Sakai SV400 Series Vibratory Soil Compactor Service Repair Manual

SV400 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 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 i

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 Operator’s 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 ii

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 iii

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 iv

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 v

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 vi

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 vii

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 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 viii

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 ix

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Sakai SV400 Series Vibratory Soil Compactor Service Repair Manual

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