Sakai SW884/994 SHOP MANUAL 3498-6568B-0 – PDF DOWNLOAD

Sakai SW884/994 SHOP MANUAL 3498-6568B-0 – PDF DOWNLOAD

FILE DETAILS:

Sakai SW884/994 SHOP MANUAL 3498-6568B-0 – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Sakai SW884/994 SHOP MANUAL 3498-6568B-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. 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
SW884/994 ○0
0-002
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
SW884/994 ○0
0-003
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
SW884/994 ○0
0-004
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
SW884/994 ○0
0-005
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
SW884/994 ○0
0-006
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
SW884/994 ○0
0-007
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
SW884/994 ○0
0-008
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
SW884/994 ○0
0-009
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
SW884/994 ○0
0-010
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

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Sakai SW884994 SHOP MANUAL 3498-6568B-0