Sakai Vibrating Roller Sw884/994 Shop Manual PDF

Sakai Vibrating Roller Sw884/994 Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Sakai Vibrating Roller Sw884/994 Shop Manual – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Sakai Vibrating Roller Sw884/994 Shop 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
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
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
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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