Related Manuals for Sakai TENTATIVE SW770
Summary of Contents for Sakai TENTATIVE SW770
- Page 1 SW770/770HF/770ND TENTATIVE SHOP MANUAL This manual is a preliminary version. Please replace with the officially published version once it is available. 3498-64315-0...
- Page 2 SAFETY...
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Page 3: General Safety
SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol. DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and CAUTION are displayed, become alert. Your safety or those around you may be involved. NOTICE is used to provide important information that is not hazard related. - Page 4 SAFETY • The machine is designed specifically for the compaction of asphalt or soil road construction 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.
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Page 5: Pre-Start Inspection
SAFETY • Observe all safety instructions and warnings attached to the machine. • Make sure all safety instructions and warnings on the machine are complete and perfectly legible. • Stop the machine immediately in the event of any malfunction. Report any malfunction immediately to the supervisor or other person of authority. - Page 6 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. •...
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Page 7: Maintenance
SAFETY • Park behind a safe barrier, use proper flags, and warning devices, especially when parking in areas of heavy traffic. 1-10. Maintenance • In any performing any work concerning the operation, adjustment or modification of the machine or it’s safety devices or any work related to maintenance, inspection or repair, always follow the start-up and shut-down procedures in the Operator’s Manual and the Maintenance Manual. - Page 8 Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. • Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers.
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Page 9: Transporting The Machine
SAFETY • Observe all product safety regulations when handling fuel, oils, grease, engine coolant and other chemical substances. Be careful especially when these items are hot as there is a risk of burning or scalding. • Operate internal combustion engines and fuel operated heating systems only in adequately ventilated premises. -
Page 10: Specifications
SPECIFICATIONS... -
Page 12: Specification Data
SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW770 1700 1800 1800 1700 3600 4950 0431-99007-0-10253-A Model SW770 Operating weight 10,800 kg 23,810 lbs. ) Weight Front axle 5,200 kg 11,465 lbs. ) Rear axle 5,600 kg 12,345 lbs. ) Overall length Frame 4,950 mm 195 in. - Page 13 SPECIFICATIONS ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) Name with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, Model direct-injection type, with turbocharger Number of cylinders - Bore × Stroke 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.) Displacement 2.999 L 183 cu.in Rated speed...
- Page 14 SPECIFICATIONS 1-2. SW770HF 1700 1800 1800 1700 3600 4950 0431-99004-0-10230-A Model SW770HF Operating weight 10,800 kg 23,810 lbs. ) Weight Front axle 5,200 kg 11,465 lbs. ) Rear axle 5,600 kg 12,345 lbs. ) Overall length Frame 4,950 mm 195 in. Overall width Frame 1,860 mm...
- Page 15 SPECIFICATIONS ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) Name with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, Model direct-injection type, with turbocharger Number of cylinders - Bore × Stroke 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.) Displacement 2.999 L 183 cu.in Rated speed...
- Page 16 SPECIFICATIONS 1-3. SW770ND 1700 1800 1800 1700 3600 4950 0431-99015-0-10579-A Model SW770ND Operating weight 11,320 kg 24,955 lbs. ) Weight Front axle 5,460 kg 12,035 lbs. ) Rear axle 5,860 kg 12,920 lbs. ) Overall length Frame 4,950 mm 195 in. Overall width Frame 1,860 mm...
- Page 17 SPECIFICATIONS ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) Name with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, Model direct-injection type, with turbocharger Number of cylinders - Bore × Stroke 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.) Displacement 2.999 L 183 cu.in Rated speed...
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Page 18: Tightening Torque Chart
SPECIFICATIONS 2. TIGHTENING TORQUE CHART N·m (lbf·ft) Strength Classification Nominal Pitch Dia. 10.9 12.9 (3.6) (4.4) (5.8) (5.8) (5.8) (7.2) (9.6) (9.6) 1.25 (13) (17) (23) (23) (29) (36) (44) (44) 1.75 (51) (58) (80) (80) (72) (94) (123) (123) (116) (145) (195) -
Page 19: Engine Removal And Installation
ENGINE REMOVAL AND INSTALLATION... - Page 20 ENGINE REMOVAL AND INSTALLATION 1. PRECAUTIONS FOR REMOVAL AND INSTALLATION • When removing or installing the engine, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.
- Page 21 ENGINE REMOVAL AND INSTALLATION 2. ENGINE REMOVAL Time of procedures: • To remove engine takes about 3.5 hour × 2 people • To install the engine takes about 6 hours × 2 people Tools and equipment you need: • Box (10 mm, 12 mm, 13 mm, 17 mm, 19 mm, 24 mm) •...
- Page 22 ENGINE REMOVAL AND INSTALLATION 2-1. Left and Right Side Cover Removal • Uninstall left and right side cover. (7 bolts, 17 box); 2 people • Uninstall 2 small and 1 big cover under radiator. (17 box) • Uninstall left cover. (17 box) •...
- Page 23 ENGINE REMOVAL AND INSTALLATION 2-2. Radiator Removal (Step 1) • Remove coolant tank with hose. Remove cleaner hose. (10 box) • Uninstall hoses connected to radiator except oil hose. Intake hose 10 box + screw driver Coolant hose 10 box + screw driver CAC hose 3-004...
- Page 24 ENGINE REMOVAL AND INSTALLATION 2-2. Radiator Removal (Step 2) Uninstall CAC hose. Uninstall hose connected to upper part of radiator. Oil cooler hose uninstall. (36 spanner) Install the cap. 3-005...
- Page 25 ENGINE REMOVAL AND INSTALLATION 2-2. Radiator Removal (Step 3) (NOTICE) • Oil cooler hose is connected with oil tank. Please use vacuum effect or put cap for oil hose to avoid oil leakage from the hose. 2100-12020-1, 4 bolts 2100-12020-1, 4 bolts •...
- Page 26 ENGINE REMOVAL AND INSTALLATION 2-3. Fan and Air Cleaner Removal Unscrew 4 bolts. (12 mm box). Correct position of fan. Priority – order of fan elements Remove clamp of air cleaner. (17 mm spanner) Unscrew hose clamp. (13 mm box) Use “flat”...
- Page 27 ENGINE REMOVAL AND INSTALLATION 2-4. Battery Relay; Bracket Removal Unscrew 2 earth cables. (13 box) Unscrew battery cable “positive”. (14 spanner) Remove battery relay with bracket. (17 box) Put electric wires in a safe position. Prepare isolation. 3-008...
- Page 28 ENGINE REMOVAL AND INSTALLATION 2-5. Engine Hoses Removal Turbo charger hose keep in this position. Pay attention on air sensor. Remove from circle A in ③ photo. CAC hose clamp. (10 box) CAC hose clamp. (10 box) Lower hose clamp. (10 box) 3-009...
- Page 29 ENGINE REMOVAL AND INSTALLATION 2-6. Support Frame Removal Keep free hose. Unscrew 2 front bolts. (24 box; torque 265 N·m (194 lbf·f)) Be careful on water sensor temperature. Be careful. Washers inside. Unscrew back side 4 bolts. (24 box. Torque 265 N·m (194 lbf·f)) Push up a frame to unload the front frame.
- Page 30 ENGINE REMOVAL AND INSTALLATION 2-7. Hydraulic Hose Removal Disconnect vibration pressure oil hose and put cap. (36 Spanner) Remove 2 clamp hose brackets. Remove pipe frame above the engine. 4 bolts. (19 box) Need two people for this operation. Lift up hydr. and elect. hoses and remove carefully pipe frame from below.
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Page 31: Exhaust System Removal
ENGINE REMOVAL AND INSTALLATION 2-8. Exhaust System Removal Unscrew 4 bolts. (17 box) Make loose of the clamp and remove exhaust pipe. Remove clamp. (17 box and wrench) Unscrew 3 nuts of exhaust pipe and rotate the pipe remove it from the machine. 3-012... - Page 32 ENGINE REMOVAL AND INSTALLATION 2-9. Main Hydraulic Pump Removal Remove carefully cables. (10 box, spanner, 19 spanner × 2). Unscrew and push aside electric harness. • Unscrew main hydr. pump. (use 24 – 22 wrench. 24 box and handle bar) Do it with two people.
- Page 33 ENGINE REMOVAL AND INSTALLATION 2-10. Bolts and Hoses Removal (NOTICE) • Remove below bolts and hoses before removing engine. Engine oil drain hose. (U bolt. 13 box) Pay attention on hose. Unscrew hose clamp. (13 box, 3 clamps.) Engine earth cables. (19 box) Starter cable.
- Page 34 ENGINE REMOVAL AND INSTALLATION 2-11. Hoses Removal Cut hose clamp Engine electric harness - disconnect Unscrew oil tank hose. (41 spanner) Use vacuum effect if possible. (Connect flowing high pressure air to the oil tank to avoid leakage of hydraulic hose during unscrew the hose from oil cooler).
- Page 35 ENGINE REMOVAL AND INSTALLATION 2-12. Engine Removal (Step 1) Use crane. Fix 2 ropes in special lifting points. Hydraulic Pump must be separate. • Pay attention during lifting up the engine. Pay attention on all cables, harness and hoses. After you will lift up the engine, please remove steering hydraulic hoses.
- Page 36 ENGINE REMOVAL AND INSTALLATION 2-12. Engine Removal (Step 2) Be careful to not hit engine to front bracket frame. • Keep fuel hose clean. Protect against dust. • Keep clean other hoses. • Protect engine intake system. 3. ENGINE INSTALLATION Installation process of the engine is exactly opposite order of removing process.
- Page 37 SYSTEM CIRCUIT DIAGRAMS...
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Page 38: Hydraulic Circuit Diagrams
SYSTEM CIRCUIT DIAGRAMS 1. HYDRAUlIC CIRCUIT DIAGRAMS 1-1. SW770, 770ND 1/2" 3/8" 3/8" 1/2" 1/4" 1/2" M14×1.5 5/8" Lo→Ｈi 1.0MPa WIRING WIRING 1700 HARNESS HARNESS R1 T2 (SOL.C) (SOL.D) SAE 3/4 54.8 /25.5 FRONT i=43.80 cc/rev 33.0ＭＰa ENGINE 34.5ＭＰa 1.6MPa (ISUZU 4JJ1 SAE 3/4 46.0 ... - Page 39 SYSTEM CIRCUIT DIAGRAMS 1-2. SW770HF 1/2" 3/8" 3/8" 1/2" 1/4" 1/2" M14×1.5 5/8" Lo→Ｈi 1.0MPa 1700 WIRING WIRING HARNESS HARNESS (SOL.D) (SOL.C) SAE 3/4 54.8 FRONT /25.5 i=43.80 cc/rev 43.0ＭＰa ENGINE 35.0ＭＰa 1.6MPa (ISUZU 4JJ1 SAE 3/4 56.0 46.0 9/16 92.0kW/2200rpm) cc/rev ...
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Page 40: Electrical Circuit Diagrams
SYSTEM CIRCUIT DIAGRAMS 2. ElECTRICAl CIRCUIT DIAGRAMS 1-1. SW770, 770ND 14 RL TAIL LAMP(5W) 45 GY STOP LAMP(21W) 39 GB TURN SIGNAL LAMP(R)(21W) 51 RY BACK-UP LAMP(21W) HAZARD SWITCH TURN SIGNAL WATER SPRAY WATER PUMP 2 B 39 GB 39 GB LAMP(R) (25W) 49 G BRAKE RELAY(A) 20 Y 56 Lg 14 RL SOL.VALVE SIDE MARKER 84 BY 5 BrW 1.25LB 55 1.25LY 55 2LY 2 B FLOOD 40 GR LAMP (5W) - Page 41 SYSTEM CIRCUIT DIAGRAMS 1-2. SW770HF 14 RL TAIL LAMP(5W) 45 GY STOP LAMP(21W) 39 GB TURN SIGNAL LAMP(R)(21W) 51 RY BACK-UP LAMP(21W) HAZARD SWITCH TURN SIGNAL WATER SPRAY WATER PUMP 2 B 39 GB 39 GB LAMP(R) (25W) 49 G RELAY(A) 20 Y BRAKE 56 Lg 14 RL SIDE MARKER SOL.VALVE 84 BY 5 BrW 1.25LB 55 1.25LY 55 2LY 2 B 136 RB GR FLOOD 40 GR LAMP (5W) 1.25RG...
- Page 42 HYDRAULIC PUMP AND MOTORS LOCATION...
- Page 43 HYDRAULIC PUMP AND MOTORS LOCATION 1. LOCATION (1/5) Valve block TO FRONT DRUM assembly SECTION X-X Valve PA1/PB1 block PA/PB assembly Hydraulic pump Rear propulsion motor and gear box SEE STEERING HYD SYS ...
- Page 44 HYDRAULIC PUMP AND MOTORS LOCATION 2. LOCATION (2/5) Valve block assembly Valve block assembly TO (NO.4) SEE STEERING HYD SYS (NO.4) (NO.7) (NO.3) (NO.1) (NO.6) (NO.5) (NO.1) (NO.5) (NO.4) (NO.4) (NO.4) (NO.6) (NO.6) (NO.3) (NO.3) ...
- Page 45 HYDRAULIC PUMP AND MOTORS LOCATION 3. LOCATION (3/5) TANK TO OIL COOLER FROM FROM FROM BOTTOM FROM Hydraulic oil tank ROUT-DR Valve block assembly RIN-BA BA-PT1 BH1-PT BC1-OUT SVP-PX2 CONNECT HOSES AS FOLLOWS. NO. 1 SVP-PX2 PA1-VALVE PA1-VALVE Hydraulic pump ROUT-TANK 0431-36802-0-10079-C 5-003...
- Page 46 HYDRAULIC PUMP AND MOTORS LOCATION 4. LOCATION (4/5) Hydraulic pump TANK Valve block assembly TO Hydraulic pump CONNECT HOSES AS FOLLOWS. 0431-49801-0-10081-C 5-004...
- Page 47 HYDRAULIC PUMP AND MOTORS LOCATION 5. LOCATION (5/5) P-PT2 R-R3 L2-R1 NO.2 NO.6 SECTION A-A L-L3 L1-R2 IN-T TO TANK TO Hydraulic tank TO TO CONNECT HOSES AS FOLLOWS. FROM TANK FROM Steering Charge pump 0431-32803-0-10078-B 5-005...