Sakai Asphalt Roller SW884/994 Service Manual – PDF

Sakai Asphalt Roller SW884/994 Service Manual – PDF DOWNLOAD

The Sakai Asphalt Roller SW884/994 Service Manual PDF provides comprehensive instructions for maintenance, repair, and troubleshooting of Sakai SW884 and SW994 asphalt rollers. It includes diagrams, specifications, and procedures to ensure optimal performance and longevity of the equipment.

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Sakai Asphalt Roller SW884/994 Service Manual – PDF DOWNLOAD

Language : English
Pages : 518
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Sakai Asphalt Roller SW884/994 Service Manual – PDF DOWNLOAD

• 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 modifications of the model.

TABLE OF CONTENTS:

Sakai Asphalt Roller SW884/994 Service Manual – PDF DOWNLOAD

1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words 1-001
1-2. General 1-001
1-3. Qualifications 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. SW884 2-001
1-2. SW994 2-003
1-3. SW884ND 2-005
1-4. SW994ND 2-007
1-5. Common Specifications 2-009
2. TABLE OF STANDARD VALUES
2-1. Engine 2-010
2-2. Propulsion 2-010
2-3. Hydraulic System 2-010
2-4. Steering 2-011
2-5. Brakes 2-011
2-6. Capacities 2-011
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating 2-012
3-2. Recommended Lubricants 2-012
4. TIGHTENING TORQUE CHART 2-013
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount 3-001
2. FUEL SYSTEM 3-002
3. EXHAUST SYSTEM
3-1. Exhaust System 3-004
3-1-1. DRT ASSY 3-005
3-1-2. SCR ASSY 3-006
3-2. Urea Piping 3-007
4. CONTROL SYSTEM
4-1. Forward-reverse Control 3-008
5. PUMP MOUNT
5-1. Pump Mount 3-009
5-1-1. Installation of pump 3-010
4. HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM
1-1. Graphic Symbols for Hydraulic Circuits 4-001
1-2. Hydraulic Circuit Diagram 4-003
1-2-1. Hydraulic circuit diagram (SW884/994) 4-003
1-2-2. Hydraulic circuit diagram (SW884ND/994ND) 4-004
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping 4-005
2-1-1. Propulsion hydraulic piping (1) 4-005
2-1-2. Propulsion hydraulic piping (2) 4-006
2-2. Hydraulic Component Specifications 4-007
2-2-1. Hydraulic pump ASSY (propulsion + vibrator) 4-007
2-2-2. Propulsion hydraulic motor (F) 4-009
2-2-3. Propulsion hydraulic motor (R) 4-011
2-2-4. Neutral solenoid valve 4-013
2-2-5. Parking brake solenoid valve 4-014
2-3. Description and Operation of Propulsion System 4-016
3. VIBRATOR HYDRAULIC SYSTEM
3-1. Vibrator Hydraulic Piping 4-019
3-1-1. Vibrator hydraulic piping (SW884/994) 4-019
3-1-2. Vibrator hydraulic piping (SW884ND/994ND) 4-020
3-2. Hydraulic Component Specifications 4-021
3-2-1. Vibrator hydraulic motor (SW884/994) 4-021
3-2-2. Vibrator hydraulic motor (SW884ND/994ND) 4-022
3-2-3. Flush and boost pressure valve 4-023
3-3. Description and Operation of Vibrator System 4-025
4. STEERING SYSTEM
4-1. Steering Hydraulic Piping 4-026
4-2. Steering Wheel 4-027
4-3. Hydraulic Component Specifications 4-028
4-3-1. Steering • charge pump 4-028
4-3-2. Orbitrol 4-029
4-4. Description and Operation of Steering System 4-031
4-4-1. Description and operation of steering system 4-031
4-4-2. Structure and operation of Orbitrol 4-032
5. ELECTRICAL SYSTEM
1. Precautions for wor k
1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in
Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses 5-001
1-2. Electrical Equipment Installation 5-002
2. SYSTEM CIRCUIT DIAGRAM
2-1. Electrical Circuit Diagram (SW884/994) 5-003
2-2. Electrical Circuit Diagram (SW884ND/994ND) 5-004
3. ELECTRICAL COMPONENTS
3-1. Wiring Harness Layout (1) 5-005
3-2. Wiring Harness Layout (2) 5-006
3-3. Wiring Harness Layout (3) 5-007
3-4. Wiring Harness Layout (4) 5-008
4. WIRING HARNESSES
4-1. Main Harness 5-009
4-1-1. Main harness (1) 5-009
4-1-2. Main harness (2) 5-011
4-1-3. Main harness (3) 5-013
4-2. Fuse • Relay Harness 5-015
4-3. Engine Harness 5-017
4-4. Hydraulic Pump Harness 5-018
4-5. ECM Harness 5-019
4-5-1. ECM harness (1) 5-019
4-5-2. ECM harness (2) 5-021
4-6. Battery Harness 5-023
4-7. F-R Lever Harness 5-025
4-8. Panel (L) Harness 5-027
4-9. Panel (R) Harness 5-029
4-10. Water Spray Pump (R) Harness 5-031
4-11. Frame (F) Harness 5-032
4-12. Floor Board Harness 5-033
4-13. Solenoid Harness 5-034
4-14. SCR Harness 5-035
4-15. DRT Harness 5-036
4-16. Backup Buzzer Harness 5-037
4-17. Horn Harness 5-038
5. ELECTRICAL COMPONENT SPECIFICATIONS
5-1. Potentiometer 5-039
5-2. Exact Meter 5-040
5-3. Resistor Unit 5-041
5-4. Lever Switch 5-042
5-5. Fuse Box (1) 5-043
5-6. Fuse Box (2) 5-044
5-7. Combination Meter 5-045
6. VIBRATORY DRUM
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 6-008
3. VIBRATORY DRUM ASSY (SW884/994)
3-1. Vibratory Drum ASSY 6-009
3-2. Disassembly and Reassembly of Vibratory Drum 6-010
3-2-1. Disassembly of vibratory drum 6-010
3-2-2. Reassembly of vibratory drum 6-023
4. VIBRATORY DRUM ASSY (SW884ND/994ND)
4-1. Vibratory Drum ASSY 6-046
4-2. Disassembly and Reassembly of Vibratory Drum 6-047
4-2-1. Disassembly of vibratory drum 6-047
4-2-2. Reassembly of vibratory drum 6-059
7. BRAKE
1. BRAKE PEDAL 7-001
2. BRAKE SYSTEM 7-003
2-1. Description and Operation of Brake Circuit 7-003
8. OPERATOR STATION
1. FLOORBOARD
1-1. Structure of Operator Station 8-001
1-2. Adjustment of Swivel Lock Release Pedal 8-002
9. WATER SPRAY SYSTEM
1. WATER SPRAY PIPING 9-001
10. INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT
1-1. Safety Precautions for Inspection and Adjustment 10-001
1-2. Preparation for Inspection and Adjustment 10-001
1-3. Precautions for Inspection and Adjustment 10-001
1-4. Warm-up 10-001
1-5. Inspection and Adjustment of Engine Related Items 10-001
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement 10-002
2-2. Adjustment 10-003
2-2-1. If pressures on both forward and reverse sides deviate from maximum
circuit pressure range by same value 10-003
2-2-2. If pressure on either forward or reverse side deviates from maximum
circuit pressure range 10-004
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE 10-005
3-1. Measurement 10-005
3-2. Adjustment 10-006
4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1. Measurement 10-007
5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 10-008
5-1. Measurement 10-008
6. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE
6-1. Measurement 10-009
6-2. Adjustment 10-010
7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT
PRESSURE 10-011
7-1. Measurement 10-011
7-2. Adjustment 10-012
8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
8-1. Measurement 10-013
8-2. Inspection 10-014
9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
9-1. Measurement of Propulsion Pump Case Pressure 10-015
9-2. Measurement of Vibrator Pump (F) Case Pressure 10-016
9-3. Measurement of Vibrator Pump (R) Case Pressure 10-017
10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
10-1. Measurement 10-018
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE
11-1. Measurement (SW884/994) 10-019
11-2. Measurement (SW884ND/994ND) 10-020
12. ADJUSTMENT OF F-R LEVER POTENTIOMETER
12-1. Adjustment of F-R Lever Operating Force 10-021
12-1-1. Adjustment of disc spring tension 10-021
12-1-2. Adjustment of steel ball thrust 10-022
12-2. Adjustment of Potentiometer 10-023
12-2-1. Adjustment of potentiometer 1 voltage when F-R lever is in “N” 10-023
12-2-2. Adjustment of potentiometer 1 voltage when F-R lever switch
operates 10-024
12-2-3. Adjustment of potentiometer 1 voltage when backup buzzer switch
operates 10-025
11. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting 11-001
1-2. Important Information for Troubleshooting 11-001
1-3. Before Starting 11-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING
2-1. When Performing Electrical System Fault Diagnosis 11-003
2-1-1. Precautions to take during electrical circuit fault diagnosis 11-003
2-1-2. Inspection procedures using a tester 11-004
2-1-3. Inspection of electrical system 11-009
2-2. Engine Diagnosis Trouble Code 11-011
2-2-1. Description of fault code (SPN,FMI) 11-011
2-2-2. Fault code list 11-012
2-3. Error Codes 11-033
2-3-1. Description of error codes 11-033
2-3-2. Error code list 11-033
2-4. Engine 11-036
2-4-1. Engine will not start (Starter motor does not run) 1/15 11-036
2-4-1. Engine will not start (Starter motor does not run) 2/15 11-038
2-4-1. Engine will not start (Starter motor does not run) 3/15 11-040
2-4-1. Engine will not start (Starter motor does not run) 4/15 11-042
2-4-1. Engine will not start (Starter motor does not run) 5/15 11-044
2-4-1. Engine will not start (Starter motor does not run) 6/15 11-046
2-4-1. Engine will not start (Starter motor does not run) 7/15 11-048
2-4-1. Engine will not start (Starter motor does not run) 8/15 11-050
2-4-1. Engine will not start (Starter motor does not run) 9/15 11-052
2-4-1. Engine will not start (Starter motor does not run) 10/15 11-054
2-4-1. Engine will not start (Starter motor does not run) 11/15 11-056
2-4-1. Engine will not start (Starter motor does not run) 12/15 11-058
2-4-1. Engine will not start (Starter motor does not run) 13/15 11-060
2-4-1. Engine will not start (Starter motor does not run) 14/15 11-062
2-4-1. Engine will not start (Starter motor does not run) 15/15 11-064
2-4-2. No charging 11-066
2-4-3. Grid heater does not work
(Engine starting performance is bad in cold weather) 11-066
2-4-4. Starter motor runs even when F-R lever is not at “N”
and parking brake is not applied 11-068
2-4-5. Engine speed cannot be switched 11-070
2-5. Propulsion 11-072
2-5-1. Machine and engine suddenly stops 1/9 11-072
2-5-1. Machine and engine suddenly stops 2/9 11-074
2-5-1. Machine and engine suddenly stops 3/9 11-076
2-5-1. Machine and engine suddenly stops 4/9 11-078
2-5-1. Machine and engine suddenly stops 5/9 11-080
2-5-1. Machine and engine suddenly stops 6/9 11-082
2-5-1. Machine and engine suddenly stops 7/9 11-084
2-5-1. Machine and engine suddenly stops 8/9 11-086
2-5-1. Machine and engine suddenly stops 9/9 11-088
2-5-2. Machine and engine suddenly stops in automatic speed mode 1/2 11-090
2-5-2. Machine and engine suddenly stops in automatic speed mode 2/2 11-092
2-5-3. Machine moves neither forward nor backward 1/6 11-094
2-5-3. Machine moves neither forward nor backward 2/6 11-096
2-5-3. Machine moves neither forward nor backward 3/6 11-098
2-5-3. Machine moves neither forward nor backward 4/6 11-100
2-5-3. Machine moves neither forward nor backward 5/6 11-102
2-5-3. Machine moves neither forward nor backward 6/6 11-104
2-5-4. Machine speed cannot be changed 11-106
2-5-5. Auto speed function does not work 1/10 11-108
2-5-5. Auto speed function does not work 2/10 11-110
2-5-5. Auto speed function does not work 3/10 11-112
2-5-5. Auto speed function does not work 4/10 11-114
2-5-5. Auto speed function does not work 5/10 11-116
2-5-5. Auto speed function does not work 6/10 11-118
2-5-5. Auto speed function does not work 7/10 11-120
2-5-5. Auto speed function does not work 8/10 11-122
2-5-5. Auto speed function does not work 9/10 11-124
2-5-5. Auto speed function does not work 10/10 11-126
2-5-6. Brake cannot be released 11-128
2-5-7. Brake does not work 11-130
2-5-8. Emergency exit propulsion switch does not work 11-132
2-6. Vibration 11-134
2-6-1. No vibration occurs 1/5 11-134
2-6-1. No vibration occurs 2/5 11-136
2-6-1. No vibration occurs 3/5 11-138
2-6-1. No vibration occurs 4/5 11-140
2-6-1. No vibration occurs 5/5 11-142
2-6-2. Vibration frequency cannot be switched (SW884/994) 1/3 11-144
2-6-2. Vibration frequency cannot be switched (SW884/994) 2/3 11-146
2-6-2. Vibration frequency cannot be switched (SW884/994) 3/3 11-148
2-6-3. Vibration type cannot be switched (SW884ND/994ND) 1/2 11-150
2-6-3. Vibration type cannot be switched (SW884ND/994ND) 2/2 11-152
2-6-4. Continuous/automatic vibration mode cannot be switched 1/2 11-154
2-6-4. Continuous/automatic vibration mode cannot be switched 2/2 11-156
2-6-5. Front and rear vibratory drums cannot perform one-drum vibration 11-158
2-7. Exact Meter 11-160
2-7-1. Exact meter indicator lamp does not illuminate while driving 1/10 11-160
2-7-1. Exact meter indicator lamp does not illuminate while driving 2/10 11-162
2-7-1. Exact meter indicator lamp does not illuminate while driving 3/10 11-164
2-7-1. Exact meter indicator lamp does not illuminate while driving 4/10 11-166
2-7-1. Exact meter indicator lamp does not illuminate while driving 5/10 11-168
2-7-1. Exact meter indicator lamp does not illuminate while driving 6/10 11-170
2-7-1. Exact meter indicator lamp does not illuminate while driving 7/10 11-172
2-7-1. Exact meter indicator lamp does not illuminate while driving 8/10 11-174
2-7-1. Exact meter indicator lamp does not illuminate while driving 9/10 11-176
2-7-1. Exact meter indicator lamp does not illuminate while driving 10/10 11-178
2-7-2. No vehicle speed indication on display 1/3 11-180
2-7-2. No vehicle speed indication on display 2/3 11-182
2-7-2. No vehicle speed indication on display 3/3 11-184
2-8. Water Spray 11-186
2-8-1. Continuous water spray does not operate 1/4 11-186
2-8-1. Continuous water spray does not operate 2/4 11-188
2-8-1. Continuous water spray does not operate 3/4 11-190
2-8-1. Continuous water spray does not operate 4/4 11-192
2-8-2. Continuous water spray works,
but intermittent water spray does not operate 1/2 11-194
2-8-2. Continuous water spray works,
but intermittent water spray does not operate 2/2 11-196
2-8-3. Continuous water spray works,
but automatic water spray does not operate 11-198
2-9. Lighting 11-200
2-9-1. Head lamp and flood lamp do not light 11-200
2-9-2. Illumination of combination meter does not light 11-202
2-9-3. Hour meter is abnormal 11-204
2-9-4. Fuel meter is abnormal 11-204
2-9-5. Hydraulic oil filter warning lamp remains ON 11-206
2-9-6. Vibration indicator lamp does not light 11-208
2-9-7. Water spray indicator lamp does not light 11-210
2-9-8. ECO mode indicator lamp does not light 11-212
2-9-9. Parking brake indicator lamp does not light 11-212
2-9-10. Horn does not sound 11-214
2-9-11. Backup buzzer does not sound 11-214
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 11-215
3-2. Propulsion System 11-216
3-2-1. Machine moves neither forward nor backward 1/2 11-216
3-2-1. Machine moves neither forward nor backward 2/2 11-217
3-2-2. Machine moves in one direction only (forward or backward) 11-217
3-2-3. Slow machine speed or small drive force 1/2 11-217
3-2-3. Slow machine speed or small drive force 2/2 11-218
3-2-4. Machine speed cannot be switched 11-218
3-2-5. Machine does not stop completely with F-R lever in “N” 11-218
3-2-6. Propulsion system is overheating 11-219
3-2-7. Abnormal noise from propulsion system 11-219
3-3. Vibrator System 11-220
3-3-1. No vibration 11-220
3-3-2. Vibration wheel does not switch 11-221
3-3-3. Vibrator frequency is too low 1/2 11-221
3-3-3. Vibrator frequency is too low 2/2 11-222
3-3-4. Vibration mode does not switch 11-222
3-3-5. Vibratory drum does not changeover vibrating 11-222
3-3-6. Vibrator does not stop 11-222
3-3-7. Vibrator system is overheating 11-223
3-3-8. Abnormal noise from vibrator system 11-223
3-4. Steering System 11-224
3-4-1. Steering wheel is hard to turn 11-224
3-4-2. Steering response is slow 11-224
3-4-3. Steering wheel backlash or play is large 11-225
3-4-4. Steering system is overheating 11-225
3-4-5. Abnormal noise from steering system 11-225