Sakai SV540 Series Operating & Maintenance Instructions
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Sakai SV540 Series Operating & Maintenance Instructions

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K
DIC212
M
O
D
Read this handbook thoroughly and understand the whole information
E
contained before trying to operate, inspect and service your machine!
L
S
V
5
4
0
/
6
4
0
S
E
OPERATING
&
R
I
MAINTENANCE
E
S
INSTRUCTIONS
VIBRATING
ROLLER
No.
3498-36310-2
Series
→ 3SV53 ­ – 10101
From
SV540D
→ 3SV53 ­ – 10101
SV540T
→ 3SV53 ­ – 10101
SV540DF
→ 3SV53 ­ – 10101
SV540TF
→ 3SV53 ­ – 10101
SV540TB
→ 3SV53 ­ – 10101
SV540FB
→ 3SV55 ­ – 10101
SV640D
→ 3SV55 ­ – 10101
SV640T

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Summary of Contents for Sakai SV540 Series

  • Page 1 DIC212 3498-36310-2 Read this handbook thoroughly and understand the whole information contained before trying to operate, inspect and service your machine! OPERATING & MAINTENANCE INSTRUCTIONS Series VIBRATING ROLLER → 3SV53 ­ – 10101 From SV540D → 3SV53 ­ – 10101 SV540T →...
  • Page 2 PREFACE PREFACE This operator’s manual serves as a guide for the use of your SAKAI SV540 Series and SV640 Series Vibrating Roller for those who are new to the machine, and also for the people who have experience in using the machine and want to refresh their knowledge for the machine.

  • Page 3: Table Of Contents

    CONTENTS CONTENTS PREFACE MACHINE AND ENGINE IDENTIFICATION NUMBERS ........1 SAFETY NOTICES ....................2 1 BASIC SAFETY PRECAUTIONS..............4 General Precautions ................4 Preparation for Safe Operation ..............8 Before Starting the Engine ............... 9 After Starting the Engine ................11 During Operation ..................
  • Page 4 CONTENTS Precautions for Work ................51 2 5.1 Compaction operation ............... 51 2.5.2 When going downhill ................. 51 2.5.3 On a slope ..................51 Applicable Jobs ..................52 After Operation ..................53 Loading and Unloading ................53 2.8.1 Use of a trailer equipped with a winch ..........54 2.8.2 Self-propelling ...................

  • Page 6: Machine And Engine Identification Numbers

    MACHINE AND ENGINE IDENTIFICATION NUMBERS When ordering parts or making inquiries about your machine, the following information is requested: (1) Machine model Indicated on the nameplate of the right side of the operator's seat. (2) Machine serial number 3SV53 – ◯◯◯◯◯ SV540D 3SV53 –...

  • Page 7: Safety Notices

    SAFETY NOTICES For the safe use of your machine, correct handling and periodical maintenance are of utmost importance. Thoroughly read the safety precautions described in this manual. Do not attempt to operate and maintain your machine until you gain a full understanding of these safety statements.
  • Page 8 It is almost impossible for the safety notices in this manual and on the machine to cover all the potential dangers. Keep alert to possible dangers not mentioned in this manual and on the decales. WARNING Do not operate your machine before you read its operator’s manual thoroughly.

  • Page 9: Basic Safety Precautions

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY 1.1 General Precautions ■ Ensure proper management of health • People under the influence of alcohol, drugs, lack of sleep or health problems must avoid driving or repairing the machine at all times, as it may lead to serious accidents. ■...
  • Page 10 WARNING: Negligence of these instructions can lead to accidents. ■ Wear protective clothing appropriate to work • Wear clothing, safety shoes and hard hat to suit your work. • Do not wear clothing and accessories that tend to get caught in the controls or protruded portions of the machine.
  • Page 11 WARNING: Negligence of these instructions can lead to accidents. ■ Do not use a machine which has not been serviced correctly at regular intervals • Before working, perform necessary inspections. Start operation only after making certain the machine is in good operating condition. If found to be abnormal, report to the responsible person and have the fault corrected.
  • Page 12 WARNING: Negligence of these instructions can lead to accidents. ■ Be careful with fire • The fuel, oil, and anti-freeze will catch fire if open flames or ignition sources are used close to them. Particularly, the fuel is highly flammable. •...

  • Page 13: Preparation For Safe Operation

    WARNING: Negligence of these instructions can lead to accidents. ■ To handle the hydraulic fluid • Wear safety goggles to protect your eyes from contact with hydraulic fluid. It can irritate your eyes. If the fluid contacts your eyes, flush with clean water for 15 minutes and get medical aid.

  • Page 14: Before Starting The Engine

    • Tighten bolts with the specified torques after ROPS are removed. Tightening torque : 883 N･m • Do not weld nor drill holes to the ROPS parts without the permissions from SAKAI, because it may decrease strengths of the ROPS.
  • Page 15 WARNING: Negligence of these instructions can lead to accidents. ■ Check that the horn, lamps and gauges work correctly ■ Before starting, make certain that each lever is in the neutral position and the parking brake is applied ■ When starting, sound the horn •...

  • Page 16: After Starting The Engine

    WARNING: Negligence of these instructions can lead to accidents. 1.4 After Starting the Engine ■ Secure safety around the machine • Ensure that the area around the machine is clear of personnel and obstructions. Moreover, honk the horn, indicate your intention to move, and wait a while before moving off.

  • Page 17: During Operation

    WARNING: Negligence of these instructions can lead to accidents. 1.5 During Operation ■ Strictly observe the traffic regulations • Follow all the traffic regulations when driving on a public road. ■ Sit in the driver's seat before starting operation • Sit in the driver’s seat before starting operation. Be sure to wear the seat belt when provided.
  • Page 18 WARNING: Negligence of these instructions can lead to accidents. ■ Do not let anyone enter the work area • There is the danger of being run over causing serious injuries or death. • If the driver does not have a clear field of vision, assign a conductor ensure peripheral safety.
  • Page 19 WARNING: Negligence of these instructions can lead to accidents. ■ At night, carefully drive the machine • Nighttime driving tends to frustrate the sense of distance. Carefully drive the machine at a speed suited to illumination. Keep the headlamps and flood lamps lighted. If necessary, provide extra lighting in the work area.
  • Page 20 WARNING: Negligence of these instructions can lead to accidents. ■ Do not make turns on a slope and do not travel across sidehill. If necessary to do so, go down straight along the slope to the flat ground, move sideways and go up straight to the destination ■...

  • Page 21: Loading And Unloading

    WARNING: Negligence of these instructions can lead to accidents. 1.6 Loading and Unloading • Loading and unloading can accompany any danger. Use extreme care. • Select level and hard ground leaving a sufficient distance from the shoulder of a road or bank. •...

  • Page 22: Handling The Battery

    WARNING: Negligence of these instructions can lead to accidents. 1.8 Handling the Battery ■ When handling the battery • Battery electrolyte contains sulphuric acid. It will destroy clothing and skin. If it touches your clothing or skin, flush with large quantities of water. •...

  • Page 23: Towing

    WARNING: Negligence of these instructions can lead to accidents. ■ Jump-starting the engine • Wear safety goggles when jump-starting the machine. • When starting from another machine, do not allow the two machines to make contact with each other. • When connecting the battery cables, start with the positive terminal.

  • Page 24: Before Servicing

    WARNING: Negligence of these instructions can lead to accidents. 1.10 Before Servicing ■ Attach warning tags when servicing the machine • Serious accidents can occur if the machine is unexpectedly started or controls carelessly touched by an unauthorized person. • Attach a warning tag at a clearly visible location in the operator’s station and insure the key has been removed from the starter switch.
  • Page 25 WARNING: Negligence of these instructions can lead to accidents. ■ Inspect or service your machine with the engine stopped • If required to keep the engine running in such a case as radiator interior cleaning, perform the work with two persons. One of them should sit on the operator’s seat getting ready for shutting down the engine.

  • Page 26: During Servicing

    WARNING: Negligence of these instructions can lead to accidents. 1.11 During Servicing ■ Keep unauthorized persons away • During service, do not allow persons not concerned to enter the work area, particularly when grinding or welding operation is performed or heavy hammers are being used.
  • Page 27 WARNING: Negligence of these instructions can lead to accidents. ■ Carefully handle high pressure hoses • Do not try to bend or hit hoses against a hard object. Do not use hoses or pipes that are bent or damaged. They will burst. •...
  • Page 28 WARNING: Negligence of these instructions can lead to accidents. ■ Used oil disposal • Do not throw used oil into a drain or waterway. Drain the oil from the machine into a proper container. Do not drain directly on the ground. •...

  • Page 29: Safety Decals

    WARNING: Negligence of these instructions can lead to accidents. 1.12 Safety Decals Keep all decals clean. If lost, replace with new one. There are decals other than those shown below: Treat them in the same manner as the one shown here. ①...
  • Page 30 WARNING: Negligence of these instructions can lead to accidents. – 25 –...

  • Page 31: Operation

    2. OPERATION 2 OPERATION 2.1 Instruments and Controls 2.1.1 Operator’s station ＊ ① Vibrator switch ⑦ Steering wheel ⑬ Starter switch ② Vibration selector switch ⑧ Combination meter ⑭ Brake pedal ③ Engine stop lamp ⑨ Eco lamp ⑮ Forward-Neutral-Reverse (F-N-R) lever ④...

  • Page 32: Gauges, Indicator Lamps And Warning Lamps

    Indicates the fuel level in the tank. E: The tank is empty. F: The tank is full. Replenish fuel appropriately before the fuel runs down. CAUTION Be sure to use fuel recommended by SAKAI (refer to page 90). – 27 –...
  • Page 33 2. OPERATION Monitor display ★ Indicator lamps [ Light up when corresponding systems have been operated. ★ Parking brake indicator lamp [ " position. It will flash once when the starter switch is turned to the " After that it will remain on while the parking brake is engaged, and turn off when it is released.
  • Page 34 2. OPERATION IMPORTANT • Hydraulic oil filter warning lamp Go on when the engine rpm is increased before the engine has been warmed up enough. Keep the engine idling until the lamp goes off, before starting your work. In that case, warm up the engine sufficiently, and operate the machine after the warning light has gone out.
  • Page 35 2. OPERATION Engine check lamp When the start switch is set to the " " position ,self-diagnosis of the engine will start. When the result is normal. Three lamps will goes out. If the lamp remains lit or it lights during operation, it means there is any trouble with the engine.

  • Page 36: Switches

    2. OPERATION 2.1.3 Switches Starter switch Starts and stops the engine. " " position : The key can be removed in this position. All the electric systems are switched off. To shut down the engine, move the key to this position. "...
  • Page 37 2. OPERATION Parking brake switch is pressed down, the parking brake will be If switch applied with the indicator lamp on the dashboard lit up. When pressed again, the brake is released and the indicator lamp goes off. NOTE: When pressing the parking brake switch during machine running, the brake is activated and the engine is stopped at the same time.
  • Page 38 2. OPERATION Vibrator switch By means of vibrator switch located on the panel, selection of vibration amplitude and On-Off is mode. " " position : Turning the vibration switch clockwise causes the vibration to start with high amplitude. " " position : Vibration is shut down. " "...
  • Page 39 2. OPERATION Speed change switch Selects two machine speed ranges. km / h (mile / h) (Low) (High) 0 – 6 (0 – 3.7 ） 0 – 10 (0 – 6.2 ） Speed IMPORTANT Be sure to shift gears while the machine is stopped. Can not shift gears during operation.

  • Page 40: Operating Levers / Pedals

    2. OPERATION 2.1.4 Operating levers / pedals Forward - Neutral -Reverse (F-N-R) lever Moving the F-N-R lever forward or backward makes the machine travel forward or backward respectively. The neutral position brings the machine to a stop. The machine speed increases or decreases in proportion to the lever displacement.

  • Page 41: Unloader Valve

    2. OPERATION Brake pedal In an emergency, push down on the pedal to the full extent, and the machine will come to a sudden stop. NOTE: When pressing the brake pedal, the brake is activated and the engine is stopped at the same time.

  • Page 42: Fuse Box

    2. OPERATION 2.1.6 Fuse box WARNING When changing a fuse, cut the power supply by turning the starter switch to the " " position. The fuse box is located at the back of the driver’s seat. Recline the back of the seat towards the front, turn the stud in a counterclockwise direction by 90 degrees, and then open the panel cover.

  • Page 43: Handling And Adjustments

    2. OPERATION 2.2 Handling and Adjustments 2.2.1 Seat adjustment Adjust the seat for your best operating position. Move the lever as shown by arrow. With the lever held in that position, slide the seat forward or backward as desired. When properly adjusted, release the lever. Adjust your seat position to suit you as follows: 1) Pull the lever ①...

  • Page 44: Scraper Adjustment And Replacement

    2. OPERATION 2.2.2 Scraper replacement and adjustment SV540D, SV540TF, SV540FB, SV640D 1) Clearance adjustment of scraper Ⓐ ① Loosen bolts and nuts Ⓑ at 8 locations. ② Provide a clearance of 20 mm between scraper blades Ⓐ and the drum. ③ Retighten bolts and nuts Ⓑ at 8 locations. 2) Clearance adjustment of scraper Ⓒ...

  • Page 45: Disengaging The Brake When Towing

    2. OPERATION 2) Replacement of scraper Ⓐ (Nine pieces are mounted on both the top surface and the undersurface for each in front of the machine.) ① Remove bolts and nuts Ⓑ ② Replace scraper Ⓐ with new ones. 3) Change from DF to D types ①...

  • Page 46: Engine Troubleshooting

    2. OPERATION 1) Turn the unloader valve counterclockwise to release it. Refer to “Unloader valve” on page 36 for its operation method. 2) Loosen Ⓒ : lock ring of Ⓑ : selector valve counterclockwise. And turn Ⓑ counterclockwise. 3) Pull up and press the Ⓐ : knob of the pump slowly.

  • Page 47: Operation

    2. OPERATION 2.3 Operation WARNING • This machine is a one-man roller. • Operate the machine from the operator’s seat. • Be sure to wear the seatbelt during operation. 2.3.1 Before-starting inspection 1) Check that the steering lock pin is in the carrying position. WARNING Make sure that the steering lock pin is in the carrying position before putting the machine in...

  • Page 48: Starting The Engine

    2. OPERATION 2.3.2 Starting the engine WARNING Check that the F-N-R lever is in the neutral position, and press down the parking brake switch and sound the horn when starting the engine after making certain that there are no one and no objects close to the machine. 1) Set the engine speed select switch in the IDLE position.

  • Page 49: After Starting The Engine

    2. OPERATION 4) Turning the key to the " " position makes the engine start. Release the key the moment the engine has " started. The key will automatically return to the " position. CAUTION • Do not allow the starter key to stay in the " "...

  • Page 50: Traveling

    2. OPERATION 2.3.4 Traveling CAUTION While travelling, do not turn the starter switch " " position. WARNING • When starting, operate the horn after securing the safety around the machine. • Be sure to wear the seatbelt during operation. 1) Select the desired speed by the speed change switch. km / h (mile / h) (Low) (High)
  • Page 51 2. OPERATION 3) Press down the parking brake switch button to release the brake. Check that indicator lamp on the monitor display goes off. 4) Move the F-N-R lever in the direction to travel, and the machine will begin traveling. CAUTION Avoid abrupt operation of the F-N-R lever.

  • Page 52: Stopping / Parking

    2. OPERATION 2.3.5 Stopping / Parking WARNING • Avoid abrupt braking. Leave enough space for braking safety. • Avoid parking on a grade. • If necessary to park on a grade, chock the drum and tires to prevent unexpected moving down the grade. 1) Bring the F-N-R lever to the neutral position Ⓝ...

  • Page 53: Stopping The Engine

    2. OPERATION 2.3.6 Stopping the engine 1) Set the engine speed select switch at the IDLE position, wait for about 5 minutes with the engine idling to gradually cool the engine. Engine speed select switch IMPORTANT • Do not bring a hot engine to a sudden stop except for an emergency. This will shorten the life of its component parts.

  • Page 54: Vibratory Operation

    2. OPERATION 2.4 Vibratory Operation 1) Turn the engine speed select switch clockwise to set the engine RPM to FULL or ECO. NOTE: It is possible to conduct the rolling compactions as much as the vibration specifications when setting the engine speed select switch to FULL and ECO.
  • Page 55 2. OPERATION Vibration can be turned ON / OFF with the vibration switch Ⓒ . Select a suitable setting depending on a working site condition . " " position : Vibration can be turned ON or OFF with the switch located on the F-N-R lever. Pressing Vibration selector switch Ⓑ...

  • Page 56: Precautions For Work

    2. OPERATION 2.5 Precautions for Work 2.5.1 Compaction operation ■ Understand the intended purposes of the rollers • This roller is developed and manufactured mainly for compacting soil. Working with vibrations under excessive rolling compactions or using for crushing operations may cause damages to this machine.

  • Page 57: Applicable Jobs

    2. OPERATION 2.6 Applicable Jobs The machines do a variety of jobs as listed below. 1) This machine is mainly used for: • Static compacting work • Vibratory compacting work 2) Road rollers do a variety of jobs as listed below. This machine most effectively handles works or materals marked ☆...

  • Page 58: After Operation

    2. OPERATION 2.7 After Operation Check for the coolant temperature,engine oil pressure and fuel level. Follow the procedures below to prevent the machine from falling into an unworkable condition the following morning caused by muds and other extraneous matter on the drum, or frozen drums: 1) Check to see if the engine coolant temperature is too high and the engine oil pressure is not normal.

  • Page 59: Use Of A Trailer Equipped With A Winch

    2. OPERATION 2.8.1 Use of a trailer equipped with a winch WARNING Placing the unloader valve in UNLOAD position disrupts the power for traction. Do not enter the areas ahead of and behind the machine. It is very dangerous. 1) Engage the trailer brake and chock its wheels. Fix the ramps so that the machine and trailer are completely aligned.

  • Page 60: After Loading The Machine

    2. OPERATION 2) Decide the correct direction of run and conduct loading or unloading at low speed. For loading, run forward at low speed. For unloading, run backward at low speed. 3) Locate the machine correctly on the trailer. 2.9 After Loading the Machine When the machine has been located properly on the trailer, tie it down as follows: 1) Press the parking switch button to apply the parking brake.

  • Page 61: Coolant

    2. OPERATION 2.11.2 Coolant WARNING Do not bring an open flame to the antifreeze or do not smoke when handling it. It is flamable. CAUTION Use ethylene glycol-base antifreeze. For the cooling water, mix the antifreeze in water. Use softened water as the water to be mixed. Please refer to the following table for the mixing ratio.

  • Page 62: Battery

    2. OPERATION WARNING • Do not remove the radiator cap while the coolant is hot. • Hot water may be spouted out that can cause scald. Relieve pressure by slowly turning the cap after the water temperature is dropped, then remove the cap. 2.11.3 Battery WARNING •...

  • Page 63: When The Cold Season Is Over

    2. OPERATION When the temperature decreases, the battery capacity will lower, possibly freezing the electrolyte. The battery should be maintained in a good state at all times, with care taken to keep it warm in preparation for use the next morning. Hydrometer atop the battery permits confirmation of the condition of the battery.

  • Page 64: During The Storage Period

    2. OPERATION 2.14 During the Storage Period WARNING If necessary to operate the machine in indoor storage space, ensure good ventilation keeping windows and doors open to prevent gas poisoning. • During storage, operate the machine at least once a month to prevent the oil films on the lubricated parts from deteriorating and to charge the batteries.

  • Page 65: Connection And Disconnection Of Booster Cables

    2. OPERATION 2.15.1 Connection and disconnection of booster cables When jump-starting the engine, connect the booster cables as follows: ■ Connection of booster cables 1) Connect one end of the positive booster cable Ⓐ to the positive (+) terminal of the dead battery on the machine.
  • Page 66 2. OPERATION WARNING • Do not allow the positive (+) terminal to make contact with the negative (–) terminal when connecting the booster cables. • Wear safety goggles when jump-staring the engine. • Do not allow the machine to make contact with the booster supply.

  • Page 67: Periodic Maintenance

    General precautions 1) Always use SAKAI genuine parts for replacement. 2) Use lubricants recommended by SAKAI. Avoid mixing different brand lubricants. 3) For hydraulic oil replenishment, changing, level checking, filter cleaning or replacement, oiling and greasing, use extreme care to prevent dust from entering.
  • Page 68 3. PERIODIC MAINTENANCE Periodic replacement of essential maintenance parts In order secure safety for work and travel, conduct inspection and services. Further, for enhanced safety, following parts and components should be replaced periodically. These parts are prone to material deterioration due to aging or physical change due to friction, it is difficult to determine their useful limit by regular inspection, which makes it necessary to replace with new ones after certain period of service to ensure they function as intended.
  • Page 69 3. PERIODIC MAINTENANCE CAUTION • With a new machine, change the engine oil and change the engine oil filter elements after 50 hours of operation for the first time only. (refer to page 75) • When trouble occurs in the location indicated by the indicator lamp on the dashboard display, sensor will work and corresponding lamp comes on.

  • Page 70: Lifting The Machine By Hoist

    3. PERIODIC MAINTENANCE 3.1.1 Lifting the machine by hoist WARNING • Get a qualified personnel to lift and lower the machine on a hoist. • Use sturdy wire ropes. • Lock articulation by means of lock pin located at the center of machine. CAUTION Remove ROPS before starting lifting work.

  • Page 71: Walk-Around Checking

    3. PERIODIC MAINTENANCE 3.2 Walk-around Checking For efficient operation, daily, before-operation checking is very important. Before starting, perform walk-around checking for loose bolts, nuts and signs of leakage in addition to items as shown below – 66 –...

  • Page 72: Tire Inflation Pressure Check

    3. PERIODIC MAINTENANCE 3.2.1 Tire inflation pressure check Inflation pressure Check that the inflation pressure of a tire is 137.3 kPa ( 20psi ) with a pressure gauge when the tire has cooled down. If the pressure reading exceeds the above range, adjust the pressure accordingly.

  • Page 73: Periodic Maintenance Points

    3. PERIODIC MAINTENANCE 3.3 Periodic Maintenance Points – 68 –...
  • Page 74 3. PERIODIC MAINTENANCE Interval Item Service Lubricant Q’ty ⑥ Fuel pre-filter Check, drain water and dirt ⑦ Air cleaner Check indicator Every 10 service ⑮ Auxiliary tank Check coolant level Coolant hours or ⑰ daily Engine oil level gauge Check oil level Engine oil ㉖...

  • Page 75: Maintenance Procedure

    3. PERIODIC MAINTENANCE 3.4 Maintenance Procedure For servicing the engine, see the separate engine manual. (1) Every 10 service hours or daily ⑥ Fuel pre-filter Check the filter for water at regular intervals and drain as necessary. ⑦ Air cleaner When the red float of the dust indicator reaches the service level (a mark on the indicator), change the filter element (refer to page 84).
  • Page 76 3. PERIODIC MAINTENANCE ⑮ Auxiliary tank Check to see coolant level in the sight glass, if coolant can not be seen, replenish with the auxiliary tank cap removed.Use soft water only. CAUTION Failure to follow this procedure can result in severe engine damage. Fill : 1) Open heater valves that can be found beneath the engine, and turn the heater to "heat"...
  • Page 77 Please start checking it by waiting until the temperature is dropped. CAUTION Be sure to use engine oil recommended by SAKAI (refer to page 90). ㉖ Fan belt Check the fan belt for wear and damage. Replace as necessary.

  • Page 78: Every 50 Service Hours

    Check the oil level with the sight glass on the side of tank. The level is proper if it is between H and L marks. Of necessary, add the hydraulic fluid from the fill port. CAUTION Be sure to use hydraulic oil recommended by SAKAI (refer to page 90). ⑫ Brake When the engine is completely stopped, step on the brake pedal by two or three times.
  • Page 79 3. PERIODIC MAINTENANCE ⑬ Batteries Maintenance-free batteries are installed at the time of delivery. Inspection and maintenance methods for installed batteries. 1) Check the color of the hydrometer attached to the battery top to charge or replace the battery. Green … Satisfactory Black …...

  • Page 80: Every 250 Service Hours

    3. PERIODIC MAINTENANCE CAUTION • Use only batteries recommended by SAKAI (refer to page 92). • The power-supply voltage of this machine is 24V. ⑲ Blade cylinders (For model SV540TB, SV540FB) Push rod anchor pins (For model SV540TB, SV540FB) Apply grease at 6 locations.
  • Page 81 3) Check the oil level and fill the oil through the fill port until it overflows at the level port as necessary. 4) Refit the fill / level plugs. CAUTION Be sure to use gear oil recommended by SAKAI (refer to page 90). ⑳ Vibrator Check for the oil level and leakage.
  • Page 82 ㉒ Center pin and tilt pin bearings Apply grease at 6 locations. CAUTION Be sure to use grease recommended by SAKAI (refer to page 90). Steering cylinders Apply grease at 4 locations. The steering cylinder is provided on both sides of the machine.

  • Page 83: Every 500 Service Hours

    3. PERIODIC MAINTENANCE (4) Every 500 service hours ⑥ Fuel pre-filter Change the filter elements. ⑧ Hydraulic oil line filter ⑨ Hydraulic oil return filter Change the filter elements. ⑭ Control link 1) Check the nuts for looseness. 2) Apply grease to F-N-R lever shaft. –...
  • Page 84 4) Fill oil through the fill port until oil starts overflowing from the level port. 5) Refit the level plug and fill port plug. CAUTION Be sure to use gear oil recommended by SAKAI (refer to page 90). – 79 –...
  • Page 85 4) When the final drive case is filled to the specified level, refit the removed plugs. CAUTION Be sure to use gear oil recommended by SAKAI (refer to page 90). Differential case 1) Drain oil by removing the drain plug, fill port plug and level plug.

  • Page 86: Every 1000 Service Hours

    WARNING When draining a hot oil, use care not to get burned. CAUTION Be sure to use hydraulic oil recommended by SAKAI (refer to page 90). ⑪ Gear case : Wheel moter 1) Position the drum so that the drain plug comes to the bottom.Keep the three salient parts (indicated in black...
  • Page 87 When draining a hot oil, use care not to get burned. CAUTION • The oil capacity of the vibrator is 34 liters. Do not fill more than 34 liters. • Be sure to use gear oil recommended by SAKAI (refer to page 90). – 82 –...

  • Page 88: As Required

    3. PERIODIC MAINTENANCE (6) As required ④ Tires 1) Check if there are wears and flaws. Please check if there are any cracks and damages such as wears on one side, partial wares, step-shaped wares, nails and stones stuck or cut into the tires on the contacting surfaces with the grounds, both side surfaces and all around of the tires.
  • Page 89 3. PERIODIC MAINTENANCE CAUTION • Turn the wheel hub nut in the tightening direction during inspection. • Excessive tightening of the wheel hub nut will lead to breakage of bolts or cracks in the disc wheel. Be sure to observe the specified torque. NOTE: Tighten the wheel hub nut 50 hours after purchase of a new machine or replacement of tires.
  • Page 90 3. PERIODIC MAINTENANCE 3) Secondary Element CAUTION Take caution when removing the secondary element. Any loose debris can fall into the air intake plumbing leading directly to the engine. Clean the area around the secondary filter element and replace the secondary promptly to avoid engine contamination ingestion.
  • Page 91 3. PERIODIC MAINTENANCE ⑱ Breather ➡ See the separate engine manual. Provide inspection and cleaning of the breather hoses and breather filter element. When you find any damage, make sure to replace it. ㉔ Radiator Clean the cooling fins. WARNING Use the safety glasses or goggles during the use of compressed air.
  • Page 92 3. PERIODIC MAINTENANCE ㉘ Fuel tank 1) With the drain plug removed, remove the water and sediment from the bottom of the tank. 2) If sedimentation is substantial, remove the drain plug and clean the interior of the tank. 3) When the necessary work and refueling are complete, tighten the filler cap positively.

  • Page 93: Consumable Parts

    Proper replacement of consumable parts will improve the overall life of the machine, resulting in cost-effective operations. Use genuine SAKAI parts as replacement parts. The part numbers are subject to change due to the improvements to the parts. When...
  • Page 94 3. PERIODIC MAINTENANCE – 89 –...

  • Page 95: Fluid And Lubricant Capacities

    4) When replacing oil, drain it completely and clean the container with flushing oil before filling new oil. 5) When fueling SAKAI machines, be sure to use the fuel that we specify or recommend. Nonconformance resulting from use of fuel and lube oil other than those specified or recommended by SAKAI is not covered by our warranty and repair service.
  • Page 96 3. PERIODIC MAINTENANCE (4) Recommended lubricants Lubricant Engine oil Gear oil Hydraulic oil Grease API – CJ4 (NLGI − 2) API GL 5 ISO-VG 46 company RPM Universal Rando Multifak DELO 400 LE CHEVRON Gear Lubricants HDZ 46 EP 2 BP Energear Bartran BP Energrease...

  • Page 97: Electric Wiring Diagram

    3. PERIODIC MAINTENANCE 3.7 Electric Wiring Diagram – 92 –...
  • Page 98 3. PERIODIC MAINTENANCE Fuse box The fuse box houses eight 20A-fuses, seven 15A-fuses, three 5A-fuses, lined up with spares fitted for 20A-fuses,15A-fuses, 5A-fuses and 10A-fuse. Use fuses of correct capacity. (refer to page 37) NOTE: When a fuse is burned, determine the cause before replacing. –...
  • Page 99 3. PERIODIC MAINTENANCE Battery IMPORTANT When this machine is shipped, maintenance free battery is installed. ★ Leaving the battery unused for long without attention or using its power excessively at a time can cause damage to the plates, leading to a shortened life. ★...

  • Page 100: Specifications

    4. SPECIFICATIONS 4 SPECIFICATIONS (1) SV540D Model SV540D Weight: Vibrating power: High Gross weight 10,710 kg (23,610 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 5,470 kg (12,060 lbs) Centrifugal force 172 kN (38,666 lbs) 255 kN (57 ,324 lbs) On rear axle 5,240 kg (11,550 lbs) Gradability...
  • Page 101 4. SPECIFICATIONS (2) SV540DF Model SV540DF Weight: Vibrating power: High Gross weight 12,385 kg (27,305 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 7,215 kg (15,905 lbs) Centrifugal force 172 kN (38,666 lbs) 255 kN (57 ,324 lbs) On rear axle 5,170 kg (11,400 lbs) Gradability...
  • Page 102 4. SPECIFICATIONS (3) SV540T Model SV540T Weight: Vibrating power: High Gross weight 11,090 kg (24,450 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 5,855 kg (12,910 lbs) Centrifugal force 172 kN(38,666 lbs) 255 kN(57 ,324 lbs) On rear axle 5,235 kg (11,540 lbs) Gradability...
  • Page 103 4. SPECIFICATIONS (4) SV540TF Model SV540TF Weight: Vibrating power: High Gross weight 13,350 kg (29,430 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 8,120 kg (17,900 lbs) Centrifugal force 172 kN(38,666 lbs) 255 kN(57,324 lbs) On rear axle 5,230 kg (11,530 lbs) Gradability...
  • Page 104 4. SPECIFICATIONS (5) SV540TB Model SV540TB Weight: Vibrating power: High Gross weight 11,770 kg (25,950 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 6,760 kg (14,905 lbs) Centrifugal force 172 kN(38,666 lbs) 255 kN(57 ,324 lbs) On rear axle 5,010 kg (11,045 lbs) Gradability...
  • Page 105 4. SPECIFICATIONS (6) SV540FB Model SV540FB Weight: Vibrating power: High Gross weight 14,035 kg (30,940 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 9,040 kg (19,930 lbs) Centrifugal force 172 kN(38,666 lbs) 255 kN(57,324 lbs) On rear axle 4,995 kg (11,010 lbs) Gradability...
  • Page 106 4. SPECIFICATIONS (7) SV640D Model SV640D Weight: Vibrating power: High Gross weight 13,150 kg (28,990 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 7,150 kg (15,760 lbs) Centrifugal force 172 kN (38,666 lbs) 255 kN (57 ,324 lbs) On rear axle 6,000 kg (13,230 lbs) Gradability...
  • Page 107 4. SPECIFICATIONS (8) SV640T Model SV640T Weight: Vibrating power: High Gross weight 13,525 kg (29,820 lbs) Frequency 33.3 Hz 2,000 vpm 28.3 Hz 1,700 vpm On front axle 7,485 kg (16,500 lbs) Centrifugal force 172 kN(38,666 lbs) 255 kN(57,324 lbs) On rear axle 6,040 kg (13,320 lbs) {17,500kgf}...
  • Page 108 SAKAI HEAVY INDUSTRIES, LTD. Head Office: 1-4-8, Shiba Daimon, Minato-ku, Tokyo, Japan Telephone: Tokyo 81-3-3431-9971 Facsimile: 81-3-3436-6212 Printed in Japan 2015 08. dataonly ①Ⓒ...

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