Sakai SW800-II/850-II- Shop Manual 3498-65547-0 – PDF DOWNLOAD

Sakai SW800-II/850-II- Shop Manual 3498-65547-0 – PDF DOWNLOAD

FILE DETAILS:

Sakai SW800-II/850-II- Shop Manual 3498-65547-0 – PDF DOWNLOAD

Language : English
Pages :258
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sakai SW800-II/850-II- Shop Manual 3498-65547-0 – 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 SW800- 2-001
1-2 SW850- 2-003
2 TABLE OF STANDARD VALUES
2-1 Engine 2-005
2-2 Propulsion 2-005
2-3 Hydraulic System 2-005
2-4 Steering 2-006
2-5 Brakes 2-006
2-6 Water System 2-006
2-7 Oil and Grease Capacity 2-006
3 FUEL AND LUBRICANTS SPECIFICATION
3-1 Rating 2-007
3-2 Recommended Lubricants 2-007
4 TIGHTENING TORQUE CHART 2-008
3 ENGINE AND CONTROLS
1 ENGINE
1-1 Engine Mount 3-001
1-2 Engine Exterior 3-002
SW800- /850- ○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 (SW800- ) 4-003
1-3 Hydraulic Circuit Diagram (SW850- ) 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 assembly (propulsion + vibrator) 4-007
2-2-2 Propulsion hydraulic motor (front) (SW800- ) 4-009
2-2-3 Propulsion hydraulic motor (front) (SW850- ) 4-011
2-2-4 Propulsion hydraulic motor (rear) (SW800- ) 4-013
2-2-5 Propulsion hydraulic motor (rear) (SW850- ) 4-015
3 VIBRATOR HYDRAULIC SYSTEM
3-1 Vibrator Hydraulic Piping 4-017
3-1-1 Vibrator hydraulic piping (1) 4-017
3-1-2 Vibrator hydraulic piping (2) 4-018
3-2 Hydraulic Component Specifications 4-019
3-2-1 Vibrator hydraulic motor 4-019
3-2-2 Vibration solenoid valve 4-020
4 STEERING SYSTEM
4-1 Steering Hydraulic Piping 4-021
4-1-1 Steering hydraulic piping 4-021
4-2 Hydraulic Component Specifications 4-022
4-2-1 Orbitrol 4-022
4-2-2 Steering pump 4-023
4-3 Frame (Center Pin) 4-024
5 ELECTRICAL SYSTEM
1 ELECTRICAL CIRCUIT
1-1 Electrical Circuit Diagram 5-001
SW800- /850- ○0
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
3-2 Control Box (EMR3) 5-005
3-3 Resistor 5-006
3-4 Combination Meter 5-007
3-5 Diode Unit 5-008
6 VIBRATORY DRUM
1 PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001
2 REMOVAL AND INSTALLATION OF VIBRATORY DRUM
2-1 Removal of Vibratory Drum 6-003
2-2 Installation of Vibratory Drum 6-006
3 VIBRATORY DRUM ASSEMBLY
3-1 Vibratory Drum Assembly (SW800- ) 6-007
3-1-1 Vibratory drum exploded diagram 6-008
3-2 Vibratory Drum Assembly (SW850- ) 6-009
3-2-1 Vibratory drum exploded diagram 6-010
4 DISASSEMBLY AND REASSEMBLY OF VIBRATORY DRUM
4-1 Disassembly of Vibratory Drum 6-011
4-2 Reassembly of Vibratory Drum 6-025
7 BRAKE
1 BRAKE PEDAL 7-001
2 BRAKE CIRCUIT CONFIGURATION 7-002
3 HYDRAULIC COMPONENT SPECIFICATIONS
3-1 Valve 7-003
8 WATER SPRAY SYSTEM
1 WATER SPRAY PIPING 8-001
2 WATER SPRAY COMPONENT SPECIFICATION
2-1 Water Spray Pump 8-002
9 INSPECTION AND ADJUSTMENT
1 INSPECTION AND ADJUSTMENT
1-1 Safety Precautions for Inspection and Adjustment 9-001
1-2 Preparation for Inspection and Adjustment 9-001
SW800- /850- ○0
1-3 Precautions for Inspection and Adjustment 9-001
1-4 Warm-up 9-001
1-5 Inspection and Adjustment of Engine Related Items 9-001
2 MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1 Measurement 9-002
2-2 Adjustment 9-003
2-2-1 If the pressures on both the forward and reverse sides deviate
from the maximum circuit pressure range by the same value 9-003
2-2-2 If the pressure on either the forward or reverse side deviates from
the maximum circuit pressure range 9-004
3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1 Measurement 9-005
3-2 Adjustment 9-006
4 MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1 Measurement 9-007
5 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
5-1 Measurement 9-008
6 MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE
6-1 Measurement 9-009
6-1-1 Measurement of main relief pressure 9-009
6-1-2 Measurement of port relief pressure 9-010
6-2 Adjustment 9-011
6-2-1 Adjustment of the main relief valves 9-011
6-2-2 Adjustment of the port relief valves 9-012
7 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1 Measurement 9-013
7-2 Inspection 9-014
8 ADJUSTMENT OF FORWARD-REVERSE LEVER LINKAGE
8-1 Adjustment 9-015
10 TROUBLESHOOTING
1 TROUBLESHOOTING
1-1 Safety Precautions for Troubleshooting 10-001
1-2 Important Information for Troubleshooting 10-001
1-3 Before Starting 10-002
1-4 Wire Color Code and Number 10-002
2 ELECTRICAL SYSTEM TROUBLESHOOTING
2-1 When Performing Electrical System Fault Diagnosis 10-003
SW800- /850- ○0
2-1-1 Precautions to take during electrical circuit fault diagnosis 10-003
2-1-2 Inspection procedures using a tester 10-004
2-1-3 Inspection of electrical system 10-009
2-2 Blink Codes 10-011
2-2-1 Description of blink codes 10-011
2-2-2 Blink code list 10-012
2-3 Engine 10-017
2-3-1 Engine will not start (starter motor does not run) 1/2 10-017
2-3-1 Engine will not start (starter motor does not run) 2/2 10-019
2-3-2 Engine will not start (But starter motor runs) 10-021
2-3-3 No charging 10-023
2-3-4 Engine speed cannot be switched 10-023
2-3-5 Glow plug is not heated (Engine starting performance is bad
in cold weather) 10-025
2-3-6 Starter motor runs even when F-R lever is not at neutral position 10-025
2-4 Propulsion 10-027
2-4-1 Vehicle moves neither forward nor backward 10-027
2-4-2 Brake cannot be released 10-029
2-4-3 Brake does not operate 10-031
2-5 Vibrator 10-033
2-5-1 No vibration occurs 10-033
2-5-2 Amplitude does not change (Remains either Low or High) 10-035
2-5-3 Vibration frequency does not change 1/4 10-037
2-5-3 Vibration frequency does not change 2/4 10-039
2-5-3 Vibration frequency does not change 3/4 10-041
2-5-3 Vibration frequency does not change 4/4 10-043
2-5-4 Continuous/automatic-vibration mode does not change 10-045
2-5-5 Automatic-vibration mode does not work 1/2 10-047
2-5-5 Automatic-vibration mode does not work 2/2 10-049
2-6 Water Spray 10-051
2-6-1 Continuous water spray does not operate 1/2 10-051
2-6-1 Continuous water spray does not operate 2/2 10-053
2-6-2 Continuous water spray works, but intermittent water spray
does not operate 10-055
2-7 Lighting 10-057
2-7-1 Headlamps or flood lamps do not light 10-057
2-7-2 Illumination of combination meter does not turn on 10-059
2-7-3 Combination meter warning lamp or indicator lamp is abnormal 10-059
2-7-4 Tachometer reading is abnormal 10-061
SW800- /850- ○0
2-7-5 Hour meter is abnormal 10-063
2-7-6 Temperature gauge is abnormal 10-063
2-7-7 Fuel gauge is abnormal 10-065
2-7-8 Hydraulic oil filter warning lamp remains ON 10-065
2-7-9 Charge warning lamp remains ON 10-067
2-7-10 Vibrator indicator lamp does not light 1/2 10-067
2-7-10 Vibrator indicator lamp does not light 2/2 10-069
2-7-11 Parking brake indicator lamp does not light 10-069
2-7-12 Water spray indicator lamp does not light 10-071
2-7-13 Flood lamp indicator lamp does not light 10-071
2-7-14 Horn does not sound 10-073
2-7-15 Backup buzzer does not sound 10-073
3 HYDRAULIC SYSTEM TROUBLESHOOTING
3-1 When Performing Hydraulic System Troubleshooting 10-074
3-2 Propulsion 10-075
3-2-1 Vehicle moves neither forward nor backward 1/2 10-075
3-2-1 Vehicle moves neither forward nor backward 2/2 10-076
3-2-2 Vehicle moves in one direction only (forward or backward) 10-076
3-2-3 Slow vehicle speed or small drive force 10-076
3-2-4 Vehicle does not stop completely with forward-reverse lever
in neutral position 10-077
3-2-5 Propulsion system is overheating 10-077
3-2-6 Abnormal noise from propulsion system 10-077
3-3 Vibrator System 10-078
3-3-1 No vibration 10-078
3-3-2 Vibrator frequency does not change 10-078
3-3-3 Vibrator frequency is too low 10-079
3-3-4 Amplitude does not switch between high and low 10-079
3-3-5 Vibrator does not stop 10-079
3-3-6 Vibrator system is overheating 10-080
3-3-7 Abnormal noise from vibrator system 10-080
3-4 Steering 10-081
3-4-1 Steering wheel is hard to turn 10-081
3-4-2 Steering response is slow 10-081
3-4-3 Steering wheel backlash or play is large 10-082
3-4-4 Steering system is overheating 10-082
3-4-5 Abnormal noise from steering system 10-082

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