Sakai SV505-1 (SV505T) shop manual

Sakai SV505-1 (SV505T) shop manual

Sakai SV505-1 shop manual. This is the factory shop manual, 410 pages.

Section of Contents
Section Page
Introduction
About the Manual 1-1
How to Use the Manual1-2
Panel Symbols1-3
General Safety Instructions1-5
Acronyms and Abbreviations 1-15
Identification
Compactor Controls Identification
Left View 2-2
Right View2-3
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 Network2-9
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 Assembly2-16
Rear Drive Propulsion Motor2-17
Front Drive Propulsion Motor 2-18
Vibrator Motor2-19
Electric Components2-20
Instrument Panel and Relays2-21
Rear Axle 2-22
Intake System2-23
Exhaust System.2-24
Cooling Hose and Radiator2-25
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
Brake2-31
Final Drive 2-32
Orbitrol2-33
Steering Cylinder 2-34
Operation
Operating Systems Description
Diesel Engine.3-1
Hydraulic Drive System3-2
Hydraulic Drive Circuit 3-3
Hydraulic Vibratory System 3-4
Hydraulic Vibratory Circuit 3-5
Hydraulic Steering System3-6
Hydraulic Steering Circuit 3-7
Brake System .3-8
Combination Meter .3-9
Monitor Display3-10
Tachometer 3-11
Temperature Gauge..3-11
Fuel Gauge3-11
Engine Lamps 3-12
Starter Switch3-12
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 Switch3-14
Engine Diagnostic Switches .3-15
Forward/Reverse Lever3-15
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 Parking3-22
Stopping the Engine.3-23
Vibratory Operation .3-23
Loading Using a Winch Equipped Trailer .3-25
Self Propelled Loading 3-27
Working With the Compactor3-28
Maintenance
Periodic Maintenance
Compactor Maintenance4-2
Compactor Component Replacement Schedule4-2
Prior to Starting the Compactor .4-3
Lifting Compactor with Hoist 4-4
Maintenance Procedures Every 10 Hours or Daily4-4
Maintenance Procedures Every 50 Hours4-5
Maintenance Procedures Every 250 Hours4-6
Maintenance Procedures Every 500 Hours4-9
Maintenance Procedures Every 1,000 Hours4-9
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 Circuit5-2
Adjust Hydraulic Pressure Main Propulsion Circuit..5-3
Measure Propulsion Charge Pressure 5-4
Adjust Propulsion Charge Pressure .5-4
Measure Parking Brake Release Pressure5.5
Measure Vibrator Circuit Pressure.5-5
Adjust Vibrator Circuit Pressure5-6
Measure Vibrator Charge Pressure 5-7
Adjust Vibrator Charge Pressure 5-8
Measure Steering Circuit Pressure5-9
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 Illuminated6-8
Wait to Start Lamp is Illuminated6-12
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 Work6-55
Fuel Gauge Does Not Work6-60
Backup Alarm Does Not Work6-64
Horn Does Not Work.6-71
Compactor Steering Malfunction6-80
Vibration Does Not Work..6-85
Low Amplitude Vibration Setting Does Not Work .6-98
High Amplitude Vibration Setting Does Not Work6-104
Can Not Turn Vibration From Forward/Reverse Lever6-110
Compactor Will Not Start .6-116
Engine Will Not Idle Correctly.6-134
Engine Will Not Reach MID Speed6-139
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 Side7-9
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
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
Remove7-49
Install 7-50
Engine Start Switch
Remove .7-51
Install .7-51
Directional Control Lever Cable
Remove7-54
Install7-55
Directional Control Lever Micro-Switches
Remove 7-56
Disassemble7.57
Assemble..7-57
Install 7-58
Foot Brake Switch
Remove .7-58
Disassemble7-59
Assemble7-59
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
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
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 Literature9-1
Specifications
Compactor General Specifications10-1
Compactor Overall Specifications 10-4
Overall Coolant Levels .10-4
Battery Electrolyte Reading 10-4
Compactor Capacity..10-4
Fuel Oil and Grease Rating10-5
Recommended Lubricants.10-5
Rear Drive Specifications ..10-6
Hydraulic Motor Specifications 10-7
Metric to US Torque .10-8
Fraction to Decimal to Millimeter Conversions10-9
Metric Drill and Tap Chart10-11
Weights and Measures Conversion Factors .10-15

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