Sakai SW300 Installation and operation manual

No. 3498-35580-A
A Read this handbook thoroughly and understand the whole information
contained before trying
to operate, inspect and service your machine!
OPERATING &
MAINTENANCE
INSTRUCTIONS
MODEL
SW300
SW32 0
SW33 0
From SW300 ~ VSW22 ~ 20101
SW320 ~ VSWf23 ~ 20101
SW330 ~ VSW24 ~ 20101
SAKAI®

[ CONTENTS
CONTENTS
PREFACE
MACHINE
AND ENGINE IDENTIFICATION NUMBERS 1
SAFETY NOTiCES.................. 2
1. BASIC PRECAUTIONS FOR SAFETY
1
.1 General Precautions 4
1.2 Preparation for Safe Operation............................................. 6
1.3 Before Starting the Engine.......... 7
1.4 After Starting the Engine.... 8
·1.5 Di.Jring·operation : .. : ~ 8
1.6 Loading and Unloading 10
1.7 Transportation : :
11
1.8 Handling the Battery.; ~ , 11
1.9 Towing : 12
1.10 Before Servicing 13
1.11 During Servicing 14
1.12 Safety Decals 16
2. OPERATION
2.1 Instruments and Controls 18
2.1 .1 Operator's station 18
2.1.2 Gauges, indicator lamps and warning lamps 19
2.1.3 Switches 21
2.1.4 Operating levers and pedals 24
2.1.5 Fuse box 25
2.2 Handling and Adjustments : : 25
2.2.1 Seat adjustment. 25
2.2.2 Scraper adjustment and replacement.. 26
2.2.3 Disengaging the brake when towing 26
2.3 Operation 27
2.3.1 Before-starting inspection ; 27
2.3.2 Startinglhe·engine 28
2.3.3 After starting the engine
29
2.3.4 Ti·avelit"lg 30
2.3.5 Stopping / Parking
31
2.3.6 Stopping the Engine 32
2.3.7 Check after Stopping the Engine 32
2.4 Vibratory Operation 33

PREFACE]
PREFACE
This operator's manual serves as a guide for the use of your Sakai SW300,SW320, SW330
Vibrating Roller for those who are new to the machine, and also for the people who have
experience
in using the Machine and want to refresh their knowledge for the machine.
Read this manual thoroughly and try to fully understand the information before operating your
machine. Keep this handbook at hand whenever you do your work.
The main subjects of this manual are:
(1) Basic precautions for safety,
(2) Operation, (3) Daily maintenance and (4) Specifications.
For operation and maintenance
of the engine, refer to the Engine Instruction Manual
furnished separately. Descriptions
in this manual can differ from the machine instructions of
your machine due to the results of the investigation and improvement
in its design. If you
have any inquiry regarding your Machine or this manual, contact our distributors.
FRONT
~
LEFT REAR
SW300,320,330
o
RIGHT
<;;;J

I CONTENTS
2.5 Sprinkler 34
2.6 Precautions for Work 36
2.6.1 Compaction operation 36
2.6.2 When going downhill 36
2.6.3
On a slope 36
2.7 Applicable Jobs 37
2.8 After Operation
37
2.9 Loading and Unloading 38
2.9.1 Use of a trailer equipped with a winch 38
2.9.2 Self-propelling
39
2.9.3 Use of a hoist. 40
2.10 After Loading the Machine
.41
2.11 Transportation 41
2.12 Operation in Cold Weather .41
2.12.1 Fuel oil and grease .41
2.12.2 Coolant 42
2.12.3 Battery 43
2.13 When the Cold Season
is Over .43
2.14 For a Long Storage Period .44
2.15 During the Storage Period .44
2.16 When the Battery Has Discharged
.45
2.16.1 Connection and disconnection of booster cables .46
3. PERIODICAL MAINTENANCE
3.1 Precautions 47
3.2 Walk-Around Checking
51
3.3 Periodical Maintenance Points 52
3.4 Maintenance Procedure 54
(1) Every 10 hours or daily 54
(2) Every 100 hours 56
(3) Every 500 hours 57
(4) Every 1000 ~lours 59
(5) As required 69
3.5 Feeding Water and Lubricants ,
72
3.6 Electric Wiring Diagram 74
4. SPECIFICATIONS 76

MACHINE AND ENGINE IDENTIFICATION NUMBERS
MACHINE AND ENGINE IDENTIFICATION NUMBERS
When ordering parts or making inquiries about your machine, the following information is
requested:
(1) Machine model
Indicated on the dashboard in the operator's station.
~[~
MODEL_ •
CHASSIS NO. __
SAKAI HEAVY INDUST~IES, ~TD.
(2) Machine serial number
SW300 ¢ VSW22....()CXXXJ
SW320 ¢ VSW23....()CXXXJ
SW330 ¢ VSW24....()CXXXJ
(3) Engine serial number
-1-

[ SAFETY NOTICES
SAFETY NOTICES
For the safe use of your machine, correct handling and periodical maintenance are of utmost
importance. Thoroughly read the safety precautions described
in this manual. Do not attempt
to operate and maintain your machine until you gain a full understanding of these safety
statements.
This manual covers the proper and safe method of driving and handling of this machine for its
intended use. When this machine
is used a manner, other than that covered in this manual,
you must assume responsibility for your own personal safety.
In this manual and on the machine, you will find safety notices. Each safety notice starts with
a signal word as shown below:
A DANGER Denotes that there
is an extreme hazard. If you fail to
take proper precautions, it
is highly likely that you could
be killed or seriously injured (The color of the symbol A
is red).
A WARNING Denotes that there is a hazard. If you fail to take proper
precautions, you could be killed or seriously injured
(Symbol A
is orange).
A CAU1"ION
Calls attention to safety practices. If you fail to take
proper precautions, you could be injured
or cause
damage to the machine (Symbol A
is yellow).
-2-

ISAFETY NOTICES
It is almost impossible for the safety notices in this manual and or the machine to cover all
the potential dangers. Keep alert to possible dangers not mentioned
in this manual and on
the decales.
A WARNING
Do n()t operate your machine before you read its operator's
manual thoroughly.
Incorrect"operation can kill
or cause injury.
It is your responsibility to operate the machine safely.
*,Non-approved modifications can pose safety-related problems. Before making any
modifications, consult your distributor. For an injury or damage to the machine caused by
non-approved modifications, Sakai accepts
no responsibility.
*' Basic precautions for safe operation of your machine are discussed beginning on page 4.
*' To operate and work with your machine, you must be qualified.
-3-

A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECAUTIONS FOR SAFETY I
1. BASIC PRECAUTIONS FOR SAFETY
1.1 General Precautions
• Read thoroughly the operator's manual.
• Understand the functions of the controls and gauges.
Familiarize yourself with
their location and how to
operate them. Understand the meaning of all the
symbols.
• Obey the worksite rules.
• Follow the worksite rules such as matters forbidden or to be attended to, and working
procedures.
• Wear protective clothing to suit the work.
• Wear clothing, safety shoes and hard hat to suit your work.
• Do not wear clothing and accessories that tend to get caught
in the controls or protruded
portions of the machine.
Do not wear oily clothing.
• According to the type of jobs, wear safety goggles or mask.
W
~
~~i51l
F>
• Know the work area in advance.
• Know the terrain, geology and conditions of the road surface at the worksite. Start working
after securing safety such as stationing a guardsman or putting
up barriers where there is
a risk of falling of the machine or collapse of shoulder.
• Provide against an accident.
• Decide in advance the means of communication in an emergency. Know the location and
use of an extinguisher and first-aid kit.
• Know the capability of the machine.
• Thoroughly understand the performance of your machine and correctly operate the
machine to meet the requirements of the job site. Operating the machine beyond its
capabilities may lead to
an accident. Use your machine within its capability.

A WARNING: Negligence of these instructions can lead to accidents.
I 1. BASIC PRECAUTIONS FOR SAFETY
• Do not use a machine which has not been serviced correctly at regular intervals.
• Before working, perform necessary inspections. Start operation only after making certain
the machine is in good operating condition. If found to be abnormal, report to the
responsible person and have the fault corrected. Operate the machine after making sure
that
it is safe to operate.
• Do
not allow anyone to enter the work area except for authorized personnel.
• Always
conduct the work paying attention to the
workers around the machine.
• Be careful
of hot parts.
• After your machine has operated for some time, the
coolant, engine oil and hydraulic fluid will become hot
and the pressure will build up. If, in this state, you try to
remove the filler caps, drain the
oil or replace the filters,
you can get burned. Perform this work in accordance
with the correct procedures with the machine cooled
down.
•
To remove the radiator cap, slowly loosen the cap to
relieve the pressure with the engine shut down and the
coolant cooled down. (For the radiator cap with a
lever,
lift the lever to release the trapped pressure.)
• When removing the filler cap
on the hydraulic tank, release the trapped pressure by turning
it out slowly to prevent the oil from gushing out.
•
Do not touch the muffler while the engine is running or immediately after it has been shut
down.
You can get burned.
• Be careful
with fire.
• The fuel, oil, and anti-freeze will catch fire if open
flames or ignition sources are used close to them.
Particularly, the fuel
is highly flammable. £
•
Do not smoke or use a match or cigarette lighter close
to inflammables (combustibles).
• When refueling, stop the engine and do not smoke.
• The filler caps of the fuel and oil tanks must be kept
tight.
88

I
A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECAUTIONS FOR SAFETY
• Mount on or dismount from your machine after it has come to a complete stop.
• For getting on and off, face the machine and use the handrail and step.
• Do not jump on or off a machine, particularly when it is moving.
• To handle the hydraulic fluid.
• Wear safety goggles to protect your eyes from contact A
with hydraulic fluid. It can irritate your eyes.
If the fluid contacts your eyes, flush with clean water for
~
15 minutes and get medical aid.
• The fluid can also irritate your skin. When handling
it,
wear rubber gloves to avoid contact with it. In case of
skin contact, wash with soap and water.
•
Be careful not to swallow the fluid. It can cause
diarrhea and emesis. ,
If swallowed, do not
try to vomit. Get medical help
immediately.
1.2 Preparation for Safe Operation
• Clean the step, operator's station and floor board.
• Do not place parts, tools or unnecessary articles on the step, operator's station and floor
board.
• Keep the step, floor board, controls and handholds free from muds, oil, ice or water, as
they can cause slippage. Repair them if found to be damaged. Tighten loose bolts.
• Keep your boot soles free of oil or muds. They can slip, leading to
an accident.
• Inspectyour machine before operation
• Check your machine for damage such as cracks and deformation. If found to be abnormal,
operate the machine after taking a proper measure to secure safety.
• Check the level of fluids (fuel, engine oil, coolant, anti-freeze and hydraulic oil). Add as
necessary.
• Check the area where the machine has parked for signs of leakage of oil, fuel and water. If
any leakage is noticeable, determine the cause·and make corrections immediately.

I
A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECAUTIONS FOR SAFETY
• Know the stopping distance.
• When traveling on a road, bear
in mind the stopping
distance. Avoid excessive speed, and abrupt starting
and stopping, and moving
in a zigzag direction.
1.3 Before Starting the Engine
• Adjust the operator's seat to your most effective operating position.
• Sit on the operator's seat. Adjust the seat so that your back will make contact with the seat
back when the brake pedal is depressed to the full extent. Check to be sure that the brake
pedal can be fully depressed without difficulty when you twist your body for reverse
run.
• Secure good visibility (with canopy)
• Keep the windowpane clean.
• Lock the windows and doors no matter whether they are open or closed.
•
Do not leave the doors half-closed.
• Secure forward and backward visibilities.
• Adjust the rear view mirrors and under mirrors for good visibility. If dirty, clean them. If
damaged, replace.
• Check that the horn, lamps and gauges work correctly.
• Before
starting, make certain that each lever is in the neutral position and the
parking brake is applied.
• When starting, sound the horn.
• Before starting the engine. Make sure there is no one
in the immediate vicinity and there are no obstructions
around the machine.
~
-7-

I
A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECAUTIONS FOR SAFETY
• Pay attention to ventilation.
• Exhaust fumes are dangerous if breathed in. When
starting the engine
in an enclosed area, provide good
ventilation
wit~1 windows and doors opened.
~!i:i!{:i:_!ii}r
• Do
not stand close to the exhaust gas pipe opening.
• Exhaust fumes are noxious if breathed
in.
1.4 After Starting the Engine
• Secure safety around the machine.
• Ensure that the area around the machine is clear of
personnel and obstructions.
Pay particular attention to
dead spaces. Before starting, sound the horn.
~
• Warm up the Engine
• Do not put your machine into motion immediately after the engine has started, let it idle for
several minutes until it is at operating temperature.
• Have a
trial run.
• Make a test run
in a safe place to check that there are no abnormal signs. If found to be
abnormal, rectify the fault before traveling again.
• Listen for unusual sounds, and check for abnormal temperature rise. If abnormal, park the
machine
in a safe location and find the source of trouble before operating.
1.5 During Operation
• No other person but the operator
• This machine is a one-man roller. Do not allow anyone to get on. Only the operator is
allowed
on this machine while it is running or in operation. Radios are not permitted.
• Before
mounting, be sure areas around the machine are safe.
• Before getting
on the machine, make certain that there are no obstacles around the
machine and
no workers under it. Hsome workers are present or close to the machine, tell
them
thatthe machine is about to move, warning them to stay away from it.
-8-

A WARNING: Negligence of these instructions can lead to accidents.
I 1. BASIC PRECAUTIONS FOR SAFETY
• Do not try to get on or off a moving machine.
• Get on or off the machine after making sure it has come to a complete stop.
.....
.....
• To go uphill or downhill, run at low speeds. Do
not attempt to shift speeds while traveling on a
grade.
• Shifting speeds on a slope can cause unexpected
running down the slope.
,. -.......;
• Going down hill at speeds other than low range can
~-.
•... ..• """-----
cause the machine to
run down violently.
• Refrain from inattentive driving.
• Inattentive driving or driving relying on guess work can cause an accident. Use extreme
care for workers present
in the path of the roller or around it. In case of danger, stop and
sound the horn, and proceed when the area is clear of personnel or obstructions.
• When changing the direction of travel, secure the safety on the path in the travel
direction.
• Keep everyone away from the pinch points.
• When making turns, do not allow anyone to come close
to the pinch point.
• At night, carefully drivethe machine.
• Nighttime driving tends to frustrate the sense of distance. Carefully drive the machine at a
speed suited to illumination. Keep the headlamps and flood lamps lighted. If necessary,
provide extra lighting
in the work area.
• Repair as soon as possible if found to be defective.
• If the machine is found to be faulty, stop the machine and repair. Do not operate the
machine until the problem
is corrected. When any warning lamp indicates faulty operation,
inspect the machine after moving it to the nearest safe location.
-9-

I
A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECAUTIONS FOR SAFETY
• Do not operate the machine except from the operator's seat. Do not drive in a
standing posture.
• While
making turns, do not run at abnormally high speed and do not turn the
steering wheel abruptly and sharply.
• For the traveling on structures such as a bridge, make certain that they can support
your machine. Before traveling on the structure, you must know the load capacity
of
the structure and the load weight of the machine you are operating to insure safe
travel across the structure.
• Do
not make turns on a slope and do not travel across sidehill. If necessary to do
so, go down straight along the slope to the flat ground, move sideways and go up
straight to the destination.
x
• When parking.
• Select level and hard ground. lof necessary to park on a
slope, block the front of the drums
on the downside of
the slope.
• When required to park on the public road, provide
necessary markings such as flag, barriers and
illumination. However, be sure they do not obstruct
traffic.
• When getting off the machine, stop the engine and
remove the
key from the ignition switch.
1.6 Loading and Unloading
• Loading and unloading can accompany any
danger. Use extreme care.
• Select level and hard ground leaving a sufficient
distance from the shoulder.
• Use sturdy ramps with proper width, length and
thickness which allow safe loading and unloading.
If they deflect considerably under load, apply
wooden blocks to reinforce the ramps.
-10-

A WARNING: Negligence of these instructions can lead to accidents.
I 1. BASIC PRECAUTIONS FOR SAFETY I
• To prevent your machine from crosswise slippage, keep the ramps free from oil, mud,
debris, etc. The drum must also be free from extraneous matter that can cause slippage.
• Do not steer your machine on the ramps. If the machine is facing in the wrong direction,
allow it to dismount from the ramps, correct the direction and try again.
• Do not use kinked, twisted or damaged wireropes for crane or winch operation. Use ones
with ample strength.
• When loading is complete,
"fix the machine with wooden blocks placed under the drums
and chains fastened to the machine.
1.7 Transportation
• Follow required regulations.
• Select a transporting route according to the overall width, overall height and gross weight
of the trailer with the roller loaded.
1.8 Handling the Battery
• When handling the battery:
•
Battery electrolyte contains sulphuric acid. It will
destroy clothing and skin. If it touches your clothing or
skin, flush with large quantities of water.
•
In case of eye contact, flush with clean water and seek
medical help.
• If swallowed, drink large amount of water, milk, beaten •
egg or vegetable oil, and get medical help.
• Wear safety goggles when handling the battery. a 0
Wear safety goggles, full face shield, rubber gloves and .
rubber apron when adding fluids to the battery.
• The battery generates flammable gases that can cause an explosion. Do not smoke close
to the battery. Keep the battery away from flames, sparks and ignition sources.
(l9
®
A WARNING -------------------------,
Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and
reproductive harm.
Wash hand after handing.
-11 -

A WARNING: Negligence of these instructions can lead to accidents.
[ 1. BASIC PRECA UTiONS FOR SAFETY I
• Inspect or bandle the battery with the engine shut down
and the starter key
in the OFF position.
£.1>-\ OFF 0
~ lI ,N
• Keep
metallic items such as tools away from the
S,r
'1,,?,r
battery terminals.
•
Loose terminals can cause sparks leading to an
explosion. Secure the terminals tightly.
• Jump-starting the engine.
• Wear safety goggles when jump-starting the machine.
• When starting from another machine, do not allow the
two machines to make contact with each other.
• When connecting the battery cables, start with the
positive terminal. For disconnection,
start with the
negative one. )
1///-/
• Do not allow a tool to bridge between the positive I
terminal and machine body. This can generate
dangerous sparks.
• Do not connect the booster cable to wrong terminal. NEVER connect the positive terminal
to the negative.
• Final connection to the engine block of the disabled machine can cause sparks. The
connecting point sbould be
as far as possible from the battery.
1.9 Towing
• To tow the machine, use wire ropes with ample strength.
• Do not perform towing
on a slope.
• Do not use towing ropes twisted, kinked or damaged.
• Do not stride towing cables.
• Keep everyone away from the space between the machine and the towing vehicle when
connecting the
two.
• Align the connecting portions of the machine and towing vehicle straight when coupling the
machine.

A WARNING: Negligence of these instructions can lead to accidents.
1. BASIC PRECA UTiONS FOR SAFETY I
1.10 Before Servicing
• Attach warning tags when servicing the machine.
• Serious accidents can occur if the machine is unexpectedly started or controls carelessly
touched by
an unauthorized person.
• Attach a warning tag at a clearly visible location
in the operator's station and insure the key
has been removed from the ignition switch.
AOANGER
Do not operate.
Keep this warning tag, if not used, in tool box.
• Use
proper tools.
• It is very dangerous to use damaged or deteriorated
tools or to use tools for other purposes than intended.
Use correct tools for their intended use
only.
)1'
• Change safety-related parts at regular intervals.
• Replace fuel hose and high pressure hydraulic hoses regularly to prevent fire. Replace
high pressure hoses of the power steering system every two years.
*Change these parts at regular intervals even i'f found to be normal. They will deteriorate
*Change any hose found to
as time goes on.
be abnormal even if it is within its recommended service
interval.
•
Inspect or service your machine with the engine stopped.
xJ'-\ OFF 0
~ l ~ ,N
• If required to keep the engine running in such a case
as radiator interior cleaning, perform the work with two
persons. One of them should sit
on the operator's seat
getting ready for shutting down the engine. He must
take care not to
touch any of controls carelessly.
Maintenance personnel must exercise extreme caution
not to make contact with moving parts.
S'~
-s''91'
-13-

A WARNING: Negligence of these instructions can lead to accidents.
I 1. BASIC PRECAUTIONS FOR SAFETY I
• Supplying fuel and oils
• Spilled fuel or oil will be slippery. Wipe up immediately. Keep the filler caps tight. Do not
use fuel for flushing oil. Handle fuel and oil in a well ventilated area.
• Check the
coolant level in the radiator.
•
To check the coolant level, shut down the engine and allow the engine and radiator to cool
down.
• Illumination
• For inspecting the level of the fuel, oil, coolant and
battery electrolyte, use burn-proof illuminations. Failure
to use this type of illumination can result in an
explosion.
1.11 During servicing
• Keep unauthorized persons away
• During service, do not allow persons not concerned to
enter the work area, particularly when grinding or
welding operation is performed or heavy hammers are
being used.
• Keep
your machine clean
• Spilled oil, grease or scattered debris are dangerous. Always keep your machine clean.
Moisture that penetrates into the electrical system can cause malfunctions.
Do not use
water to clean sensors, connectors and the operator's station.
• When repairing the electrical system
• For repairing the electrical system or for conducting
welding, disconnect the negative cable from the battery
to shut off the electricity.
• Carefully handle
high pressure hoses.
•
Do not try to bend or hit hoses against a hard object. Do not use hoses or pipes that are
bent or damaged. They will burst.
• Replace damaged fuel hose and hydraulic hoses.
An oil or hydraulic fluid spill can cause a
fire.