K DIC212

M
O No. 3498-36310-2
D Read this handbook thoroughly and understand the whole information
E
L contained before trying to operate, inspect and service your machine!
S
V
5
4
0
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6
4
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S
E
R OPERATING &
I
E MAINTENANCE
S
INSTRUCTIONS

Series

VIBRATING
ROLLER

From SV540D → 3SV53 ­ 10101

­–
SV540T → 3SV53 ­­– 10101
SV540DF → 3SV53 ­­– 10101
SV540TF → 3SV53 ­­– 10101
SV540TB → 3SV53 ­­– 10101
SV540FB → 3SV53 ­­– 10101
SV640D → 3SV55 ­­– 10101
SV640T → 3SV55 ­­– 10101
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.

Read this manual thoroughly and try to fully understand the information before operating your
machine. Keep this handbook at 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 machine instructions of
your machine due to the results of the investigation and improvement in its design. If you have
any inquiry regarding your Machine or this manual, contact our distributors.
CONTENTS

CONTENTS
PREFACE
MACHINE AND ENGINE IDENTIFICATION NUMBERS ...................................... 1
SAFETY NOTICES................................................................................................ 2

1 BASIC SAFETY PRECAUTIONS...................................................................... 4

1.1 General Precautions ................................................................................ 4
1.2 Preparation for Safe Operation ................................................................ 8
1.3 Before Starting the Engine....................................................................... 9
1.4 After Starting the Engine.......................................................................... 11
1.5 During Operation ..................................................................................... 12
1.6 Loading and Unloading ............................................................................ 16
1.7 Transportation.......................................................................................... 16
1.8 Handling the Battery ................................................................................ 17
1.9 Towing ..................................................................................................... 18
1.10 Before Servicing ...................................................................................... 19
1.11 During Servicing ...................................................................................... 21
1.12 Safety Decals........................................................................................... 24

2 OPERATION ..................................................................................................... 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 Fuse box ........................................................................................... 37
2.2 Handling and Adjustments ....................................................................... 38
2.2.1 Seat adjustment ................................................................................ 38
2.2.2 Scraper adjustment and replacement ............................................... 39
2.2.3 Disengaging the brake when towing ................................................. 40
2.2.4 Engine troubleshooting ..................................................................... 41
2.3 Operation ................................................................................................. 42
2.3.1 Before-starting inspection ................................................................. 42
2.3.2 Starting the engine ............................................................................ 43
2.3.3 After starting the engine .................................................................... 44
2.3.4 Traveling ........................................................................................... 45
2.3.5 Stopping / Parking ............................................................................. 47
2.3.6 Stopping the engine .......................................................................... 48
2.3.7 Check after stopping the engine ....................................................... 48
2.4 Vibratory Operation.................................................................................. 49
CONTENTS

2.5 Precautions for Work ............................................................................... 51

2 5.1 Compaction operation ....................................................................... 51
2.5.2 When going downhill ......................................................................... 51
2.5.3 On a slope ......................................................................................... 51
2.6 Applicable Jobs........................................................................................ 52
2.7 After Operation ........................................................................................ 53
2.8 Loading and Unloading ............................................................................ 53
2.8.1 Use of a trailer equipped with a winch .............................................. 54
2.8.2 Self-propelling ................................................................................... 54
2.9 After Loading the Machine ....................................................................... 55
2.10 Transportation.......................................................................................... 55
2.1 1 Operation in Cold Weather ...................................................................... 55
2.1 1.1 Fuel oil and grease............................................................................ 55
2.1 1.2 Coolant .............................................................................................. 56
2.1 1.3 Battery ............................................................................................... 57
2.12 When the Cold Season is Over ............................................................... 58
2.13 For a Long Storage Period ...................................................................... 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 the machine by hoist............................................................... 65
3.2 Walk-around Checking ............................................................................ 66
3.2.1 Tire inflation pressure check ............................................................. 67
3.2.2 Checking for external injury to a tire.................................................. 67
3.3 Periodic Maintenance Points ................................................................... 68
3.4 Maintenance Procedure........................................................................... 70
(1) Every 10 service hours or daily ......................................................... 70
(2) Every 50 service hours...................................................................... 73
(3) Every 250 service hours.................................................................... 75
(4) Every 500 service hours.................................................................... 78
(5) Every 1000 service hours.................................................................. 81
(6) As required ........................................................................................ 83
3.5 Consumable Parts ................................................................................... 88
3.6 Fluid and Lubricant Capacities ................................................................ 90
3.7 Electric Wiring Diagram ........................................................................... 92

4 SPECIFICATIONS ............................................................................................ 95
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

–1–
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.

This manual covers the proper and safe method of driving and handling of this machine for
its intended use. When this machine is used in a manner other than those 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 Denotes that there is a hazard. If you fail to take proper

precautions, you could be killed or seriously injured
(Symbol is orange).

CAUTION Calls attention to safety practices. If you fail to take

proper precautions, you could be injured or cause
damage to the machine (Symbol is yellow).

–2–
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.
Incorrect operation can kill or cause injury.
It is your responsibility to operate the machine safely.

☆ 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 beginning on page 4.

☆ To operate and work with your machine, you must be qualified.

–3–
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.

■ Turn off cell phones

• Turn off cell phones while driving or repairing the machine. Never drive while talking on a
cell phone, as it may lead to serious accidents.

■ Read the operator’s manual 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 manual is lost or is damaged and is not legible, replace it

immediately

■ Understanding the uses for the machine

• This machine was developed and manufactured mainly for the purpose of rolling
compaction in engineering works. Do not use it for any other purpose. Vibration rolling
compaction under conditions of excessive compaction, or using it to crush rocks can
damage the machine.

■ Obey the worksite rules

• Follow noise standards and worksite rules such as matters forbidden or to be attended to,
and working procedures.

–4–
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. Do not wear oily clothing.
• Depending on the type of job, wear gloves, earplugs safety goggles or a mask.

■ Know the work area in advance

• Know the terrain, geology and conditions of the road surface at the worksite. Start working
after securing safety such as stationing a guardsman or putting up barriers 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 performance of your machine and correctly operate the
machine to meet the requirements of the job site. Operating the machine beyond its
capabilities may lead to an accident. Use your machine within its capability.

■ The machines not equipped with ROPS must not be operated on the slope or unsafe
ground

■ The machines not equipped with CABIN must not be operated in the bad weather or
a harmful contaminated zone

–5–
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. Operate the machine after making sure
that it is safe to operate.

■ Do not allow anyone to enter the work area except for authorized personnel
• Always conduct the work paying attention to the
workers around the machine.

■ Beware when operating moving parts

• When operating moving parts such as covers, be sure to understand the way they move
and take care not to get the hands and feet caught.

■ Operator must sit in the seat when operating the machine

■ Be careful of hot parts

• After your machine has operated for some 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
coolant cooled down (For the radiator cap with a lever,
lift the lever to release the trapped pressure).
• When removing the filler cap on the hydraulic tank, release the trapped pressure by
turning it out slowly to prevent the oil from gushing out (For the cap with a lever, lift the
lever to release the trapped pressure).
• While the engine is running or immediately after it has been stopped, do not touch the
engine, muffler, exhaust pipes, oil hydraulic pumps, oil hydraulic motors, lights, etc., as
they will be hot.
• Resin and metallic parts may become hot under direct sunlight on a hot day. Direct contact
with such parts may cause burns, so be sure to wear clothing and protective equipment
appropriate for the job.

–6–
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.

• Do not smoke or use a match or cigarette lighter close to

inflammables (combustibles).
• When refueling, stop the engine and do not smoke.
• The filler caps of the fuel and oil tanks must be kept tight.

■ Ensuring safety in a fire

• Machine fires may cause serious injuries or death, so stop the engine by turning the starter
switch to the “OFF” position, then move away from the machine as quickly 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 handrail and step.
• Watch your step when getting on or off the machine.
• Do not jump on or off a machine, particularly when it is moving.

■ Be careful not to fall

• Falling off the machine may cause serious injuries or death, so do not place your feet
anywhere other than on the steps, and in the driver’s seat.

■ Do not lock out yourself when leaving the machines

• Always bring the key with you by pulling it out from the starting switch when leaving the
machine.

–7–
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.
• The fluid can also irritate your skin. When handling it, wear
rubber gloves to avoid contact with it. In case of skin contact,
wash with soap and water.
• Be careful not to swallow the fluid. It can cause diarrhea and
emesis.
If swallowed, do not try to vomit. Get medical help
immediately.

■ Do not use worn tires (Tire installed)

• Tires may be damaged when they are scratched on curb stones, when the machine runs
over irregular surfaces of roads or projections on roads, and when the machine is operated
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 cause slippage. Repair them if found to be damaged. Tighten loose
bolts.
• Keep your boot soles free of oil or muds. They can slip, leading to an accident.

■ Inspect your machine before operation

• Check your machine for damage such as cracks and deformation. If found to be abnormal,
operate the machine after taking a proper measure to secure safety.
• Check the level of fluids (fuel, engine oil, coolant, anti-freeze and hydraulic oil). Add as
necessary.
• Check the area where the machine has parked for signs of leakage of oil, fuel and water. If
any leakage is noticeable, determine the cause and make corrections immediately.

–8–
WARNING: Negligence of these instructions can lead to accidents.

■ Watch your distance

• When traveling on a road, bear in mind the
stopping distance. Avoid excessive speed,
and abrupt starting and stopping, and
moving in a zigzag direction.

■ Understand ROPS functions (with ROPS)

• Ensure that there is no loose bolt, crack nor rust on the bodies and the attaching portions,
of ROPS.
• 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.

1.3 Before Starting 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 can be fully pressed down without difficulty when you twist your body for
reverse run.
• Adjust the seat to allow proper operation of the steering wheel, levers, switches, etc.

■ Secure good visibility (with CABIN)

• Keep the windowpanel clean.
• Lock the windows and doors no matter whether they are open or closed.
• Do not leave the doors half-closed.

■ Secure forward and backward visibilities

• Adjust the rear view mirrors and under mirrors for good visibility. If dirty, clean them. If
damaged, replace.

–9–
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

• Before starting the engine. Make sure there is no one
in the immediate vicinity 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 operational mistakes.

■ Pay attention to ventilation

• Exhaust fumes are dangerous 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.

– 10 –
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.

■ Warm up the Engine

• Do not put your machine into motion immediately after the 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 noticeable, determine the cause and make corrections immediately.

■ Have a trial run

• Make a test run in a safe place to check that there are no abnormal signs. If found to be
abnormal, correct the fault before traveling again.
• Listen for unusual sounds, and check for abnormal temperature rise. If abnormal, park the
machine in a safe place and find the source of trouble before operating.

– 11 –
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.

■ Seat belt (with 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 under it. If some workers are present or close to the machine, tell
them that the machine is about to move, warning them to stay away from it.

■ Do not try to get on or off a moving machine

• Get on or off the machine after making sure it has come to a complete stop and the
parking brake is applied.

– 12 –
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.

■ To go uphill or downhill, run at a low speed.

Do not attempt to shift speeds while traveling
on a slope
• Shifting speeds on a slope can cause unexpected
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 guess work can cause an accident. Use extreme
care for workers present in the path of the machine or around it. In case of danger, stop
and sound the horn, and proceed when the area is clear of personnel or obstructions.

■ When 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.

– 13 –
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.

■ Avoid long hours of continual operation

• Avoid long hours of continual operation as it may lead to loss of health.

■ Repair as soon as possible if found to be defective

• If the machine is found to be faulty, stop the machine and repair. Do not operate the
machine until the problem is corrected. When any warning lamp indicates faulty operation,
inspect the machine after moving 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
a harmful contaminated

■ Do not operate the machine except from the operator’s seat. Do not drive in a
standing posture
• Do not throw your legs out or lean forward. Be sure to sit in the proper position while
driving 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 load weight of the machine you are operating to insure safe
travel across the structure

– 14 –
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

■ On a step slope, run the machine at low 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
necessary markings such as flag, barriers and
illumination. However, be sure they do not obstruct
traffic.
• Stop the engine when getting off the machine. Remove
the key from the starter switch, and make sure it is
stored appropriately.
• Be sure not to get your hands caught in the chocks
when handling them.

– 15 –
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.
• Use 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 facing in the wrong direction, go
back off the ramp, correct the direction and try again.
• Do not use kinked, twisted or damaged wireropes for crane or winch operation. Use ones
with ample strength.
• When loading is complete, fix the machine with wooden blocks placed under the drums
and chains fastened to the machine.

1.7 Transportation
• Follow required regulations.
• Select a transporting route according to the overall width, overall height and gross weight
of the trailer with the machine loaded.
• Know the maximum height clearance of the machine loaded on the transport trailer before
hauling under bridges and other structures.

– 16 –
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.
• In case of eye contact, flush with clean water and get
medical help.
• If swallowed, drink large amount of water, milk, beaten
egg or vegetable oil, and get medical help.
• Wear safety goggles when handling the battery.
Wear safety goggles, full face shield, rubber gloves and
rubber apron when adding fluids to the battery.
• Keep cigarettes and flames away, and avoid
recharging the battery in poorly ventilated places when
there is a danger or generating sparks.

WARNING
Battery posts, terminals, and related accessories 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 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.
• Do not charge battery when the top surfaces of the liquids are at the LOWER level (the
minimum liquid level) or below. Not only the internal parts of the battery are degraded and
the battery lifetime are shortened but also it can cause explosions if you continue on using
the battery when the top surfaces of the liquids are at the LOWER level or below.
Immediately supply water until the water level is between the UPPER and LOWER levels.

– 17 –
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. For disconnection, start with the
negative one.
• Do not allow a tool to bridge between the positive
terminal and machine body. This can generate
dangerous sparks.
• Do not connect the booster cable to wrong the terminal. Never connect the positive
terminal to the negative terminal or the body of the machine.
• Final connection to the engine block 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 broken down, as it is dangerous.
• To tow the machine, use cables with ample strength.
• Do not perform towing on a slope.
• Be sure to attach a wire rope firmly to the towing hook.
• Do not use twisted, kinked or damaged cables when towing.
• Do not step over the wire rope.
• Keep everyone away from the space between the machine and the towing machine when
connecting the two.
• Align the connection points of the disabled machine and the towing machine in a straight
line when connecting the machines.

– 18 –
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.

DANGER
Do not operate.
Keep this warning tag, if not used, in tool box.

■ Setting the chocks

• Set chocks in front of and behind the roller drum (wheels) to prevent the machine from
moving before 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 even if it is within its recommended service
interval.
• Replace fuel hose, high pressure hydraulic hoses and liquid hoses regularly to prevent fire.
Replace high pressure hoses of the power steering system every two years.

☆ Change these parts at regular intervals even if found to be normal. They will deteriorate
as time goes on.
☆ Change any hose found to be abnormal even if it is within its recommended service
interval.

– 19 –
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. He
must take care not to touch any of controls carelessly.
Maintenance personnel must exercise extreme caution
not to make contact with moving parts.

■ Supplying fuel, oils and grease

• Do not cover the filler port when refueling. Feeding fuel in an airtight tank might damage
the fuel tank.
• Spilled fuel or oil will be slippery. Wipe up immediately. Keep the filler caps tight. Do not
use fuel for flushing oil. Handle 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 and
battery electrolyte, use explosion-proof illuminations.
Failure to use this type of illumination can result in an
explosion.

■ Make sure the gas dampers are properly maintained

• Before inspecting the engine room, make sure the gas dampers holding up the hood are
firmly engaged. Furthermore, in machines with stays to prevent the hood from closing,
make sure they are firmly in place.

■ Points to beware of when filling the sprinkler tank with water (on machines
equipped with a sprinkler tank)
• Do not fill the tank with the water inlet blocked. It may damage the sprinkler tank.

– 20 –
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.

■ Assume an appropriate posture while working

• An unnatural posture during maintenance work may cause injuries. Assume a posture that
is appropriate for the work being carried out.

■ Keep your machine clean

• Spilled oil, grease or scattered debris are dangerous. Always keep your machine clean.
Moisture that penetrates into the electrical system 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 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
thorough understanding in order to handle them
appropriately and safely.
• When repairing the electrical system or welding,
disconnect the negative cable from the battery to shut
off the electricity. Carrying out work while the cables
are connected to the negative terminal may cause
electrocution or explosions.

– 21 –
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.
• Replace damaged fuel hose, hydraulic hoses and liquid hoses.
An oil, hydraulic and liquid fluid spill can cause a fire.

■ Be careful of high pressure hydraulic fluid

• Bear in mind that the working equipment hydraulic
systems are under internal spressure. Do not perform
adding, draining, inspection or servicing of the
hydraulic systems until the internal pressure has 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 affected by high
pressure oil, get medical help immediately.

■ Be careful of hot 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 in moving parts.
• Do not let your body or tools make contact with the fan
blades or belts. They can be cut seriously.

– 22 –
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.
• Obey all local, state and federal environment
regulations for the proper disposal of oil, fuel, coolant,
battery electrolyte or any other fluids.

■ Take care in handling the gas damper

• Never dismantle it.
• Do not throw it into a fire.
• Do not damage the rod.
• Do not bend the tube or rod, or use it as a handle.
• When disposing of it, be sure to fix the 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 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.
• An improperly fitted tire can separate from the rim
when inflating.
• When dismounting a tire, chock other tires for safety.
• When welding job is carried out near the tires, use
extreme care, as this can cause an explosion of the
tires.

– 23 –
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 3998-16501-0 ⑧ 3998-16504-0 ⑭ 3998-06139-0 ⑮ 3998-16724-0

② 2998-96001-1
⑯ 3998-16559-0

③ 3998-16499-0 (2 locations) ⑨ 3998-16701-0 ⑩ 3998-19678-0

(3 locations) (2 locations)
⑰ 3998-16680-0

⑱ 3998-16696-0

④ 3998-16489-0

⑤ 3998-16510-0
⑫ 1411-19036-2

⑲ 3998-16500-0

⑥ 3998-16507-1

⑬ 3998-16646-1

⑦ 3998-16468-1

– 24 –
WARNING: Negligence of these instructions can lead to accidents.

– 25 –
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 Engine warning lamp ⑩ Speed change switch with vibration switch
⑤ Engine wait to start lamp ⑪ Engine speed select switch ⑯ Leveling blade lift lever
⑥ Horn switch button ⑫ Parking brake switch
＊
For SV540TB, SV540FB only.

– 26 –
2. OPERATION

2.1.2 Gauges, indicator lamps and warning lamps

For safe execution of your job, fully understand the role and function of the systems
involved.

Combination meter

Tachometer / Hour meter

Indicates the engine RPM. The hour meter shows total
operating hours. The service interval recommendation
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 before the fuel runs down.

CAUTION
Be sure to use fuel recommended by SAKAI (refer to page 90).

– 27 –
2. OPERATION

Monitor display

★ Indicator lamps [ ]
Light up when corresponding systems have been operated.
★ Parking brake indicator lamp [ ]
It will flash once when the starter switch is turned to the " " position.
After that it will remain on while the parking brake is engaged, and turn off when it is
released.
★ Hydraulic oil filter warning lamp [ ]
It will flash once when the starter switch is turned to the " " position.
After that it will 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 " " position.
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 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 when a problem arises with the electric system.
Stop the machine and carry out an inspection.

– 28 –
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. When the warning light 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, there is some trouble.
Check and repair the combination 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.

– 29 –
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. Stop the machine to
check the engine.

★ ENGINE STOP
When the engine stop lamp lights, it means a serious
abnormality occurs with the engine. Stop the machine and
the engine, and receive proper checking / maintenance or
repairing.

★ WARNING
When the warning lamp lights, water may be accumulated in the fuel pre-filter.
Drain the fuel pre-filter (refer to page P.78).
If 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 or repairing before a serious failure occurs.

★ WAIT TO START
When the wait to start lamp is lit, it means self-diagnosis of the engine, and the engine
should not be started.
Must wait to start the engine. The most common reason for this is to wait for the intake air
heaters to complete a pre-heat cycle during cold ambient conditions.

IMPORTANT
For the details of the engine check lamp, see the instruction Manual of the engine.

Eco lamp
ECO lamp is turned on if the Engine speed select switch
is shifted to “ECO” position. It runs under the fuel-efficient
mode when the ECO lamp is turned on.
Normal vibrator speed occurs in ECO mode.

– 30 –
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.
" " position : The charging circuit and 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 key. It will
automatically return to the " " position.

CAUTION
Set the Forward - Neutral - Reverse (F-N-R) lever in the neutral position and press
down the parking brake switch before starting the engine. Unless these conditions
are met, the engine will not start.

– 31 –
2. OPERATION

Parking brake switch

If switch is pressed down, the parking brake will be
applied with the indicator lamp P 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. 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 the engine.

WARNING
• To disengage the brake, be sure to press the button again instead of pulling it.
• Always press the button to apply the parking brake before dismounting from the
machine.

CAUTION
Never pull the switch up.

Horn switch button

Pressing the button at the center of the
steering wheel sounds the horn.

– 32 –
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.
" " position : Turning the vibrator switch counter clockwise Vibrator swich
causes vibration to start with low amplitude.
NOTE : For Vibratory rolling, run the engine at FULL and ECO.

Vibration selector switch

Selection can be mode between the vibrator switch
installed to the Foward - Neutral - Reverse (F-N-R) lever
and the other one located on the panel.
" " position : Vibration can be turned ON or OFF
with the switch located on the Foward -
Vibration selector swich
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 used with the vibrator switch on the
panel placed at " " or " " position.
" 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.
Vibration swich

NOTE : For vibratory rolling, run the engine at FULL and ECO.

IMPORTANT
• Do not operate the vibrator on a hard area such as cement concrete pavement
surface or the ground covered by thick steel sheets.
• Keep the vibrator stopped when the machine is at rest.
• Shut off the vibrator immediately when the machine has been caught in the mud
during vibratory operation.

– 33 –
2. OPERATION

Speed change switch

Selects two machine speed ranges.

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 min-1）
IDLE ECO FULL
Engine speed
900 min-1 1850 min-1 2200 min-1

– 34 –
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.

Provided at the knob of the lever is the vibration 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.

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 lever backward. The lever
automatically returns to the Hold position when released.
Hold : When this position is selected, the blade stays in any
position.
Lower: To lower the blade, push the lever forward. The lever
automatically returns to the Hold position when released.
Float : Push the lever forward to its full extent. In this position, the blade becomes free
to ride up and down over the ground, following the ground configration as the
machine travels. The lever stays in the Float position even if it is released.

– 35 –
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. 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 the engine.

IMPORTANT
• Do not use the pedal wherever practicable except for an emergency.
• The F-N-R lever permits usual 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 or less than 0.5 km / h (0.3 mile / h)
Towing Distances : Within 100 m (328 ft)

For towing:
Turn the knob counter-clockwise (Unload).
For normal traveling:
Turn the knob clockwise (Onload).

WARNING
• On a slope, chock the wheels and use extreme care when handling the unloader
valve and towing the machine.
• Be sure to apply the parking brake when operating the unloader valve.
• Unloading the unload valve will disengage the engine, so never get in front of or
behind the machine.

NOTE: For normal travel, be sure to close the unloader in the ONLOAD position.

– 36 –
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.
Fuses protect electrical components and wiring
from burning. Change any fuse which has
become powder-coated due to deterioration or
which has play between it and fuse holder. To
replace fuses, take off the cover. Be sure to use
fuses of correct capacity.

Using improperly rated fuses may result in poor

machine performance, damage to the electrical
system, or safety problems, such as an electrical
fire.

– 37 –
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 and adjust seat position longitudinally.
2) Turn the backrest adjust dial ② for optimum angle.
3) Move the suspension lever ③ to select suitable
suspension for your body weight.

WARNING
• The seat shall be adjusted before starting any works or when the 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 fingers, hands or legs while adjusting the seat.
• Adjust seat only when one person rides on the machine.
• Adjust seat only when the machine stays on the flat ground.
• Adjust the seat so that your back is in close contact with the back of the seat
while seated and when stepping on the brake pedal down to the floor. Adjust
the seat so as to be able to certainly step on the brake pedal when twisting your
body around to look back in order to move the machine backwards.

IMPORTANT
Be sure to wear the seatbelt during operation.

– 38 –
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 Ⓒ

① Loosen bolts Ⓓ at 8 locations.
② Provide a clearance of 20 mm between scraper
blades Ⓒ and the drum.
③ Retighten bolts Ⓓ at 8 locations.

SV540TF, SV540FB

3) Change from TF to T types

① Loosen bolts and nuts Ⓑ at 8 locations.
② Adjust the scraper blade Ⓐ by changing its direction
so that it does not interfere the pads.
③ Retighten bolts and nuts Ⓑ at 8 locations.
④ Loosen bolts Ⓓ at 8 locations.
⑤ Adjust the scraper blade Ⓒ so that it does not 　
SV540TF
(at the time of T type specification )
interfere the pads.
⑥ Loosen bolts Ⓓ at 8 locations.
⑦ Loosen bolts and nuts Ⓕ at 18 locations.
⑧ Adjust the scraper blade Ⓔ by changing provide a
clearance of 20 mm between scraper Ⓔ and the
drum.
⑨ Retighten bolts and nuts Ⓕ at 18 locations.

SV540T, SV540DF, SV540TB, SV640T

1) Clearance adjustment of scraper Ⓐ
(Nine pieces are mounted on both the top surface and
the undersurface for each in front of the machine.)
① Loosen bolts and nuts Ⓑ at 18 locations.
② Provide a clearance of 20 mm between scraper Ⓐ
and the drum.
③ Retighten bolts and nuts Ⓑ at 18 locations.

– 39 –
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 Loosen bolts and nuts Ⓑ at 18 locations. SV540DF

② Adjust the scraper blade Ⓐ by changing its direction

so that it does not interfere the pads.
③ Retighten bolts and nuts Ⓑ at 18 locations.
④ Loosen bolts and nuts Ⓓ at 8 locations
⑤ Move the scraper blade Ⓒ to the undersurface at the
rear of the frame such that there is a gap by 20 mm
between the scraper blade Ⓒ and the drum.
⑥ Retighten bolts Ⓓ at 8 locations. 　
SV540DF
⑦ Loosen bolts and nuts Ⓕ at 8 locations. (at the time of D type specification)

⑧ Adjust the scraper blade Ⓔ by changing provide

a clearance of 20mm between scraper Ⓔ and the
drum.
⑨ Retighten bolts and nuts Ⓕ at 8 locations.

2.2.3 Disengaging the brake when towing

WARNING
• On a slope, chock the drums and prepare for towing before disengaging the
brake.
• Avoid a long-distance towing.

For towing the machine when the engine is disabled or when trouble has developed in the
hydraulic propulsion, system disengage the brake as instructed below:

– 40 –
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. The brake can be released by pressing
it about 35 times. When the operation force
is felt heavy, the brake is released. Stop the
operation at that time. Continued oparation
may cause damage to the machine.
4) After 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 try to release the brake immediately
after a hot engine has been stopped. Let the oil
cool down.

• For the brake disengagement, wear hard hat ,

safety goggles and safety gloves.

2.2.4 Engine troubleshooting

Engine troubleshooting can be

conducted using the trouble code
selector switch.
During normal operation, do not
operate switches.
Set switch as shown in the figure
during the normal operation.

IMPORTANT
When operating the trouble code selector switch, see the engine manual.

– 41 –
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
motion. Steering is impossible if the pin is in
the steering lock position.

The pin is located at the right of the center of the

machine.
To unlock the pin.
① Pull out the lock pin.
② Set the pin in the carrying position.

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 interlocking system goes into
operation and the engine will not turn on. Be sure
to confirm that the F-N-R lever is in the neutral
(middle) position, and that the parking brake is
engaged before starting the engine.

– 42 –
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.

（± 50 min-1）
IDLE ECO FULL
Engine speed
900 min-1 1850 min-1 2200 min-1

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 lights up

and goes out.

– 43 –
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 " " position for more than 15
seconds.
• When the engine fails to start, or you want to restart the engine immediately after
turning it off, wait around 30 seconds before restarting it.
• Check that the warning lamps on the monitor display go off immediately after
the engine is started. If any of these warning lamps stay on while the engine is
running, shut down the machine, determine the cause and rectify the fault.

2.3.3 After starting the engine

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 idling 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 operation, check that:
• Temperature gauge .............................. Pointer falls near the center zone
• Fuel gauge ........................................... Pointer falls between the E and F marks
• Charge lamp......................................... Has gone off
• Engine oil pressure warning lamp ........ Has gone off
• Engine check lamp ............................... Has gone off
3) Check for the color of exhaust gas, listen for unusual sounds and vibration. If abnormal,
determine the cause and correct the problem.

WARNING
Stay in the driver seat during operation.

– 44 –
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)

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
running.

WARNING
On a steep slope, run the machine at low speed.

2) Turn the engine speed select switch to increase the

engine speed.

– 45 –
2. OPERATION

3) Press down the parking brake switch button to release

the brake. Check that indicator lamp P 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. Forward F
Neutral N
Reverse R
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 brake is activated and the engine is stopped at
the same time.
Pay extreme attention to the area behind the machine when backing, since the
space just behind it tends to be a blind spot.

– 46 –
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 Ⓝ , and the

machine will come to a halt.
CAUTION
For normal braking, move the F-N-R lever back to
the neutral position. In an emergency, depress the
brake pedal.

IMPORTANT
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 switch button, otherwise the machine will
not start.

2) Press the parking switch button securely, and check

that indicator lamp P illuminates.

NOTE: When pressing the parking brake switch during machine running, the brake is
activated 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 the engine.

– 47 –
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.
• Do not also allow an overheated engine to come to a sudden stop, but run it at
middle idling speed for gradual cooling down.

2) Turn the starter key to the " " position to stop the
engine.
CAUTION
Do not turn the starter switch " " position 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 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 water leakage, abnormal signs around the
drums.
2) Fill the fuel tank.
3) Remove waste paper if any from the engine compartment, as this will pose a possible fire
hazard.
4) Scrape mud or other materials from and around the drums.
5) When transporting the machines, please ensure safety by strictly complying with the
applicable laws and regulations.

– 48 –
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.
MID is fuel-efficient position called the "ECO MODE".
The ECO MODE is recommended when working on Engine speed select switch

flat road surfaces as the maximum speeds and the hill-

climbing 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 the control panel on the

top of the dashboard to select low or high amplitude and ON /
OFF of vibration.

" " position : Turning the vibrator switch clockwise causes the
vibration to start with high amplitude.
" " position : Vibration is shut down.
" " position : Turning the vibrator switch counter clockwise
causes vibration to start with low amplitude.

Vibrator switch Ⓐ
NOTE: For vibratory rolling, run the engine at FULL. or ECO.

– 49 –
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 Ⓑ
this switch causes the vibration to start and
pressing it again to stop.
This vibration switch on the lever should be
used with the vibrator switch on the panel
placed at or position.
" 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 / h (1.2 – 3.1 mile / h) , however,
select speeds depending upon job requirements.

IMPORTANT
• Keep the vibrator shut off when the machine is not rolling.
• Stop vibration if the machine has encountered a running difficulty, for example,
when it gets stuck in the mud.
• Set the speed change switch in the position during vibratory rolling
compaction. Use the position only for driving on flat straight roads.

– 50 –
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. Do not use for any other purposes than rolling compactions in
civil engineering works.

■ Do not operate the vibration on a hard location

• Do not work the vibration on a hard surface such as concrete pavement, as this can cause
the machine to jump and give abnormal shock load. Damage to shock isolators will result.

■ Change the direction of travel 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 going downhill

■ Use the F-N-R lever
• Run slowly going downhill. Do not use excessive speed. Avoid changing speed if possible
when going downhill. Start slowly and end slowly on steep downgrades.

■ Use the engine brake

• Go downhill by applying the engine brake along with the F-N-R lever operation.
WARNING
• When going uphill, run at low speed. Can not attempt to shift speeds during
travelling. The machine can slip down the slope.
• When going downhill, adjust the travel speed not to allow the engine speed to
exceed 2,500 rpm.

2.5.3 On a slope
■ Working on a sidehill
• Work in an uphill / downhill direction, and avoid working on sidehill with the machine
inclining sideways.

– 51 –
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 ☆ .

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 course
☆ Base course
☆ Subgrade
☆ Embankment
• Shoulder
• Sidewalk

– 52 –
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. Also check the fuel level.
2) Remove muds and water from the machine. Muds can get into the seals together with
water drops on the hydraulic cylinder piston rod. Damaged seals will result.
3) Park the machine on a hard and dry surface. If such a place is not available, 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 and Unloading

WARNING
• Use sturdy ramps with proper width, length and thickness which allow safe
loading and unloading.
• If the ramps deflect considerably under load, apply wooden blocks to reinforce
them.
• Loading should be conducted on a level and hard ground. Leave a sufficient
distance between the machine and the shoulder.
• To prevent slippage on the ramps, keep the drums free from mud, oils, etc.
The ramps must also be free of grease, oil and ice.
• Do not steer the machine on the ramps. If the machine is facing in the wrong
direction, allow it to dismount from the ramps and correct the direction.

For loading and unloading, use ramps or a proper loading stand.

– 53 –
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.

☆ The angle between the ramps and ground must be

less than 15 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 ① or ② ( One each on
right and left ) of the roller.

4) Place the unloader valve located at the inside of a

frame to the UNLOAD position (refer to “Unloader
valve” on page 36).

5) With the engine running at idle, perform loading by means of the trailer winch.

6) When the loading is completed, set the unloader valve back in the ONLOAD position.

7) Locate the machine correctly on the trailer.

2.8.2 Self-propelling
1) Engage the trailer brake and chock its wheels. Fix the
ramps so that the machine and trailer are completely
aligned.
☆ The angle between the ramps and ground must be less
than 15 degrees.
☆ Leave a proper space between the ramps according to
the width of the roller drum.

– 54 –
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. 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
To decide the transporting route, check the width of the road, height and weight
(including the roller) of the trailer.

For transportation,obey traffic regulations.

2.11 Operation in Cold Weather

In cold weather, take the following measures to prevent troubles such as starting difficulty and
coolant freeze-up.

2.11.1 Fuel oil and grease

Use fuel and oil with low viscosity. Refer to “Rating” on page 90.

– 55 –
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.

Ambient temperature Always

Amount of anti-freeze 11.5 L (3.0 gal)

Amount of water 11.5 L (3.0 gal)

Ratio 50%

Our machines are filled with a long-life coolant.

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 heater valves that can be found beneath the engine, and turn the
heater to "heat" mode (only the appropriate machine.)
2) 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 engine and run at "mid" speed for 1 minute or until engine warning
lamp comes on.
4) Turn off engine and top up coolant to bottom of fill neck if needed.
5) Replace coolant cap.

– 56 –
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
• The battery contains diluted sulfuric acid, which 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 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 wear safely 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 when there is a danger of generating sparks.
• The inspection and handling of batteries should be carried out with the engine
turned off and the starter switch in the "OFF" 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.

CAUTION
The power-supply voltage of this machine is 24V.

IMPORTANT
When this machine is shipped, maintenance free battery is installed.

– 57 –
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.
Green .................. Satisfactory
Black.................... Charging is necessary
Semitransparent .. Replacement is necessary

Please refer to “3 PERIODICAL MAINTENANCE” Battery (P.74) for inspection and

maintenance of battery.

2.12 When the Cold Season is Over

When winter is over and the 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 than one month, proceed as follows:
1) Store the machine in a closed area after cleaning.
2) Conduct oiling, greasing and changing of oil.
3) Grease lubricate the exposed portion of hydraulic cylinder piston rods.
4) Cover the battery after disconnecting the negative cable or take off the battery from the
machine and store in a safe place.
5) If the temperature is expected to go down below 0°C, 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 key.

– 58 –
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.
• To prevent the brake linings from sticking to the brake drum, disengage the brake once a
month. Exercise care not to allow the machine to move unexpectedly.

2.15 When the Battery has Discharged

WARNING
• To check and handle the batteries, keep the
engine stopped with the starter switch in the
OFF 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 skin. If the electrolyte has
come into contact with your clothing or skin,
flush with sufficient amount of water. In case
the electrolyte has gotten into your eyes, flush
with water and get medical help.
• To disconnect the battery cables, start with the
negative terminal (earth). When connecting,
start with the positive terminal. 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 24V.

– 59 –
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.
2) Connect the other end of the positive booster cable
to 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 earth ground on the engine block of the
machine.

■ Disconnection of booster cables

1) Disconnect the negative booster cable Ⓑ from the
engine block earth.
2) Disconnect the negative booster cable Ⓑ from the
booster supply.
3) Disconnect the positive booster cable Ⓐ from the
booster supply.
4) Disconnect the positive booster cable Ⓐ from the
machine.

– 60 –
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.
• 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 of the equal capacity for the machine and booster supply.
• Check booster cables and end clips for signs of damage and corrosion.
• Securely connect the clips.
• The power-supply voltage of this machine is 24V.

– 61 –
3. PERIODIC MAINTENANCE

3 PERIODIC MAINTENANCE

3.1 Precautions
Whether or not the inspection service and lubrication are performed at the correct regular
intervals exerts significant influence on the occurrence of problems and service life of the
machine. In this manual, typical intervals for inspection and service are given. However,
flexibility should be exercised as to interval or type of services to enable your machine to
always operate in the best condition.

IMPORTANT
• After maintenance and inspection record the result of inspection. Remember that
replacement of filter elements, replenishment and change of oil and grease, and
cleaning the radiator fines are important.
When draining a hot oil, use care not to get burned.
• The disposal of waste oil and coolant, and used filters, elements, etc., should 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 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.
4) For checking oil level or changing oil, park the machine on a level and hard surface.
5) Change oil while warm.
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 freezing weather, add antifreeze to the coolant according to the ambient temperature.
8) For the hydraulic pump and motor, have them serviced at authorized service shops.
9) Turn the starter switch OFF when performing services such as repairing broken wires,
short circuits and tightening loose terminals.

– 62 –
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.
If any defects are detected such as crack, deformation or oil leakage, go ahead and replace
them even if it is within scheduled replacement time.

System or Periodical replacement Replacement

Part name Remarks
Mechanism maintenance part period
Master cylinder Seals (rubber parts) 2 years
Wheel cylinder Seals (rubber parts) 2 years
1 Brake system Brake hose 2 years
Brake piping parts
Air hose 2 years
Operating parts Cable 4 years
Orbitrol Seals (rubber parts) 2 years
Hydraulic piping parts Hydraulic hose 2 years
2 Steering system
Steering cylinder Seals (rubber parts) 2 years
Hydraulic pump Seals (rubber parts) 4 years
Axle Seals (rubber parts) 4 years

3 Power transmission Travel pump Seals (rubber parts) 4 years

system Travel motor Seals (rubber parts) 4 years
(inclusive of axle) Hydraulic piping parts Hydraulic hose 4 years
Isolation rubber Isolation rubber itself 4 years
4 Fuel system Piping parts Fuel hose 2 years
Engine mounting parts Isolation rubber 4 years
Seals (rubber parts) Packing and others 4 years
5 Engine related
Drive parts V-belt 2 years or 500 hours
Piping parts Engine drain hose 4 years
Radiator hose 2 years
6 Cooling system Piping parts
Radiator drain hose 4 years
7 Control related parts Cable parts Cable 4 years
Intake hose 2 years
8 Intake system Piping parts
CAC hose 2 years
9 Hydraulic system Hydraulic piping parts Hydraulic hose 4 years

– 63 –
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. If this
occurs, conduct necessary 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 month, when
there is abnormality, replace it.
If there are some trouble on the electric wiring, replace them with new one.
1) Damage to the wire harness and loose clamps
2) Loose sockets
3) Function of electrical systems
• For the parts other than listed above, If there are some trouble on the parts at
periodic inspection or daily check. Replace them as soon as possible.

– 64 –
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.

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 ballanced.

– 65 –
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 –
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.

WARNING
Improper handling of a tire is dangerous and may cause flat tire and a rim to come
off.
Do not work on a tire facing the rim, but from behind the tread of the tire while
checking the inflation pressure or replenishing air into a tire.

3.2.2 Checking for external injury to a tire

Check any external injury to a tire, its size and its depth
(whether it has reached 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 exceeds one thirds of the tire width
4) When a tire has ply separation (peeling)
5) When radial cracks reach the carcass
6) When the tire is not regarded as durable due to abrasion, deformation, or abnormal flaw
growth.

Please consult with dealer for maintenance in the following cases.

• When injury is found on the surface of a tire.
• When the degree of wear on the front, rear, right and left sides of a tire are extremely
different.
• When a bent rim is found.

– 67 –
3. PERIODIC MAINTENANCE

3.3 Periodic Maintenance Points

– 68 –
3. PERIODIC MAINTENANCE

Interval No. Item Service Lubricant Q’ty

⑥ Fuel pre-filter Check, drain water and dirt 1
Every 10 ⑦ Air cleaner Check indicator 1
service
hours or ⑮ Auxiliary tank Check coolant level Coolant 1
daily ⑰ Engine oil level gauge Check oil level Engine oil 1
㉖ Fan belt Check tension and unusual wear 1
① Hydraulic oil level gauge Check oil level Hydraulic oil 1
Check function and adjust
⑫ Brake
Grease 1 places
1
Every
50
Check looseness of terminal and
service ⑬ Batteries
appearance
2
hours
＊
⑲ Blade cylinders Grease 4 places Grease 4
＊
Push rod anchor pins Grease 2 places Grease 2
⑤ Engine oil filter Change filter element 1
SV540 : 10
⑩ Rubber dampers Check for cracks
SV640 : 12
⑪ Gear case: Wheel motor Check oil level, add as necessary Gear oil 1
Every ⑳ Vibrator Check oil level Gear oil 1
250
service Center pin and tilt pin
㉒ bearings
Grease 6 places Grease 6
hours
Steering cylinders Grease 4 places Grease 4
Transmission, differential
case and final drive
Check oil level, add as necessary Gear oil 1

㉗ Engine oil pan Change engine oil Engine oil 1

⑥ Fuel pre-filter Change filter element 1
⑧ Hydraulic oil line filter Change filter element 1

Every ⑨ Hydraulic oil return filter Change filter element 1

500 Check for loose bolts and nuts
service ⑭ Control link
Grease 1 place
Grease 1
hours
⑯ Fuel filter Change filter element 1
Transmission, differential
case and final drive
Change gear oil Gear oil 1

② Hydraulic oil suction filter Clean filter element 1

Every
1000 ③ Hydraulic oil tank Change hydraulic oil Hydraulic oil 1
service ⑪ Gear case: Wheel motor Change gear oil Gear oil 1
hours
⑳ Vibrator Change gear oil Gear oil 1
④ Tires Check inflation 2
⑦ Air cleaner Change element 1

As ⑱ Breather Clean filter element 1

required ㉔ Radiator Clean fin 1
㉘ Fuel tank Drain water and dirt 1
㉙ Fuel tank breather Clean breather 1
＊
SV540TB, SV540FB only

– 69 –
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).

– 70 –
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" mode (only the appropriate machine.)
2) 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 engine and run at "ECO" speed for 1 minute or until engine warning
lamp comes on.
4) Turn off engine and top up coolant to bottom of fill neck if needed.
5) Replace the cap.

WARNING
• Do not remove the radiator cap and auxiliary tank cap
while the coolant is hot.
• Hot water may be spouted out that can cause scald.

NOTE: Replace long-life coolant every two years. Replace the other types every year.

– 71 –
3. PERIODIC MAINTENANCE

⑰ Engine oil level gauge

See the separate engine manual.
Check the amount of engine oil after the engine is
completely stopped. Pull out the oil level gauge and wipe
off oils by waste clothes. Re-insert the oil level gauge into
the full length of the oil dip pipe and pull it out. Check that
the oil level is between “ FULL ” and “ ADD ”. In case of
shortage, feed oils through the engine oil fill port.

NOTE: When checking the amount of oils after running the engine, please check at least 15
minutes after the engine is stopped. 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 and the oils may be raised. 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.

IMPORTANT
Please see the separate engine manual for engine for more details on fan belts.

WARNING
Make certain that the engine is completely stopped to avoid any risks when
checking looseness, tensions and damages for the fan belts.
Also make certain that the key is removed from the starter switch.

– 72 –
3. PERIODIC MAINTENANCE

(2) Every 50 service hours

① 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.
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. 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 15 mm ±5 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.

Apply grease to the brake pedal shaft.

– 73 –
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 … Charging is necessary
Semitransparent … Replacement is necessary
2) Retighten any loose terminal. Apply grease or vaseline to the terminals to retard rusting.
3) Be sure to tighten the battery holder if it is loose.

Inspection and maintenance methods for non-maintenance-free batteries.

1) With the caps removed, check to see if the electrolyte
level is above the 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.

WARNING
• The battery contains diluted sulfuric acid, which 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 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 wear safely 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 when there is a danger of generating sparks.
• The inspection and handling of batteries should be carried out with the engine
turned off and the starter switch in the "OFF" 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.

– 74 –
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.

CAUTION
Be sure to use grease recommended by SAKAI
(refer to page 90).

(3) Every 250 service hours

⑤ Engine oil filter

㉗ 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 draining a hot oil, use care not to get burned.

2) Put the shield tape on it, refit the drain plug Ⓐ and fill
the crankcase with the engine oil from the fill port Ⓑ .
3) Change the oil filter Ⓒ .

NOTE: For a new machine, change oil at 50 operating

hours for the initial time only.

CAUTION
Be sure to use engine oil recommended by SAKAI
(refer to page 90).

– 75 –
3. PERIODIC MAINTENANCE

⑩ Rubber dampers
Check the rubber blocks for cracks, and their mounting
bolts for looseness.

⑪ Gear case : Wheel moter

1) Position the drum so that the drain plug comes to the
bottom. Keep the three sailent parts (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 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.

CAUTION
Be sure to use gear oil recommended by SAKAI
(refer to page 90).

– 76 –
3. PERIODIC MAINTENANCE

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.

CAUTION
Be sure to use grease recommended by SAKAI
(refer to page 90).

Transmission, Differential case and final drive

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 90).

– 77 –
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.

– 78 –
3. PERIODIC MAINTENANCE

⑯ Fuel filter

➡ See the separate engine manual.

Change the filter cartridge.

Transmission
1) Drain 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 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 –
3. PERIODIC MAINTENANCE

Final drive
1) Rotate the wheel till the drain port is located at the
lowest position. Remove plug to drain oil.
2) At the final drive, adjust the position of plug until it is
parallel to the ground.
3) Fill oil through the fill port till oil 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 case
1) Drain oil by removing the drain plug, fill port 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 plugs.

CAUTION
Be sure to use gear oil recommended by SAKAI
(refer to page 90).

– 80 –
3. PERIODIC MAINTENANCE

(5) Every 1,000 service hours

② Hydraulic oil suction filter

Take off the hydraulic tank cover. Take out and clean the strainer, change the strainer if
necessary.

③ Hydraulic oil tank

1) Remove the drain 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 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).

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
in the figure) on the axle shaft to face upward.
2) Remove the drain plug and fill / level plugs and drain
the oil while it is warm.
3) Refit the drain plug and fill the oil through the fill port
until it overflows at the level port.
4) Refit the fill / level plugs.

CAUTION
Be sure to use gear oil recommended by SAKAI (refer to page 90).

– 81 –
3. PERIODIC MAINTENANCE

⑳ Vibrator
1) Rotate the drum till the drain plug comes to bottom.
2) Remove drain plug, level gauge plug and filler plug.
3) Drain oil from vibrator.
4) Clean the 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 34 liters. Do not fill more than 34 liters.
• Be sure to use gear oil recommended by SAKAI (refer to page 90).

– 82 –
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. If you find any
abnormal conditions, replace tires.
2) Check air pressures.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 the wheel nuts are loose. Check
if the wheel hub nuts are loose or fallen off or if wheel
hub bolts are broken. Also check if there are any rust
fluids and/or whether or NOT the lengths of all the
wheel hub bolts projected out of the wheel hub nuts are
the same.

Check the wheel hub nut for looseness. If it is loose,

tighte’n it. Be sure to torque it to the specified value.
Tightening torque: 630 N·m

– 83 –
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.

Drum
The drum may 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.

⑦ Air cleaner
When the red float of the dust indicator reaches the service level (a mark on the indicator),
change the element as described below.

1) Release the service door clips to remove the primary element from the main filter housing.
2) Primary Element:
Grasp the handle in the center of the element and pull the filter element outward.
Clean the inside of the housing with a damp rag to remove all loose dirt and dust.

– 84 –
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.

CAUTION
Do not attempt to clean the filter element. Cleaning filter elements by impact or
compressed air voids the warranty and can degrade or damage the filter media
leading to malfunction.

NOTE: The secondary 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 necessary.
The secondary element is removed by pulling on the plastic ring tabs on the inside
face of the filter element.

WARNING
• Stop the engine before inspection, cleaning, or maintenance, otherwise dust will
enter the 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.
• Be sure to use our genuine element.

4) Attach the element and service door it with a clips.

– 85 –
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.

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 the core surface.

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.

IMPORTANT
Don’t use any driver or steel spatula (or paddle). If it rubs the fins, it can damage
the tubing.

– 86 –
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.

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
• The fuel 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.

㉙ Fuel tank breather

1) Remove four bolts.
2) Open a cover and clean an inside.
3) Attach a cover and bind four bolts tight.

– 87 –
3. PERIODIC MAINTENANCE

3.5 Consumable Parts

Replace consumable parts such as filter elements and air cleaner elements during periodical
maintenance or before reaching the wear limit. 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
ordering parts, make sure to obtain the latest part numbers by checking with our
distributorship or one of our certified service shops of the version, model name and model
number of the machine in use.

Interval
Consumable Part Part No. Annual Replacement per Remark
replacement (year) operation (hours)

Engine oil filter element 4033-26005-0 0.25 250

Return filter assembly 4218-71000-0 As required

Return filter element (hydraulic oil) 4211-41001-0 500

Line filter assembly 4218-71000-0 As required

Line filter element (hydraulic oil) 4211-41001-0 500

Fuel pre-filter assembly 4423-42000-0 As required

Fuel pre-filter element 4423-42001-0 0.5 500

Fuel filter element 4033-26003-0 0.5 500

Suction filter element (hydraulic oil) 4207-79000-0 1000

Air cleaner assembly 4423-44000-0 As required

　Primary element 4423-44001-0 As required

They should be replaced

with new ones once
　Secondary element 4423-35002-0 As required in every three times
of Primary elements’
replacement.

– 88 –
3. PERIODIC MAINTENANCE

– 89 –
3. PERIODIC MAINTENANCE

3.6 Fluid and Lubricant Capacities

(1) General rules
1) Never feed water or lubricant with the strainer removed.
2) Use recommended lubricant and hydraulic fluid.
3) Do not use lubricants and hydraulic fluid of different brands.
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.

(2) Capacity

Compartment Type of fluid Capacity in liters (gal.)

Fuel tank Diesel oil 265 (70.0)

Engine oil pan Engine oil 12 (3.2)
Hydraulic oil tank Hydraulic oil 50 (13.0)
Wheel motor Gear oil 4.5 (1.2)
Radiator Coolant 23.4 (6.2)
Vibrator Gear oil 34 (9.0)
Transmission Gear oil 2.0 (0.5)
Differential Gear oil 11 (2.9)
Final drives Gear oil 1.75 x 2 (0.5 x 2)

(3) Rating

Ambient temp. and applicable viscosity rating

Service Applicable
Lubricant −15 – 30°C 0 – 40°C 15 – 55°C
classification (5 – 86°F) (32 – 104°F) (59 – 131°F) standards
Cold Moderate Tropical

Engine oil API grade CJ-4 SAE 15W-40 SAE 15W-40 SAE 15W-40 MIL-L-2104B

Gear oil API grade GL5 SAE 80W-90 SAE 90 SAE 140 MIL-L-2105

ISO-VG32 ISO-VG46 ISO-VG68

Hydraulic oil Anti wear ISO-3448
over VI 140 over VI 140 over VI 110

Grease Lithium type extreme pressure NLGI-2

Fuel Diesel oil ASTM D975-2D

– 90 –
3. PERIODIC MAINTENANCE

(4) Recommended lubricants

Lubricant Engine oil Gear oil Hydraulic oil Grease

Oil
company API – CJ4 API GL 5 ISO-VG 46 (NLGI − 2)

RPM Universal Rando Multifak

CHEVRON DELO 400 LE
Gear Lubricants HDZ 46 EP 2

BP Energear Bartran BP Energrease

BP —
HYPO - U HV 46 LS − EP 2

EXP Gear Castrol Hyspin Castrol Spheerol

CASTROL Tection Extra
OILS AWH 46 ELP 2

Mobil DTE Mobilux

EXXON MOBIL Mobil Delvac 1 ESP Mobilube HD
10 Excel 46 EP 2

Shell Spirax Shell Tellus Shell Alvania Greases

SHELL Shell Rimula R4 L
S2 A 90 S2V 46 EP 2

CAUTION: 1) Fill the fluid reservoirs with the filters installed.

2) Use recommended fuels and lubricants only.
3) Use the hydraulic oils which specifications are as clean as ISO4406 18/13 or
above.

– 91 –
3. PERIODIC MAINTENANCE

3.7 Electric Wiring Diagram

– 92 –
CAUTION: Size of wires not indicated by letters are AV 0.85.
Color of wire Brown/ Green/ Blue/ Red/ White/ Yellow/ Blue/
B Black BrR GR LR P Pink RW WR YR LB
Red stripe Red stripe Red stripe White stripe Red stripe Red stripe Black stripe
Black/ Brown/ Green/ Blue/ Red/ Yellow/ White/
BR BrW GW LW R Red RY Y Yellow YW WG
Red stripe White stripe White stripe White stripe Yellow stripe White stripe Green stirpe
Black/ Green/ Blue/ Red/ Yellow/ Brown/
BW G Green GY LY RB W White YB BrY
White stripe Yellow stripe Yellow stripe Black stripe Black stripe Yellow stripe
Black/ Green/ Red/ White/ Yellow/
BY GB Gr Gray Lg Light green RG WB YG Sb Blue
Yellow stripe Black stripe Green strope Black stripe Green stripe
Green/ Red/ White/ Yellow/ Black/
Br Brown GL L Blue O Orange RL WL YL BG
Blue strope Blue stripe Blue stripe Blue stripe Green stripe
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.

– 93 –
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.
★ 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.
★ Maintain the level of charge above 75%.
★ In cold weather, it is desirable to start the engine
with the battery charged 100%. Do not try to start the
engine with less than 75%.

WARNING
• The battery contains diluted sulfuric acid, which 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 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 wear safely 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 when there is a danger of generating sparks.
• The inspection and handling of batteries should be carried out with the engine
turned off and the starter switch in the "OFF" 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.

CAUTION
The power-supply voltage of this machine is 24V.

– 94 –
4. SPECIFICATIONS

4 SPECIFICATIONS

(1) SV540D

Model SV540D
Weight: Vibrating power: Low 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)
Dimension: Gradability 62％ (32°)
Overall length 5,840 mm (230'') Rolling width 2,130 mm (84”)
Overall width 2,295 mm ( 90'') Minimum turning radius 5.6 m (221”)
Overall height 3,050 mm (120'')
Wheelbase 2,970 mm (117'') Engine:
Wheel Model CUMMINS “QSB4.5” Diesel Engine
Front Roll (dia. x width) with turbo chager
Smooth 1,530 x 2,130 mm (60” x 84”) Total displacement 4.460 litres (271.7 cu.in)
Rear Tire Rated output 119kW {160HP} / 2,200min-1
23.1– 26 – 8 PR (OR) Max. torque 624 N・m / 1,500 min-1
Performance:
Travel speed Tank capacity:
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Fuel tank 265 litres (70 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h ) Hydraulic oil tank 50 litres (13 gal)

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 95 –
4. SPECIFICATIONS

(2) SV540DF

Model SV540DF
Weight: Vibrating power: Low 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 48％ (26° )
Dimension:
Rolling width 2,130 mm (84”)
Overall length 5,840 mm (230'')
Minimum turning radius 5.6 m (221”)
Overall width 2,295 mm ( 90'')
Overall height 3,130 mm (123'') Engine:
Wheelbase 2,970 mm (117'') Model CUMMINS “QSB4.5” Diesel Engine
Wheel with turbo chager
Front Roll (dia. x width) Total displacement 4.460 litres (271.7 cu.in)
Smooth 1,530 x 2,130 mm (60” x 84”) Rated output 119kW {160HP} / 2,200min-1
Pad 1,708 x 2,130 mm (67” x 84”) Max. torque 624 N・m / 1,500 min-1
Rear Tire
23.1– 26 – 10 PR (OR) Tank capacity:
Performance: Fuel tank 265 litres (70 gal)
Travel speed Hydraulic oil tank 50 litres (13 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h )
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 96 –
4. SPECIFICATIONS

(3) SV540T

Model SV540T
Weight: Vibrating power: Low 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)
Dimension: Gradability 62％ (32°)
Overall length 5,835 mm (230'') Rolling width 2,130 mm (84”)
Overall width 2,295 mm ( 90'') Minimum turning radius 5.6 m (221”)
Overall height 3,110 mm (122'') Engine:
Wheelbase 2,970 mm (117'') Model CUMMINS “QSB4.5” Diesel Engine
Wheel with turbo chager
Front Roll (dia. x width) Total displacement 4.460 litres (271.7 cu.in)
Pad 1,600 x 2,130 mm (63” x 84”) Rated output 119kW {160HP} / 2,200min-1
Rear Tire Max. torque 624 N・m / 1,500 min-1
23.1– 26 – 10 PR (OR)
Performance: Tank capacity:
Travel speed Fuel tank 265 litres (70 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Hydraulic oil tank 50 litres (13 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 97 –
4. SPECIFICATIONS

(4) SV540TF

Model SV540TF
Weight: Vibrating power: Low 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)
Dimension: Gradability 46％ (25°)
Overall length 5,840 mm (230'') Rolling width 2,130 mm (84”)
Overall width 2,295 mm ( 90'') Minimum turning radius 5.6 m (221”)
Overall height 3,115 mm (123'')
Wheelbase 2,970 mm (117'') Engine:
Wheel Model CUMMINS “QSB4.5” Diesel Engine
Front Roll (dia. x width) with turbo chager
Smooth 1,650 x 2,130 mm (65” x 84”) Total displacement 4.460 litres (271.7 cu.in)
Pad 1,600 x 2,130 mm (63” x 84”) Rated output 119kW {160HP} / 2,200min-1
Rear Tire Max. torque 624 N・m / 1,500 min-1
23.1– 26 – 10 PR (OR)
Performance: Tank capacity:
Travel speed Fuel tank 265 litres (70 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Hydraulic oil tank 50 litres (13 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 98 –
4. SPECIFICATIONS

(5) SV540TB

Model SV540TB
Weight: Vibrating power: Low 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)
Dimension: Gradability 58％ (30°)
Overall length 6,250 mm (246'') Rolling width 2,130 mm (84”)
Overall width 2,800 mm (110'') Minimum turning radius 5.6 m (221”)
Overall height 3,110 mm (122'') Engine:
Wheelbase 2,970 mm (117'') Model CUMMINS “QSB4.5” Diesel Engine
Wheel with turbo chager
Front Roll (dia. x width) Total displacement 4.460 litres (271.7 cu.in)
Pad 1,600 x 2,130 mm (63” x 84”) Rated output 119kW {160HP} / 2,200min-1
Rear Tire Max. torque 624 N・m / 1,500 min-1
23.1– 26 – 10 PR (OR)
Performance: Tank capacity:
Travel speed Fuel tank 265 litres (70 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Hydraulic oil tank 50 litres (13 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 99 –
4. SPECIFICATIONS

(6) SV540FB

Model SV540FB
Weight: Vibrating power: Low 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)
Dimension: Gradability 43％ (23°)
Overall length 6,245 mm (246'') Rolling width 2,130 mm (84”)
Overall width 2,800 mm ( 110'') Minimum turning radius 5.6 m (221”)
Overall height 3,110 mm (122'') Engine:
Wheelbase 2,970 mm (117'') Model CUMMINS “QSB4.5” Diesel Engine
Wheel with turbo chager
Front Roll (dia. x width) Total displacement 4.460 litres (271.7 cu.in)
Pad 1,600 x 2,130 mm (63” x 84”) Rated output 119kW {160HP} / 2,200min-1
Rear Tire Max. torque 624 N・m / 1,500 min-1
23.1– 26 – 10 PR (OR)
Performance: Tank capacity:
Travel speed Fuel tank 265 litres (70 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Hydraulic oil tank 50 litres (13 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

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4. SPECIFICATIONS

(7) SV640D

Model SV640D
Weight: Vibrating power: Low 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)
Dimension: Gradability 50％ (27°)
Overall length 5,840 mm (230'') Rolling width 2,130 mm (84”)
Overall width 2,295 mm ( 90'') Minimum turning radius 5.6 m (221”)
Overall height 3,050 mm (120'')
Wheelbase 2,970 mm (117'') Engine:
Wheel Model CUMMINS “QSB4.5” Diesel Engine
Front Roll (dia. x width) with turbo chager
Smooth 1,530 x 2,130 mm (60” x 84”) Total displacement 4.460 litres (271.7 cu.in)
Rear Tire Rated output 119kW {160HP} / 2,200min-1
23.1– 26 – 8 PR (OR) Max. torque 624 N・m / 1,500 min-1
Performance:
Travel speed Tank capacity:
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Fuel tank 265 litres (70 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h ) Hydraulic oil tank 50 litres (13 gal)

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 101 –
4. SPECIFICATIONS

(8) SV640T

Model SV640T
Weight: Vibrating power: Low 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} {26,000kgf}
Dimension: Gradability 46％ (25°)
Overall length 5,835 mm (230'') Rolling width 2,130 mm (84”)
Overall width 2,295 mm ( 90'') Minimum turning radius 5.6 m (221”)
Overall height 3,110 mm (122'') Engine:
Wheelbase 2,970 mm (117'') Model CUMMINS “QSB4.5” Diesel Engine
Wheel with turbo chager
Front Roll (dia. x width) Total displacement 4.460 litres (271.7 cu.in)
Pad 1,600 x 2,130 mm (63” x 84”) Rated output 119kW {160HP} / 2,200min-1
Rear Tire Max. torque 624 N・m / 1,500 min-1
23.1 – 26 – 10 PR (OR)
Performance: Tank capacity:
Travel speed Fuel tank 265 litres (70 gal)
1st 0 – 6 km/h ( 0 – 3.7 mile/h ) Hydraulic oil tank 50 litres (13 gal)
2nd 0 – 10 km/h ( 0 – 6.2 mile/h )

NOTE: Gradability is the calculated value. It may vary with ground surface conditions.

– 102 –
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Ⓒ