SAKAI SV505-I Series Vibrating Roller Repair Service Shop Manual

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This service manual PDF download for the SV505-I Series SAKAI Vibrating Roller has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


TABLE OF CONTENTS :

Introduction
Identification
Operation
Maintenance
Testing and Adjustment
Troubleshooting
Compactor Repair
Schematics
Service Literature
Specifications


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 410


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Panel Symbols.pdf
    Panel Symbols
General Safety Instructions.pdf
    Use spark proof illumination when inspecting this area.
Operating Systems Description and Operating the Compactor.pdf
    Hydraulic Drive Circuit
    Tachometer
    Temperature Gauge
    Fuel Gauge
    Engine Lamps
    Starter Switch
    Horn Button
    Vibrator Amplitude Switch
    Vibration Selector Switch
    Forward/Reverse Lever Vibration ON/OFF Switch
    Engine Speed Change Switch
    Compactor Speed Change Switch
    Engine Diagnostic Switches
    Forward/Reverse Lever
    Unloader Valve
    Fuse Box
    Before Starting Inspection
    Starting the Engine
    Traveling
    Stopping and Parking
    Stopping the Engine
    Vibratory Operation
    Loading Using a Winch Equipped Trailer
    Self Propelled Loading
Periodic Maintenance.pdf
    Lifting Compactor with Hoist
    Maintenance Procedures Every 10 Hours or Daily
    Maintenance Procedures Every 50 Hours
    Maintenance Procedures Every 250 Hours
    Maintenance Procedures Every 500 Hours
    Maintenance Procedures Every 1,000 Hours
    Booster Cable Connection
Testing and Adjustment.pdf
    Seat Adjustment
    Scraper Adjustment
    Measure Hydraulic Pressure Main Propulsion Circuit
    Measure Propulsion Charge Pressure
    Adjust Main Propulsion Charge Pressure
    Measure Parking Brake Release Pressure
    Measure Vibrator Circuit Pressure
    Adjust Vibrator Circuit Pressure
    Measure Vibrator Charge Pressure
    Adjust Vibrator Charge Pressure
    Measure Steering Circuit Pressure
    Adjust Forward/Reverse Lever Cable
Specifications.pdf
    Compactor Capacity
    Fuel Oil and Grease Rating
    Vibrator Motor Specifications
    Propulsion Motor Specifications
    Capscrew Body Size
    Metric to US Torque Values
Troubleshooting Section.pdf
    Symbol on Wiring Diagram
    Wire Color on Compactor
        Symbol on Wiring Diagram
    Wire Color on Compactor
        
            STEP 1: Check for Active Fault Code(s)
            STEP 1A: Check Lamp Illumination
            STEP 1B: Check for Active Fault Code(s)
            STEP 2 Check Wiring Harness
            STEP 2A: Inspect Wiring Harness Connector
            STEP 2B: Check Engine Warning Lamp Wire
            STEP 1: Check for Active Fault Code(s)
            STEP 1A: Check Lamp Illumination
            STEP 1B: Check for Active Fault Code(s)
            STEP 2 Check Wiring Harness
            STEP 2A: Inspect Wiring Harness Connector
            STEP 2B: Check Engine Warning Lamp Wire
    Symptoms
        
            STEP 1: Check for Active Fault Code(s)
            STEP 1A: Check Lamp Illumination
            STEP 1B: Check for Active Fault Code(s)
            STEP 2 Check Wiring Harness
            STEP 2A: Inspect Wiring Harness Connector
            STEP 2B: Check Wait to Start Lamp Wire
    Symptoms
        
            STEP 1: Will Engine Run at Full Speed
            STEP 1A: Check Full Speed Operation
            STEP 2: Does the Compactor Operate in High and Low Vibration
            STEP 2A: Operate Compactor at Low Amplitude Vibration
            STEP 2B: Operate Compactor at High Amplitude Vibration
            STEP 3: Check Vibration Lamp
            STEP 3A: Replace Vibration Lamp
            STEP 4: Check Harness Connectors
            STEP 4A: Check Connectors for Damage
            STEP 5: Check Vibration Lamp Wires
            STEP 5A: Check Supply Wire From Vibration Lamp to Diode Unit
            STEP 5B: Check Wire From Diode Unit to Low Side Input of Vibration Solenoid
            STEP 5C: Check Wire From Diode Unit to High Side Input of Vibration Solenoid
            STEP 6: Check Diode Unit
            STEP 6A: Check Compactor Low Amplitude Side of Diode
            STEP 6B: Check Compactor High Amplitude Side of Diode
    Symptoms
        
            STEP 1: Check Parking Bake Lamp
            STEP 1A: Check Parking Brake Lamp
            STEP 2: Check Harness Connectors
            STEP 2A: Check Connectors for Damage
            STEP 3: Check Parking Brake Lamp Wire
            STEP 3A: Check Parking Brake Supply Wire
            STEP 4: Check Parking Brake Switch
            STEP 4A: Check Parking Brake Switch Contacts
    Symptoms
        
            STEP 1: Check for Active Fault Code(s)
            STEP 1A: Check for Active Fault Code(s)
            STEP 2 Check ECM Connector
            STEP 2A: Check ECM Connector for Damage
            STEP 2B: Check for Short Circuit in ECM Connector
            STEP 3: Check Relay
            STEP 3A: Check Relay Contacts
            STEP 4: Check Combination Meter
            STEP 4A: Check Oil Pressure Warning Wire
    Symptoms
        
            STEP 1: Check System Maintenance
            STEP 1A: Check Hydraulic Oil Level
            STEP 1B: Check Hours on Hydraulic Oil Filter
            STEP 2: Check Hydraulic Systems Function
            STEP 2A: Check Vibration, Steering and Propulsion Systems Function
            STEP 3: Check for Ground
            STEP 3A: Check Hydraulic Oil Lamp Supply Wire
            STEP 4: Check Hydraulic Oil Switch
            STEP 4A: Check Hydraulic Oil Switch Contacts
    Symptoms
        
            STEP 1: Check Dash Lamps
            STEP 1A: Check Engine Warning, Engine Stop and Wait to Start Lamps
            STEP 2: Check Speed Sensor (Combination Meter Tachometer)
            STEP 2A: Check Speed Sensor (Combination Meter Tachometer) Adjustment
            STEP 2B: Check for Damage to Speed Sensor (Combination Meter Tachometer)
            STEP 3 Check Power Circuit
            STEP 3A: Check Fuse Box Fuse
            STEP 3B: Check Wire From Fuse Box to Control Box
            STEP 3C: Check Control Box Chassis Ground
            STEP 3D: Check Fuse Box to Alternator Wire
            STEP 3E: Check the Alternator to Battery Relay Wire
            STEP 3F: Check 75 Amp Fuse
            STEP 4: Check Speed Sensor (Combination Meter Tachometer) Sensor Wiring
            STEP 4A: Check Speed Sensor (Combination Meter Tachometer) Pick-up Wires
            STEP 5: Check Tachometer and Control Box
            STEP 5A: Check Tachometer Signal Wire
    Symptoms
        
            STEP 1: Check Dash Lamps
            STEP 1A: Check Engine Warning, Engine Stop and Wait to Start Lamps
            STEP 2 Check Power Circuit
            STEP 2A: Check Fuse Box Fuse
            STEP 2B: Check Wire From Fuse Box to Combination Meter
            STEP 2C: Check Fuse Box to Alternator Wire
            STEP 2D: Check the Alternator to Battery Relay Wire
            STEP 2E: Check 75 Amp Fuse
            STEP 3: Check Hour Meter Wire
            STEP 3A: Check Hour Meter to Charge Wire
    Symptoms
        
            STEP 1: Check Coolant Temperature Sensor Systems
            STEP 1A: Check Coolant Temperature Gauge on Combination Meter
            STEP 1B: Check for Engine Fault Code
            STEP 2: Check Coolant Temperature Sensor Wires
            STEP 2A: Check Temp. Meter Wire
            STEP 2B: Make Sure Coolant Temperature Sensor is Chassis Grounded
            STEP 3: Coolant Temperature System Validation
            STEP 3A: Check Coolant Temperature Gauge on the Combination Meter
    Symptoms
        
            STEP 1: Combination Meter Fuel Gauge Indication
            STEP 1A: Check Combination Meter Fuel Gauge Indication
            STEP 2: Check Combination Meter Fuel Gauge Wires
            STEP 2A: Check the Fuel Meter Wire
            STEP 2B: Check Fuel Meter Sending Unit Ground Wire
            STEP 3: Verify Combination Meter Fuel Level Gauge Operation
            STEP 3A: Check Combination Meter Fuel Level Gauge Reading
    Symptoms
        
            STEP 1: Check Backup Buzzer Switch
            STEP 1A: Check Backup Buzzer Switch Adjustment
            STEP 1B: Check Backup Buzzer Switch Contacts
            STEP 1C: Check Backup Buzzer Switch to Backup Buzzer Wire
            STEP 2 Check Power Circuit
            STEP 2A: Check Fuse Box Fuse
            STEP 2B: Check Wire From Fuse Box to Battery Backup Buzzer Switch
            STEP 2C: Check Fuse Box to Alternator Wire
            STEP 2D: Check the Alternator to Battery Relay Wire
            STEP 2E: Check 75 Amp Fuse
            STEP 3: Check Backup Buzzer
            STEP 3A: Check Backup Buzzer Ground Wire
    Symptoms
        
            STEP 1: Check Horn Switch
            STEP 1A: Check Horn Switch Contacts
            STEP 1B: Check Horn Assembly
            STEP 1C: Check Horn Switch Output Wire
            STEP 2 Check Power Circuit
            STEP 2A: Check Fuse Box Fuse
            STEP 2B: Check Wire From Fuse Box to Horn Relay Coil
            STEP 2C: Check Wire From Fuse Box to Horn Relay Contact
            STEP 2D: Check Fuse Box to Alternator Wire
            STEP 2E: Check the Alternator to Battery Relay Wire
            STEP 2F: Check 75 Amp Fuse
            STEP 3: Check Horn Relay
            STEP 3A: Test Horn Relay
            STEP 4: Check Horn
            STEP 4A: Check Horn Ground Wire
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Hydraulic Oil Level
            STEP 1B: Check for Hydraulic Leaks
            STEP 2: Check Steering Pump
            STEP 2A: Check Steering Pump Pressure
            STEP 2B: Adjust Steering Pump Pressure
            STEP 3: Check Steering Cylinders
            STEP 3A: Inspect Steering Cylinders and Center Pin for Damage
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Compactor Vibratory Operation Set Up
            STEP 1B: Check Hydraulic Oil Level
            STEP 1C: Check for Hydraulic Leaks
            STEP 2: Check Engine Speed Change Switch
            STEP 2A: Check Engine Speed Change Switch to Fuse Box F8 Wire
            STEP 2B: Check Contacts 4 and 5
            STEP 2C: Check Engine Speed Change Switch to Fuse Box F8 Wire
            STEP 2D: Check Fuse Box to Alternator Wire
            STEP 2E: Check the Alternator to Battery Relay Wire
            STEP 2F: Check 75 Amp Fuse
            STEP 3: Check Vibration Switch
            STEP 3A: Check Wire From Engine Speed Change Switch to Vibration Switch
            STEP 3B: Check Wire From Vibration Switch to Vibration Amplitude Switch LOW
            STEP 3C: Check Wire From Vibration Switch to Vibration Amplitude Switch HIGH
            STEP 3D: Check Vibration Switch Contacts
            STEP 4: Check Vibration Amplitude Switch
            STEP 4A: Check Wire From Vibration Amplitude Switch LOW to Solenoid LOW
            STEP 4B: Check Wire From Vibration Amplitude Switch HIGH to Solenoid HIGH
            STEP 4C: Check Vibration Amplitude Switch Contacts 4 and 5
            STEP 4D: Check Vibration Amplitude Switch Contacts 1and 2
            STEP 5: Check Vibratory Pump
            STEP 5A: Check Vibratory Pump Pressure
            STEP 5B: Adjust Vibratory Pump Pressure
            STEP 6: Check Shaft
            STEP 6A: Check Hydraulic Motor to Vibratory Shaft Splines and Eccentric Shaft Rotation
            STEP 6B: Check Motor for Operation
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Compactor for Vibratory Operation Set Up
            STEP 2: Check Vibration Switch
            STEP 2A: Check Wire From Engine Speed Change Switch to Vibration Switch
            STEP 2B: Check Wire From Vibration Switch to Vibration Amplitude Switch LOW
            STEP 2C: Check Vibration Switch Contacts
            STEP 3: Check Vibration Amplitude Switch
            STEP 3A: Check Wire From Vibration Amplitude Switch LOW to Solenoid LOW
            STEP 3B: Check Vibration Amplitude Switch Contacts
            STEP 4: Check Vibration Amplitude Solenoid
            STEP 4A: Check Vibration Solenoid Operation
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Compactor Vibratory Operation Set Up
            STEP 2: Check Vibration Switch
            STEP 2A: Check Wire From Engine Speed Change Switch to Vibration Switch
            STEP 2B: Check Wire From Vibration Switch to Vibration Amplitude Switch HIGH
            STEP 2C: Check Vibration Switch Contacts
            STEP 3: Check Vibration Amplitude Switch
            STEP 3A: Check Wire From Vibration Amplitude Switch HIGH to Solenoid HIGH
            STEP 3B: Check Vibration Amplitude Switch Contacts
            STEP 4: Check Vibration Amplitude Solenoid
            STEP 4A: Check Vibration Solenoid Operation
    Symptoms
        
            STEP 1: Check Vibration Switch
            STEP 1A: Check Vibration Switch to Forward/Reverse Lever Switch Wire
            STEP 1B: Check Vibration Switch Contacts
            STEP 2: Check Forward/Reverse Lever Switch
            STEP 2A: Check Wire From Forward/Reverse Lever Switch to Vibration Amplitude Switch LOW
            STEP 2B: Check Wire From Forward/Reverse Lever Switch to Vibration Amplitude Switch HIGH
            STEP 2C: Check Vibration Amplitude Switch Contacts
            STEP 3: Check Vibration Amplitude Solenoid
            STEP 3A: Check Vibration Solenoid Operation
    Symptoms
        
            STEP 1: Engine or Start Circuit
            STEP 1A: Crank the Engine
            STEP 1B: Inspect Wiring Harness Connector
            STEP 1C: Check Start Switch to ECM Wire
            STEP 1D: Check for Active Fault Code(s)
            STEP 2 Check Start Circuit
            STEP 2A: Check Battery Voltage
            STEP 2B: Check Neutral Safety Switch
            STEP 2B1: Check the Neutral Safety Switch Adjustment
            STEP 2B2: Check the Neutral Safety Switch Contacts
            STEP 2B3: Check Fuse Box Fuse
            STEP 2B4: Check Wire From Fuse Box to Neutral Safety Switch
            STEP 2B5: Check Fuse Box to Alternator Wire
            STEP 2B6: Check the Alternator to Battery Relay Wire
            STEP 2B7: Check 75 Amp Fuse
            STEP 2B8: Check Neutral Safety Switch to Interlock Relay Coil Wire
            STEP 2C: Check Interlock Relay
            STEP 2C1: Check Fuse F10
            STEP 2C2: Check Start Switch to Interlock Relay Wire
            STEP 2C3: Check Interlock Relay to Fuse Box Wire
            STEP 2C4: Test Interlock Relay.
            STEP 2D:Check Starter Relay
            STEP 2D1: Check Fuse Box to Starter Relay Input Coil Wire
            STEP 2D2: Check Starter Relay Output Coil to Starter Wire
            STEP 2D3: Check Starter Relay Input Contact to Starter Wire
            STEP 2D4: Check Starter Relay Output Contact to Starter Wire
            STEP 2D5: Check Starter to Chassis Ground Wire
            STEP 2D6: Test Starter Relay
            STEP 2E:Check Battery Relay
            STEP 2E1: Check Battery Relay Input Coil Wire to Start Switch
            STEP 2E2: Check Battery Relay Output Coil Wire to Chassis Ground
            STEP 2E3: Check Battery Supply Wire to Battery Relay Input Contact
            STEP 2E4: Test Battery Relay
            STEP 2F:Check Start Switch
            STEP 2F1: Check Start Switch to Battery Relay Output Contact Wire
            STEP 2F2: Check 65 Amp Fuse
            STEP 2F3: Check Start Switch B to BR Contacts
            STEP 2F4: Check Start Switch B to C Contacts
    Symptoms
        
            STEP 1 Check ECM Connector
            STEP 1A: Inspect Wiring Harness Connector
            STEP 2 Check Engine Speed Change Switch
            STEP 2A: Check Engine Speed Change Switch to ECM Connector Wire
            STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Output Contact
            STEP 2C Check Engine Speed Change Switch Contacts
            STEP 3: Check Throttle Relay
            STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector
            STEP 3B: Test Throttle Relay.
    Symptoms
        
            STEP 1 Check ECM Connector
            STEP 1A: Inspect Wiring Harness Connector
            STEP 2 Check Engine Speed Change Switch
            STEP 2A: Check Engine Speed Change Switch to ECM Connector Wire
            STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Output Contact
            STEP 2C Check Engine Speed Change Switch Contacts
            STEP 3: Check Throttle Relay
            STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector
            STEP 3B: Test Throttle Relay.
    Symptoms
        
            STEP 1 Check ECM Connector
            STEP 1A: Inspect Wiring Harness Connector
            STEP 2 Check Engine Speed Change Switch
            STEP 2A: Check Engine Speed Change Switch to Fuse Box F8 Wire
            STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Coil
            STEP 2C: Check Engine Speed Switch Contacts
            STEP 3: Check Power Circuit
            STEP 3A: Check Fuse Box to Alternator Wire
            STEP 3B: Check the Alternator to Battery Relay Wire
            STEP 3C: Check 75 Amp Fuse
            STEP 4: Check Throttle Relay
            STEP 4A: Check Throttle Relay Ground Wire
            STEP 4B: Test Throttle Relay.
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Hydraulic Oil Level
            STEP 1B: Check for Hydraulic Leaks
            STEP 1C: Check Unloader Valve
            STEP 2 Check Directional Control Lever
            STEP 2A: Check Forward/Reverse Lever Cable Connection
            STEP 2B: Check Forward/Reverse Lever Cable Pump Connection
            STEP 2C: Verify Directional Control Lever Adjustment
            STEP 3: Check Charge Pressure (Steering Pump)
            STEP 3A: Check Steering Operation
            STEP 3B: Check Steering Pump Pressure
            STEP 4: Check Propulsion System
            STEP 4A: Check Propulsion Pump Pressure
            STEP 4B: Check Drive Motor Operation
    Symptoms
        
            STEP 1: Check Power Circuit
            STEP 1A: Check Fuse Box Fuse
            STEP 1B: Check Wire From Fuse Box to Foot Brake Switch Wire
            STEP 1C: Check Fuse Box to Alternator Wire
            STEP 1D: Check the Alternator to Battery Relay Wire
            STEP 1E: Check 75 Amp Fuse
            STEP 2: Check Foot Brake Switch
            STEP 2A: Check Foot Brake Switch Adjustment
            STEP 2B: Check Foot Brake Switch to Parking Brake Switch Wire
            STEP 2C: Check the Foot Brake Switch Contacts
            STEP 3: Check Parking Brake Switch and Solenoid
            STEP 3A: Check Parking Brake Switch to Parking Brake Solenoid Wire
            STEP 3B: Check Parking Brake Solenoid to Ground Wire
            STEP 3C: Check the Parking Brake Switch Contacts
            STEP 3D: Check Parking Brake Solenoid Operation
    Symptoms
        
            STEP 1: Check Compactor
            STEP 1A: Check Hydraulic Oil Level
            STEP 1B: Check for Hydraulic Leaks
            STEP 2: Check Speed Change Switch
            STEP 2A: Check Speed Change Switch to Fuse Box F5 Wire
            STEP 2B: Check Speed Change Switch Contacts
            STEP 2C: Check Fuse Box to Alternator Wire
            STEP 2D: Check the Alternator to Battery Relay Wire
            STEP 2E: Check 75 Amp Fuse
            STEP 5: Check Speed Change Solenoid
            STEP 5A: Check Solenoid to Speed Change Switch Wire
            STEP 5B: Check Solenoid to Chassis Ground Wire
            STEP 5C: Check Speed Change Solenoid Operation
Section of Contents.pdf
    Introduction
    Identification
        Compactor Controls Identification
        Compactor Component Identification
    Operation
        Operating Systems Description
        Operating the Compactor
    Maintenance
        Periodic Maintenance
    Testing and Adjustment
        Mechanical Adjustments
        Hydraulic Pump Testing and Adjustment
    Troubleshooting
    Compactor Repair
        Roller
        Center Pin
        Operators Station
        Manual Vibration Control Switch
        Vibratory Control Panel Switches
        Combination Meter
        Parking Brake Button
        Engine Status Lamps
        Engine Start Switch
        Directional Control Lever Cable
        Directional Control Lever Micro-Switches
        Foot Brake Switch
        Battery Relay
        Operator’s Station Relay and Diodes
        Horn
        Hydraulic Oil Filer Switch
        Tachometer Control Box
        Radiator and Cooling System
        Hydraulic Tank
        Engine and Pump Assembly
        Rear End
        Back Up Alarm
        Starter Relay
        Engine Speed Change Switch
        Forward/Reverse Lever Vibration Switch
        Fuses 65 Amp and Above
        Parking Brake Valve
        Vibration Amplitude Solenoid
        Compactor Speed Solenoid
        Orbitrol Steering Valve
    Schematics
    Service Literature
    Specifications
Compactor Repair.pdf
    Install
    Compactor Repair 51_100.pdf
        Remove
        Install
        Install
        Back Up Alarm
        Remove
        Install
                        Starter Relay
        Remove
        Install
                        Engine Speed Change Switch
                        Remove
        Install
                        Forward/Reverse Lever Vibration Switch
        Remove
        Install
                        Fuses 65 Amp and Above
        Remove
        Install
    
                        Parking Brake Valve
        Remove

                        Vibration Amplitude Solenoid
        Remove
        Install
    
                        Compactor Speed Solenoid
        Remove
        Install
        
                        Orbitrol Steering Valve
        Remove
        Install

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