Sakai SV540 Series Operating & Maintenance Instructions Download Page 6

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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

SV540D

3SV53 –

◯◯◯◯◯

SV540T

3SV53 –

◯◯◯◯◯

SV540DF

3SV53 –

◯◯◯◯◯

SV540TF

3SV53 –

◯◯◯◯◯

SV540TB

3SV53 –

◯◯◯◯◯

SV540FB

3SV53 –

◯◯◯◯◯

SV640D

3SV55 –

◯◯◯◯◯

SV640T

3SV55 –

◯◯◯◯◯

(3) Engine serial number

Summary of Contents for SV540 Series

Page 1: ...trying to operate inspect and service your machine No 3498 36310 2 M O D E L S V 5 4 0 6 4 0 S E R I E S OPERATING MAINTENANCE INSTRUCTIONS From SV540D 3SV53 10101 SV540T 3SV53 10101 SV540DF 3SV53 10...

Page 2: ...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 Operat...

Page 3: ...ON 26 2 1 Instruments and Controls 26 2 1 1 Operator s station 26 2 1 2 Gauges indicator lamps and warning lamps 27 2 1 3 Switches 31 2 1 4 Operating levers pedals 35 2 1 5 Unloader valve 36 2 1 6 Fus...

Page 4: ...riod 58 2 14 During the Storage Period 59 2 15 When the Battery has Discharged 59 2 15 1 Connection and disconnection of booster cables 60 3 PERIODIC MAINTENANCE 62 3 1 Precautions 62 3 1 1 Lifting th...

Page 5: ......

Page 6: ...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 SV540D 3SV53 SV540T 3SV53 SV540DF 3SV53...

Page 7: ...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 DA...

Page 8: ...oughly 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 with...

Page 9: ...nual thoroughly 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 manua...

Page 10: ...e 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 Decid...

Page 11: ...nt 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...

Page 12: ...ile 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...

Page 13: ...inued 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 part...

Page 14: ...nd 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 Adj...

Page 15: ...inity and there are no obstructions around the machine Sit in the driver s seat and turn on the engine Do not start the engine anywhere other than from the driver s seat as there is the danger of oper...

Page 16: ...e engine has started let it idle for several minutes until it is at operating temperature Check the area where the machine has parked for signs of leakage or oil fuel and water If any leakage is notic...

Page 17: ...erson 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 aro...

Page 18: ...pected running down the slope Going down hill at speeds other than low range can cause the machine to run down violently Refrain from inattentive driving Inattentive driving or driving relying on gues...

Page 19: ...it to the nearest safe location The machines not equipped with ROPS must not be operated on the slopes or unsafe ground The machines not equipped with CABIN must not be operated in the bad weather or...

Page 20: ...speed When parking Select level and hard ground If necessary to park on a slope chock the front of the drum and tire on the downside of the slope When required to park on the public road provide nece...

Page 21: ...also be free from extraneous matter that can cause slippage Do not steer your machine on the ramps If the machine is facing in the wrong direction go back off the ramp correct the direction and try a...

Page 22: ...nd 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...

Page 23: ...ed 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...

Page 24: ...spections 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...

Page 25: ...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...

Page 26: ...m can cause malfunctions Do not use water to clean sensors connectors and the operator s station Take care not to get caught or crushed Be sure to fix the hood and other covers after opening them to p...

Page 27: ...s been relieved Hydraulic fluid leaking through a fine hole at high pressure can penetrate your skin and eyes Inspect leakage by holding a hard board close to suspected leaks wearing goggles If affect...

Page 28: ...gas damper and drill a hole around 2 to 3 mm in diameter about 20 to 30 mm from the edge on the tube bracket side Dispose of it after releasing the gas pressure When doing this be sure to wear protec...

Page 29: ...s other than those shown below Treat them in the same manner as the one shown here 3998 06139 0 3998 16646 1 3998 16724 0 3998 16701 0 3 locations 3998 16696 0 3998 16504 0 3998 16501 0 3998 16468 1 3...

Page 30: ...25 WARNING Negligence of these instructions can lead to accidents...

Page 31: ...gine stop lamp Engine warning lamp Engine wait to start lamp Horn switch button Steering wheel Combination meter Eco lamp Speed change switch Engine speed select switch Parking brake switch Starter sw...

Page 32: ...ndation 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 engi...

Page 33: ...l turn on when the hydraulic oil filter becomes clogged Stop the machine and carry out an inspection Engine oil pressure warning lamp It will flash once when the starter switch is turned to the positi...

Page 34: ...ight will not go out the filter may be clogging up Check the filter Checking for warning lamp and parking brake indicator lamp They should turn on light when the starter switch in ON position If not t...

Page 35: ...f the lamp lights just because the water is accumulated in the fuel pre filter it will go out after draining If the lamp does not go out the engine may be abnormal Receive proper checking maintenance...

Page 36: ...nd lamp circuit are charged with electricity Leave the key in this position after the engine has started position The engine is cranked and gets started The moment the engine has started release the k...

Page 37: ...and the engine is stopped at the same time When starting the engine again shift the F N R lever back to the neutral position set engine speed to idle activate the parking brake switch and then start...

Page 38: ...N or OFF with the switch located on the Foward Neutral Reverse F N R lever Pressing this switch causes the vibration to start and pressing it again to stop This vibration switch on the lever should be...

Page 39: ...s km h mile h Low High Speed 0 6 0 3 7 0 10 0 6 2 IMPORTANT Be sure to shift gears while the machine is stopped Can not shift gears during operation Engine speed select switch Shifts the engine RPM 50...

Page 40: ...ke pedal Leveling blade lift lever SV540TB SV540FB The leveling blade is operated from a single control lever The lever has four positions RAISE HOLD LOWER and FLOAT Raise To raise the blade pull the...

Page 41: ...e 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...

Page 42: ...ockwise direction by 90 degrees and then 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 h...

Page 43: ...etely 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 t...

Page 44: ...so that it does not interfere the pads Retighten bolts and nuts at 8 locations Loosen bolts at 8 locations Adjust the scraper blade so that it does not interfere the pads Loosen bolts at 8 locations L...

Page 45: ...ace at the rear of the frame such that there is a gap by 20 mm between the scraper blade and the drum Retighten bolts at 8 locations Loosen bolts and nuts at 8 locations Adjust the scraper blade by ch...

Page 46: ...r towing is completed turn clockwise until it stops And fix with the 5 Turn the unloader valve clockwise to engage the drive Refer to Unloader valve on page 36 for its operation method WARNING Do not...

Page 47: ...pin is in the steering lock position The pin is located at the right of the center of the machine To unlock the pin Pull out the lock pin Set the pin in the carrying position 2 Check that the F N R le...

Page 48: ...certain that there are no one and no objects close to the machine 1 Set the engine speed select switch in the IDLE position 50 min 1 Engine speed IDLE ECO FULL 900 min 1 1850 min 1 2200 min 1 2 Turn t...

Page 49: ...gine Try not to move the machine immediately after starting but practice the following IMPORTANT Avoid increasing the engine speed abruptly before warming up run is completed 1 Run the engine at idlin...

Page 50: ...achine Be sure to wear the seatbelt during operation 1 Select the desired speed by the speed change switch km h mile h Low High Speed 0 6 0 3 7 0 10 0 6 2 IMPORTANT Be sure to shift gears while the ma...

Page 51: ...begin traveling CAUTION Avoid abrupt operation of the F N R lever NOTE The travel speed can be controlled by the engine speed select switch and F N R lever WARNING When pressing the brake pedal the br...

Page 52: ...TANT When pressing the brake pedal the brake is activated and the engine is stopped at the same time After depressing the brake pedal return F N R lever to the neutral position and press the parking s...

Page 53: ...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 block the wheel...

Page 54: ...mbing performances are degraded Please conduct the rolling compactions by setting to the FULL position when working on soft steep sloped and rugged road surfaces 2 Use the vibrator switch installed at...

Page 55: ...CONT position When the vibrator switch is set to the or position you can perform vibration work without turning the vibration switch ON and OFF 3 Proper travel speed for vibratory compaction is 2 5 km...

Page 56: ...gently When changing the direction of travel during 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 goi...

Page 57: ...s 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 buildin...

Page 58: ...ble cover the ground with hard plates IMPORTANT Do not wash clean with high pressure water around the instrument panel or reverse side of the dash board This can cause instrument failures 2 8 Loading...

Page 59: ...rd to the ramps 3 Draw the wire rope from the trailer winch and put its hook on the hooking point or One each on right and left of the roller 4 Place the unloader valve located at the inside of a fram...

Page 60: ...Place chock under the drums to prevent movement 2 Fix the machine with chains tied at the front and rear towing hook holes Particularly pay attention to sidewise skidding 2 10 Transportation WARNING...

Page 61: ...nt The life of the antifreezer is for two years Use non amine type long life coolant when changing coolant CAUTION Failure to follow this procedure can result in severe engine damage Fill 1 Open heate...

Page 62: ...ely glasses when handling the battery The battery generates hydrogen gas so there is a danger of explosions Avoid recharging the battery keep cigarettes and flames away etc in poorly ventilated places...

Page 63: ...he warm season has come proceed as follows Change oil and fuel with those for use in warm season referring to Rating on page 92 2 13 For a Long Storage Period For leaving the machine unused for longer...

Page 64: ...FF position The batteries give off explosive gases Do not smoke close to the batteries Keep flames and sparks away from the batteries The electrolyte is very corrosive and will harm your clothing or s...

Page 65: ...the positive terminal of the live power supply 3 Connect the negative live power cable to the negative terminal of the booster supply 4 Connect the other end of the negative booster cable to a good ea...

Page 66: ...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...

Page 67: ...ould be handled by specialized disposal companies WARNING Be sure to take adequate care not to burn yourself when replacing filters elements oil etc General precautions 1 Always use SAKAI genuine part...

Page 68: ...als rubber parts 2 years Brake piping parts Brake hose 2 years Air hose 2 years Operating parts Cable 4 years 2 Steering system Orbitrol Seals rubber parts 2 years Hydraulic piping parts Hydraulic hos...

Page 69: ...service regardless of the periodic service interval recommendation 1 The hydraulic filter line filter warning lamp Replace elements Check the electric wiring at a regular interval not exceeding one m...

Page 70: ...tion by means of lock pin located at the center of machine CAUTION Remove ROPS before starting lifting work 1 Put wire ropes securely on the hook and lifting points as shown 2 If wire ropes make conta...

Page 71: ...6 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...

Page 72: ...he 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 a...

Page 73: ...3 PERIODIC MAINTENANCE 68 3 3 Periodic Maintenance Points...

Page 74: ...ter pin and tilt pin bearings Grease 6 places Grease 6 Steering cylinders Grease 4 places Grease 4 Transmission differential case and final drive Check oil level add as necessary Gear oil 1 Engine oil...

Page 75: ...parate engine manual 1 Every 10 service hours or daily Fuel pre filter Check the filter for water at regular intervals and drain as necessary Air cleaner When the red float of the dust indicator reach...

Page 76: ...Fill coolant at 3 gallons per minute 12 liters per minute until coolant reaches the bottom of the fill neck Wait for 1 minute then top up coolant to the bottom of the fill neck if needed 3 Start engi...

Page 77: ...pped If the machine is inclined please move it to the flat ground before start checking it WARNING It may cause scald immediately after that the engine is stopped because the temperature of the parts...

Page 78: ...ge 90 Brake When the engine is completely stopped step on the brake pedal by two or three times After this while forcefully keep stepping on the brake pedal for more than five seconds check the gap be...

Page 79: ...h will dissolve clothes and skin Should you get battery fluid on your clothes or skin wash it off immediately with copious quantities of clean water If you get it in your eyes rinse them straight away...

Page 80: ...250 service hours Engine oil filter Engine oil pan See the separate engine manual 1 After completion of operation and while the oil is warm drain the oil with the drain plug removed WARNING When drai...

Page 81: ...rts indicated in black in the figure on the axle shaft to face upward 2 Remove the fill level plugs 3 Check the oil level and fill the oil through the fill port until it overflows at the level port as...

Page 82: ...eering cylinders Apply grease at 4 locations The steering cylinder is provided on both sides of the machine CAUTION Be sure to use grease recommended by SAKAI refer to page 90 Transmission Differentia...

Page 83: ...Every 500 service hours Fuel pre filter Change the filter elements Hydraulic oil line filter Hydraulic oil return filter Change the filter elements Control link 1 Check the nuts for looseness 2 Apply...

Page 84: ...ain the gear reducer oil by removing the drain plug 2 Refit the drain plug 3 Take off the level plug and fill port plug 4 Fill oil through the fill port until oil starts overflowing from the level por...

Page 85: ...overflows from the level port 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 ca...

Page 86: ...s stop the engine 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 90 Gear case Wheel moter...

Page 87: ...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 ho...

Page 88: ...s Check air pressures with tire gauges when tires are cool enough and make certain that they are at 137 3 kPa 20psi Adjust air pressures of the tires if they are NOT appropriate 3 Check whether or not...

Page 89: ...be worn deeply and broken depending on the operation method and the condition of the site Check the drum occasionally in the same way as tires Air cleaner When the red float of the dust indicator reac...

Page 90: ...y element should be changed every third time that the primary element is changed If the primary element has been breached then an inspection of the secondary filter must be performed and changed if ne...

Page 91: ...pressed air IMPORTANT If the discharge rate of compressed air or tap water is too high it can damage the radiator or the fins of the oil cooler Keep a distance of 500mm or more between the nozzle and...

Page 92: ...re complete tighten the filler cap positively NOTE When removing the water and sediment from the tank filled with the fuel the fuel will gush out if the drain plug is screwed out completely WARNING Th...

Page 93: ...d model number of the machine in use Consumable Part Part No Interval Remark Annual replacement year Replacement per operation hours Engine oil filter element 4033 26005 0 0 25 250 Return filter assem...

Page 94: ...3 PERIODIC MAINTENANCE 89...

Page 95: ...ating Lubricant Service classification Ambient temp and applicable viscosity rating Applicable standards 15 30 C 5 86 F Cold 0 40 C 32 104 F Moderate 15 55 C 59 131 F Tropical Engine oil API grade CJ...

Page 96: ...y 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 Energre...

Page 97: ...White stripe LW Blue White stripe R Red RY Red Yellow stripe Y Yellow YW Yellow White stripe WG White Green stirpe BW Black White stripe G Green GY Green Yellow stripe LY Blue Yellow stripe RB Red Bla...

Page 98: ...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...

Page 99: ...s rinse them straight away with clean water and immediately seek the help of a doctor If you accidentally ingest it drink copious quantities of water and immediately seek the help of a doctor Always w...

Page 100: ...dth Smooth 1 530 x 2 130 mm 60 x 84 Rear Tire 23 1 26 8 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz...

Page 101: ...30 mm 60 x 84 Pad 1 708 x 2 130 mm 67 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm...

Page 102: ...1 600 x 2 130 mm 63 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz 1 700 vp...

Page 103: ...30 mm 65 x 84 Pad 1 600 x 2 130 mm 63 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm...

Page 104: ...d 1 600 x 2 130 mm 63 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz 1 700 v...

Page 105: ...ad 1 600 x 2 130 mm 63 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz 1 700...

Page 106: ...th 1 530 x 2 130 mm 60 x 84 Rear Tire 23 1 26 8 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz 1 700 v...

Page 107: ...130 mm 63 x 84 Rear Tire 23 1 26 10 PR OR Performance Travel speed 1st 0 6 km h 0 3 7 mile h 2nd 0 10 km h 0 6 2 mile h Vibrating power Low High Frequency 33 3 Hz 2 000 vpm 28 3 Hz 1 700 vpm Centrifu...

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...

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Sakai SV540 Series, Operating & Maintenance Instructions

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