Sakai SV505-1 Series Install guide

SV505-1 Series Shop Manual
Sakai®

Section of Contents
Section Page
Introduction
About the Manual ....................................................................................................................1-1
How to Use the Manual ...........................................................................................................1-2
Panel Symbols..........................................................................................................................1-3
General Safety Instructions......................................................................................................1-5
Acronyms and Abbreviations ................................................................................................1-15
Identification
Compactor Controls Identification
Left View .................................................................................................................................2-2
Right View...............................................................................................................................2-3
Top View .................................................................................................................................2-4
Operators Station .....................................................................................................................2-5
Compactor Component Identification
Rear Drive Hydraulic Hoses ....................................................................................................2-6
Front Drive Hydraulic Hoses ...................................................................................................2-7
Steering Hoses .........................................................................................................................2-8
Hydraulic Brake Hose Network...............................................................................................2-9
Brake Pedal and Linkage .......................................................................................................2-10
Center Pin ..............................................................................................................................2-11
Vibrator Hydraulic Hoses ......................................................................................................2-12
Drum and Vibrator (Model D)...............................................................................................2-13
Drum and Vibrator Motor (Model T and TF) ........................................................................2-14
Fuel System............................................................................................................................2-15
Hydraulic Propulsion, Vibrator and Steering Pump Assembly..............................................2-16
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Rear Drive Propulsion Motor.................................................................................................2-17
Front Drive Propulsion Motor ...............................................................................................2-18
Vibrator Motor.......................................................................................................................2-19
Electric Components..............................................................................................................2-20
Instrument Panel and Relays..................................................................................................2-21
Rear Axle ...............................................................................................................................2-22
Intake System.........................................................................................................................2-23
Exhaust System......................................................................................................................2-24
Cooling Hose and Radiator....................................................................................................2-25
Travel Controls (Forward/Reverse) .......................................................................................2-26
Hydraulic Coupling................................................................................................................2-27
Engine Mount ........................................................................................................................2-28
Differential (1of 2).................................................................................................................2-29
Differential (2 of 2)................................................................................................................2-30
Brake......................................................................................................................................2-31
Final Drive .............................................................................................................................2-32
Orbitrol...................................................................................................................................2-33
Steering Cylinder ...................................................................................................................2-34
Operation
Operating Systems Description
Diesel Engine...........................................................................................................................3-1
Hydraulic Drive System...........................................................................................................3-2
Hydraulic Drive Circuit ...........................................................................................................3-3
Hydraulic Vibratory System ....................................................................................................3-4
Hydraulic Vibratory Circuit.....................................................................................................3-5
Hydraulic Steering System.......................................................................................................3-6
Hydraulic Steering Circuit .......................................................................................................3-7
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Brake System ...........................................................................................................................3-8
Combination Meter ..................................................................................................................3-9
Monitor Display.....................................................................................................................3-10
Tachometer ............................................................................................................................3-11
Temperature Gauge................................................................................................................3-11
Fuel Gauge.............................................................................................................................3-11
Engine Lamps ........................................................................................................................3-12
Starter Switch.........................................................................................................................3-12
Parking Brake Switch ............................................................................................................3-12
Horn Button ...........................................................................................................................3-13
Vibrator Amplitude Switch....................................................................................................3-13
Vibrator Selector Switch........................................................................................................3-13
Forward/Reverse Lever Vibration ON/OFF Switch ..............................................................3-14
Engine Speed Change Switch ................................................................................................3-14
Compactor Speed Change Switch..........................................................................................3-14
Engine Diagnostic Switches ..................................................................................................3-15
Forward/Reverse Lever..........................................................................................................3-15
Unloader Valve ......................................................................................................................3-15
Fuse Box ................................................................................................................................3-16
Operating the Compactor
Release Brakes for Towing....................................................................................................3-17
Before Starting Inspection .....................................................................................................3-18
Starting the Engine.................................................................................................................3-19
Traveling................................................................................................................................3-21
Stopping and Parking.............................................................................................................3-22
Stopping the Engine...............................................................................................................3-23
Vibratory Operation ...............................................................................................................3-23
Loading Using a Winch Equipped Trailer .............................................................................3-25
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Self Propelled Loading ..........................................................................................................3-27
Working With the Compactor................................................................................................3-28
Maintenance
Periodic Maintenance
Compactor Maintenance ..........................................................................................................4-2
Compactor Component Replacement Schedule.......................................................................4-2
Prior to Starting the Compactor ...............................................................................................4-3
Lifting Compactor with Hoist..................................................................................................4-4
Maintenance Procedures Every 10 Hours or Daily..................................................................4-4
Maintenance Procedures Every 50 Hours................................................................................4-5
Maintenance Procedures Every 250 Hours..............................................................................4-6
Maintenance Procedures Every 500 Hours..............................................................................4-9
Maintenance Procedures Every 1,000 Hours...........................................................................4-9
Long Term Storage ................................................................................................................4-14
Connecting Booster Cable .....................................................................................................4-15
Testing and Adjustment
Mechanical Adjustments
Seat Adjustment .......................................................................................................................5-1
Scraper Adjustment..................................................................................................................5-1
Hydraulic Pump Testing and Adjustment
Measure Hydraulic Pressure Main Propulsion Circuit.............................................................5-2
Adjust Hydraulic Pressure Main Propulsion Circuit................................................................5-3
Measure Propulsion Charge Pressure ......................................................................................5-4
Adjust Propulsion Charge Pressure .........................................................................................5-4
Measure Parking Brake Release Pressure................................................................................ 5.5
Measure Vibrator Circuit Pressure...........................................................................................5-5
Adjust Vibrator Circuit Pressure..............................................................................................5-6
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Measure Vibrator Charge Pressure ..........................................................................................5-7
Adjust Vibrator Charge Pressure .............................................................................................5-8
Measure Steering Circuit Pressure...........................................................................................5-9
Adjust Forward/Reverse Cable ..............................................................................................5-10
Troubleshooting
Troubleshooting Guidelines.....................................................................................................6-1
Wiring Diagram Color Codes. .................................................................................................6-2
Engine Warning Lamp is Illuminated......................................................................................6-4
Engine Stop Lamp is Illuminated.............................................................................................6-8
Wait to Start Lamp is Illuminated..........................................................................................6-12
Vibration Lamp Does Not Illuminate When Vibration Engaged...........................................6-16
Parking Brake Lamp Does Not Illuminate When Parking Brake Engaged ...........................6-25
Engine Oil Pressure Lamp Illuminated ..................................................................................6-29
Hydraulic Oil Filter Lamp Illuminated ..................................................................................6-34
Tachometer Does Not Indicate Engine Speed .......................................................................6-39
Hour Meter Does Not Work ..................................................................................................6-49
Coolant Temperature Gauge Does Not Work........................................................................6-55
Fuel Gauge Does Not Work...................................................................................................6-60
Backup Alarm Does Not Work..............................................................................................6-64
Horn Does Not Work.............................................................................................................6-71
Compactor Steering Malfunction...........................................................................................6-80
Vibration Does Not Work......................................................................................................6-85
Low Amplitude Vibration Setting Does Not Work ...............................................................6-98
High Amplitude Vibration Setting Does Not Work.............................................................6-104
Can Not Turn Vibration From Forward/Reverse Lever.......................................................6-110
Compactor Will Not Start ....................................................................................................6-116
Engine Will Not Idle Correctly............................................................................................6-134
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Engine Will Not Reach MID Speed.....................................................................................6-139
Engine Will Not Reach Full Speed ......................................................................................6-144
Compactor Will Not Move Forward and/or Reverse or Does Not Drive Correctly ............6-151
Parking Brake Does Not Work ............................................................................................6-158
Compactor Will Not Change Speeds ...................................................................................6-166
Compactor Repair
Roller
Remove ....................................................................................................................................7-1
Disassemble (Vibratory Motor Side) .......................................................................................7-4
Disassemble (Drive Motor Side)..............................................................................................7-9
Clean and Inspect for Reuse ..................................................................................................7-12
Assemble (Drive Motor) ........................................................................................................7-16
Assemble (Vibratory Motor)..................................................................................................7-20
Install .....................................................................................................................................7-27
Center Pin
Remove ..................................................................................................................................7-29
Disassemble ...........................................................................................................................7-30
Clean ......................................................................................................................................7-32
Assemble................................................................................................................................7-32
Install .....................................................................................................................................7-36
Operators Station
Remove ..................................................................................................................................7-38
Install .....................................................................................................................................7-40
Manual Vibration Control Switch
Remove ..................................................................................................................................7-42
Install .....................................................................................................................................7-43
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Vibratory Control Panel Switches
Remove ..................................................................................................................................7-43
Install .....................................................................................................................................7-44
Combination Meter
Remove ..................................................................................................................................7-45
Install .....................................................................................................................................7-46
Parking Brake Button
Remove ..................................................................................................................................7-48
Install .....................................................................................................................................7-48
Engine Status Lamps
Remove ..................................................................................................................................7-49
Install .....................................................................................................................................7-50
Engine Start Switch
Remove ..................................................................................................................................7-51
Install .....................................................................................................................................7-51
Directional Control Lever Cable
Remove ..................................................................................................................................7-54
Install .....................................................................................................................................7-55
Directional Control Lever Micro-Switches
Remove ..................................................................................................................................7-56
Disassemble ........................................................................................................................... 7.57
Assemble................................................................................................................................7-57
Install .....................................................................................................................................7-58
Foot Brake Switch
Remove ..................................................................................................................................7-58
Disassemble ...........................................................................................................................7-59
Assemble................................................................................................................................7-59
Install .....................................................................................................................................7-59
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Speed Sensor (Combination Meter Tachometer)
Remove ..................................................................................................................................7-60
Install .....................................................................................................................................7-60
Coolant Temperature Sensor (Combination Meter Temperature Gauge)
Remove ..................................................................................................................................7-61
Install .....................................................................................................................................7-62
Fuel Level Sensor (Combination Meter Fuel Level Gauge)
Install .....................................................................................................................................7-62
Remove ..................................................................................................................................7-63
Battery Relay
Remove ..................................................................................................................................7-63
Install .....................................................................................................................................7-64
Operator’s Station Relay and Diodes
Remove ..................................................................................................................................7-65
Install .....................................................................................................................................7-65
Horn
Remove ..................................................................................................................................7-66
Install .....................................................................................................................................7-66
Hydraulic Oil Filer Switch
Remove ..................................................................................................................................7-66
Install .....................................................................................................................................7-66
Tachometer Control Box
Remove ..................................................................................................................................7-67
Install .....................................................................................................................................7-67
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Radiator and Cooling System
Remove ..................................................................................................................................7-67
Install .....................................................................................................................................7-69
Hydraulic Tank
Remove ..................................................................................................................................7-71
Install .....................................................................................................................................7-72
Engine and Pump Assembly
Remove ..................................................................................................................................7-73
Disassemble ...........................................................................................................................7-78
Assemble................................................................................................................................7-80
Install .....................................................................................................................................7-83
Rear End
Remove ..................................................................................................................................7-90
Install .....................................................................................................................................7-91
Back Up Alarm
Remove ..................................................................................................................................7-92
Install .....................................................................................................................................7-93
Starter Relay
Remove ..................................................................................................................................7-93
Install .....................................................................................................................................7-94
Engine Speed Change Switch
Remove ..................................................................................................................................7-94
Install .....................................................................................................................................7-95
Forward/Reverse Lever Vibration Switch
Remove ..................................................................................................................................7-96
Install .....................................................................................................................................7-97
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