustment of Throttle Lever329
Adjustment of Linkage329
Adjustment of Operating Force330
Adjustment of F-R Lever331
Adjustment of Linkage331
Adjustment of Operating Force332
Measurement and Inspection of Propulsion Circuit Pressure (Sw504)334
Inspection335
Measurement and Adjustment of Propulsion Charge Circuit Pressure (Sw504)336
Measurement336
Adjustment337
Measurement of Machine High/Low Speed Change Circuit338
Measurement338
Measurement of Vibrator Circuit Pressure (Sw504)339
Measurement339
Measurement and Inspection of Steering Circuit Pressure340
Measurement340
Inspection341
Measurement of Hydraulic Pump Case Pressure (Sw504)342
Measurement of Propulsion Pump Case Pressure342
Adjustment of Throttle Lever (Sw504)343
Adjustment of Potentiometer343
Adjustment of Operating Force344
Adjustment of F-R Lever (Sw504)345
Adjustment of Linkage345
Troubleshooting347
Safety Precautions for Troubleshooting349
Important Information for Troubleshooting349
Before Starting350
Electrical System Troubleshooting351
When Performing Electrical System Fault Diagnosis351
Precautions to Take During Electrical Circuit Fault Diagnosis351
Inspection Procedures Using a Tester352
Inspection of Electrical System357
Engine361
Engine will Not Start (Starter Motor Does Not Run) 1/3365
Engine will Not Start (but Starter Motor Runs)365
Engine Does Not Stop Running367
No Charging367
Glow Plugs Is Not Heated367
Starter Motor Runs Even When F-R Lever Is Not at "N369
Propulsion371
Machine Moves Neither Forward nor Backward371
Machine Speed Cannot be Changed373
Brake Cannot be Released375
Brake Does Not Work377
Vibration378
No Vibration Occurs 1/2379
No Vibration Occurs 2/2381
Vibration Mode Cannot be Switched383
Vibratory Drum Cannot be Switched (SW354 ROPS)385
Amplitude Does Not Change (Remains Either Low or High) (TW504)387
Water Spray389
Continuous Water Spray Does Not Operate389
Continuous Water Spray Works, but Auto Water Spray Does Not Operate391
Liquid Cannot be Sprayed (TW354, 504)393
Lighting394
Head Lamp and Tail Lamp Do Not Light395
Flood Lamp Does Not Light395
Turn Signal Lamp Does Not Blink397
Hazard Lamp Does Not Light (Turn Signal Blinks) (ROPS Type)399
Stop Lamp Does Not Light401
Illumination of Combination Meter Does Not Light403
Combination Meter Warning Lamp or Indicator Lamp Is Abnormal403
Tachometer Reading Is Abnormal405
Hour Meter Is Abnormal405
Temperature Meter Is Abnormal407
Fuel Meter Is Abnormal407
Hydraulic Oil Filter Warning Lamp Remains on409
Charge Warning Lamp Remains on409
Engine Oil Pressure Warning Lamp Remains on411
Vibration Indicator Lamp Does Not Light413
Water Spray Indicator Lamp Does Not Light415
Liquid Spray Indicator Lamp Does Not Light (TW354, 504)415
Flood Lamp Indicator Lamp Does Not Light417
Parking Brake Indicator Lamp Does Not Light417
Turn Signal Indicator Lamp Does Not Light419
Horn Does Not Sound421
Backup Buzzer Does Not Sound421
Hydraulic System Troubleshooting422
When Performing Hydraulic System Troubleshooting422
Propulsion System423
Machine Moves Neither Forward nor Backward 1/2423
Machine Moves Neither Forward nor Backward 2/2424
Machine Moves in One Direction Only (Forward or Backward)424
Slow Machine Speed or Small Drive Force 1/2424
Slow Machine Speed or Small Drive Force 2/2425
Machine Speed Cannot be Switched425
Machine Does Not Stop Completely with F-R Lever in "N425
Driving Not Possible with Differential Locked (TW354, 504)426
Propulsion System Is Overheating426
Abnormal Noise from Propulsion System426
Vibrator System427
No Vibration427
Vibrator Frequency Is too Low428
Vibratory Drum Does Not Changeover Vibrating (SW354 ROPS)428
Vibration Mode Does Not Switch (TW504)428
Vibrator Does Not Stop428
Vibrator System Is Overheating429
Abnormal Noise from Vibrator System429
Steering System430
Steering Wheel Is Hard to Turn430
Steering Response Is Slow430
Steering Wheel Backlash or Play Is Large431
Steering System Is Overheating431
Abnormal Noise from Steering System431
Cooling System432
Cooling Fan Does Not Rotate432
Cooling System Is Overheating432
Electrical System Troubleshooting (Sw504)433
Engine Diagnosis Trouble Code433
Description of Diagnostic Trouble Code (SPN, FMI)433
Table of the Diagnostic Trouble Code (DTC)434
Engine441
Engine will Not Start (Starter Motor Does Not Run) 1/3441
Engine will Not Start (Starter Motor Does Not Run) 2/3443
Engine will Not Start (Starter Motor Does Not Run) 3/3445
Engine will Not Start (but Starter Motor Runs)445
Glow Plugs Is Not Heated447
Engine Speed Does Not Change When Operating Throttle Lever449
Propulsion451
Vibration452
No Vibration Occurs 1/3453
No Vibration Occurs 2/3455
No Vibration Occurs 3/3457
Vibratory Drum Cannot be Switched (ROPS)459
Water Spray461
Lighting462
Illumination of Combination Meter Does Not Light463
Combination Meter Warning Lamp or Indicator Lamp Is Abnormal465
Tachometer Reading Is Abnormal465
Hour Meter Is Abnormal467
Fuel Meter Is Abnormal467
Hydraulic Oil Filter Warning Lamp Remains on469
Charge Warning Lamp Remains on469
Vibration Indicator Lamp Does Not Light471
Water Spray Indicator Lamp Does Not Light473
Flood Lamp Indicator Lamp Does Not Light475
Parking Brake Indicator Lamp Does Not Light475
Turn Signal Indicator Lamp Does Not Light477
Hydraulic System Troubleshooting (Sw504)478

Brand	Sakai
Model	TW504
Category	Construction Equipment
Language	English

Sakai TW504 - User Manual

Table of Contents

Sakai TW504 Specifications

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