Sakai SV204 Series Page 2 Operating & Maintenance Instructions Download

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Summary of Contents for SV204 Series

Page 1: ...inspect and service your machine No 3498 36540 0 OPERATING MAINTENANCE INSTRUCTIONS M O D E L S V 2 0 4 S e r i e s VIBRATING ROLLER From SV204D 1SV65 30101 SV204T 1SV65 30101 SV204TB 1SV65 30101 SV204TF 1SV65 30101 Series Read this handbook thoroughly and understand the whole information contained before trying to operate inspect and service your machine No 3498 36540 0 OPERATING MAINTENANCE INST...

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Page 3: ...t hand whenever you do your work When an instruction manual is lost or is damaged and is not legible replace it immediately The main subjects of this manual are 1 Basic precautions for safety 2 Operation 3 Daily maintenance and 4 Specifications For operation and maintenance of the engine refer to the Engine Instruction Manual furnished separately Descriptions in this manual can differ from the mac...

Page 4: ...rator s station 24 2 1 2 Gauges indicator lamps and warning lamps 25 2 1 3 Switches 28 2 1 4 Operating levers pedals 31 2 1 5 Unloader valve 32 2 1 6 Fuse box 33 2 2 Handling and Adjustments 34 2 2 1 Handling the DPF 34 2 2 2 Seat adjustment 38 2 2 3 Fusible link 39 2 2 4 Accessory soket 39 2 2 5 Scraper adjustment and replacement 40 2 2 6 Disengaging the brake when towing 41 2 3 Operation 42 2 3 ...

Page 5: ...attery Has Discharged 57 2 15 1 Connection and disconnection of booster cables 57 3 PERIODICAL MAINTENANCE 59 3 1 Precautions 59 3 1 1 Lifting the machine on a hoist 61 3 2 Walk around Checking 62 3 2 1 Tire inflation pressure check 63 3 2 2 Checking for external injury to a tire 63 3 3 Periodical Maintenance Points 64 3 4 Maintenance Procedure 67 1 Every 10 hours or daily 67 2 Every 50 hours 68 3...

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Page 7: ...ERS When ordering parts or making inquiries about your machine the following information is requested 1 Machine model Indicated on the nameplate of the left side of the operator s seat 2 Machine serial number SV204D 1SV65 SV204T 1SV65 SV204TB 1SV65 SV204TF 1SV65 3 Engine serial number ...

Page 8: ... covered in this manual you must assume responsibility for your own personal safety In this manual and on the machine you will find safety notices Each safety notice starts with a signal word as shown below DANGER Denotes that 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 color of the symbol is red WARNING De...

Page 9: ...ual thoroughly Incorrect operation can kill or cause injury It is your responsibility to operate the machine safely WARNING Making alterations to the machine Please do not make alterations to the machine without permission for safety reaseons We shall not be held responsible for injures death or breakdowns caused by alterations Basic precautions for safe operation of your machine are described beg...

Page 10: ...y Understand the functions of the controls and gauges Familiarize yourself with their location and how to operate them Understand the meaning of all the symbols When an instruction manual is lost or is damaged and is not legible replace it immediately Understand the intended use of the machine This machine is developed and manufactured mainly for rolling compactions of road constructions and repai...

Page 11: ...riers where there is a risk of falling of the machine or collapse of shoulder The operator must make prior checks when moving the machine to a hazardous area under unusual conditions Provide against an accident Decide in advance the means of communication in an emergency Know the location and use of an extinguisher and first aid kit Realize the capability of the machine Thoroughly understand the p...

Page 12: ...e time the coolant engine oil and hydraulic fluid will become hot and the pressure will build up If in this state you try to remove the filler caps drain the oil or replace the filters you can get burned Perform this work in accordance with the correct procedures with the machine cooled down To remove the radiator cap slowly loosen the cap to relieve the pressure with the engine stopped and the co...

Page 13: ...as possible While the engine is running or immediately after it has been turned off do not touch the muffler exhaust pipe or DPF While the engine is running or immediately after it has been turned off do not touch the muffler exhaust pipe or DPF as they will be hot Mount on or dismount from your machine after it has come to a complete stop For getting on and off face the machine and use the handra...

Page 14: ...ed suddenly Continued use of damaged tires will cause them to blow out Replace them with new ones 1 2 Preparation for Safe Operation Clean the step operator s station and floor board and brake pedal Do not place parts tools or unnecessary articles on the step operator s station and floor board Keep the step floor board brake pedal controls and handholds free from muds oil ice or water as they can ...

Page 15: ...the Engine It is confirmed that hood and door is closed Please confirm hood and door has put it away in the confirmation before it gets on Adjust the operator s seat to your most effective operating position Sit on the operator s seat Adjust the seat so that your back will make contact with the seat back when the brake pedal is pressed down to the full extent Check to be sure that the brake pedal ...

Page 16: ...gerous if breathed in When starting the engine in an enclosed area provide good ventilation with windows and doors opened Do not stand close to the exhaust gas pipe opening The exhaust gas from the engine is dangerous Exhaust fumes are harmful if breathed in 1 4 After Starting the Engine Secure safety around the machine Ensure that the area around the machine is clear of personnel and obstructions...

Page 17: ...ith seat belt Be sure to wear the seat belt during operation No other person but the operator This machine is a one man roller Do not allow anyone to get on Only the operator is allowed on this machine while it is running or in operation Before mounting be sure areas around the machine are safe Before getting on the machine make certain that there are no obstacles around the machine and no workers...

Page 18: ...n changing the direction of travel secure the safety on the path in the travel direction Keep everyone away from the pinch points When making turns do not allow anyone to come close to the pinch point 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 lighte...

Page 19: ...iving the machine While making turns do not run at abnormally high speed and do not turn the steering wheel abruptly and sharply High speed turns especially on soft or uneven ground could result in a rollover For the traveling on structures such as a bridge make certain that they can support your machine Before traveling on the structure you must know the load capacity of the structure and the loa...

Page 20: ...se sturdy ramps with proper width length and thickness which allow safe loading and unloading If they deflect considerably under load apply wooden blocks to reinforce the ramps To prevent your machine from crosswise slippage keep the ramps free from oil mud debris etc The drum must also be free from extraneous matter that can cause slippage Do not steer your machine on the ramps If the machine is ...

Page 21: ...s contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hand after handing Inspect or handle the battery with the engine stopped and the starter switch in the position Keep metallic items such as tools away from the battery terminals Tangled terminals may generate sparks due to improper connections resulting in the danger of explosion...

Page 22: ...ck of the disabled machine can cause sparks The connecting point should be as far as possible from the battery 1 9 Towing Towing should only be carried out in emergencies and over short distances A trailer should be used for long distance transport The machine should not be operated while being towed Follow the instructions in this manual to enable towing Do not tow if the braking system has broke...

Page 23: ...ore beginning inspections or maintenance work Use proper tools It is very dangerous to use damaged or deteriorated tools or to use tools for other purposes than intended Use correct tools for their intended use only Change safety related parts at regular intervals Change any seatbelt found to be abnormal even if it is within its recommended service interval Change any ROPS found to be abnormal eve...

Page 24: ...ndle fuel and oil in a well ventilated area Check the coolant level in the radiator To check the coolant level stop the engine and allow the engine and radiator to cool down before removing the radiator cap Remove the cap by covering it with a rag before removing to prevent any fluid that could spray under pressure from causing a burn Illumination For inspecting the level of the fuel oil coolant a...

Page 25: ...ght or crushed Be sure to fix the hood and other covers after opening them to prevent closing and avoid getting caught in them If there is a need to crawl under the machine after it has been lifted be sure to support it from underneath with a solid prop or block When repairing the electrical system Read the warnings in this manual regarding the handling of batteries and make sure to have a thoroug...

Page 26: ... parts After the machine has been operated for some time the coolant engine oil and hydraulic fluid will become hot Removing the radiator cap or draining the coolant or oil can burn you Perform this work in accordance with correct procedures after the systems have cooled down Use care when inspecting or servicing fan or belts in motion Do not wear clothing and accessories that tend to get caught i...

Page 27: ...er releasing the gas pressure When doing this be sure to wear protective goggles because of the danger of oil inside or swarfs getting sprayed everywhere by the compressed gas inside Exercise extreme care when replacing and repairing tires Tire installed Disassembly repair and reassembly of tires require special facility and knowledge Have them repaired at work shop specialized in handling tires A...

Page 28: ...ew one There are decals other than those shown below Treat them in the same manner as the one shown here 3998 16504 0 3998 16497 1 3998 16489 0 3998 16499 0 2 locations 1202 19062 0 3998 16505 0 3998 16501 0 3998 16507 1 3998 16510 0 3998 16468 1 3998 16670 0 3998 16559 0 2998 96001 1 3998 19678 0 2 locations 3998 06139 0 3998 16500 0 3998 16700 0 3998 16730 0 ...

Page 29: ...1 BASIC PRECAUTIONS FOR SAFETY 23 WARNING Negligence of these instructions can lead to accidents ...

Page 30: ...lector switch Combination meter Auto regeneration lamp green Parked regeneration request lamp amber DPF meter Parking brake switch Lamp switch option Throttle lever Parked regeneration switch black Turn signal lever option Brake pedal Starter switch Steering wheel Forward Neutral Reverse F N R lever with vibrator switch Leveling blade lift lever for SV204TB only ...

Page 31: ...ion in this manual should be based upon the hour meter readings Temperature gauge Indicates the coolant temperature Zone close to symbol H indicates overheating In case of overheating run the engine at idling for about ten minutes before shutting it down Then determine the cause Fuel gauge Indicates the fuel level in the tank E The tank is empty F The tank is full Replenish fuel appropriately befo...

Page 32: ...hydraulic oil filter becomes clogged Stop the machine and carry out an inspection Engine oil pressure warning lamp It will turn on when the starter switch is turned to the position and turn off when the engine starts running It will turn on while the engine is running if the engine oil pressure drops below the specified value Stop the machine and carry out an inspection Battery charge lamp It will...

Page 33: ... meter or wirings harness The window of the combination meter The window of the combination meter may become invisible because of aged deterioration coused by fine sand or dust or ultraviolet When any flaw or mist is found on the window contact our branch offices or designated factory DPF meter This meter indicates the amount of PM particulate matter that has accumulated on the DPF diesel particul...

Page 34: ...ding Stop the machine put the throttle lever in the idling position and let the engine idle to gradually cool it If the lamp does not turn off contact one of our sales offices or a factory designated by our company for advice 2 1 3 Switches Starter switch Starts and stops the engine The key can be removed in this position All the electric systems are switched off To shut down the engine move the k...

Page 35: ...is recommended that the rear work lamp only be turned on when the lever is in the full position Parking brake switch If switch is pressed down the parking brake applies with the indicator lamp on the monitor display lighted up When pressed again the brake is released and the indicator lamp goes off WARNING To disengage the brake be sure to press the button again instead of pulling it When dismount...

Page 36: ...ver Pressing this switch causes the vibration to start and pressing it again to stop position Vibration is shut down CONT position Have this switch placed at this position when vibration is not to be actuated NOTE For vibratory rolling run the engine at 1 800 rpm or higher IMPORTANT Do not operate the vibrator on a hard area such as cement concrete pavement surface or the ground covered by thick s...

Page 37: ...Provided at the knob of the lever is the vibrator switch for turning on or off the vibration IMPORTANT For normal braking return the F N R lever back to neutral In an emergency depress the brake pedal Throttle lever Shifts the engine RPM The engine RPM increases when moved toward the operator Turn signal lever option Turn signal lamp flashes when the turn signal lever is operated Left turn Move th...

Page 38: ...al braking 2 1 5 Unloader valve The unloader valve disengages the drive playing a role like a clutch Use this valve for towing the machine when the engine is disabled or when troubles have developed in the hydraulic drive Towing speed At of less than 0 5km h 0 3mile h Towing distances With in 100m 328ft For towing Turn the knob counter clockwise Unload For normal traveling Turn the knob clockwise ...

Page 39: ...fuse box is found under the dashboard Pull on the grips to open the panel cover Fuses protect electrical components and wiring from burning Change any fuse which has become powder coated due to deterioration or which has a play between it and fuse holder To replace fuses take off the cover Be sure to use fuses of correct capacity ...

Page 40: ...d the PM will be automatically burned regenerated If the conditions do not allow automatic regenerating the parked regeneration request lamp amber will flash to enable manual regenerating WARNING Do not carry out regenerating in enclosed spaces with poor ventilation such as inside a garage or a room There is the danger of carbon monoxide poisoning Check to make sure there are no inflammables near ...

Page 41: ...egeneration request lamp amber will flash then turn on after which the engine will automatically rev up and manual regeneration will begin Manual regeneration will finish when the engine returns to idling and the parked regeneration request lamp amber turns off Manual regeneration will stop if the parking brake switch F N R lever throttle lever or accelerator pedal are operated during regeneration...

Page 42: ...mpossible In this condition DPF may only be regenerated using special service tools Contact your Sakai dealer or company Techs Blinking Off Lamp On 5 DPF Cleaning Not Applicable Not Applicable YES The engine controller may shut down the engine if above request for parked RGN are ignored The engine will not restart until the DPF unit is replaced or cleaned using special tools Contact your Sakai dea...

Page 43: ...r button Diagnosis Select Active DM1 and press at Right button If no problem display shows No Faults and then press at Center button to move next display If there are problems display shows Source 0 Engine Press at Right button SPN and FMI code numbers are displayed after showing Polling Source with bar graph See SPN 171 and FMI 3 as an example To see another error codes press at Left button then ...

Page 44: ...driver is switched over the other person while the machine is completely stopped Do NOT adjust the seat while the machine is in motion Some unexpected troubles may be accidentally caused if moving the machine without completely fixing the seat such as while sliding the seat Before moving the machine make certain that the seat is completely fixed after making proper adjustments Do not pinch your fi...

Page 45: ... sure to replace the fusible link with one of the same capacity 2 2 4 Accessory socket The accessory socket may be used when the starter switch is turned to the position Open the cover and a 12 V DC can be drawn from the socket for powering electronic equipment WARNING When connecting electronic equipment to the accessory socket make sure it does not obstruct the raising and lowering of the F N R ...

Page 46: ...de a clearance of 20mm between scrapers Ⓐ and the drum Retighten bolts and nuts Ⓑ 6 locations and Ⓓ 14 locations 2 Replacement of scrapers Ⓐ 7 pieces on top and 7 pieces at rear Remove bolts and nuts Ⓒ and Ⓓ Replace scrapers Ⓐ with new ones Refit and retighten bolts and nuts Ⓒ and Ⓓ SV204TF 1 Clearance adjustment of scraper blades Ⓐ Loosen bolts and nuts Ⓑ 4 locations front and rear Provide a clea...

Page 47: ...t Ⓑ tighten bolts Ⓐ 2 on each side alternately until resistance gets greater After towing remove bolt Ⓐ nut Ⓑ and seal Ⓒ and replace seal Ⓒ with a new one Apply grease to bolt Ⓐ lithium type extreme pressure type NLG1 2 and return all parts to their original positions Tighten bolt Ⓐ at its original position the distance between the bolt head and attachment surface is 34 mm Then lock it using lock ...

Page 48: ... pin is in the steering lock position The lock pin is located at the right of the center of the machine To unlock the lock pin Pull out the lock pin Fit the lock pin to the front frame 2 Check that the F N R lever and is in the neutral position Ⓝ 3 Confirm that the parking brake is engaged NOTE When the F N R lever is not in the neutral middle position or the parking brake has been released the in...

Page 49: ... the engine after making certain that there are no one and no objects close to the machine 1 Set the throttle lever in a position slightly higher than IDLING 2 Turn the starter switch to the position and check that the warning lamps and parking brake indicator lamp on the monitor display are on 3 Start the engine after the engine check lamp has turned on once then turned off ...

Page 50: ...ting but observe the following IMPORTANT Avoid increasing the engine speed abruptly before warming up run is completed 1 Run the engine at around 900 rpm for about 5 minutes to warm it up Warming up run allows the lubricating oil to reach the vital parts of the engine and hydraulic system gradually warm the engine engine oil and hydraulic oil to prepare the machine for driving 2 After the warm up ...

Page 51: ...er towards you 2 Press down the parking brake switch button to release the brake Check that indicator lamp on the monitor display goes off CAUTION Never pull the switch 3 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 NOTE The travel speed can be controlled by the throttle lever and F N R lever WARNING Pay extr...

Page 52: ...ing move the F N R lever back to the neutral position In an emergency depress the brake pedal Stepping on the brake pedal all the way down will stop the engine and operate the brakes at the same time IMPORTANT After the vehicle has stopped upon stepping on the brake pedal lift the foot off the pedal put the forward reverse lever into neutral middle make sure that the parking brake switch has been ...

Page 53: ...ION Do not turn the starter switch while the machine is in motion 3 Remove the starter key WARNING When dismounting from the machine apply the brake by pressing the parking switch button If necessary to park on a grade chock the wheels to prevent unexpected moving down the grade Never fail to remove the starter key 2 3 7 Check after stopping the engine 1 Perform the walk around checks for oil and ...

Page 54: ...erse lever Pressing this switch causes the vibration to start and pressing it again to stop position Vibration is shut down CONT position Have this switch placed at this position when vibration is not to be actuated 3 Proper travel speed for vibratory compaction is 2 5 km h however select speeds depending upon job requirements IMPORTANT Keep the vibrator shut off when the machine is not rolling St...

Page 55: ...lators will result Change the direction of travel gently When changing the direction of travel during asphalt mix compaction slowly shift the F N R lever Drive at a speed appropriate for the road surface conditions Drive slowly on uneven surfaces 2 5 2 When going downhill Use the F N R lever Run slowly by the operation of the F N R lever even if the travel distance is short Use the engine brake Go...

Page 56: ...es works or materals marked Work Asphalt road paving Dust removal treatment for road Road improvement Embankment construction Dam construction Construction of forestry and farm roads Foundation building Construction of sidewalk shoulder and gutter foundation Material to be compacted Asphalt pavement Crusher run Cement concrete Sands Soils Slag Soft rock Layers to be compacted Surface course Binder...

Page 57: ...r the following day s operation There is a danger of battery fluid leaking when removing the battery from the machine so take care not to tilt the battery when doing so IMPORTANT Avoid carrying out high pressure cleaning around the meter panel or behind the dashboard as it may damage meters and other equipment 2 8 Loading and Unloading WARNING Use sturdy ramps with proper width length and thicknes...

Page 58: ...degrees Leave a proper space between the ramps according to the width of the roller drum 2 Decide the correct direction of run and make the machine run forward to the ramps 3 Draw the wire rope from the trailer winch and put its hook on the hooking point or of the roller 4 Place the unloader valve located at the operator s station to the UNLOAD position See Unloader valve on page 32 5 With the eng...

Page 59: ...d 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 brake switch to apply the parking brake Place chocks under the drums to prevent movement 2 Fix the machine with ropes tied at the front and rear towing hook holes Parti...

Page 60: ...ure has dropped turn it slowly to release the pressure before opening CAUTION Never use methanol ethanol and propanol base antifreeze Use soft water for coolant In freezing weather add antifreeze to the coolant referring to the table below Select the most suitable mix ratio according the lowest temperature in the job location Ambient temperature 33 C 26 C 20 C 16 C 11 C 27 4 F 14 8 F 4 F 3 2 F 12 ...

Page 61: ...position Be careful not to accidentally connect the two battery terminals with tools or other metallic objects Tangled terminals may generate sparks due to improper connections resulting in the danger of explosions Make sure terminals are connected firmly The battery is for starting the engine and operating electrical equipment on the machine Do not use it for any other purpose IMPORTANT The batte...

Page 62: ...0 degree add antifreeze to the coolant 6 With F N R lever placed at neutral position Ⓝ and vibrator switch at position have the parking brake engaged 7 Chock the machine 8 Remove the starter switch key 2 14 During the Storage Period WARNING If necessary to operate the machine for anti corrosive purpose in closed area ensure good ventilation keeping windows and doors open to prevent gas poisoning D...

Page 63: ... Do not allow a metallic item to bridge between the positive terminal and machine body This can generate sparks causing an explosion Loose battery terminals can cause sparks An explosion will result When connecting the terminals make certain that they are tight CAUTION The power supply voltage of this machine is 12V 2 15 1 Connection and disconnection of booster cables When jump starting the engin...

Page 64: ...nnecting the booster cables Wear safety goggles when jump staring the engine Do not allow the machine to make careless contact with the booster supply Do not make wrong connections Connect the negative cable to the engine block earth far away from the battery as sparks may occur when connecting CAUTION Use booster cables and end clips of proper size suited to the battery capacity Use the batteries...

Page 65: ...l checking filter cleaning or replacement oiling and greasing use extreme care to prevent dust from entering 4 For checking oil level or changing oil park the machine on a level and hard surface 5 Change oil while its temperature remains high after operation 6 For a long term storage fill the fuel tank lubricate necessary points and run the machine for more than 20 minutes once a month 7 In freezi...

Page 66: ...oling system Piping parts Radiator hose 2 years Radiator drain hose 4 years 7 Control related parts Cable Cable 4 years 8 Intake system Piping parts Intake hose 2 years CAC hose 2 years 9 Hydraulic system Hydraulic piping parts Hydraulic hose 4 years 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 ...

Page 67: ...on by means of lock pin located at the center of machine CAUTION To do the lifting and lowering work fold the awning 1 Put wire ropes securely on the hook and lifting points as shown 2 If wire ropes make contact with other parts of the machine put pieces of cloth or wooden blocks at the contact points Carefully perform lifting 3 When lifting keep the machine properly balanced ...

Page 68: ... 62 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 ...

Page 69: ... the carcass or not etc 1 Check for any cuts on the tread 2 Check for any cracks on a rim or deformation of rim flanges When a tire shows one or more of the following conditions regard it as defective and replace the tire with a new one for safety 1 When the bead wire is cut bent or significantly deformed 2 When the carcass ply is showing due to excessive wear 3 When damaged portion of the carcass...

Page 70: ...3 PERIODICAL MAINTENANCE 64 3 3 Periodical Maintenance Points 1 SV204D SV204T SV204TF ...

Page 71: ...3 PERIODICAL MAINTENANCE 65 2 SV204TB ...

Page 72: ... oil 3 Every 500 service hours Engine oil filter Change filter element 1 Fuel filter Change filter element 2 Fuel sedimenter Change filter element 1 Control links Check looseness adjust as necessary Apply grease Grease 1 Line filter Change filter element 1 Final drive Differential case Change gear oil Gear oil 3 Engine oil pan Change engine oil Engine oil 1 Every 1000 service hours Suction filter ...

Page 73: ...as it may cause the engine to break down CAUTION When intervals between DPF cleaning become five hours or shorter it is time to change the engine oil Be sure to use engine oil recommended by SAKAI refer to page 84 Radiator Reserve tank Remove the cap from the radiator to make sure it is filled to the top with coolant and top it up if it is not Moreover let the engine idle for 2 to 3 minutes and ch...

Page 74: ...urchasing a new machine adjust the fan belt after 50 hours of operation for the first time only 2 Every 50 hours Hydraulic oil level gauge 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 If necessary add the hydraulic fluid from the fill port CAUTION Be sure to use hydraulic oil recommended by SAKAI refer to page 84 Blade cylinder hea...

Page 75: ...e plates 2 Add distilled water or battery fluid commercially available if the level is too low 3 Retighten any loose terminal Apply grease or vaseline to the terminals to retard rusting 4 Be sure to tighten the battery holder if it is loose 5 Confirm that there is no abnormality in appearance WARNING Using or charging battery with electrolyte level below LOWER LEVEL mark on its side could result i...

Page 76: ...by two or three times After this while forcefully keep stepping on the brake pedal for more than five seconds check the gap between the brake pedal and the floor panel by rulers It is appropriate if the gap between the brake pedal and floor panel is 100 mm Also check that each bolt is not loose the motion of the brake pedal is smooth and the brake pedal is properly resilient when stepping it on 3 ...

Page 77: ...lake pedal shaft CAUTION Be sure to use grease recommended by SAKAI refer to page 84 Gear case Wheel motor 1 Position the drum so that the drain plug comes to the bottom 2 Check for oil level and add oil through the fill port as necessary CAUTION Be sure to use gear oil recommended by SAKAI refer to page 84 ...

Page 78: ...KAI refer to page 84 Steering cylinder Apply grease at 2 locations CAUTION Be sure to use grease recommended by SAKAI refer to page 84 Final drive Differential case Check for oil level and add oil through the fill port as necessary CAUTION Be sure to use grease recommended by SAKAI refer to page 84 ...

Page 79: ...n draining a hot oil use care not to get burned 2 Refit the drain plug and fill the crankcase with the engine oil from the fill hole on the cylinder head cover 3 Change the oil filter CAUTION Be sure to use engine oil recommended by SAKAI refer to page 84 NOTE For a new machine change oil and oil filter at 50 operating hours for the initial time only Fuel filter See the separate engine manual Chan...

Page 80: ...3 PERIODICAL MAINTENANCE 74 Fuel sedimenter See the separate engine manual Change the filter element Control links Check the nuts for looseness Line filter Change the filter cartridge ...

Page 81: ... with oil until the drain level filler port start to overflow 4 When filling is complete attach the drain level filler plug CAUTION Be sure to use gear oil recommended by SAKAI refer to page 84 Differential case 1 Drain oil by removing the drain plug filler plug and level plug 2 Refit the drain plug 3 Fill oil through the fill port till it overflows from the level port 4 Refit the removed plug fil...

Page 82: ...rain plug and drain oil while it is warm 2 Clean inside of the tank and fill fresh oil to the specified level 3 Start and run the engine at idling for 2 to 5 minutes When the hydraulic oil has become free from air bubbles stop the engien and recheck the oil level 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 84 ...

Page 83: ... vibrator before reinstalling it 5 Feed oil at filler port until oil flows out of level gauge hole 6 Reinstall the level gauge plug as well as filler plug after cleaning them WARNING When draining a hot oil use care not to get burned CAUTION The oil capacity of the vibrator is 4 0 liters Do not fill more than 4 0 liters Be sure to use gear oil recommended by SAKAI refer to page 84 ...

Page 84: ...on 5 Supply 1 6 liters 0 4 gallons of gear oil from the extension pipe 6 After setting the extension pipe at the original position and attaching the drain plug wrapped up in seal tape attach the hole plug CAUTION Be sure to use gear oil recommended by SAKAI refer to page 84 6 Every 1 500 hours Engine oil separator Open the cover take out the oil separator element wipe off the oil and replace it wi...

Page 85: ...ay it is used or on site conditions As with the tires the drum too must be inspected regularly Radiator Clean the cooling fins In case dirt or dust is attached clean the radiator the oil cooler and the core with compressed air or tap water It is to prevent performance decline of the cooling system WARNING When cleaning the radiator fins be sure to wear safety glasses dust proof masks and other pro...

Page 86: ...e engine causing the breakdown of the engine Wear protective goggles a dust respirator and other protective gear before cleaning the air cleaner and outer element in order to prevent dust from entering your eyes or nose 4 Attach the outer element and clamp it with a clip CAUTION Clean only the outer element Do not remove the inner element If the red moving piece of the dust indicator still reaches...

Page 87: ...will catch fire if open flames or ignition sources are used close to it Do not smoke or use a match or cigarette lighter close to it Gas damper Open the hood and check to make sure it is held up by the gas dampers If it is not replace the gas dampers WARNING Even if the hood is held up by the gas dampers make sure to lock it in place using the stay to prevent it from falling when inspecting the en...

Page 88: ... the machine in use Consumable Part Part No Interval Remark Annual replacement year Replacement per operation hours Engine oil element 4032 71010 0 500 Engine oil separator element 4033 37016 0 1500 Fuel pre filter assembly 4033 37006 0 500 Filter element 4032 73005 0 500 Fuel filter assembly 4033 37004 0 500 Filter element 4033 37005 0 500 Suction filter element Hydraulic oil 4207 79000 0 1000 Fu...

Page 89: ...3 PERIODICAL MAINTENANCE 83 ...

Page 90: ...f fluid Capacity in liters gal Fuel tank Diesel oil 100 26 4 Engine oil pan Engine oil 11 2 3 0 Hydraulic oil tank Hydraulic oil 38 10 0 Wheel motor Gear oil 1 6 0 4 Radiator Coolant 6 7 1 8 Vibrator Gear oil 4 0 1 1 Differential Gear oil 8 3 2 2 Final drives Gear oil 0 9 x 2 0 22 x 2 Lubricant Service classification Ambient temp and applicable viscosity rating Applicable standards 15 30 C 5 86 F ...

Page 91: ...any Engine oil API CJ4 Gear oil API GL 5 Hydraulic oil ISO VG 46 Grease NLGI 2 CHEVRON DELO 400 LE RPM Universal Gear Lubricants Rando HDZ 46 Multifak EP 2 BP BP Energear HYPO U Bartran HV 46 BP Energrease LS EP 2 CASTROL Tection Extra EXP Gear OILS Castrol Hyspin AWH 46 Castrol Spheerol ELP 2 EXXON MOBIL Mobil Delvac 1 ESP Mobilube HD Mobil DTE 10 Excel 46 Mobilux EP 2 SHELL Shell Rimula R4 L She...

Page 92: ...Y Yellow YW White stripe WG Green stirpe Black Green Blue Red Yellow Brown BW White stripe G Green GY Yellow stripe LY Yellow stripe RB Black stripe W White YB Black stripe BrY Yellow stripe Black Green Red White Yellow BY Yellow stripe GB Black stripe Gr Gray Lg Light green RG Green strope WB Black stripe YG Green stripe Sb Blue Green Red White Yellow Black Br Brown GL Blue strope L Blue O Orange...

Page 93: ...to a shortened life For long term storage charge it fully tighten the caps securely store in a cool and dry place and check the level of charge at least once a month Make sure the battery is charged at over 75 of capacity at all times When starting the engine on a cold day the battery will ideally be fully charged but avoid starting the engine at all times when the battery is less than 75 charged ...

Page 94: ...uency 30 Hz 1 800 vpm Centrifugal force 74kN 16 185 lbs Gradability 52 27 Rolling width 1 370 mm 54 Minimum turning radius 4 1 m 162 Engine Model KUBOTA V3307 CR T EF05 Diesel Engine Total displacement 3 331 litres 203 3 cu in Rated output 54 6 kW 2 200 min 1 73 HP 2 200 rpm Max torque 261 N m 1 500 min 1 193 ft lb 1 500 rpm Tank capacity Fuel tank 100 litres 26 4 gal Hydraulic oil tank 38 litres ...

Page 95: ... vpm Centrifugal force 74kN 16 185 lbs Gradability 49 26 Rolling width 1 370 mm 54 Minimum turning radius 4 1 m 162 Engine Model KUBOTA V3307 CR T EF05 Diesel Engine Total displacement 3 331 litres 203 3 cu in Rated output 54 6 kW 2 200 min 1 73 HP 2 200 rpm Max torque 261 N m 1 500 min 1 193 ft lb 1 500 rpm Tank capacity Fuel tank 100 litres 26 4 gal Hydraulic oil tank 38 litres 10 gal NOTE 1 Gra...

Page 96: ...0 Hz 1 800 vpm Centrifugal force 74kN 16 185 lbs Gradability 46 24 Rolling width 1 370 mm 54 Minimum turning radius 4 3 m 170 Engine Model KUBOTA V3307 CR T EF05 Diesel Engine Total displacement 3 331 litres 203 3 cu in Rated output 54 6 kW 2 200 min 1 73 HP 2 200 rpm Max torque 261 N m 1 500 min 1 193 ft lb 1 500 rpm Tank capacity Fuel tank 100 litres 26 4 gal Hydraulic oil tank 38 litres 10 gal ...

Page 97: ...quency 30 Hz 1 800 vpm Centrifugal force 74kN 16 185 lbs Gradability 41 22 Rolling width 1 370 mm 54 Minimum turning radius 4 1 m 162 Engine Model KUBOTA V3307 CR T EF05 Diesel Engine Total displacement 3 331 litres 203 3 cu in Rated output 54 6 kW 2 200 min 1 73 HP 2 200 rpm Max torque 261 N m 1 500 min 1 193 ft lb 1 500 rpm Tank capacity Fuel tank 100 litres 26 4 gal Hydraulic oil tank 38 litres...

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Page 99: ...SAKAI HEAVY INDUSTRIES LTD Head Office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone 81 3 3431 9971 Facsimile 81 3 3436 6212 Printed in Japan 2017 02 55 Ⓒ ...

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Summary of Contents for SV204 Series

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Sakai SV204 Series, Operating & Maintenance Instructions

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Summary of Contents for SV204 Series

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