Sakai SV540 Series Install guide
SV540
SHOP MANUAL
3498-6418A-0
Introduction
This manual provides important information to familiarize you with safe operating
and maintenance procedures for your SAKAI roller. Even though you may be
familiar with similar equipment you must read and understand this manual before
operating or servicing this unit.
Safety is everyone’s business and it is one of your primary concerns. Knowing the
guidelines presented in this manual will help provide for your safety, for the safety
of those around you and for the proper operation and maintenance of the machine.
Improper operation is dangerous and can result in injury or death.
Sakai Heavy Industries cannot foresee all possible circumstances or varying
conditions to which the operator, serviceman or machine may be exposed to that
might lead to a potential hazard. Therefore, the warnings and cautions listed in
this manual and those placed on the machine are not intended to be all inclusive
and liability for personal injury or damage to equipment or property cannot be
assumed.
the product information available at the time that the publication was written. The
SV540 ○
0
0-001
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-002
1-002
1-003
1-6. Safety Instructions1-003
1-7. Starting 1-004
1-004
1-9. Stopping1-004
1-005
1-007
2. SPECIFICATIONS
A
2-001
1-2. SV540T 2-003
1-3. SV540TF 2-005
2-007
2-009
1-6. SV640T 2-011
S
2-1. Engine2-013
2-013
2-3. Hydraulic System 2-013
2-4. Steering2-014
2-5. Brakes2-014
2-014
N
3-1. Rating 2-015
3-2. Recommended Lubricants2-015
2-016
SV540 ○
0
0-002
3. ENGINE AND CONTROLS
1. ENGINE
3-001
1-2. Engine Exterior 3-002
3-003
3-004
T
3-005
4-1-1. Installation of pump 3-006
4. HYDRAULIC SYSTEMS
4-001
4-003
4-004
4-004
4-005
4-006
4-007
4-007
4-009
2-2-3. Gear box 4-010
4-011
4-012
4-013
4-014
3-2-1. Vibrator hydraulic motor 4-014
4. STEERING SYSTE
4-015
4-2. Steering Wheel 4-016
4-017
4-017
4-3-2. Steering • charge pump 4-018
SV540 ○
0
0-003
5. ELECTRICAL SYSTEM
1. K
1-1.
5-001
1-2. Electrical Equipment Installation5-002
5-003
S
3-1. Battery Layout5-004
5-005
5-006
4. WIRING HARNESSES
4-1. Engine Harness5-007
5-009
5-011
5-013
5-015
4-6. Battery Relay Harness5-017
4-7. Starter Switch Harness 5-019
5-020
5-021
5-022
4-11. Fuel Unit Harness5-023
5-024
S
5-025
5-026
5-027
6. VIBRATORY DRUM • REAR AXLE
6-001
6-003
2-1-1. Removal of vibratory drum6-003
2-1-2. Installation of vibratory drum 6-006
6-007
6-008
6-008
2-3-2. Reassembly of vibratory drum 6-019
SV540 ○
0
0-004
3. REAR AXLE
6-037
6-038
3-3. Rear Axle Lubrication 6-039
3-4. Rear Axle Structure6-040
6-040
6-041
3-4-3. Hub reduction gear6-042
3-4-4. Brake6-043
3-4-5. Gear box 6-044
7. BRAKE
7-001
7-002
7-003
S
4-1. Brake Solenoid Valve 7-004
4-2. Valve Block7-005
8. INSPECTION AND ADJUSTMENT
T
8-001
8-001
8-001
1-4. Warm-up8-001
1-5. Inspection and Adjustment of Engine Related Items8-001
E
8-002
2-2. Adjustment8-003
E 8-004
8-005
3-2. Adjustment8-006
E
8-007
rear8-008
SV540 ○
0
0-005
E
8-009
E
8-010
6-2. Inspection 8-011
E 8-012
8-013
7-2. Adjustment8-014
E
8-015
E
8-016
9-2. Inspection 8-017
E
8-018
8-019
E
8-020
8-021
E
8-022
E
13-1. Adjustment 8-023
T
8-024
8-025
9. TROUBLESHOOTING
G
9-001
1-2. Important Information for Troubleshooting 9-001
1-3. Before Starting 9-002
9-002
G
9-003
9-003
2-1-2. Inspection procedures using a tester 9-004
2-1-3. Inspection of electrical system 9-009
SV540 ○
0
0-006
9-011
2-2-1. Fault detection 9-011
2-2-2. Fault lamps 9-011
2-2-3. Flash out of fault codes 9-012
2-2-4. Fault code list9-013
9-022
2-4. Engine 9-025
9-025
9-027
9-029
9-031
9-033
2-4-3. No charging 9-035
2-4-4. Grid heater does not work
9-035
2-4-5. Starter motor runs even when F-R lever is not at “N” and
parking brake is not applied9-037
2-4-6. Engine speed cannot be switched 9-037
9-039
9-039
9-041
9-043
9-045
9-047
9-049
2-5-3. Brake cannot be released9-051
2-5-4. Brake does not work 9-053
2-6. Vibration9-055
9-055
9-057
9-059
9-061
9-063
9-065
2-6-3. Vibration mode cannot be switched
9-067
9-069
2-7. Lighting9-071
9-071
SV540 ○
0
0-007
2-7-2. Tachometer reading is abnormal9-073
2-7-3. Hour meter is abnormal 9-073
2-7-4. Temperature meter is abnormal 9-075
2-7-5. Fuel meter is abnormal9-075
9-077
9-079
2-7-8. Vibration indicator lamp does not light 9-081
9-083
9-085
2-7-11. Horn does not sound 9-087
2-7-12. Backup buzzer does not sound9-087
G
9-088
9-089
9-089
9-090
9-090
9-090
9-091
9-091
9-091
9-092
3-2-7. Abnormal noise from propulsion system 9-092
3-3. Vibrator System9-093
3-3-1. No vibration 9-093
3-3-2. Vibrator frequency is too low 9-094
3-3-3. Amplitude does not switch between high and low9-094
3-3-4. Vibrator does not stop9-095
3-3-5. Vibrator system is overheating9-095
3-3-6. Abnormal noise from vibrator system 9-095
3-4. Steering System9-096
3-4-1. Steering wheel is hard to turn9-096
3-4-2. Steering response is slow9-096
3-4-3. Steering wheel backlash or play is large 9-097
3-4-4. Steering system is overheating 9-097
3-4-5. Abnormal noise from steering system 9-097
SAFETY
1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
can result in serious personal injury or death.
can result in serious personal injury or death.
may result in moderate personal injury or damage to the machine or
personal property.
machine that may cause damage, breakdown, or shortened service life of
the machine if you fail to observe or important point to maintain of quality in
maintenance works.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
N•m
In the assembly operation, tightening torque in locations that require particular
attention.
1-2. General
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
★
1-002
SAFETY
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
1-3. Qualications of Operators and Maintenance Personnel
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
instructions that are contrary to safety.
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.
1-003
SAFETY
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position and the parking
brake is applied.
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection
• Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly
performed. Repair or replace any malfunctioning, broken or missing parts before using the
• Always clean up any spilled fuel.
repairs have been made and warning tags have been removed by authorized personnel.
mounting hardware is tight.
slipping.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed, gradeability, steering
and braking.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions
• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
functional.
• Always use the hand rails and steps to get on and off your machine maintaining 3-point
1-004
SAFETY
1-7. Starting
• Start the machine only from the driver’s seat and always wear the seat belt.
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
traveling with the machine.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Never climb on and off the machine while it is in motion.
• Always remain seated with the seat belt fastened when traveling, compacting or loading or
unloading the machine.
• Use caution and be very observant when operating in close quarters and congested areas.
compatible with these regulations.
• Never carry passengers.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
when passing under overhead power lines.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
dark.
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground. If this is not possible,
always park at a right angle to the slope and block the drums or tires.
• Lock all lockable compartments.
1-005
SAFETY
1-10. Maintenance
machine or it’s safety devices or any work related to maintenance, inspection or repair,
• Ensure that the maintenance area is safe and secure.
• If the machine is shut down for maintenance or repair work
it must be secured against inadvertent starting by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground
with the drums or tires blocked to prevent inadvertent
movement.
• Immediately after the engine has stopped, the exhaust
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
Wait until the machine has cooled down.
• Use care when attaching and securing lifting tackle to
individual parts and large assemblies being removed
or repositioned for repair purposes to avoid the risk of
accident. Use lifting devices that are in perfect condition and
loads.
• Always use the proper tools and workshop equipment in
good condition when performing maintenance or repairs on
the machine.
• Always use specially designed safety ladders and working
machine parts as a climbing aid.
• Keep all steps, handles, handrails, platforms and ladders free from mud, dirt, grease, ice or
snow.
carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free
cleaning rags.
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Whenever possible, avoid servicing or maintenance when the engine is running unless the
drums or tires are adequately blocked, the articulation lock bar is in the locked position and
the parking brake is applied.
Always clean up any spilled fuel.
• Ensure safe operation, optimum performance of the machine and its warranty by using only
genuine SAKAI replacement parts.
1-006
SAFETY
from reputable manufacturers.
or when welding on the compactor.
necessary to connect a jumper cable or battery charger. Fumes can
ignite from a spark and may explode.
trouble occurs in the electrical system.
specially trained person according to electrical engineering principles.
connections or burnt or scorched wires must be repaired or replaced immediately.
machine.
operations.
• Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of
or other damage which may affect their function or strength.
pressure. The hydraulic system remains pressurized even after the engine has stopped.
• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece
of cardboard and always wear gloves and safety glasses.
from a pin hole leak can cause severe injury or death.
with the technical requirements.
other chemical substances. Be careful especially when these items are hot as there is a risk
of burning or scalding.
only in adequately ventilated premises. Before starting the engine in an
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