Sakai SV400 shop manual

Sakai SV400 shop manual

Sakai SV400 shop manual. This is a factory shop manual, 149 pages.

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
Operators Station ……………………………………………………………………………………………………..2-4
Compactor Component Identification
Rear Drive Hydraulic Hoses ……………………………………………………………………………………….2-5
Front Drive Hydraulic Hoses ………………………………………………………………………………………2-6
Steering Hoses ………………………………………………………………………………………………………….2-7
Hydraulic Brake Hose Network…………………………………………………………………………………..2-8
Vibration Hose Network …………………………………………………………………………………………….2-9
Brake Linkage…………………………………………………………………………………………………………2-10
Compactor Left Side View ……………………………………………………………………………………….2-11
Compactor Top View……………………………………………………………………………………………….2-12
Forward/Reverse Cable…………………………………………………………………………………………….2-13
Cooling System……………………………………………………………………………………………………….2-14
Engine Components …………………………………………………………………………………………………2-15
Exhaust System……………………………………………………………………………………………………….2-16
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Fuel Lines ………………………………………………………………………………………………………………2-17
Intake Air System ……………………………………………………………………………………………………2-18
Battery Cable Routing………………………………………………………………………………………………2-19
Operators Station …………………………………………………………………………………………………….2-20
Electric Component Locations…………………………………………………………………………………..2-21
Brake Cylinder ………………………………………………………………………………………………………..2-22
Brake Pedal …………………………………………………………………………………………………………….2-23
Center Pin ………………………………………………………………………………………………………………2-24
Roller (D)……………………………………………………………………………………………………………….2-25
Roller (T) ……………………………………………………………………………………………………………….2-26
Roller (TF) ……………………………………………………………………………………………………………..2-27
Differential……………………………………………………………………………………………………………..2-28
Drive Wheels ………………………………………………………………………………………………………….2-29
Final Drive ……………………………………………………………………………………………………………..2-30
Front Drive Propulsion Motor …………………………………………………………………………………..2-31
Hydraulic Pump Assembly ……………………………………………………………………………………….2-32
Pump to Engine Coupling…………………………………………………………………………………………2-33
Orbitrol…………………………………………………………………………………………………………………..2-34
Operators Seat ……………………………………………………………………………………………………….2-35
Parking Brake …………………………………………………………………………………………………………2-36
Rear Drive Propulsion Motor…………………………………………………………………………………….2-37
Reduction Gear ……………………………………………………………………………………………………….2-38
Steering Cylinder …………………………………………………………………………………………………….2-39
Vibration Motor ………………………………………………………………………………………………………2-40
Operation
Operating Systems Description
Diesel Engine……………………………………………………………………………………………………………3-1
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Hydraulic Drive System……………………………………………………………………………………………..3-2
Hydraulic Drive Circuit ……………………………………………………………………………………………..3-3
Hydraulic Vibratory System ……………………………………………………………………………………….3-5
Hydraulic Vibratory Circuit ………………………………………………………………………………………..3-6
Hydraulic Steering System………………………………………………………………………………………….3-7
Hydraulic Steering Circuit ………………………………………………………………………………………….3-8
Brake System ……………………………………………………………………………………………………………3-9
Combination Meter ………………………………………………………………………………………………….3-11
Monitor Display………………………………………………………………………………………………………3-12
Tachometer …………………………………………………………………………………………………………….3-13
Temperature Gauge………………………………………………………………………………………………….3-13
Fuel Gauge……………………………………………………………………………………………………………..3-13
Engine Lamps …………………………………………………………………………………………………………3-13
Starter Switch………………………………………………………………………………………………………….3-13
Parking Brake Switch ………………………………………………………………………………………………3-14
Horn Button ……………………………………………………………………………………………………………3-14
Vibrator Amplitude Switch……………………………………………………………………………………….3-14
Vibrator Selector Switch…………………………………………………………………………………………..3-15
Forward/Reverse Lever Vibration ON/OFF Switch ……………………………………………………..3-15
Compactor Speed Change Switch………………………………………………………………………………3-15
Forward/Reverse Lever…………………………………………………………………………………………….3-16
Unloader Valve ……………………………………………………………………………………………………….3-16
Throttle Lever …………………………………………………………………………………………………………3-17
Fuse Box ………………………………………………………………………………………………………………..3-17
Operating the Compactor
Release Brakes for Towing……………………………………………………………………………………….3-18
Before Starting Inspection ………………………………………………………………………………………..3-19
Starting the Engine…………………………………………………………………………………………………..3-20
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Traveling………………………………………………………………………………………………………………..3-22
Stopping and Parking……………………………………………………………………………………………….3-23
Stopping the Engine…………………………………………………………………………………………………3-24
Vibratory Operation …………………………………………………………………………………………………3-24
Loading Using a Winch Equipped Trailer …………………………………………………………………..3-26
Self Propelled Loading …………………………………………………………………………………………….3-28
Working With the Compactor……………………………………………………………………………………3-29
Maintenance
Periodic Maintenance
Compactor Maintenance Schedule……………………………………………………………………………….4-2
Compactor Component Replacement Schedule……………………………………………………………..4-3
Prior to Starting the Compactor …………………………………………………………………………………..4-4
Lifting Compactor with Hoist ……………………………………………………………………………………..4-5
Maintenance Procedures Every 10 Hours or Daily…………………………………………………………4-5
Maintenance Procedures Every 50 Hours……………………………………………………………………..4-6
Maintenance Procedures Every 250 Hours……………………………………………………………………4-7
Maintenance Procedures Every 500 Hours………………………………………………………………….4-10
Maintenance Procedures Every 1,000 Hours……………………………………………………………….4-13
As Required ……………………………………………………………………………………………………………4-15
Booster Cable Connection ………………………………………………………………………………………..4-17
Long Term Storage ………………………………………………………………………………………………….4-19
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
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Adjust Hydraulic Pressure Main Propulsion Circuit……………………………………………………….5-3
Measure Propulsion Charge Pressure …………………………………………………………………………..5-4
Adjust Propulsion Charge Pressure ……………………………………………………………………………..5-5
Measure Propulsion Motor Speed Shift Valve ………………………………………………………………5-6
Measure Vibrator Circuit Pressure……………………………………………………………………………….5-7
Adjust Vibrator Circuit Pressure………………………………………………………………………………….5-8
Measure Vibrator Charge Pressure ………………………………………………………………………………5-9
Adjust Vibrator Charge Pressure ……………………………………………………………………………….5-10
Measure Steering Circuit Pressure……………………………………………………………………………..5-10
Adjust Forward/Reverse Cable ………………………………………………………………………………….5-11
Throttle Linkage Adjustment …………………………………………………………………………………….5-12
Parking Bake Adjustment …………………………………………………………………………………………5-13
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
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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
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
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Install …………………………………………………………………………………………………………………….7-36
Operators Station
Remove ………………………………………………………………………………………………………………….7-38
Install …………………………………………………………………………………………………………………….7-40
Manual Vibration Control Switch
Remove ………………………………………………………………………………………………………………….7-42
Install …………………………………………………………………………………………………………………….7-43
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
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Assemble………………………………………………………………………………………………………………..7-57
Install …………………………………………………………………………………………………………………….7-58
Foot Brake Switch
Remove ………………………………………………………………………………………………………………….7-58
Disassemble ……………………………………………………………………………………………………………7-59
Assemble………………………………………………………………………………………………………………..7-59
Install …………………………………………………………………………………………………………………….7-59
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
Operators 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
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Tachometer Control Box
Remove ………………………………………………………………………………………………………………….7-67
Install …………………………………………………………………………………………………………………….7-67
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
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Install …………………………………………………………………………………………………………………….7-97
Fuses 65 Amp and Above
Remove ………………………………………………………………………………………………………………….7-98
Install …………………………………………………………………………………………………………………….7-98
Parking Brake Valve
Remove ………………………………………………………………………………………………………………….7-98
Install …………………………………………………………………………………………………………………….7-99
Vibration Amplitude Solenoid
Remove ………………………………………………………………………………………………………………….7-99
Install …………………………………………………………………………………………………………………..7-100
Compactor Speed Solenoid
Remove ………………………………………………………………………………………………………………..7-100
Install …………………………………………………………………………………………………………………..7-101
Orbitrol Steering Valve
Remove ………………………………………………………………………………………………………………..7-101
Install …………………………………………………………………………………………………………………..7-102
Schematics
Electrical ………………………………………………………………………………………………………………….8-1
Hydraulic …………………………………………………………………………………………………………………8-2
Service Literature
Additional Service Literature………………………………………………………………………………………9-1
Specifications
Compactor General Specifications……………………………………………………………………………..10-1
Hydraulic Pump Pressures ………………………………………………………………………………………..10-5
Overall Coolant Levels …………………………………………………………………………………………….10-5
Battery Electrolyte Reading ………………………………………………………………………………………10-5
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