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Sakai SV505-1 Series Shop Manual

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SV505-1 Series Shop Manual
Sakai®

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Summary of Contents for Sakai SV505-1 Series

  • Page 1 SV505-1 Series Shop Manual Sakai®...

  • Page 2: Table Of Contents

    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 Top View ..........................2-4 Operators Station ........................2-5 Compactor Component Identification Rear Drive Hydraulic Hoses ....................2-6 Front Drive Hydraulic Hoses ....................2-7...
  • Page 3 Rear Drive Propulsion Motor....................2-17 Front Drive Propulsion Motor ....................2-18 Vibrator Motor ........................2-19 Electric Components ......................2-20 Instrument Panel and Relays....................2-21 Rear Axle ..........................2-22 Intake System.........................2-23 Exhaust System........................2-24 Cooling Hose and Radiator....................2-25 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 Brake............................2-31 Final Drive ..........................2-32...
  • Page 4 Brake System ...........................3-8 Combination Meter ........................3-9 Monitor Display ........................3-10 Tachometer ..........................3-11 Temperature Gauge........................3-11 Fuel Gauge..........................3-11 Engine Lamps ........................3-12 Starter Switch.........................3-12 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 Switch..................3-14 Engine Diagnostic Switches ....................3-15 Forward/Reverse Lever......................3-15...
  • Page 5 Self Propelled Loading ......................3-27 Working With the Compactor....................3-28 Maintenance Periodic Maintenance Compactor Maintenance ......................4-2 Compactor Component Replacement Schedule...............4-2 Prior to Starting the Compactor ....................4-3 Lifting Compactor with Hoist ....................4-4 Maintenance Procedures Every 10 Hours or Daily..............4-4 Maintenance Procedures Every 50 Hours................4-5 Maintenance Procedures Every 250 Hours................4-6 Maintenance Procedures Every 500 Hours................4-9 Maintenance Procedures Every 1,000 Hours................4-9...
  • Page 6 Measure Vibrator Charge Pressure ..................5-7 Adjust Vibrator Charge Pressure .....................5-8 Measure Steering Circuit Pressure...................5-9 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 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...
  • Page 7 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...
  • Page 8 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...
  • Page 9 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...
  • Page 10 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...
  • Page 11 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...
  • Page 12 Fuel Oil and Grease Rating....................10-5 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 Conversions..............10-9 Metric Drill and Tap Chart....................10-11 Weights and Measures Conversion Factors .................10-15...

  • Page 13: How To Use The Manual

    How to Use the Manual Prior to operation of the compactor read the following sections: • Introduction • System Identification • Familiarization. Use the Maintenance section to schedule and perform maintenance. The maintenance is performed at the following intervals: • Every 10 hours or daily •...

  • Page 14: Panel Symbols

    Panel Symbols The symbols listed below appear in the combination meter. The lamps are located adjacent to the meter. Battery Charge Symbol – Illuminates when charging system is not functioning correctly. The engine must be running for the lamp to illuminate. Hydraulic Oil Filter Symbol –...
  • Page 15 Engine Stop Lamp – Illuminates when the engine must be shut down. Shut down the engine when this lamp is on. Warning Lamp – Illuminates when water has accumulated in the fuel sedimeter. Drain the sedimeter. The lamp will extinguish when the water is removed. Wait to Start Lamp - Illuminates when engine electronic control module is performing a self-diagnostics test.

  • Page 16: General Safety Instructions

    Non-approved modifications can pose safety-related problems. Before making any modifications, consult your distributor. Non-approved modifications to this machine can cause personal injury and machine damage. Sakai accepts no responsibility for un-approved modifications. • Follow all worksite rules and working procedures.
  • Page 17 • Decide in advance the means of communication in case of an emergency. Know the location and use of a fire extinguisher and first-aid kit. • Thoroughly understand the performance of your machine and correctly operate the machine to meet the requirements at the job site. Operating the machine beyond its capability can lead to an accident.
  • Page 18 • Inattentive driving or driving relying on guesswork can cause an accident. Use extreme caution when workers are in the path of the roller or around it. In case of danger, stop and sound the horn. Proceed when the area is clear of personnel or obstructions. •...
  • Page 19 • When connecting the batteries from another machine for jump-starting, do not allow the machines to touch, wear safety goggles. Connect the positive (+) jumper cable first and disconnect the negative (-) jumper cable first. When connecting the negative (-) jumper cable to ground, select an area on the machine as far from the battery as possible.
  • Page 20 Below is an example of a tag used to secure an engine from operation. This page may be removed and the tag cut out. There is a front and back view of the tags. It is recommended to join the front with the back and laminate the tag.
  • Page 21 The table below lists commonly used Caution, Warning and Danger symbols. Denotes there is an extreme hazard. If you fail to take proper precautions, it is highly likely that you could be killed or seriously injured (the symbol color is red). Denotes there is a hazard.
  • Page 22 Sounding horn is required for safe operation. Hot surface during and after machine operation. High-pressure hydraulic leak check and warning. No open flames allowed. No open flame, smoking or ignition allowed. Area is pinch hazard when machine is operating. Respiratory equipment is required in work area. No high speed on down hill grade with machine.
  • Page 23 Safety shoes required in work area. Tire penetration with hot spark explosion warning. No unauthorized people in work area. Use spark proof illumination when inspecting this area. Use the proper tool for the proper job. Ventilation required to eliminate toxic fumes. Disconnect battery prior to welding on machine.
  • Page 24 The safety decals used on the SV505 are shown below. 1-13...
  • Page 25 1-14...

  • Page 26: Acronyms And Abbreviations

    Acronyms and Abbreviations The table below contains commonly used acronyms and abbreviations. American Petroleum Institute ASTM American Society of Testing and Materials British Thermal Unit °C Celsius °F Fahrenheit CARB California Air Resources Board C.I. D. Cubic Inch Displacement Electronic Control Module Environmental Protection Agency Gross Vehicle Weight Horsepower...

  • Page 27: Compactor Controls Identification

    Compactor Controls Identification This procedure identifies all of the components used in normal operation of the SV505 compactor. The first graphic illustrates travel directions when sitting in the operator’s seat The model number is stamped onto a metal tag and located on the vibration control panel (upper frame of graphic).

  • Page 28: Left View

    Left View 1. Operator information panel 2. Steering wheel 3. Radiator access door 4. Fuel tank 5. Battery box 6. Battery box door 7. Hood.

  • Page 29: Right View

    Right View 1. Operators seat 2. Forward/Reverse lever and vibration control button 3. Operator information panel door 4. Roller scraper plate 5. Left steering cylinder 6. Vibration control panel 7. Fuel tank 8. Fuel tank door.

  • Page 30: Top View

    Top View 1. Roller 2. Brake pedal 3. Hydraulic tank 4. Radiator 5. Fuel tank door 6. Engine oil fill 7. Air filter 8. Pneumatic tire.

  • Page 31: Operators Station

    Operators Station 1. Combination meter 2. Parking brake button 3. Starter switch 4. Steering wheel 5. Vibration amplitude switch (minimum or maximum) 6. Vibration control switch (shift lever button or continuous) 7. Vibration speed switch (minimum or maximum) 8. Shift lever and momentary vibration button 9.

  • Page 32: Compactor Component Identification

    Compactor Component Identification This procedure will illustrate the systems used in the SV505 compactor and show illustrated views of subcomponents. Rear Drive Hydraulic Hoses 1. Hydraulic tank 2. Rear hydraulic propulsion motor 3. Forward travel high pressure hydraulic hose 4. Motor to pump hydraulic hose 5.

  • Page 33: Front Drive Hydraulic Hoses

    Front Drive Hydraulic Hoses 1. Return hydraulic hose 2. Rear propulsion motor 3. Reverse travel high pressure hose 4. Forward travel high pressure hose 5. Front propulsion motor 6. Hydraulic motor return hose.

  • Page 34: Steering Hoses

    Steering Hoses 1. Orbitrol 2. Right turn high pressure hydraulic hose 3. Right steering cylinder 4. Left turn high pressure hydraulic hose 5. Right turn high pressure hydraulic hose 6. Feed hydraulic hose 7. Filter to propulsion pump hydraulic hose 8.

  • Page 35: Hydraulic Brake Hose Network

    Hydraulic Brake Hose Network 1. Right disc 2. Brake valve to right brake disc hydraulic hose 3. Brake valve to left brake disc hydraulic hose 4. Left disc 5. Filter inlet charge hose 6. Hydraulic filter 7. Filter to brake valve hydraulic hose 8.

  • Page 36: Brake Pedal And Linkage

    Brake Pedal and Linkage 1. Brake pedal 2. Rod 3. Forward/Reverse lever neutral rod 4. Forward/Reverse lever neutral rod 5. Forward/Reverse lever neutral rod 6. Foot brake switch 7. Return Spring. 2-10...

  • Page 37: Center Pin

    Center Pin 1. Yoke 2. Cover 3. Upper bracket 4. Grease fitting 5. Grease fitting 6. Roller bearing 7. Lower bracket 8. Bearing. 2-11...

  • Page 38: Vibrator Hydraulic Hoses

    Vibrator Hydraulic Hoses 1. Hydraulic tank 2. Pump to pump hydraulic hose 3. High pressure hydraulic hose (port B) 4. Pump to filter hydraulic hose 5. Hydraulic filter to hydraulic tank hydraulic hose 6. Return hydraulic filter 7. High pressure hydraulic hose (port A) 8.

  • Page 39: Drum And Vibrator (Model D)

    Drum and Vibrator (Model D) 1. Damper 16. Disc 2. Propulsion motor 17. Roller Bearing 3. Axel shaft 18. Oil seal 4. Roller bearing 19. Shaft 5. Drum 20. Axle shaft 6. Plug 21. Roller bearing 7. Housing 22. Vibrator shaft 8.

  • Page 40: Drum And Vibrator Motor (Model T And Tf)

    Drum and Vibrator Motor (Model T and TF) 1. Holder 15. Cover 2. Damper 16. Oil seal 3. Propulsion motor 17. Disc 4. Axle shaft 18. Roller bearing 5. Roller bearing 19. Oil seal 6. Tamping drum 20. Shaft 7. Plug 21.

  • Page 41: Fuel System

    Fuel System 1. Feed pump to filter pipe 2. Feed pump 3. Fuel tank to sedimeter hose 4. Fuel filter 5. Fuel sending unit 6. Sedimeter to feed pump hose 7. Sedimeter 8. Tank hose 9. Fuel filter 10. Filter to injection pump pipe 11.
  • Page 42 Fuel Controls 2-16...

  • Page 43: Hydraulic Propulsion, Vibrator And Steering Pump Assembly

    Hydraulic Propulsion, Vibrator and Steering Pump Assembly 1. Vibrator pump low amplitude port 12. Vibrator pump amplitude selector valve 2. Vibrator pump high amplitude port 13. Vibrator pump charge relief valve 3. Vibrator pump high-pressure relief port 14. Vibrator pump high pressure relief valve 4.

  • Page 44: Rear Drive Propulsion Motor

    Rear Drive Propulsion Motor 1. Speed shift circuit port (operate servo piston) 2. Drain port 3. Speed select solenoid valve 4. Reverse travel port 5. Forward travel port. 2-18...

  • Page 45: Front Drive Propulsion Motor

    Front Drive Propulsion Motor 1. Forward travel port 2. Reverse travel port 3. Cylinder block 4. Piston 5. Swash plate 6. Fill hole 7. Reduction gear 8. Drain port 9. High pressure gauge port (B) 10. High pressure gauge port (A) 11.

  • Page 46: Vibrator Motor

    Vibrator Motor 1. Low side delivery port 2. High side delivery port 3. Drain port. 2-20...

  • Page 47: Electric Components

    Electric Components 1. Right headlamp 17. Back up alarm switch 2. Alternator 18. Interlock switch 3. Intake air heater 19. Brake switch. 4. Starter motor 5. Tachometer 6. Amplitude select switch 7. Back up alarm 8. Battery relay 9. Fuel tank 10.

  • Page 48: Instrument Panel And Relays

    Instrument Panel and Relays 1. Lighting switch 2. Speed selector switch 3. CONT/MAN selector switch 4. Amplitude selector switch 5. Starter switch 6. Panel (combination meter) 7. Parking brake switch 8. Fuse box 9. Diode 10. Lamp check relay 11. Interlock relay 12.

  • Page 49: Rear Axle

    Rear Axle 1. Final drive 2. Tires 3. Brakes 4. Differential. 2-23...

  • Page 50: Intake System

    Intake System 1. Restriction indicator 2. Air cleaner 3. Intake hose 4. Turbocharger 5. Feed pipe. 2-24...

  • Page 51: Exhaust System

    Exhaust System 1. Muffler 2. Exhaust pipe 3. Turbocharger 4. Exhaust pipe. 2-25...

  • Page 52: Cooling Hose And Radiator

    Cooling Hose and Radiator 1. Radiator overflow tank 2. Radiator 3. Oil cooler 4. Radiator inlet hose 5. Radiator outlet hose 6. Drain hose. 2-26...

  • Page 53: Travel Controls (Forward/Reverse)

    Travel Controls (Forward/Reverse) 1. Interlock switch 2. Forward/Reverse lever 3. Reverse alarm switch 4. Cable 5. Control lever 6. Vibrator switch. 2-27...

  • Page 54: Hydraulic Coupling

    Hydraulic Coupling 1. Hub 2. Flange 3. Bolt 4. Flywheel 5. Bolt. 2-28...

  • Page 55: Engine Mount

    Engine Mount 1. Front engine mount 2. Rear engine mount. 2-29...

  • Page 56: Differential (1Of 2)

    Differential (1 of 2) 1. Housing 17. Washer 2. Bevel pinion shaft 18. Gear 3. Bearing 19. Bearing 4. Shim 20. Seal 5. Shim 21. Bolt. 6. Spacer 7. Housing 8. Bolt 9. Seal 10. Gear 11. Nut 12. Cover 13.

  • Page 57: Differential (2 Of 2)

    Differential (2 of 2) 1. O-ring 2. Cover 3. Vent 4. Bolt 5. Seal washer 6. Seal washer 7. Plug 8. Snap ring 9. Magnetic plug 10. Ring 11. Housing. 2-31...

  • Page 58: Brake

    Brake 1. Spring 16. Pinion 2. O-ring 17. O-ring 3. O-ring 18. Locking plate 4. Grub bolt 19. Hexagon bolt 5. Vent 20. Bolt 6. Bolt 21. Nut 7. Seal washer 22. Lock washer 8. Bolt 23. Intermediate brake disc. 9.

  • Page 59: Final Drive

    Final Drive 1. Stud 17. Planetary gear 2. Spring washer 18. Bearing 3. Bolt 19. Circlip 4. Seal 20. Ring gear 5. Bearing 21. Ring gear support 6. Wheel stud 22. Friction washer 7. Half shaft 23. Planetary carrier gear 8.

  • Page 60: Orbitrol

    Orbitrol 1. Dust seal ring 2. Lip-seal 3. Bearing assembly 4. Ring 5. Cross pin 6. Spring set 7. Housing, spool and sleeve (not supplied separately) 8. Thread bushing 9. Ball 10. Housing, spool and sleeve (not supplied separately) 11. Complete relief valve without seat 12.

  • Page 61: Steering Cylinder

    Steering Cylinder 1. Grease fitting 15. Piston 2. Piston rod 16. Nut 3. Spherical bearing 17. Tube assembly. 4. Ring 5. Dust seal 6. Stopper 7. End cap 8. Back up ring 9. O-ring 10. Bushing 11. Back up ring 12.

  • Page 62: Operating Systems Description

    Operating Systems Description The SV505 compactor series is comprised of the following operating systems: • Diesel Engine • Hydraulic Drive System • Hydraulic Vibratory System • Hydraulic Steering System • Brake System • Operating Controls. All of the above listed systems integrate together and allow the compactor to operate as designed. This procedure will define the systems and provide a description of the components of each system.
  • Page 63 Hydraulic Drive System The diagram below illustrates the drive system for the SV505 compactor: 1. Engine 2. Coupling 3. Propulsion pump assembly a. Control valve b. Charge relief valve c. Servo cylinder d. High pressure relief valve e. Check valves 4.

  • Page 64: Hydraulic Drive Circuit

    Hydraulic Drive Circuit The hydraulic propulsion is comprised of the following items: • Propulsion pump (3) • Rear propulsion motor (6) • Front propulsion motor (16) • Rear axel assembly (7) • Drum (15) • Brake valve (8). NOTE: The reference numbers (*) are used in the hydraulic drive circuit on the preceding page. Propulsion Pump The propulsion pump is a variable pump.

  • Page 65: Hydraulic Vibratory System

    Hydraulic Vibratory System The diagram below illustrates the vibratory system for the SV505 compactor: 1. Engine 2. Coupling 3. Propulsion pump assembly 4. Vibrator pump Amplitude select valve Charge relief valve High pressure relief valves Check valves 5. Steering pump 6.

  • Page 66: Hydraulic Vibratory Circuit

    Hydraulic Vibratory Circuit The vibratory system is comprised of the following components: • Vibrator pump (4) • Vibrator motor (6) • Vibrator (7). Vibrator Pump A variable displacement pump is used for the pump. Changing the pump swash plate angle varies the piston stroke to allow for the selection of low amplitude, neutral and high amplitude.

  • Page 67: Hydraulic Steering System

    Hydraulic Steering System The diagram below illustrates the hydraulic steering system for the SV505: 1. Engine 2. Coupling 3. Propulsion pump assembly 4. Vibrator pump 5. Steering pump 6. Orbitrol Relief valve b. Check valve 7. Steering Cylinder Piston rods b.

  • Page 68: Hydraulic Steering Circuit

    Hydraulic Steering Circuit The hydraulic steering system is comprised of the following components: • Steering/charge pump (5) • Orbitrol (6) • Steering cylinders (7) • Hydraulic filter (8). The steering mechanism is articulated and located so the compactor articulates between the front and rear frame.

  • Page 69: Brake System

    Brake System The diagram below illustrates the brake system for the SV505. Brake System 1. Brake pedal 2. Brake pedal switch 3. Forward/Reverse lever 4. Return to neutral rod 5. Return to neutral rod 6. Parking brake switch 7. Brake valve 8.

  • Page 70: Combination Meter

    Operator station controls are defined by function below: Combination Meter 1. Monitor display – Illuminates when an alarm condition exists. 2. Tachometer – Indicates engine speed. 3. Hour meter – Indicate amount of time compactor has operated. 4. Temperature gauge – Indicates temperature. 5.

  • Page 71: Monitor Display

    Monitor Display 1. Battery charge lamp – Illuminates when the battery is not charging to specifications. 2. Hydraulic filter warning lamp – Illuminates when the hydraulic filter is restricted. 3. Turn signal indicator lamp (optional) – Illuminates when a turn signal is engaged. 4.

  • Page 72: Tachometer

    Tachometer The tachometer is located in the combination meter. The tachometer indicates engine speed in rpm. An hour meter is located below the tachometer and indicates total compactor operating time. The service intervals are based on the hour meter. Temperature Gauge The temperature gauge measures coolant temperature of the engine.

  • Page 73: Engine Lamps

    Engine Lamps All three lamps illuminate when the engine is cranked and extinguish when the engine is started. If they do not illuminate and extinguish, shutdown the engine and troubleshoot the condition. ENGINE STOP Lamp When the engine stop lamp illuminates the engine must be shut down and troubleshoot the condition prior to operation.

  • Page 74: Horn Button

    Horn Button The horn button is located in the center of the steering wheel. Press the button to activate the horn. Vibrator Amplitude Switch To reduce the possibility of equipment damage, do not operate the vibration option unless the engine rpm is set to full.

  • Page 75: Forward/Reverse Lever Vibration On/Off Switch

    Forward/Reverse Lever Vibration ON/OFF Switch The ON/OFF switch on the forward/reverse lever can be used to activate vibration when the following conditions are met: • Vibration amplitude switch in minimum or maximum vibration position. • Vibration selector switch in the lever position. Push the button on the lever to activate the vibration.

  • Page 76: Engine Diagnostic Switches

    Engine Diagnostic Switches Two switches that communicate with the engine ECM are located in the dash riser of the compactor. The switches are the diagnostic ON/OFF switch and the increment/decrement switch. ® Do not use these switches unless directed by a Cummins representative.

  • Page 77: Fuse Box

    Fuse Box To reduce the possibility of equipment damage secure power to the fuse box by turning the key switch to the OFF position Fuses protect the electrical and electrical components from damage because of a short circuit. Change any fuse that is corroded or does not sit in the fuse holder securely.

  • Page 78: Operating The Compactor

    Operating the Compactor This procedure outlines the correct operating procedure for the compactor. For safe operation of the compactor all operating instructions must be followed. Release Brakes for Towing To reduce the possibility of personal injury and equipment damage do not attempt to release the brake immediately after the engine is stopped.

  • Page 79: Before Starting Inspection

    Before Starting Inspection To reduce the possibility of personal injury and equipment damage, only allow one operator on the compactor at one time. To reduce the possibility of personal injury and equipment damage, operate the compactor from the operator seat only. To reduce the possibility of personal injury and equipment damage, make sure the steering bar is in the carrying position.

  • Page 80: Starting The Engine

    Starting the Engine To reduce the possibility of personal injury, inspect the area around the compactor for personal that are not necessary. Sound the horn prior to starting. Set the engine speed change switch to the IDLE position. Turn the starter switch to the ON position and make sure the following lamps are illuminated on the monitor: •...
  • Page 81 To reduce the possibility of equipment damage when starting the engine: • Do not allow the key switch to remain in the start position longer than 15 seconds. • If the engine does not start in 15 seconds, allow 30 seconds for the starter to cool down. •...

  • Page 82: Traveling

    Traveling To reduce the possibility of personal injury, inspect the area around the compactor for personnel that are not necessary. Sound the horn prior to starting. To reduce the possibility of personal injury and equipment damage, the compactor must be adjusted to the turtle speed when operated on a steep slope.

  • Page 83: Stopping And Parking

    The compactor tends to have blind spots in the rear. To reduce the possibility of personal injury and/or equipment damage, make sure nothing is behind the compactor prior to placing the forward/reverse lever in the reverse position. Avoid abrupt operation of the forward/reverse lever. The hydraulic drive system responds to the speed the lever travels and the location of the lever.

  • Page 84: Stopping The Engine

    Stopping the Engine To reduce the possibility of equipment damage: • Do not suddenly shut down a hot engine, except in emergency conditions. • Do not shut down an overheating engine, move the engine speed selector switch to the idle position and allow the engine to cool down.
  • Page 85 Set the vibration amplitude switch to the desired position. Clockwise to OFF position is minimum vibration. Counter clockwise to OFF position is maximum vibration. To reduce the possibility of equipment damage: • Do not operate the vibrator on a hard surface such as cement, concrete or steel plates.

  • Page 86: Loading Using A Winch Equipped Trailer

    Loading Using a Winch Equipped Trailer To reduce the possibility of personal injury and equipment damage: • Use ramps of the proper width, length and thickness to allow for safe compactor load. • If the ramps deflect under load, place wooden blocks under the ramp to reinforce it.
  • Page 87 To reduce the possibility of personal injury and equipment damage: • To reduce the possibility of the compactor slipping on the ramps, keep drum and ramps free from any debris and oil. • Do not attempt to steer the compactor while on ramp.

  • Page 88: Self Propelled Loading

    Self Propelled Loading To reduce the possibility of personal injury and equipment damage: • Use ramps of the proper width, length and thickness to allow for safe compactor load. • If the ramps deflect under load, place wooden blocks under the ramp to reinforce it. •...

  • Page 89: Working With The Compactor

    Working With the Compactor To reduce the possibility of personal injury and equipment damage: • When traveling up an incline the compactor must be operated at low speed. • Do not attempt to shift to high speed when traveling up an incline. The compactor can slip during the speed change.
  • Page 90 • Always use Sakai genuine parts for replacement. • Use lubricants recommended by Sakai. Never mix different brands of lubricants. • When checking hydraulic oil level, engine oil level, or changing hydraulic, fuel and engine oil and filters, make sure dirt does not enter the system.

  • Page 91: Compactor Maintenance

    Compactor Maintenance Schedule System Component Check engine oil level. Add as necessary. Every 10 Hours or Check coolant level. Add as necessary. Daily Check fan belt tension and adjust as necessary. Check hydraulic oil level. Add as necessary. Check battery electrolyte level. Add as necessary. Every 50 Hours Check fuel filter sediment and water.

  • Page 92: Prior To Starting The Compactor

    Prior to Starting the Compactor Checking the compactor daily prior to operation is a must. Before starting the engine and operating the compactor, walk around the compactor and check for: • Loose and missing bolts and nuts • Hydraulic oil leaks •...

  • Page 93: Lifting Compactor With Hoist

    Lifting Compactor with Hoist To reduce the possibility of personal injury and equipment damage: • Only qualified personnel can raise and lower the compactor with a hoist. • Use the appropriate lifting cables. • Lock the articulation of the compactor by placing the locking bar in the lock position.

  • Page 94: Maintenance Procedures Every 50 Hours

    Check the fan belt for wear and damage. Replace the fan belt if damaged. Refer to the Operation and Maintenance Manual, QSB4.5 and QSB6.7 Engine, Bulletin 4021531 for engine information Maintenance Procedures Every 50 Hours The hydraulic tank oil level sight gauge is located on the side of the hydraulic tank.

  • Page 95: Maintenance Procedures Every 250 Hours

    Check the fuel filter sedimeter for accumulation of water. If there is water in the fuel filter sedimeter, drain the water out using the drain plug. Check the air cleaner restriction indicator. If the red float reaches the SERVICE mark, replace the air cleaner.
  • Page 96 Check the vibratory motor oil level. If the vibratory motor oil level is below the level plug, remove the fill plug and add oil. Apply grease to the brake linkages. To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity.
  • Page 97 Apply grease at the 4 locations on the center pin. There are 2 steering cylinders. One cylinder is located on each side of the compactor. Each cylinder has 2 grease locations. Apply grease to the steering cylinders. Check the transmission oil level. Add oil as necessary through the fill port.

  • Page 98: Maintenance Procedures Every 500 Hours

    Maintenance Procedures Every 500 Hours Change the hydraulic return and line filter. Change the fuel filter. Refer to the Operation and Maintenance Manual, QSB4.5 and QSB6.7 Engine, Bulletin 4021531 for fuel filter procedure. Check for loose directional control linkage nuts. If the nuts are loose, adjust the linkage and tighten the nuts.
  • Page 99 To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. To reduce the possibility of equipment damage, do not over fill the vibrator. Rotate the roller until the drain plug is located at the bottom of the roller.
  • Page 100 Rotate the wheels until the final drive drain plug is at the lowest position. Remove the drain plug and drain the oil. Rotate the wheels until the final drain plug is parallel with the ground. Fill the oil through the drain port until the oil flows out of the final drive.
  • Page 101 To reduce the possibility of personal injury, wear safety glasses when removing and cleaning the air filter element. Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. When the red float of the air filter restriction indicator reaches the service line the filter must be cleaned or replaced.
  • Page 102 Not using a battery or leaving it in storage for a long period of time can cause battery plate damage. For long-term storage, tighten the battery cell caps, store in a cool dry location and check the level of charge monthly. Maintain a charge above 75%, In cold weather, start the engine with a battery charge at 100%.

  • Page 103: Long Term Storage

    Long Term Storage When winter is over, change the oil and fuel to comply with the weather. Refer to the Specifications section of this manual DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE COMBUSTIBLE VAPORS. These vapors can be sucked through the air intake system and cause engine acceleration and over speeding that can result in a fire, an explosion, and extensive property damage.
  • Page 104 Booster Cable Connection To reduce the possibility of personal injury and equipment damage using booster cables: • Make sure the starter switch is in the OFF position. • Batteries emit explosive gasses. Do not smoke when working with batteries. Keep flames and sparks away from the battery.
  • Page 105 Disconnect Booster Cables: • Disconnect the negative (-) booster cable from chassis ground. • Disconnect the negative (-) booster cable from the negative (-) booster supply terminal. • Disconnect the positive (+) booster cable from the positive (+) booster supply terminal. •...

  • Page 106: Testing And Adjustment

    Testing and Adjustment This section is divided into two procedures: • Mechanical Adjustments – Adjustments to seat and scraper. • Hydraulic Pump Testing and Adjustment – Testing and adjustment for the propulsion, steering and vibratory pumps. Seat Adjustment To reduce the possibility of personal injury and equipment damage, the operator must adjust the seat correctly prior to operating the compactor.

  • Page 107: Measure Hydraulic Pressure Main Propulsion Circuit

    SV505TF To adjust scraper: • Loosen scraper mounting bolts and nuts. • Adjust scraper to 20 mm [0.79 in] distance from the drum. • Tighten bolts and nuts. Measure Hydraulic Pressure Main Propulsion Circuit Install a 9/16 18UNF adapter (1) into the 0 to 60 MPa [0 to 9,000 psi] pressure gauge.

  • Page 108: Adjust Hydraulic Pressure Main Propulsion Circuit

    Adjust Hydraulic Pressure Main Propulsion Circuit Multi-function valve (1) is for forward travel. Multi-function valve (2) is for reverse travel. Each has an adjustment screw and it is secured by a lock nut. Rotating the adjusting screw: • Clockwise = increases pressure •...

  • Page 109: Measure Propulsion Charge Pressure

    Measure Propulsion Charge Pressure Install a 9/16 18UNF adapter (1) into the 0 to 5 MPa [0 to 700 psi] pressure gauge. To reduce the possibility of personal injury and equipment damage, the compactor must be on level ground with the parking brakes set and chocks under tires.

  • Page 110: Measure Parking Brake Release Pressure

    Measure Parking Brake Release Pressure Install gauge adapter into the 0 to 5 MPa [0 to 700 psi] pressure gauge. To reduce the possibility of personal injury and equipment damage, the compactor must be on level ground with the parking brakes set and chocks under tires.

  • Page 111: Adjust Vibrator Circuit Pressure

    To reduce the possibility of personal injury and equipment damage, the compactor must be on level ground with the parking brakes set and chocks under tires. Park the compactor on level ground, set the parking brake and chock tires. The temperature of the hydraulic oil must 50° ± 5°C [122° ±...

  • Page 112: Measure Vibrator Charge Pressure

    Loosen the lock nut (1) on the defective relief valve. Remove the relief valve. Install a new relief valve and tighten the lock nut 176 N●m [130 ft-lb]. Measure Vibrator Charge Pressure Install a 9/16 18UNF adapter (1) into the 0 to 5 MPa [0 to 700 psi] pressure gauge.

  • Page 113: Adjust Vibrator Charge Pressure

    To reduce the possibility of personal injury and equipment damage, the compactor must be on level ground with the parking brakes set and chocks under tires. Park the compactor on level ground, set the parking brake and chock the tires. Make sure the forward/reverse lever is in the neutral position.

  • Page 114: Measure Steering Circuit Pressure

    Measure Steering Circuit Pressure Install an adapter (1) into the 0 to 25 MPa [0 to 3,500 psi] pressure gauge. To reduce the possibility of personal injury and equipment damage, the compactor must be on level ground with the parking brakes set and chocks under tires.

  • Page 115: Adjust Forward/Reverse Cable

    Adjust Forward/Reverse Lever Cable When the pump fails to stay in neutral position or the forward/reverse cable has been replaced, the cable will need to be adjusted. Secure the propulsion lever (2) in the neutral position. • Place the forward/reverse lever (2) in the neutral position. •...

  • Page 116: Troubleshooting

    Troubleshooting Guidelines To reduce the possibility of personal injury and equipment damage, adhere to all safety warnings in this manual. Understand the General Safety Instructions procedure prior to beginning troubleshooting. To reduce the possibility of personal injury and equipment damage, park the compactor on level ground, engage parking brake, set safety pins and chock the wheels prior to troubleshooting.

  • Page 117: Wiring Diagram Color Codes

    Wiring Diagram Color Codes Wiring Diagram The wiring diagram is created in basic colors for ease of individual circuit identification. The colors represent circuit type. Below are the colors for the circuits in the wiring diagram: • Red – DC voltage •...
  • Page 118 Symbol on Wiring Diagram Wire Color on Compactor White with Yellow stripe Yellow Yellow with Black stripe Yellow with Green stripe Yellow with Blue stripe Yellow with Red stripe Yellow with White stripe Gray Orange Sky Blue Pink...

  • Page 119: Engine Warning Lamp Is Illuminated

    Engine Warning Lamp is Illuminated To reduce the possibility of personal injury and equipment damage, always shut down the compactor when the Engine Warning Lamp is illuminated. Symptoms Under normal operation, the engine warning lamp will illuminate when the key switch is energized and extinguish when the engine has started.
  • Page 120 Troubleshooting Summary 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...
  • Page 121 STEP 1: Check for Active Fault Code(s) STEP 1A: Check Lamp Illumination Condition: Start the engine. Action Specifications / Repair Next Step The engine warning lamp will illuminate Did engine start and lamp extinguish? Repair Complete when the key switch is energized and extinguish when the engine has started.
  • Page 122 STEP 2 Check Wiring Harness STEP 2A: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...

  • Page 123: Engine Stop Lamp Is Illuminated

    Engine Stop Lamp is Illuminated To reduce the possibility of personal injury and equipment damage, always shut down the compactor when the Engine Warning Lamp is illuminated. Symptoms Under normal operation, the engine stop lamp will illuminate when the key switch is energized and extinguish when the engine has started.
  • Page 124 Troubleshooting Summary 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 Stop Lamp Wire...
  • Page 125 STEP 1: Check for Active Fault Code(s) STEP 1A: Check Lamp Illumination Condition: Start the engine. Action Specifications / Repair Next Step The engine stop lamp will illuminate Did engine stop and lamp extinguish? Repair Complete when the key switch is energized and extinguish when the engine has started.
  • Page 126 STEP 2 Check Wiring Harness STEP 2A: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...

  • Page 127: Wait To Start Lamp Is Illuminated

    Wait to Start Lamp is Illuminated To reduce the possibility of equipment damage, do not attempt to start the engine when the wait to start lamp is illuminated. Symptoms The ECM performs a system diagnostics check on the engine when the key switch is turned to the ON position.
  • Page 128 Troubleshooting Summary 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 6-13...
  • Page 129 STEP 1: Check for Active Fault Code(s) STEP 1A: Check Lamp Illumination Condition: Turn the key switch to the ON position. Action Specifications / Repair Next Step The wait to start lamp will illuminate Did wait to start lamp extinguish? Repair Complete when the key switch is energized and extinguish when the ECM has completed...
  • Page 130 STEP 2 Check Wiring Harness STEP 2A: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...

  • Page 131: Vibration Lamp Does Not Illuminate When Vibration Engaged

    Vibration Lamp Does Not Illuminate When Vibration Engaged Symptoms The vibration lamp on the combination meter does not illuminate when the high or low amplitude is engaged. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Vibration Lamp Does Not Illuminate When Vibration Engaged.
  • Page 132 Troubleshooting Summary STEP 1: Will the Engine Run Full Speed STEP 1A: Check Engine Full Speed Operation STEP2: Does the Compactor Operate in High and Low Amplitude Vibration STEP 2A: Operate Compactor at Low Amplitude Vibration STEP 2B: Operate Compactor at High Amplitude Vibration STEP 3: Check Vibration Lamp STEP 1A: Check Vibration Lamp STEP 4: Check Harness Connectors...
  • Page 133 STEP 1: Will Engine Run at Full Speed STEP 1A: Check Full Speed Operation Condition: Start the engine. Move the engine speed change switch to the FULL position. Action Specifications / Repair Next Step Did the engine reach full speed? Check for engine speed indication on tachometer.
  • Page 134 STEP 2B: Operate Compactor at High Amplitude Vibration Condition: Start the engine. Move the engine speed select switch to the full position. Set the vibration amplitude switch to the high setting. Turn the vibration selector switch to the CONT. position. Action Specifications / Repair Next Step...
  • Page 135 STEP 4: Check Harness Connectors STEP 4A: Check Connectors for Damage Condition: Key switch OFF Open access door on steering column. The diode unit is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for diode unit location. Disconnect the wiring harness from the diode unit.
  • Page 136 STEP 5: Check Vibration Lamp Wires STEP 5A: Check Supply Wire From Vibration Lamp to Diode Unit Condition: Key switch OFF Open access door on steering column. The diode unit is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for diode unit location.
  • Page 137 STEP 5B: Check Wire From Diode Unit to Low Side Input of Vibration Solenoid Condition: Key switch OFF Open access door on steering column. The diode unit is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for diode unit location.
  • Page 138 STEP 6: Check Diode Unit STEP 6A: Check Compactor Low Amplitude Side of Diode Condition: Key switch OFF Open access door on steering column. The diode unit is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for diode unit location.
  • Page 139 • Place one multimeter test lead on the Repair pin in the diode the solenoid high Contact Sakai America for authorization. Replace the side wire connects to. Combination Meter; refer to the Combination Meter • Place the remaining multimeter test procedure in the Compactor Repair section.

  • Page 140: Parking Brake Lamp Does Not Illuminate When Parking Brake Engaged

    Parking Brake Lamp Does Not Illuminate When Parking Brake Engaged Symptoms When the operator engages the parking brake the lamp on the combination meter does not illuminate. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Parking Brake Lamp Does Not Illuminate When Parking Brake Engaged problem.
  • Page 141 Troubleshooting Summary STEP 1: Check Parking Brake 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 Supply Wire From Parking Brake Switch to Parking Brake Lamp STEP 4: Check Parking Brake Switch STEP 4A: Check Parking Brake Switch Contacts 6-26...
  • Page 142 STEP 1: Check Parking Bake Lamp STEP 1A: Check Parking Brake Lamp Condition: Key switch OFF Remove operator’s station front cover. Refer to the Combination Meter procedure in the Compactor Repair Section. Action Specifications / Repair Next Step Replace parking brake lamp with known Did Parking Brake Lamp Illuminate? Repair Complete good lamp.
  • Page 143 STEP 3: Check Parking Brake Lamp Wire STEP 3A: Check Parking Brake Supply Wire Condition: Key switch OFF Remove operator’s station front cover. Refer to the Combination Meter procedure in the Compactor Repair Section. Disconnect the parking brake lamp supply wire from the paring brake switch. Disconnect the Combination Meter 6-pin B wire harness connector from the combination meter.

  • Page 144: Engine Oil Pressure Lamp Illuminated

    Engine Oil Pressure Lamp Illuminated Symptoms The engine oil pressure lamp is illuminated when the engine is running. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot an Engine Oil Pressure Lamp Illuminated problem. Start by performing Step 1 troubleshooting.
  • Page 145 Troubleshooting Summary 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...
  • Page 146 STEP 1: Check for Active Fault Code(s) STEP 1A: Check for Active Fault Code(s) Condition: Turn keyswitch to ON position Open diagnostic switch access cover on steering column. Action Specifications / Repair Next Step Verify active fault codes. Engine warning or stop lamp flashing fault codes? Repair Complete •...
  • Page 147 STEP 2B: Check for Short Circuit in ECM Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Check for Short Circuit in ECM connector. Less than 10 ohms? Repair Complete • Place one multimeter test lead into the SW.
  • Page 148 STEP 4: Check Combination Meter STEP 4A: Check Oil Pressure Warning Wire Condition: Key switch OFF Open access door on steering column. The engine oil pressure relay is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for diode unit location. Disconnect the oil pressure relay.

  • Page 149: Hydraulic Oil Filter Lamp Illuminated

    Hydraulic Oil Filter Lamp Illuminated To reduce the possibility of personal injury, make sure the hydraulic system does not have pressure on it prior to opening the circuit. Symptoms The hydraulic oil pressure lamp is illuminated when the engine is running. Possible reduced performance and heat with hydraulic system if oil level is low.
  • Page 150 Troubleshooting Summary 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...
  • Page 151 STEP 1: Check System Maintenance STEP 1A: Check Hydraulic Oil Level Condition: Keyswitch in OFF position. Compactor on level ground. Action Specifications / Repair Next Step Hydraulic Oil Level Correct? Check the hydraulic oil level in the sight glass on the hydraulic tank. Refer to Maintenance at Every Procedure at Every 50 Hours in the Periodic Maintenance Section.
  • Page 152 STEP 2: Check Hydraulic Systems Function STEP 2A: Check Vibration, Steering and Propulsion Systems Function Condition: Engine Started. Set up compactor for operation. Refer to the Operating the Compactor procedure in the Operating Systems and Operating the Compactor section. Action Specifications / Repair Next Step Check vibration, steering and propulsion...
  • Page 153 STEP 4: Check Hydraulic Oil Switch STEP 4A: Check Hydraulic Oil Switch Contacts Condition: Key switch OFF Disconnect the hydraulic oil filter warning wires from each of the hydraulic oil filters. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...

  • Page 154: Tachometer Does Not Indicate Engine Speed

    Tachometer Does Not Indicate Engine Speed Symptoms The engine is running and the tachometer does not indicate engine speed correctly. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Tachometer Does Not Indicate Engine Speed problem. Start by performing Step 1 troubleshooting.
  • Page 155 Troubleshooting Summary 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...
  • Page 156 STEP 1: Check Dash Lamps STEP 1A: Check Engine Warning, Engine Stop and Wait to Start Lamps Condition: Key switch ON Action Specifications / Repair Next Step Check the following lamps for illumination: Lamps Illuminate? • Engine Warning • Engine Stop •...
  • Page 157 STEP 2B: Check for Damage to Speed Sensor (Combination Meter Tachometer) Condition: Key switch OFF Remove the speed sensor (combination meter tachometer). Refer to the Speed Sensor (Combination Meter Tachometer) procedure in the Compactor Repair section. Action Specifications / Repair Next Step Sensor Damaged? Repair Complete...
  • Page 158 STEP 3 Check Power Circuit STEP 3A: Check Fuse Box Fuse Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses box location. Remove fuse box fuse (F7).
  • Page 159 STEP 3B: Check Wire From Fuse Box to Control Box Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Remove fuse box fuse (F7).
  • Page 160 STEP 3D: Check Fuse Box to Alternator Wire Condition: Key switch OFF Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 161 STEP 3F: Check 75 Amp Fuse Condition: Key switch OFF Remove the 75 amp fuse. Refer to the Fuses 65 Amp and Above Procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 162 STEP 4: Check Speed Sensor (Combination Meter Tachometer) Sensor Wiring STEP 4A: Check Speed Sensor (Combination Meter Tachometer) Pick-up Wires Condition: Key switch OFF Disconnect the speed sensor (combination meter tachometer). Refer to the Speed Sensor (Combination Meter Tachometer) procedure in the Compactor Repair section. Disconnect the control box 6-pin connector.
  • Page 163 STEP 5: Check Tachometer and Control Box STEP 5A: Check Tachometer Signal Wire Condition: Key switch OFF Disconnect the control box 6-pin connector. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section. Remove operator’s station front cover. Refer to the Combination Meter procedure in the Compactor Repair Section. Disconnect the Combination 8-pin connector.

  • Page 164: Hour Meter Does Not Work

    Hour Meter Does Not Work Symptoms The engine is running and the hour meter does not advance. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot an Hour Meter Does Not Work problem. Start by performing Step 1 troubleshooting.
  • Page 165 Troubleshooting Summary STEP 1: Check Dash Lamps STEP 1A: Check Engine Warning, Engine Stop and Wait to Start Lamps STEP 2A: 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 Alternator to Battery Relay Wire STEP 2E: Check 75 Amp Fuse...
  • Page 166 STEP 1: Check Dash Lamps STEP 1A: Check Engine Warning, Engine Stop and Wait to Start Lamps Condition: Key switch ON Action Specifications / Repair Next Step Check the following lamps for illumination: Lamps Illuminate? • Engine Warning • Engine Stop •...
  • Page 167 STEP 2B: Check Wire From Fuse Box to Combination Meter Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Remove fuse box fuse (F7).
  • Page 168 STEP 2D: Check the Alternator to Battery Relay Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the alternator that connects to the battery relay. Disconnect the wire on the battery relay that connects to the alternator.
  • Page 169 STEP 3: Check Hour Meter Wire STEP 3A: Check Hour Meter to Charge Wire Condition: Key switch OFF Disconnect the combination Meter 8-pin connector. Refer to the Combination Meter procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...

  • Page 170: Coolant Temperature Gauge Does Not Work

    Coolant Temperature Gauge Does Not Work Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50ºC [120ºf] before removing the pressure cap. Heated coolant spray can cause personal injury. Symptoms The coolant temperature gauge does not indicate engine cooling system temperature or indicates the incorrect temperature.
  • Page 171 Troubleshooting Summary 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 STEP 3: Coolant System Temperature Validation STEP 3A: Check Coolant Temperature Gauge on Combination Meter 6-56...
  • Page 172 STEP 1: Check Coolant Temperature Sensor Systems STEP 1A: Check Coolant Temperature Gauge on Combination Meter Condition: Engine running. Cooling system at operating temperature. Action Specifications / Repair Next Step Does temperature gauge indicate? Check temperature reading on the combination meter temperature gauge. Does temperature gauge indicate? STEP 1B: Check for Engine Fault Code Condition:...
  • Page 173 STEP 2: Check Coolant Temperature Sensor Wires STEP 2A: Check Temp. Meter Wire Condition: Key switch OFF Disconnect combination meter 8-pin connector. Refer to the Combination Meter procedure in the Compactor Repair Section. Disconnect coolant temperature sensor. Refer to the Coolant Temperature Sensor (Combination Temperature Gauge) procedure in the Compactor Repair section.
  • Page 174 STEP 3: Coolant Temperature System Validation STEP 3A: Check Coolant Temperature Gauge on the Combination Meter Condition: Engine running. Cooling system at operating temperature. Action Specifications / Repair Next Step Check combination meter temperature gauge Temperature Gauge Indicating? Repair Complete temperature indication.

  • Page 175: Fuel Gauge Does Not Work

    Fuel Gauge Does Not Work Diesel fuel can be flammable. To reduce the possibility of fire resulting in severe personal injury, death or property damage, never smoke or allow sparks or flames (such as pilot lights, electrical switches or welding equipment) in the work area when inspecting or performing service or repairs on the fuel system.
  • Page 176 Troubleshooting Summary 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 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 6-61...
  • Page 177 STEP 1: Combination Meter Fuel Gauge Indication STEP 1A: Check Combination Meter Fuel Gauge Indication Condition: Engine running. Fuel tank level at ½ tank minimum. Action Specifications / Repair Next Step Does fuel level gauge indicate? Check the reading on the combination meter fuel level gauge.
  • Page 178 STEP 2B: Check Fuel Meter Sending Unit Ground Wire Condition: Key switch OFF Disconnect ground wire connector from the sending unit. Refer to the Sending Unit (Combination Meter Fuel Level Gauge) procedure in the Compactor Repair section. Action Specifications / Repair Next Step Less than 10 ohms? Check sending unit ground wire:...

  • Page 179: Backup Alarm Does Not Work

    Backup Alarm Does Not Work Symptoms When the directional control lever is moved in the reverse direction the back up alarm does not sound. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Back Up Alarm Does Not Work problem. Start by performing Step 1 troubleshooting.
  • Page 180 Troubleshooting Summary 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 Backup Buzzer Switch STEP 2C: Check Fuse Box to Alternator Wire STEP 2D: Check Alternator to Battery Relay Wire...
  • Page 181 STEP 1: Check Backup Buzzer Switch STEP 1A: Check Backup Buzzer Switch Adjustment Condition: Key switch OFF Remove directional control lever panel. Refer to the Backup Buzzer Switch and Interlock Switch procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check backup buzzer switch adjustment: Switch adjusted correctly?
  • Page 182 STEP 1C: Check Backup Buzzer Switch to Backup Buzzer Wire Condition: Key switch OFF Disconnect the backup buzzer switch. Refer to the Backup Buzzer Switch and Interlock Switch procedure in the Compactor Repair section. Disconnect the supply wire to the backup buzzer. Action Specifications / Repair Next Step...
  • Page 183 STEP 2B: Check Wire From Fuse Box to Battery Backup Buzzer Switch Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses box location. Remove fuse box fuse (F9).
  • Page 184 STEP 2D: Check the Alternator to Battery Relay Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the alternator that connects to the battery relay. Disconnect the wire on the battery relay that connects to the alternator.
  • Page 185 STEP 3: Check Backup Buzzer STEP 3A: Check Backup Buzzer Ground Wire Condition: Key switch OFF Disconnect backup buzzer ground wire. Action Specifications / Repair Next Step Check backup buzzer ground wire: Less than 10 ohms? Repair Complete • Place a multimeter test lead onto the ground wire at the backup buzzer.

  • Page 186: Horn Does Not Work

    Horn Does Not Work Symptoms The compactor horn does not sound when the button on the steering wheel is pushed. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Horn Does Not Work problem. Start by performing Step 1 troubleshooting.
  • Page 187 Troubleshooting Summary STEP 1: Check the Horn Switch STEP 1A: Check Horn Switch Contacts STEP 1B: Check Horn Assembly STEP 1C: Check Horn Switch Output Wire STEP 1D: Check Horn Switch Ground 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...
  • Page 188 STEP 1: Check Horn Switch STEP 1A: Check Horn Switch Contacts Condition: Key switch OFF Disconnect the horn relay. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section. Depress horn button. Action Specifications / Repair Next Step Check the horn switch contacts: Less than 10 ohms?
  • Page 189 STEP 1C: Check Horn Switch Output Wire Condition: Key switch OFF Disconnect the horn relay. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section. Remove the horn switch button from the steering wheel. Disconnect the horn switch supply from the steering wheel. Action Specifications / Repair Next Step...
  • Page 190 STEP 2 Check Power Circuit STEP 2A: Check Fuse Box Fuse Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuse box location. Remove fuse box fuse (F8).
  • Page 191 STEP 2B: Check Wire From Fuse Box to Horn Relay Coil Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuse block location. Remove fuse box fuse (F8).
  • Page 192 STEP 2D: Check Fuse Box to Alternator Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box.
  • Page 193 STEP 2F: Check 75 Amp Fuse Condition: Key switch OFF Remove the 75 amp fuse. Refer to the Fuses 65 Amp and Above Procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 194 STEP 4: Check Horn STEP 4A: Check Horn Ground Wire Condition: Key switch OFF Disconnect horn. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step Check horn ground wire: Less than 10 ohms? Repair Complete •...

  • Page 195: Compactor Steering Malfunction

    Compactor Steering Malfunction Symptoms The compactor does not steer correctly or does not have steering. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Compactor Steering Malfunction problem. Start by performing Step 1 troubleshooting. Step 1 will ask a series of questions and will provide a list of troubleshooting steps to be performed depending on the symptom.
  • Page 196 Troubleshooting Summary 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 6-81...
  • Page 197 STEP 1: Check Compactor STEP 1A: Check Hydraulic Oil Level Condition: Key switch OFF Action Specifications / Repair Next Step Check hydraulic oil level at the hydraulic Hydraulic Oil Level Low? tank sight glass. Repair Fill the hydraulic tank to proper level. Hydraulic Oil Level Low? STEP 1B: Check for Hydraulic Leaks Condition:...
  • Page 198 STEP 2: Check Steering Pump STEP 2A: Check Steering Pump Pressure Condition: Engine running in FULL. Parking brake set. Action Specifications / Repair Next Step Check steering pump pressure. Refer to Steering circuit pressure correct? Measure Steering Circuit Pressure procedure in the Testing and Adjustment section.
  • Page 199 STEP 3: Check Steering Cylinders STEP 3A: Inspect Steering Cylinders and Center Pin for Damage Condition: Keyswitch OFF. Parking brake set. Action Specifications / Repair Next Step Inspect steering cylinders and center pin Steering cylinder damaged? Repair Complete for damage that would prevent proper operation.

  • Page 200: Vibration Does Not Work

    Vibration Does Not Work Symptoms The compactor vibration does not work in low or high amplitude from the continuous or momentary switch. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Vibration Does Not Work problem. Start by performing Step 1 troubleshooting.
  • Page 201 Troubleshooting Summary STEP 1: Check Compactor STEP1A: Check Compactor for 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 Engine Speed Switch Contacts 4 and 5 STEP 2C:Check Wire From Fuse Box to Engine Speed Change Switch STEP 2D: Check Fuse Box to Alternator Wire...
  • Page 202 STEP 1: Check Compactor STEP 1A: Check Compactor Vibratory Operation Set Up Condition: Engine running. Action Specifications / Repair Next Step Check compactor for vibratory operation set Compactor set up correctly? up. Refer to the Vibratory Operation procedure in the Compactor Operation section.
  • Page 203 STEP 1C: Check for Hydraulic Leaks Condition: Start engine. Action Specifications / Repair Next Step Check for hydraulic leaks: Hydraulic leaks? Repair Complete • Check all propulsion hoses • Check roller drive motor • Check rear end. Repair hydraulic leak. Hydraulic leaks? STEP 2: Check Engine Speed Change Switch STEP 2A: Check Engine Speed Change Switch to Fuse Box F8 Wire...
  • Page 204 STEP 2B: Check Contacts 4 and 5 Condition: Key switch OFF. Engine speed switch in the FULL position. Disconnect the engine speed change switch to throttle relay wire at the engine speed change switch. Refer to the Engine Speed Change Switch Procedure in the Compactor Repair section. Disconnect the engine speed change switch wire to fuse box F8 wire at the engine speed change switch.
  • Page 205 STEP 2D: Check Fuse Box to Alternator Wire Condition: Key switch OFF. Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box.
  • Page 206 STEP 2F: Check 75 Amp Fuse Condition: Key switch OFF. Remove the 75 Amp fuse. Refer to the Fuses 65 Amp and Above procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 207 STEP 3B: Check Wire From Vibration Switch to Vibration Amplitude Switch LOW Condition: Key switch to OFF position. Remove vibration switch wire that routes to the vibration amplitude switch. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section. Remove vibration amplitude switch wire that routes to the vibration switch.
  • Page 208 STEP 3D: Check Vibration Switch Contacts Condition: Key switch OFF. Vibration switch to the CONT position. Disconnect the wire that routes from the vibration amplitude switch to the solenoid LO. Refer to the Vibration Control Panel Switches procedure in the Compactor Repair section. Disconnect the wire that routes from the vibration amplitude switch to the vibration switch.
  • Page 209 STEP 4B: Check Wire From Vibration Amplitude Switch HIGH to Solenoid HIGH Condition: Key switch to OFF position. Remove the vibration amplitude switch wire that routes to the solenoid low side. Refer to the Vibratory Control Panel Switches procedure is the Compactor Repair section. Remove solenoid wire HIGH wire that connects to the vibration amplitude switch.
  • Page 210 STEP 4D: Check Vibration Amplitude Switch Contacts 1and 2 Condition: Key switch OFF. Vibration amplitude switch to low amplitude icon setting. Disconnect the wire that routes from the vibration amplitude switch to the solenoid HIGH. Refer to the Vibration Control Panel Switches procedure in the Compactor Repair section.
  • Page 211 Testing and Adjustment section. Propulsion pump adjusts correctly? Repair Complete Repair Contact Sakai America for Authorization to replace the propulsion pump. Refer to the Engine and Pump Assembly procedure in the Compactor Repair Section. STEP 6: Check Shaft...
  • Page 212 STEP 6B: Check Motor for Operation Condition: Remove motor from roller. Refer to the Roller procedure in the Compactor Repair section. Forward/Reverse lever in neutral. Engine running in FULL. Chocks installed under roller and drive wheels. Parking brake set. Action Specifications / Repair Next Step Turn vibratory system on and check...

  • Page 213: Low Amplitude Vibration Setting Does Not Work

    Low Amplitude Vibration Setting Does Not Work Symptoms The compactor vibration does not work in low amplitude setting but works in the high amplitude setting. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot Low Amplitude Vibration Setting Does Not Work problem. Start by performing Step 1 troubleshooting.
  • Page 214 Troubleshooting Summary STEP 1: Check Compactor STEP1A: 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...
  • Page 215 STEP 1: Check Compactor STEP 1A: Check Compactor for Vibratory Operation Set Up Condition: Engine running. Action Specifications / Repair Next Step Check compactor for vibratory operation set Compactor set up correctly? up. Refer to the Vibratory Operation procedure in the Compactor Operation section.
  • Page 216 STEP 2B: Check Wire From Vibration Switch to Vibration Amplitude Switch LOW Condition: Key switch to OFF position. Remove vibration switch wire that routes to the vibration amplitude switch. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section. Remove vibration amplitude switch wire that routes to the vibration switch.
  • Page 217 STEP 3: Check Vibration Amplitude Switch STEP 3A: Check Wire From Vibration Amplitude Switch LOW to Solenoid LOW Condition: Key switch to OFF position. Remove the vibration amplitude switch wire that routes to the solenoid low side. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section.
  • Page 218 STEP 4: Check Vibration Amplitude Solenoid STEP 4A: Check Vibration Solenoid Operation Condition: Key switch to OFF position. Remove vibration amplitude solenoid. Refer to the Vibration Amplitude Solenoid procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check vibration solenoid operation: Solenoid shifted? Repair Complete...

  • Page 219: High Amplitude Vibration Setting Does Not Work

    High Amplitude Vibration Setting Does Not Work Symptoms The compactor vibration does not work in high amplitude setting but works in the low amplitude setting. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a High Amplitude Vibration Setting Does Not Work problem.
  • Page 220 Troubleshooting Summary 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 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...
  • Page 221 STEP 1: Check Compactor STEP 1A: Check Compactor Vibratory Operation Set Up Condition: Engine running. Action Specifications / Repair Next Step Check compactor for vibratory operation set Compactor set up correctly? up. Refer to the Vibratory Operation procedure in the Compactor Operation section.
  • Page 222 STEP 2B: Check Wire From Vibration Switch to Vibration Amplitude Switch HIGH Condition: Key switch to OFF position. Remove vibration switch wire that routes to the vibration amplitude switch. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section. Remove vibration amplitude switch wire that routes to the vibration switch.
  • Page 223 STEP 3: Check Vibration Amplitude Switch STEP 3A: Check Wire From Vibration Amplitude Switch HIGH to Solenoid HIGH Condition: Key switch to OFF position. Remove the vibration amplitude switch wire that routes to the solenoid low side. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section.
  • Page 224 STEP 4: Check Vibration Amplitude Solenoid STEP 4A: Check Vibration Solenoid Operation Condition: Key switch to OFF position. Remove vibration amplitude solenoid. Refer to the Vibration Amplitude Solenoid procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check vibration solenoid operation: Solenoid shifted? Repair Complete...

  • Page 225: Can Not Turn Vibration From Forward/Reverse Lever

    Can Not Turn Vibration ON From Forward/Reverse Lever Symptoms The compactor vibration works in the low and high amplitude settings when the vibration switch is in the CONT position. When the vibration switch is set to the lever icon and the engine switch is set to the full position the vibration will not activate using the forward/reverse lever button.
  • Page 226 Troubleshooting Summary STEP 1: Check Vibration Switch STEP 1A: Check Wire 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 Forward/Reverse Lever Switch Contacts...
  • Page 227 STEP 1: Check Vibration Switch STEP 1A: Check Vibration Switch to Forward/Reverse Lever Switch Wire Condition: Key switch to OFF position. Remove wire to vibration switch from forward/reverse lever switch. Refer to the Forward/Reverse Lever Switch procedure in the Compactor Repair Section. Remove wire to vibration lever switch from vibration switch.
  • Page 228 STEP 2: Check Forward/Reverse Lever Switch STEP 2A: Check Wire From Forward/Reverse Lever Switch to Vibration Amplitude Switch LOW Condition: Key switch to OFF position. Remove forward/reverse lever switch to vibration amplitude switch LOW wire. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section.
  • Page 229 STEP 2B: Check Wire From Forward/Reverse Lever Switch to Vibration Amplitude Switch HIGH Condition: Key switch to OFF position. Remove forward/reverse lever switch to vibration amplitude switch HIGH wire. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section. Remove the vibration amplitude switch HIGH to forward/reverse lever wire.
  • Page 230 STEP 3: Check Vibration Amplitude Solenoid STEP 3A: Check Vibration Solenoid Operation Condition: Key switch to OFF position. Remove vibration amplitude solenoid. Refer to the Vibration Amplitude Solenoid procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check vibration solenoid operation: Solenoid shifted? Repair Complete...

  • Page 231: Compactor Will Not Start

    Compactor Will Not Start To reduce the possibility of personal injury and equipment damage, always shut down the compactor when the Engine Warning Lamp is illuminated. Symptoms The compactor will not start. The engine can crank but does not start or the engine does not crank. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Compactor Will Not Start condition.
  • Page 232 Troubleshooting Summary STEP 1: Engine or Start Circuit STEP 1A: Crank 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 Neutral Safety Switch Adjustment STEP 2B2: Check Neutral Safety Switch Contacts.
  • Page 233 STEP 1: Engine or Start Circuit STEP 1A: Crank the Engine Condition: Turn start switch to the START position. Action Specifications / Repair Next Step Crank the engine. Did the engine crank? Did the engine Crank? STEP 1B: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector).
  • Page 234 STEP 1C: Check Start Switch to ECM Wire Condition: Disconnect Batteries. Remove front panel on operators console. Refer to the Start Switch procedure in the Compactor Repair section. Disconnect the ECM 50-pin connector. Action Specifications / Repair Next Step Check start switch to ECM wire: Less than 10 ohms? •...
  • Page 235 STEP 2 Check Start Circuit STEP 2A: Check Battery Voltage Condition: Open battery access door on compactor. Action Specifications / Repair Next Step Check Battery Voltage: Less than 12 VDC? Repair Complete • Place the positive multimeter test lead on the positive battery terminal. Repair •...
  • Page 236 STEP 2B2: Check the Neutral Safety Switch Contacts Condition: Key switch OFF Remove the directional control lever cover. Refer to the Directional Control Lever Micro-Switches in the Compactor Repair Section. Action Specifications / Repair Next Step Check the neutral safety switch contacts: Less than 10 ohms? •...
  • Page 237 STEP 2B4: Check Wire From Fuse Box to Neutral Safety Switch Condition: Key switch OFF. Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Remove fuse box fuse (F9).
  • Page 238 STEP 2B6: Check the Alternator to Battery Relay Wire Condition: Key switch OFF. Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the alternator that connects to the battery relay. Disconnect the wire on the battery relay that connects to the alternator.
  • Page 239 STEP 2B8: Check Neutral Safety Switch to Interlock Relay Coil Wire Condition: Keyswitch to OFF. Open access door on steering column and disconnect interlock relay. The interlock relay is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Disconnect the interlock relay to neutral safety switch wire on the neutral safety switch.
  • Page 240 STEP 2C: Check Interlock Relay STEP 2C1: Check Fuse F10 Condition: Key switch OFF Remove the fuse F10. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step Check fuse F10: Less than 10 ohms? Repair Complete •...
  • Page 241 STEP 2C3: Check Interlock Relay to Fuse Box Wire Condition: Key switch OFF Remove Fuse F10. Open access door on steering column and disconnect interlock relay. The interlock relay is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Refer to the Wiring Diagram in this section for wire colors and connector pin location.
  • Page 242 STEP 2D:Check Starter Relay STEP 2D1: Check Fuse Box to Starter Relay Input Coil Wire Condition: Key switch OFF Remove Fuse F10. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Disconnect the starter relay.
  • Page 243 STEP 2D3: Check Starter Relay Input Contact to Starter Wire Condition: Key switch OFF. Disconnect the starter relay. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses block location. Disconnect the starter relay input contact wire at the starter (terminal with two wires). Refer to the Wiring Diagram in this section for wire colors and connector pin location.
  • Page 244 STEP 2D5: Check Starter to Chassis Ground Wire Condition: Key switch OFF. Disconnect the starter ground wires from the starter. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step Check starter to chassis ground wire: Less than 10 ohms? •...
  • Page 245 STEP 2E:Check Battery Relay STEP 2E1: Check Battery Relay Input Coil Wire to Start Switch Condition: Key switch OFF. Disconnect the battery relay input coil wire for the start switch at the battery relay. Refer to the Start Switch procedure in the Compactor Repair section.
  • Page 246 STEP 2E3: Check Battery Supply Wire to Battery Relay Input Contact Condition: Key switch OFF. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step Check battery supply wire to battery Repair Complete Less than 12 VDC? relay input contact:...
  • Page 247 STEP 2F:Check Start Switch STEP 2F1: Check Start Switch to Battery Relay Output Contact Wire Condition: Key switch OFF. Disconnect the starter switch power wire (B) from the start switch. Refer to the Start Switch procedure in the Compactor Repair section. Disconnect the battery start switch power wire from the battery relay.
  • Page 248 B terminal. • Connect the remaining Repair multimeter test lead to the start Contact Sakai America for authorization to replace the switch C terminal. starter. Refer to the Service Manual, ISB, ISBe4, and QSB • Turn the start switch to the (Common Rail Fuel System) Series Engines, Bulletin START position.

  • Page 249: Engine Will Not Idle Correctly

    Engine Will Not Idle Correctly Symptoms The engine starts but will not idle at the correct speed. The engine functions properly in Mid and Full range. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot an Engine Will Not Idle condition. Start by performing Step 1 troubleshooting.
  • Page 250 Troubleshooting Summary STEP 1: Check ECM Connector STEP 1A: Inspect Wiring Harness Connector STEP 2: Check Engine Speed Change Switch STEP 2A: Check Engines 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 Switch Contacts STEP 3: Check Throttle Relay STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector...
  • Page 251 STEP 1 Check ECM Connector STEP 1A: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...
  • Page 252 STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Output Contact Condition: Key switch OFF Disconnect the engine speed change switch to throttle relay wire at the engine speed change switch. Refer to the Engine Speed Change Switch Procedure in the Compactor Repair section. Disconnect the throttle relay to engine speed change switch wire at the throttle relay.
  • Page 253 STEP 3: Check Throttle Relay STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Disconnect the wire from throttle relay connector. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section.

  • Page 254: Engine Will Not Reach Mid Speed

    Engine Will Not Reach MID Speed Symptoms The engine starts but will not reach MID speed at the correct speed. The engine functions properly in Idle and Full range. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot an Engine Will Not Reach MID Speed condition. Start by performing Step 1 troubleshooting.
  • Page 255 Troubleshooting Summary STEP 1: Check ECM Connector STEP 1A: Inspect Wiring Harness Connector STEP 2: Check Engine Speed Change Switch STEP 2A: Check Engines 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 Switch Contacts STEP 3: Check Throttle Relay STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector...
  • Page 256 STEP 1 Check ECM Connector STEP 1A: Inspect Wiring Harness Connector Condition: Key switch OFF. Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...
  • Page 257 STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Output Contact Condition: Key switch OFF Disconnect the engine speed change switch to throttle relay wire at the engine speed change switch. Refer to the Engine Speed Change Switch Procedure in the Compactor Repair section. Disconnect the throttle relay to engine speed change switch wire at the throttle relay.
  • Page 258 STEP 3: Check Throttle Relay STEP 3A: Check Throttle Relay Input Contact Wire to ECM Connector Condition: Key switch OFF. Disconnect ECM 50-pin connector (compactor harness connector). Disconnect the wire from throttle relay connector. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section.

  • Page 259: Engine Will Not Reach Full Speed

    Engine Will Not Reach Full Speed Symptoms The engine starts but will not reach FULL speed. The engine functions properly in IDLE and MID range. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot an Engine Will Not Reach Full Speed condition. Start by performing Step 1 troubleshooting.
  • Page 260 Troubleshooting Summary STEP 1: Check ECM Connector STEP 1A: Inspect Wiring Harness Connector STEP 2: Check Engine Speed Change Switch STEP 2A: Check Engines 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...
  • Page 261 STEP 1 Check ECM Connector STEP 1A: Inspect Wiring Harness Connector Condition: Key switch OFF Disconnect ECM 50-pin connector (compactor harness connector). Action Specifications / Repair Next Step Inspect the 50-pin connector for the Connector Dirty or Damaged? Repair Complete following: •...
  • Page 262 STEP 2B: Check Wire From Engine Speed Change Switch to Throttle Relay Coil Condition: Key switch OFF Disconnect the engine speed change switch to throttle relay wire at the engine speed change switch. Refer to the Engine Speed Change Switch Procedure in the Compactor Repair section. Disconnect the throttle relay to engine speed change switch wire at the throttle relay.
  • Page 263 STEP 3: Check Power Circuit STEP 3A: Check Fuse Box to Alternator Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box.
  • Page 264 STEP 3C: Check 75 Amp Fuse Condition: Key switch OFF Remove the 75 Amp fuse. Refer to the Fuses 65 Amp and above procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 265 STEP 4: Check Throttle Relay STEP 4A: Check Throttle Relay Ground Wire Condition: Key switch OFF Disconnect the wire from throttle relay connector. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check Throttle Relay Ground Wire: Less than 10 ohms?

  • Page 266: Compactor Will Not Move Forward And/Or Reverse Or Does Not Drive Correctly

    Compactor Will Not Move Forward and/or Reverse or Does Not Drive Correctly Symptoms The compactor will not move: • Forward • Reverse • Forward or reverse How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Compactor Will Not Move Forward and/or Reverse problem.
  • Page 267 Troubleshooting Summary 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 Function...
  • Page 268 STEP 1: Check Compactor STEP 1A: Check Hydraulic Oil Level Condition: Key switch OFF. Action Specifications / Repair Next Step Check hydraulic oil level at the hydraulic Hydraulic Oil Level Low? tank sight glass. Repair Fill the hydraulic tank to proper level. Hydraulic Oil Level Low? STEP 1B: Check for Hydraulic Leaks Condition:...
  • Page 269 STEP 2 Check Directional Control Lever STEP 2A: Check Forward/Reverse Lever Cable Connection Condition: Key switch OFF Remove the directional control lever cover. Refer to the Directional Control Lever procedure in the Compactor Repair section. Action Specifications / Repair Next Step Check the forward/reverse lever Cable Cable connected? connection.
  • Page 270 STEP 2B: Check Forward/Reverse Lever Cable Pump Connection Condition: Key switch OFF. Open hood. Action Specifications / Repair Next Step Check forward/reverse lever cable pump Cable Connected? connection: Repair Complete Cable Connected? Repair Connect and adjust cable. Forward/Reverse Cable Adjustment procedure in the Testing and Adjustment section.
  • Page 271 STEP 3: Check Charge Pressure (Steering Pump) STEP 3A: Check Steering Operation Condition: Engine running. Action Specifications / Repair Next Step Turn the steering wheel. Does compactor steering work? Does compactor steering work? Repair Complete Repair The compactor steering pump supplies input to the propulsion pump.
  • Page 272 STEP 4: Check Propulsion System STEP 4A: Check Propulsion Pump Pressure Condition: Engine running in FULL. Parking brake set. Action Specifications / Repair Next Step Check propulsion pump pressure. Refer to Propulsion pump pressure correct? Measure Hydraulic Pressure Main Propulsion Circuit procedure in the Testing and Adjustment section.

  • Page 273: Parking Brake Does Not Work

    Parking Brake Does Not Work To reduce the possibility of personal injury and equipment damage, make sure the compactor is on level ground and the drive wheels are chocked. Symptoms The compactor parking brake will not engage or disengage. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Parking Brake Does Not Work Problem.
  • Page 274 Troubleshooting Summary 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 Alternator to Battery Relay Wire STEP 1E: Check 75 Amp Fuse STEP 2: Check Foot Brake Switch STEP 2A: Check Foot Brake Switch Adjustment...
  • Page 275 STEP 1: Check Power Circuit STEP 1A: Check Fuse Box Fuse Condition: Key switch OFF Open access door on steering column. The fuse box is located on the door. Refer to the Operator’s Station Relays and Diode procedure in the Compactor Repair section for fuses box location. Remove fuse box fuse (F9).
  • Page 276 STEP 1C: Check Fuse Box to Alternator Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box.
  • Page 277 STEP 1E: Check 75 Amp Fuse Condition: Key switch OFF Remove the 75 Amp fuse. Refer to the Fuses 65 Amp and Above procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 278 STEP 2B: Check Foot Brake Switch to Parking Brake Switch Wire Condition: Key switch OFF Disconnect the foot brake switch wire that connects to the parking brake. Refer to the Foot Brake procedure in the Compactor Repair Section. Disconnect parking brake switch wire that connects to the foot brake switch. Refer to the Parking Brake Button procedure in the Compactor Repair section.
  • Page 279 STEP 3: Check Parking Brake Switch and Solenoid STEP 3A: Check Parking Brake Switch to Parking Brake Solenoid Wire Condition: Key switch OFF Disconnect parking brake switch wire that connects to the parking brake solenoid wire. Refer to the Parking Brake Button procedure in the Compactor Repair section.
  • Page 280 Connect a ground wire to the solenoid. • Connect a 12 VDC power supply to Repair the input side terminal of the Contact Sakai America for authorization to replace the solenoid. brakes. Solenoid will shift if working correctly. Repair Complete Solenoid Shifted? Repair Replace the Solenoid.

  • Page 281: Compactor Will Not Change Speeds

    Compactor Will Not Change Speeds Symptoms The compactor will not change from speeds when the speed change switch is moved from the turtle to rabbit or rabbit icons. How to Use This Troubleshooting Procedure This symptom tree can be used to troubleshoot a Compactor will not change speeds problem. Start by performing Step 1 troubleshooting.
  • Page 282 Troubleshooting Summary STEP 1: Check Compactor STEP 1A: Check Hydraulic Oil Level STEP 1B: Check for Hydraulic Leaks STEP 2: Check Engine Speed Change Switch STEP 2A: Check Speed Change Switch to Fuse Box F5 Wire STEP 2B: Check Engine Speed Switch Contacts STEP 2C: Check Fuse Box to Alternator Wire STEP 2D: Check Alternator to Battery Relay Wire STEP 2E: Check 75 Amp Fuse...
  • Page 283 STEP 1: Check Compactor STEP 1A: Check Hydraulic Oil Level Condition: Key switch OFF Action Specifications / Repair Next Step Check hydraulic oil level at the hydraulic Hydraulic Oil Level Low? tank sight glass. Repair Fill the hydraulic tank to proper level. Hydraulic Oil Level Low? STEP 1B: Check for Hydraulic Leaks Condition:...
  • Page 284 STEP 2: Check Speed Change Switch STEP 2A: Check Speed Change Switch to Fuse Box F5 Wire Condition: Key switch to OFF position. Remove fuse F5 to the speed change switch. Refer to the Relays and Diode procedure in the Compactor Repair Procedure. Disconnect the speed switch to fuse box F5 wire at the engine speed change switch.
  • Page 285 STEP 2C: Check Fuse Box to Alternator Wire Condition: Key switch OFF Disconnect the battery. Refer to the Engine Start Switch Procedure in the Compactor Repair section. Disconnect the wire on the fuse box that connects to the alternator BAT connection. Disconnect the wire on the alternator that connects to the fuse box.
  • Page 286 STEP 2E: Check 75 Amp Fuse Condition: Key switch OFF Remove the 75 Amp fuse. Refer to the Fuses 65 Amp and Above procedure in the Compactor Repair section. Refer to the Wiring Diagram in this section for wire colors and connector pin location. Action Specifications / Repair Next Step...
  • Page 287 STEP 5B: Check Solenoid to Chassis Ground Wire Condition: Key switch to OFF position. Disconnect the chassis ground wire for the solenoid from the solenoid. Refer to the Compactor Speed Solenoid procedure in the Compactor Repair Section. Disconnect the solenoid wire at the speed change switch. Refer to the Vibratory Control Panel Switches procedure in the Compactor Repair section.

  • Page 288: Compactor Repair

    Compactor Repair This procedure describes the disassembly for the SV505 Compactor. Make sure all tag out/lock out and safety procedures are followed. The Operation section must be read and understood prior to beginning this procedure. To reduce the possibility of personal injury and equipment damage, adhere to all safety warnings in this manual.
  • Page 289 Place a hydraulic jack, with wooden blocks under each side of the front frame. Raise the front frame until the rubber isolators are relaxed. Repeat the process for the remaining side of the front frame. Hydraulic fluid is under pressure. To reduce the possibility of personal injury, make sure the hydraulic system is not under pressure prior to removing hoses.
  • Page 290 Remove the scraper bar mounting bolts and nuts from the right side of the front frame. Remove the scraper bar mounting bolts and nuts from the left side of the front frame. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity.

  • Page 291: Disassemble (Vibratory Motor Side)

    Remove the bolts and nuts for the hydraulic hose brackets on both sides of the compactor. To reduce the possibility of personal injury, station personnel at both sides of the roller with chocks to stop roller movement. Roll the compactor roller out of the front frame. Disassemble Vibratory Motor Side Remove the bolts for the vibratory motor.
  • Page 292 The roller is attached to the front frame with plate assemblies located on each side of the roller. The plate assembly consists of a base plate, rubber dampers and holders. Remove the bolts that attach the plate assembly to the roller. Remove the plate assembly.
  • Page 293 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device to the axel. Lift the axel off of the vibrator shaft and out of the roller. Some state and federal agencies have determined that used oil can be carcinogenic and cause reproductive toxicity.
  • Page 294 Remove the bearing retainer bolts and washers. Remove the bearing retainer. Vibratory shaft end play is adjusted with shims. Remove the shims. Save the shim pack for the assembly of the roller. A puller can be required to remove the axel shaft house bearing.
  • Page 295 To reduce the possibility of personal injury, wear eye protection when performing this step. Make sure the housing surface is not damaged when removing the seal. If the housing surface is damaged, premature bearing wear can result because of a seal malfunction.
  • Page 296 To reduce the possibility of personal injury, wear eye protection when performing this step. To reduce the possibility of premature bearing wear and equipment damage always replace the bearing and the outside race as a matched set. Note: Only perform this step if bearings and races are to be replaced.
  • Page 297 Remove the bolts that attach the plate assembly to the drive motor. Remove the plate assembly. Remove the bolts, nuts and washers from the holders. Remove the holders. Remove the bolts, nuts and washers from the dampers. Remove the dampers. Remove the axel housing mounting bolts.
  • Page 298 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device. Lift the hydraulic drive motor and axel shaft assembly off of the roller. Loosen the drive motor bolts.
  • Page 299 To reduce the possibility of personal injury, wear eye protection when performing this step. Note: Only perform this step if bearings and races are to be replaced. Use an inside bearing puller to remove the axel shaft housing bearing. Remove the axel shaft housing o-ring. Clean and Inspect for Reuse When cleaning with solvents, acids, or alkaline materials, follow the manufacturer’s recommendations...
  • Page 300 Note: Bearing shown disassembled to illustrate check. Do not disassemble bearing unless bearing is to be discarded. Inspect the bearings and races for the following: 1. Grooving – Caused by large particle contamination imbedding into soft cage material. 2. Abrasive Wear – Caused by fine abrasive particle contamination.
  • Page 301 Inspect the bearings and races for the following: 1. Rapid and Deep Spalling – Caused by unusually high stresses. 2. Full Race Width Fatigue Spalling - Caused by heavy loads creating a thin lubricant film at elevated temperatures (do not check for unless bearing is being replaced).
  • Page 302 Inspect the bearing races for the following: 1. Line Spalling – Caused by bearings operating after etching damage. 2. False Brinelling – Wear caused by vibration or relative axial movement rollers and races. If any bearing or race exhibits any one of the above listed conditions, it must be replaced.
  • Page 303 Note: Bearing shown disassembled to illustrate check. Do not disassemble bearing unless bearing is to be discarded. Inspect the bearing roller and outside race for the following: 1. Peeling (Roller) – Micro-spalling because of a thin lubricating film at high loads and low rpm or elevated temperatures.
  • Page 304 To reduce the possibility of premature bearing wear and damage, only apply pressure to the outside of the race when installing the bearing. Install the roller bearing into the axel shaft housing. Make sure the bearing sets flush against the housing. Lubricate a new o-ring with grease.
  • Page 305 The roller has baffles welded to the interior of the chamber. The baffles direct the flow of bearing lubricating oil when the roller is turning. Make sure the baffles are securely attached. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity.
  • Page 306 Six dampers attach to the base plate. Each damper has holes for four mounting bolts. Mounting bolts are installed from the bottom of the base plate. Insert bolts through the bottom of the base plate, into the damper mounting flange. Thread nuts with lock washers onto the bolts.
  • Page 307 Align the plate assembly mounting bolts with the drive motor holes. Thread in all mounting bolts. Tighten the bolts in sequence. Remove the lifting device. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity.
  • Page 308 To reduce the possibility of personal injury, wear eye protection when performing this step. Turn the axel drive bearing housing over. Place the bearing race on the axel drive bearing housing. Install the bearing race with a bearing driver. Make sure the race is completely installed in the axel drive bearing housing.
  • Page 309 Apply a coating of grease to the bearing. Place the axel shaft bearing housing onto the axel shaft. Pack the remaining axel shaft bearing and cavity in grease. Place the axel shaft bearing onto the shaft. Place the shims that were removed during installation into the axel shaft bearing housing.
  • Page 310 Place the bearing retainer on top of the axel shaft and align the mounting holes. Install bolts with flat washers. Tighten the bolts in sequence. Place a dial indicator torque wrench on a bolt in the 90° position. Turn the axel shaft. Record the measurement.
  • Page 311 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Thread a eyelet into the vibrator shaft. Attach a lifting device to the vibrator shaft with the splines of the shaft up.
  • Page 312 Inspect the rubber dampers for damage. If dampers are damaged they must be replaced. The vibratory motor side base plate has four dampers that mount onto it. Each damper flange has four mounting holes. Place the dampers on the base plate and align the mounting holes on the flanges.
  • Page 313 Set the holder assembly onto the axel shaft bearing assembly housing. Align the mounting holes. Thread in all bolts with washers. Tighten bolts in sequence. An extension connects the vibratory motor with the vibratory shaft. Place the extension onto the vibratory motor. Slide the vibratory motor with extension into the axel shaft.

  • Page 314: Install

    Install The pattern of the roller support holes is not symmetrical and will only align one way. Roll the roller into the front frame. Align the roller support holes. Install the roller support bolts and washers on the vibratory motor side of the roller. Tighten the bolts.
  • Page 315 Install the bolts and nuts into the scraper bar. Tighten the nuts. Remove the lifting device from the scraper. Place the hydraulic hose holders onto the front frame. Align the holes. Install bolts and nuts. Tighten the nuts. Connect the hydraulic hoses to the vibratory motor. Connect the hydraulic hoses to the propulsion motor.
  • Page 316 Lower and remove the jacks. Disengage the safety bar. Center Pin Remove Disconnect the left steering cylinder from the center pin. Disconnect the right steering cylinder from the center pin. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity.
  • Page 317 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device to the center pin. Remove the steering bearing mounting bolts and center pin from the frame.
  • Page 318 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device to the yolk (1). Use a inside bearing puller to remove the brackets from the yolk (2).
  • Page 319 Clean When cleaning with solvents, acids, or alkaline materials, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. To reduce the possibility of personal injury, wear eye and face protection when using compressed air. Bearings must be replaced.
  • Page 320 There two styles bearings in each of the brackets. A bearing with a separate outside race is installed first and a bearing assembly is installed second. Place the bracket into a fixture in a press with the lip end down. Place the bearing race into the bracket.
  • Page 321 This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device to the yoke. Place the brackets on each end of the yoke, aligning the yoke shafts with the inside bearing race of the bracket bearings.

  • Page 322: Install

    Finger-tighten all bolts. Tighten the bolts in sequence to: 265 N٠m (196 ft-lb). Thread the grease sert into the ring bearing. Turn the ring bearing so the small alignment hole and the grease sert are positioned as shown in the illustration. Install To reduce the possibility of personal injury, use protective glasses when using rotary cleaning...
  • Page 323 for use. Wear goggles and protective clothing to reduce the possibility of personal injury. Use a wire brush and or solvent to clean the area the on the front frame the center pin will be mounted. Make sure all threaded holes are free from debris and have functional threads.

  • Page 324: Operators Station

    This component requires a hoist to move. To reduce the possibility of personal injury, always use lifting equipment that has proper capacity. Make sure the rear frame is secured on stands. Place lifting straps on the front frame so when the frame is lifted the upper center pin mount will touch first.
  • Page 325 Disconnect the vibration control switches. Loosen directional control cable lock nut. Remove the bolt, washer and lock washer from the directional control cable. Hydraulic fluid is under pressure. To reduce the possibility of personal injury, make sure the hydraulic system is not under pressure prior to removing hoses. Bleed the hydraulic pressure from the steering system.
  • Page 326 Remove the lower operator station flat, lock and nut. Remove the upper operator station mounting nut. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Connect an approved lifting device to the operator’s station. Raise the operator’s station off of the mounts.

  • Page 327: Install

    Install This component requires a hoist to move. To reduce the possibility of personal injury, always use lifting equipment that has proper capacity. Connect the operator’s station to a lifting device and position over the installed mounts Route the directional control cable into rear frame. Route the cable into the rear frame.
  • Page 328 Connect the hydraulic hoses to the Orbitrol steering control valve. Place the direction control cable into the bracket. Tighten the lock nut. Place a flat washer then lock washer over the directional cable bolt. Slide the bolt through the cable. Thread the bolt into directional control valve.

  • Page 329: Manual Vibration Control Switch

    Place the cover onto the vibratory control switch panel. Align the holes. Thread in bolts with flat washers. Tighten the bolts equally. Manual Vibration Control Switch Remove The manual vibration control switch is located in the directional control lever. Remove the bolts and washers from the directional control lever console cover.

  • Page 330: Vibratory Control Panel Switches

    Place the directional control lever consol cover onto the console. Align the mounting holes. Thread in bolts with washers. Tighten the bolts. Vibratory Control Panel Switches Remove The switches contained in the vibratory control panel are: • Vibration amplitude control •...

  • Page 331: Install

    Record the location of the wires on the failed switch. Disconnect the wires on the switch. Remove the mounting nut from the switch. Slide the securing plate off of the switch. Slide the switch through the front of the panel. Install Securing plate has a tab on each corner.

  • Page 332: Combination Meter

    Thread the mounting nut onto the switch. Tighten the nut. Connect the wires. Route the switch cable through the vibration control console. Place the panel onto the console and align the mounting holes. Install the screws and tighten. Place the cover onto the side of the console aligning the mounting holes.

  • Page 333: Install

    Record the location of the wires and connectors for the engine speed switch, engine status lamps, combination meter and parking brake. Disconnect the wires to the engine speed switch. Disconnect the wires to the engine status lamps. Disconnect the connectors for the combination meter. Disconnect the parking brake.
  • Page 334 Set the dash panel onto the console. Align the mounting holes. Thread in the screws. Tighten the screws. Set the steering wheel onto the steering column with the speed knob to the left. Thread nut with washer onto steering column. Tighten nut.

  • Page 335: Parking Brake Button

    Parking Brake Button Remove Remove the dash front cover bolts and washers. Remove the dash front cover. Record the location of the wires that connect to the parking brake switch. Disconnect the parking brake switch wires. Remove the parking brake mounting nut and securing plate. Slide the parking brake switch out the front of the panel.

  • Page 336: Engine Status Lamps

    Tighten the mounting nut. Connect the wires to the parking brake switch. Place the dash front cover onto the dash. Align the mounting holes. Thread in bolts with flat washers. Tighten the bolts. Engine Status Lamps Remove Lamp The three engine status lamps on the dash panel are: •...
  • Page 337 Remove the right cooler hydraulic hose. Loosen the lower radiator hose clamp. Disconnect the lower radiator hose. Loosen the upper radiator hose clamp. Disconnect the upper radiator hose. Remove the radiator fan guard mounting bolts and spacers. Remove fan guard. 7-68...

  • Page 338: Install

    Remove the upper radiator mounting bolts from the left side of the radiator. Repeat the process for the right side of the radiator. Remove the lower radiator mounting bolts from the left side of the radiator. Repeat the process for the right side of the radiator. This component requires a hoist to move.
  • Page 339 The radiator has lower mounting brackets on the right and left side. Align the left side brackets and thread in a bolt with a flat washer. Do not tighten the bolt completely. Repeat the process for the right hand side. The radiator has upper mounting brackets on the right and left side.

  • Page 340: Remove

    Place a hose clamp around the lower radiator hose. Slide the hose onto the radiator connection. Tighten the clamp. Install the left JIC style cooler hose and tighten the fitting. Install the right JIC style cooler hose and tighten the fitting. Fill the cooling system with coolant.

  • Page 341: Install

    Remove the hydraulic suction hose from the hydraulic tank. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach an approved lifting device. Remove the bolts. Remove the hydraulic tank from the frame.

  • Page 342: Remove

    Connect the hydraulic supply hoses to the hydraulic tank. Install the hydraulic suction hose to the hydraulic tank. Engine and Pump Assembly Remove Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
  • Page 343 Remove the safety chain mounting bolts from hood and frame. Remove the safety chain. Remove the cotter key and flat washer from the hood assist cylinder. The frame has two hinges. Remove the hinge mounting bolts from frame. Repeat for removing hinge. Lift the hood off of compactor frame with a hoist.
  • Page 344 Loosen the intake manifold hose clamp. Remove the intake manifold to cooler tube from the cooler hose. Loosen the turbocharger compressor housing rubber boot clamp. Remove rubber boot. Disconnect the fuel line quick connect fitting. Disconnect the ECM connector from the engine. 7-75...
  • Page 345 The cable is factory adjusted. Do not loosen the locking nuts. Personal injury and equipment damage can result from a cable that is not adjusted correctly. Remove the nut from the back of the directional control cable connection assembly. Move the directional control cable away from the directional control valve bracket.
  • Page 346 Disconnect the hydraulic hoses from the left side of the rear pump. Disconnect the hydraulic hoses from the right rear pump. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Connect the lifting chain to engine.

  • Page 347: Disassemble

    Remove the front engine mounting bolts from the engine. Remove the engine from the frame. Remove the rear engine mount mounting bolts from the frame. Remove the rear engine mount. Remove the front engine mount mounting bolts from the frame. Remove the front engine mount.
  • Page 348 Remove the hose that connects the vibration pump to the propulsion pump. The cable is factory adjusted. Do not loosen the locking nuts. Personal injury and equipment damage can result from a cable that is not adjusted correctly. Remove the directional control cable bracket bolts and washers.

  • Page 349: Assemble

    Remove plastic flange Allen head bolts and washers. Remove the plastic flange. Remove the engine plate mounting bolts and washers. Remove the engine plate. Loosen the Allen head bolt in the pump drive gear. Slide the drive gear off of the pump shaft. Assemble Slide the drive gear onto the pump shaft.
  • Page 350 Place the engine plate over the gear and onto the pump. Align the 8 mm (0.31 in) holes in the 9 and 10 o’clock positions. Thread the bolts with washers into the engine plate. Tighten the bolts. Torque: 167 N٠m (123 ft-lb). Place the plastic flange onto the flywheel.
  • Page 351 Thread in alignment studs as shown in illustration. This component requires a hoist to move. To reduce the possibility of personal injury, always use the lifting equipment that has proper capacity. Attach a lifting device to the pump. Slide the pump into the flywheel housing until the drive gear touches the plastic flange.

  • Page 352: Install

    Install the vibration pump to propulsion pump hose. Tighten the fittings. Connect the pump solenoid connector to the harness connector. Install There are two front engine mounts, one located on the left and one located on the right side. Place the front engine mount on the frame bracket. Align the engine mount holes with holes in the frame.
  • Page 353 Lower the engine onto the rear mounts aligning the holes in the engine mount with the compactor mount. Thread the bolts into the compactor mount. Tighten the bolts. Align the front engine mount bracket holes with the engine and the compactor frame rail. Thread and finger tighten all bolts.
  • Page 354 Slide the cooler tube into the breather box. Slide two hose clamps onto the intake manifold hose. Slide one end of the hose onto the tube. Tighten the hose clamp. Slide a clamp onto the turbocharger compressor-housing boot. Slide the tube that connects the turbocharger compressor housing to the cooler into the rubber boot of the turbocharger.
  • Page 355 Tighten the connectors. Lightly grease terminals to reduce corrosion. Place the rubber caps over the battery terminals. Install the battery box cover. Some of the hydraulic supply hoses are of the split flange and o-ring style. Apply grease to the o-ring. Place the o-ring into the groove in the fitting on the end of the hose.
  • Page 356 For the flanged style hydraulic hose on right rear pump: • Align one flange on the left rear pump and thread in two bolts. • Do not tighten the bolts. • Slide the hydraulic hose, with the o-ring installed into the lower flange. •...
  • Page 357 Install the JIC style hydraulic hoses on the right front hydraulic pump. Secure all hoses for the front and rear pumps with cable ties. Place a bolt through the directional control cable. Slide a spacer onto the bolt. Attach the cable assembly to the bracket. Thread a nut with a flat washer onto the bolt.
  • Page 358 This component requires a hoist to move. To reduce the possibility of personal injury, always use lifting equipment that has proper capacity. Position the hood over the rear frame. Lower the hood onto the rear frame. Align the rear right hinge holes with the rear frame holes. Thread the bolts into the rear right hinge.

  • Page 359: Remove

    Rear End Remove Remove lug nuts from wheel and support the frame with studs. This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.
  • Page 360 Lower the rear end. Install This component requires a hoist to move. To reduce the possibility of personal injury, always use lifting equipment that has proper capacity. Make sure the rear frame is secured on stands. The frame has one rear end bracket for each side. Each bracket has 4 holes.

  • Page 361: Remove

    Connect the hydraulic hoses to the manifold on the rear end. This component or assembly weighs greater than 23 kg [50 lb]. To reduce the possibility of personal injury, get assistance or use appropriate lifting equipment. Align the tire mounting holes with the studs Lift the tire onto the studs.

  • Page 362: Remove

    Install Align the mounting holes in the back up alarm with the compactor frame. Install and tighten the bolts. Install the wires and thread the nuts onto the back up alarm terminal posts. Close the hood. Starter Relay Remove The starter relay is located under the hood on the right side of the compactor.

  • Page 363: Remove

    Install Place the rubber isolators onto the starter relay studs. Slide the starter relay up into the bracket and install the nuts. Connect the wires. Shut the hood. Engine Speed Change Switch Remove Remove the console front cover to gain access to the back of the engine speed change switch.
  • Page 364 Remove the nut from the engine speed change switch. Slide the spacer off of the engine speed change switch. Slide the engine speed change switch out front of the dash panel. Install Slide the engine speed change switch into front of the dash panel.

  • Page 365: Remove

    Connect the engine speed switch wires. Align the front dash cover with the dash. Install the bolts. Tighten the bolts. Forward/Reverse Lever Vibration Switch Remove Remove the cover bolts. Remove the cover. Disconnect the forward/reverse lever vibration switch cable connector. 7-96...

  • Page 366: Install

    Loosen the forward/reverse lever handle mounting screw. Slide the cable out of the shifter tube. Install Slide the forward/reverse lever handle cable into the shifter tube. Position the handle so the vibration button is facing towards the operator. Tighten the mounting screw. Connect the forward/reverse lever vibration switch cable.
  • Page 367 Fuses 65 Amp and Above Remove Main system fuses that are 65 amps and above are located under the hood at the rear of the compactor. The fuses plug into the connector. Unplug the faulty fuse. Install Plug the fuse into the connector. Parking Brake Valve Remove Hydraulic fluid is under pressure.
  • Page 368 Align the parking brake valve with the frame holes. Thread in all mounting bolts. Tighten the bolts. Connect the wires. Connect the hydraulic hoses. Vibration Amplitude Solenoid Remove Hydraulic fluid is under pressure. To reduce the possibility of personal injury, vent the hydraulic system prior to loosening a fitting or loosening removing a hose.
  • Page 369 Install Place the vibration amplitude solenoid onto the vibration pump and align the holes. Install the screws. Tighten the screws. Plug the connectors onto the vibration amplitude solenoid. Tighten the connector screws. Compactor Speed Solenoid Remove Hydraulic fluid is under pressure. To reduce the possibility of personal injury, vent the hydraulic system prior to loosening a fitting or loosening removing a hose.
  • Page 370 Install Place the compactor speed solenoid onto the propulsion motor and align the mounting holes. Install the mounting screws. Tighten the mounting screws. Connect the harness connector to the compactor speed solenoid. Tighten the connector screw. Orbitrol Steering Valve Remove Hydraulic fluid is under pressure.
  • Page 371 Remove the fittings. Install Lubricate fitting o-rings. Install the fittings. Tighten the fittings. Grease the splined drive. Place the Orbitrol steering valve onto the steering column aligning the mounting holes. Install the steering column bolts. Tighten the bolts. 7-102...
  • Page 372 Connect the hoses. 7-103...
  • Page 375 Additional Service Literature It is suggested the below listed service literature be purchased in order to maintain and repair the SV505 compactor. Bulletin Title of Publication 3379000 Air for Your Engine 3379001 Fuel for Cummins Engines Bulletin 3379009 Operation Cold Weather Bulletin 3810340 Cummins Engine Oil Recommendations 3666132...
  • Page 376 General Specifications Sv505D Weight Gross Weight 10,670 kg 23,525 lbs Rear Axle 5,760 kg 12,700 lbs Front Axle 4,910 kg 10,825 lbs Dimension Overall length 5,740 mm 226” Overall width 2,300 mm 91” Overall height 2,870 mm 111” Wheelbase 2,970 mm 117”...
  • Page 377 Model Sv505T Weight Gross Weight 11,030 24,320 Rear Axle 6,110 13,470 Front Axle 10,850 lbs 4,920 Dimension Overall length 5760 mm 227” Overall width 2,300 mm 91” Overall height 2,890 mm 111” Wheelbase 2,970 mm 117” Roll (dia. x width) Wheel Front Pad 1,600 x 2,130 63”...
  • Page 378 Model Sv505TF Weight Gross Weight 13,270 29,255 Rear Axle 8,380 18,475 Front Axle 4,890 10,780 Dimension Overall length 5750 mm 226” Overall width 2,300 mm 91” Overall height 2,900 mm 112” Wheelbase 2,970 mm 117” Roll (dia. x width) Wheel Front Pad 1,650 x 2,130 mm 65”...
  • Page 379 Compactor Overall Specifications Engine High Idle Low Idle Rated Speed 2,300 ± 800 ± 25 rpm 2,200 rpm 50 rpm Travel Speed High 0 ~ 6.2 ± 0.9 mph 0 ~ 3.7 ± 0.9 mph 50± 5˚C (122±41˚F) All Wheel Drive Type(Identical speed for forward and reverse travels) Hydraulic Pressure Propulsion Vibrator...
  • Page 380 Fuel Oil and Grease Rating Ambient Temp. and Applicable Viscosity Rating Service Applicable Lubricant –15 ~ 30°C 0 ~ 40°C 15 ~ 55°C Classification Standards (5 ~ 86°F) (32 ~ 104°F) (59 ~ 131°F) API grade CH- Engine oil SAE 10W-30 SAE 15W-40 SAE 15W-40 MIL-L-2104B...
  • Page 381 Rear Drive Specifications Bolt Torque Type or Bolt Bolt Size Grade 8.8 Grade 8.8 Grade 10.9 Grade 10.9 Grade 12.9 Grade 12.9 Loctite 242 Loctite 270 Loctite 242 Loctite 270 Loctite 242 Loctite 270 M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0...
  • Page 382 Hydraulic Motor Specifications Vibrator Motor Specifications Model Displacement Circuit Pressure Setting A10FM 44.5 25MPa 3260psi 255kgf/cm Propulsion Motor Specifications Circuit Pressure Low Pressure Relief Valve Model Displacement Setting Setting MV075-607 Min: 28cm /rev Max: 75cm3/rev 41.8MPa 6,050psi 2.22 MPa 330psi 10-7...
  • Page 383 Metric to US Torque Cast Iron Aluminum Cast Iron Aluminum Capscrew Body Size N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb 1/4 - 20 1/4 - 28 5/16 - 18 5/16 - 24 3/8 - 16 3/8 - 24 7/16 - 14 7/16 - 20 1/2 - 13 1/2 - 20...
  • Page 384 Fraction to Decimal to Millimeter Conversions Fraction inch Fraction inch 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.381...
  • Page 385 Metric to US Torque Conversions N•m ft-lb N•m ft-lb N•m ft-lb 9 in-lb 44 in-lb 53 in-lb 62 in-lb 71 in-lb 80 in-lb 89 in-lb 97 in-lb 106 in-lb 124 in-lb 133 in-lb 142 in-lb 159 in-lb 15 ft -lb 10-10...
  • Page 386 10-11 Metric Drill and Tap Chart Screw Size Tapping Drills Clearance Drills Close Fit Free Fit Nom. Drill Size Dec. Pitch Series Dia. (65-75% Equiv. (mm) Dec. Dec. (mm) thread) Drill Size Drill Size Equiv. Equiv. 0.20 Fine 0.80 0.0315 1.05 0.0413 1.20...
  • Page 387 Nom. Drill Size Dec. Pitch Series Dece. Dece. Dia. (65-75% Equiv. Drill Size Drill Size (mm) Equiv. Equiv. (mm) thread) 0.75 Fine 8.25 0.3248 9.50 0.3740 10.50 0.4134 1.00 Fine 8.00 0.3150 1.25 Coarse 7.80 0.3071 0.75 Fine 9.25 0.3642 1.00 Fine 9.00...
  • Page 388 Nom. Drill Size Dec. Pitch Series Dece. Dece. Dia. (65-75% Equiv. Drill Size Drill Size (mm) Equiv. Equiv. (mm) thread) 1.00 Fine 26.00 1.0236 1.50 Fine 25.50 1.0039 28.00 1.1024 32.00 1.2598 2.00 Fine 25.00 0.9843 3.00 Coarse 24.00 0.9449 1.00 Fine 27.00...
  • Page 389 Nom. Drill Size Dec. Pitch Series Dece. Dece. Dia. (65-75% Equiv. Drill Size Drill Size (mm) Equiv. Equiv. (mm) thread) 1.50 Fine 50.50 1.9882 2.00 Fine 50.00 1.9685 54.00 2.1260 62.00 2.4409 3.00 Fine 49.00 1.9291 4.00 Fine 48.00 1.8898 5.00 Coarse 47.00...
  • Page 390 Weights and Measures Conversion Factors From Quantity U.S. Customary Metric From U.S. Metric Customary To U.S. To Metric Customary Multiply By Multiply By Unit Name Abbreviation Unit Name Abbreviation Area sq. inch sq. millimeters 645.16 0.001550 sq. centimeters 6.452 0.155 sq.
  • Page 391 From From U.S. Metric Unit Name Abbreviation Unit Name Abbreviation Customary To U.S. To Metric Customary Velocity Multiply By Multiply By miles/hour kilometers/hour 1.6093 0.6214 gallon gal. liter 3.7853 0.264179 (U.S.) Volume: gallon gal. liter 4.546 0.219976 liquid (Imp*) displacement cubic inch liter 0.01639...

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