Sakai SW880-1 Install guide
SW880-1/990-1
SHOP MANUAL
3498-6568A-0
Introduction
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.
the product information available at the time that the publication was written. The
SW880-1/990-1 ○
0
0-001
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-002
1-002
1-003
1-6. Safety Instructions1-003
1-7. Starting 1-004
1-004
1-9. Stopping1-004
1-005
1-007
2. SPECIFICATIONS
A
1-1. SW880-12-001
1-2. SW990-12-004
S
2-1. Engine2-007
2-007
2-3. Hydraulic System2-007
2-4. Steering 2-008
2-5. Brakes2-008
2-008
N
3-1. Rating 2-009
3-2. Recommended Lubricants2-009
2-010
SW880-1/990-1 ○
0
0-002
3. ENGINE AND CONTROLS
1. ENGINE
3-001
3-002
33-003
T
3-004
4-1-1. Installation of pump 3-005
4. HYDRAULIC SYSTEMS
4-001
4-003
4-004
4-004
4-005
4-006
4-006
4-008
4-010
4-012
4-013
4-013
4-014
4-015
4-016
4-016
4-017
4. STEERING SYSTE
4-019
4-2. Steering Wheel 4-020
4-021
4-021
4-3-2. Steering • charge pump 4-022
SW880-1/990-1 ○
0
0-003
5. ELECTRICAL SYSTEM
1. K
5-001
1-2. Electrical Equipment Installation5-002
5-003
S
3-1. Battery Layout5-004
5-005
5-006
5-007
4. WIRING HARNESSES
5-008
5-010
4-2. Fuse • Relay Harness 5-012
4-3. Engine Harness 5-014
4-4. Battery Harness 5-016
4-5. Front Frame Harness5-018
4-6. F-R Lever Harness 5-020
5-022
5-024
4-9. Floor Bord Harness5-026
4-10. Starter Relay Harness5-028
5-029
5-030
S
5-031
5-032
5-3. Resistor Unit5-033
5-4. Lever Switch5-034
5-5. Fuse Box 5-035
5-036
SW880-1/990-1 ○
0
0-004
6. VIBRATORY DRUM
6-001
6-003
6-008
Y
6-009
6-010
6-023
7. BRAKE
7-001
2. BRAKE7-002
8. OPERATOR STATION
8-001
8-002
9. WATER SPRAY SYSTEM
9-001
10. INSPECTION AND ADJUSTMENT
T
10-001
10-001
10-001
1-4. Warm-up10-001
1-5. Inspection and Adjustment of Engine Related Items10-001
E
10-002
2-2. Adjustment10-003
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 the forward or reverse side deviates from
maximum circuit pressure range 10-004
SW880-1/990-1 ○
0
0-005
E
10-005
3-2. Adjustment10-006
E
10-007
E
10-008
E
10-009
6-2. Inspection 10-010
6-2-1. Inspection of high pressure relief valves installed in vibrator pump 10-010
vibrator valve blocks in vibrator circuit10-011
E
10-012
7-2. Inspection 10-013
E
10-014
8-2. Inspection 10-015
9.
10-016
10-017
10.
10-018
11.
10-019
R
10-020
12-1-1. Adjustment of disc spring tension10-020
12-1-2. Adjustment of steel ball thrust10-021
10-022
12-2-1. Adjustment of potentiometer 1 voltage when F-R lever is in “N”10-022
12-2-2. Adjustment of potentiometer 1 voltage when forward switch operates 10-023
12-2-3. Adjustment of potentiometer 1 voltage when reverse switch operates 10-024
SW880-1/990-1 ○
0
0-006
11. TROUBLESHOOTING
G
11-001
1-2. Important Information for Troubleshooting11-001
1-3. Before Starting 11-002
11-002
G
11-003
11-003
2-1-2. Inspection procedures using a tester 11-004
2-1-3. Inspection of electrical system 11-009
11-011
2-2-1. Fault detection 11-011
2-2-2. Fault lamps 11-011
2-2-3. Flash out of fault codes11-012
2-2-4. Fault code list11-013
11-022
11-022
2-3-2. Error code list11-023
2-4. Engine11-025
11-025
11-027
11-029
11-031
11-033
11-035
11-037
11-039
11-041
11-043
11-045
11-047
11-049
11-051
11-053
11-055
11-057
11-059
SW880-1/990-1 ○
0
0-007
2-4-3. No charging11-061
2-4-4. Grid heater does not work
11-061
2-4-5. Starter motor runs even when F-R lever is not at “N” and
parking brake is not applied11-063
2-4-6. Engine speed cannot be switched 11-063
11-065
11-065
11-067
11-069
11-071
11-073
11-075
11-077
11-079
11-081
11-083
11-085
11-087
11-089
11-091
2-5-3 11-093
2-5-3 11-095
2-5-3 11-097
2-5-3 11-099
2-5-3 11-101
11-103
11-105
2-5-5 11-107
2-5-5 11-109
2-5-5 11-111
2-5-5 11-113
2-5-5 11-115
2-5-5. Auto speed function does not work 11-117
2-5-5 11-119
2-5-5 11-121
2-5-6. Brake cannot be released11-123
2-5-7. Brake does not work11-125
2-5-8. Emergency exit propulsion switch does not work 11-127
SW880-1/990-1 ○
0
0-008
11-129
11-129
11-131
11-133
11-135
11-137
11-139
11-141
11-143
2-6-4. Front and rear vibratory drums cannot perform one-drum vibration11-145
11-147
11-147
11-149
11-151
11-153
11-155
11-157
11-159
11-161
11-163
11-165
11-167
11-169
2-8. Water Spray11-171
11-171
11-173
11-175
11-177
11-179
11-181
does not operate11-183
2-9. Lighting11-185
11-185
11-187
2-9-3. Tachometer reading is abnormal11-189
2-9-4. Hour meter is abnormal 11-189
SW880-1/990-1 ○
0
0-009
2-9-5. Temperature meter is abnormal 11-191
2-9-6. Fuel meter is abnormal 11-191
11-193
11-195
11-197
11-199
2-9-11. Water spray indicator lamp does not light 11-201
11-203
2-9-13. Horn does not sound 11-205
2-7-14. Backup buzzer does not sound11-205
G
11-206
11-207
11-207
11-208
11-208
11-208
11-209
11-209
11-210
3-2-6. Abnormal noise from propulsion system11-210
11-211
3-3-1. No vibration 11-211
11-212
11-212
3-3-4. Amplitude does not switch between high and low11-213
11-213
11-213
3-3-7. Abnormal noise from vibrator system11-214
3-4. Steering System11-215
3-4-1. Steering wheel is hard to turn11-215
3-4-2. Steering response is slow11-215
3-4-3. Steering wheel backlash or play is large 11-216
3-4-4. Steering system is overheating 11-216
3-4-5. Abnormal noise from steering system 11-216
SAFETY
1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
can result in serious personal injury or death.
can result in serious personal injury or death.
may result in moderate personal injury or damage to the machine or
personal property.
machine that may cause damage, breakdown, or shortened service life of
the machine if you fail to observe or important point to maintain of quality in
maintenance works.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
N•m
In the assembly operation, tightening torque in locations that require particular
attention.
1-2. General
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
★
1-002
SAFETY
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
1-3. Qualications of Operators and Maintenance Personnel
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
instructions that are contrary to safety.
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.
1-003
SAFETY
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position and the parking
brake is applied.
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection
• Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly
performed. Repair or replace any malfunctioning, broken or missing parts before using the
• Always clean up any spilled fuel.
repairs have been made and warning tags have been removed by authorized personnel.
mounting hardware is tight.
slipping.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed, gradeability, steering
and braking.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions
• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
functional.
• Always use the hand rails and steps to get on and off your machine maintaining 3-point
1-004
SAFETY
1-7. Starting
• Start the machine only from the driver’s seat and always wear the seat belt.
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
traveling with the machine.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Never climb on and off the machine while it is in motion.
• Always remain seated with the seat belt fastened when traveling, compacting or loading or
unloading the machine.
• Use caution and be very observant when operating in close quarters and congested areas.
compatible with these regulations.
• Never carry passengers.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
when passing under overhead power lines.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
dark.
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground. If this is not possible,
always park at a right angle to the slope and block the drums or tires.
• Lock all lockable compartments.
Other manuals for SW880-1
1
This manual suits for next models
1
Table of contents
Other Sakai Construction Equipment manuals
Sakai
Sakai SW300-1 Install guide
Sakai
Sakai R2-4 Install guide
Sakai
Sakai SW352 User manual
Sakai
Sakai SV410-2 User manual
Sakai
Sakai SV505-1 Series Install guide
Sakai
Sakai SW880-1 User manual
Sakai
Sakai CR271 Install guide
Sakai
Sakai SV540 Series Installation and operation manual
Sakai
Sakai SW800 Series Install guide
Sakai
Sakai SV414 Install guide
Sakai
Sakai SV540 Series Install guide
Sakai
Sakai SW770 Install guide
Sakai
Sakai SV510-III Install guide
Sakai
Sakai SW800-II Install guide
Sakai
Sakai SW354 Install guide
Sakai
Sakai SV400D-2 Install guide
Sakai
Sakai SV204 Series Installation and operation manual
Sakai
Sakai 544 Guide
Sakai
Sakai CR271 Installation and operation manual
Sakai
Sakai SV201-1 Install guide
