SAKAI SV505-I Series Vibrating Roller Service Repair 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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