No. 3498-36480-0 & Read this handbook thoroughly and understand the whole information contained before trying to operate, inspect and service your machine! OPERATING & MAINTENANCE INSTRUCTIONS MODEL HV Series MS Ue ms HV520 HV620 From HV520 + 5HV22 - 10101 HV620 — SHV23 - 10101 SAKAIPREFACE PREFACE This operator's manual serves as a guide for the use of your Sakai HV 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 the machine. Read this manual thoroughly and try fully understand the information before operating your machine. Keep this handbook at hand whenever you do your work. 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 MACHINE AND ENGINE IDENTIFICATION NUMBERS. 1 SAFETY NOTICES . 1 BASIC PRECAUTIONS FOR SAFETY 1.1 General Precautions . 4 1.2 Preparation for Safe Operation oe ne 1.3 Before Starting the Engine 7 1.4 After Starting the Engine. . 8 1.5 During Operation. . we aneeee g 1.6 Loading and Unloading : i seo ate etc ac ieee iac4 1.7 Transportation Se HO: 1.8 Handling the Battery ai fii Belore Servicing renee irene aritietieoeereeet tt Cece eeteneteerreier 2 1.10 During Servicing 14 1411 Safety Decals 16 2 OPERATION 21 Instruments and Controls . 7 Hf beet 18 244 Operator's station 0.2.6... eeee eens Bese 2.1.2 Instrument / Operating device . 219 2.2 Handling +. 22 2.3 Operation Ree eee eta ee Reser RHe eee tieestereaieesee eto 2.34 Before starting up......0.. 2... eee : ‘i 24 2.3.2 Starting the engine......... 0.2.2... Beene 22 5 2.3.3. After starting the engine . . - 26 2.3.4 Traveling. ... - 26 2.3.5 Stopping / Parking . ; ETSI eeitieai ieoinete eter ett 20 2.4 Vibratory Operation... 0.0... cece eee eveee neces edeee eee Hae: 2.5 General Rules for Operation........ : : eos 2.6 Operation of Unioader Valve. . . .. 29 2.7 Operation of Sprinkler System . +29 2.8 Adjustment of Scraper. Ree ee eee eee oe 3H 2.9 Precautions for Work. ... 0.2.0.6. 0ceeeeeee ees 3 2.94 Compaction operation eee fe vee 3H 2.9.2 When going downhill .. ... 23 2.9.3 Onaslope .3t 2.10 Applicable Jobs . . 32 241 After Operation ........ 7 Reo etHeet eee - 32CONTENTS 2:12_ Uoading and Unloading! sca ssc eerie rire earn eee rere gs 2.12.1 Use of a mobile crane. ad Eee ee ees eee eerste 212.2 Self-propelling. ... Sete eee eet : eee eee 2.43 After Loading the Machine........ eeeeacesnisciace rset 35 2.14 Operation in Cold Weather 36 2.14.1 Fuel oil and grease . 36 214.2 Buttery 36 244.3 Coolant 36 2.48 When the Cold Season is Over 37 2.16 Fora Long Storage Period 37 2.17 During the Storage Period . 38 2.18 When the Battery has Discharged. . 38 2.48.1 Connection and disconnention of booster cables. 39 2.49 Prevention of Engine Trouble due to Water Entering Engine Cylinder (Measures against Water Hammer) 40 2.19.1 Preventive measures against water entering : 40 2.20 Method to Open / Close the Upper Hood / Left Side Cover . 40 2.20.1 How to open the upper hood ee Mt 2.20.2 How to close the upper hood ‘i ee A 2.20.3 How to open the left side cover at 2.20.4 How to close the left side cover at 3 PERIODICAL MAINTENANCE 3.4 Precautions ......... See 3.2 Walk-Around Checking 3.3 Periodical Maintenance Points 3.4 Maintenance Procedure . (1) Every 10 service hours or daily. ... 2) Every 100 service hours (3) Every 200 service hours (4) Every 450 service hours (5) Every 500 service hours (6) As needed. . 3.5 Consumable Parts. 3.6 Feeding Water and Lubricants .. . 3.64 General rules 3.6.2 Refill capacity 3.6.3 Rating........2... 3.6.4 Recommended lubrications. 3.7 Electric Wiring Diagram. ....... .[CONTENTS 4 SPECIFICATIONS (1) HV520 (2) HV620 63 2. 64 i | j |MACHINE AND ENGINE IDENTIFICATION NUMBERS MACHINE AND ENGINE IDENTIFICATION NUMBERS When ordering parts or making inquiries about your machine, the following information is requested: (1) Machine model Indicated on the dashboard in the operator's station. (2) Machine serial number HV520 = 5HV22-OO0000, HV620 = 5HV23-OO000 (3) Engine identification number[ SAFETY NOTICES SAFETY NOTICES For the safe use of your machine, correct handling and periodical maintenance are of utmost importance. Thoroughly read the safety precautions described in this manual. Do not attempt to operate and maintain your machine until you gain a full understanding of these safety ‘statements. This manual covers the proper and safe method of driving and handling of this machine for its intended use. When this machine is used a manner, other than that 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 4 is orange). ACAUTION Calls attention to safety practices. If you fail to take proper precautions, you could be injured or cause damage to the machine (Symbol 4 is yellow).SAFETY NOTICES It is almost impossible for the safety notices in this manual and the machine to cover all the potential dangers. Keep alert to possible dangers not mentioned in this manual and on the decals. 7 Yaad Do not operate your machine before you read its operator's manual thoroughly. Incorrect operation can kill or cause injury. Itis your responsibility to operate the machine safety. 4x Non-approved modifications can pose safety-related problems. Before making any modifications, consult your distributor. For an injury or damage to the machine caused by non-approved modifications, Sakai accepts no responsibilty. + Basic precautions for safe operation of your machine are discussed beginning on page 4. 4 To operate and work with your machine, you must be qualified|_I, BASIC PRECAUTIONS FOR SAFETY 1 BASIC PRECAUTIONS FOR SAFETY 1.1 General Precautions @ Read thoroughly the operator's manual ) + 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, | Mf Obey the worksite rules Follow the worksite rules such as matters forbidden or to be attended to, and working procedures. 1 Wear protective clothing to suit the 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. + According to the type of jobs, wear safety goggles or mask. SOvOone 1 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. @ 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.& WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY | § Know 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. 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 itis safe to operate. Do not allows anyone to enter the work area except for authorized personnel + Always conduct the work paying attention to the workers around the machine. ar 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 en 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 shut down and the coolant cooled down. (For the radiator cap with a lever, lft 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. + Do not touch the muffler while the engine is running or immediately after it has been shut down. You can get burnedA WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ll 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 infiammables (combustibles). + When refueling, stop the engine and do not smoke. + The filler caps of the fuel and oil tanks must be kept tight. 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 handiing 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.& WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY 1.2 Preparation for Safe Operation Clean your machine + Do not place part, tools or unnecessary articles on your machine. + Keep the handholds free from muds, oil, ice or water, as they can cause slippage. ll 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 oll, 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. 1.3 Before Starting the Engine ™ Confirm that the hood and the door are closed + Before starting the engine, confirm that the hood and the door are closed securely. Check if the horn, lamps and electrical equipment function properly * Confirm that the horn, lamps and electrical equipment function properly. ll Before starting, make certain that each lever parking loc! in the neutral position and the is applied (parking lock lever in "APPLIED" position) ™@ When starting the engine, sound the horn and check around the machine for safety + Before starting the engine, make sure there is no one in the immediate vicinity and there are no obstructions around the machine.& WARNING: Negligence of these instructions can lead to accidents. {_1. BASIC PRECAUTIONS FOR SAFETY lt 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. ll Do not stand close to the exhaust gas pipe opening + Exhaust fumes are noxious if breathed in aasscseonaeicnitiiasneinnicaiinaiianmenicinenti 1.4 After Starting the Engine i Secure safety around the machine | + Confirm that nobody remains or no obstacles are left cover around the machine. Special attention should be ro paid to a blind spot. Sound the horn then, and start the machine after pausing a moment i Warm up the Engine + Do not put your machine into motion immediately after the engine has started, let it idle for several minutes unti it is at operating temperature. + Check under the vehicle for traces of spilled oil, fuel, water, etc. If there is any, take measures to prevent environmental pollution. Check the cause of spillage, and repair if necessary. @ 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, rectify the fault before traveling again. + Listen for unusual sounds, and check for abnormal temperature rise. if abnormal, park the machine in a safe location and find the source of trouble before operatingA WARNING: Negligence of these instructions can lead to accidents. { 1. BASIC PRECAUTIONS FOR SAFETY 1.5 During Operation @ Refrain from inattentive driving + Inattentive or hopeful driving is likely to cause serious accidents. Watch out for the driving direction and people working around the machine. Warn them by sounding the horn if any hazard is foreseen. 1 When changing the direction of travel + Secure the safety on the path in the travel direction. When travelling backward, exercise extreme care for people or obstructions. @ At night, carefully drive the machine + It becomes difficult to judge the distance to object when driving after dark. Drive the machine carefully at night at a speed fit to the lighting. Light the vehicle's headlight, and install additional lighting equipment, or other, if necessary, + Please be careful in the traveling direction of the obstacles and people. lm Repair as soon as possible if found to be defective + Ifthe 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. 1m When parking + Select level and hard ground. Be sure to apply the parking lock and chocks to the front and rear drums. Do not park or stop on a 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. Chock + Before leaving the machine, stop the engine by setting the F-N-R and parking lock levers at the neutral position @ and "Applied", respectively. + Remove the key from the starter switch. Chock& WARNING: Negligence of these instructions can lead to accidents. 1, BASIC PRECAUTIONS FOR SAFETY 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. + 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 Wooden block + 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, allow it to dismount from the ramps, correct the direction and try again + Do not use kinked, twisted or damaged wire ropes for crane or winch operation. Use ones with ample strength. + When lifting the machine, be careful to lift it perpendicularly. Application of night, left, forward, or backward lifting load on the hook is dangerous. The hook might bend or be damaged. + When loading is complete, fix the machine with wooden blocks palace under the drums and chains fastened to the machine. + Never steer the machine during loading and unloading; this is very dangerous. 1.7 Transportation + Follow required regulations. ~10-& WARNING: Negligence of these instructions can lead to accidents. 1, BASIC PRECAUTIONS FOR SAFETY 1.8 Handling the Battery @ When handling the battery Battery generates hydrogen gas which can explode. Do not allow any fire including lighted cigarette to approach or any action which may cause spark. ®A®S Battery electrolyte contains sulphuric acid. It will destroy clothing and skin. If it touches your clothing or skin, flush with large quantities of water, If swallowed, drink large amount of water, milk, beaten egg or vegetable oil, and get medical help. In case of eye contact, flush with clean water and seek 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. The battery generates flammable gases that can cause an explosion. Do not smoke close to the battery. Keep the battery away from flames, sparks and ignition sources. Inspect or handle the battery with the engine shut down and the starter switch in the OFF position. Keep metallic items such as tools away from the battery terminals. Loose terminals can cause sparks leading to an explosion. Secure the terminals tightly. Battery is for only starting this machine. Do not use it for any other purpose. Do not use or charge the battery with its electrolyte level remaining below the "Lower" mark (minimum electrolyte level). Continuing the use with the level remaining below "Lower" mark accelerates deterioration of the battery internals, not merely shortening its useful life, even causing an explosion. Immediately replenish with distilled water so it comes to between the Upper and Lower levels 1"& WARNING: Negligence of thes: 1, BASIC PRECAUTIONS FOR SAFETY _ structions can lead to accidents. 1 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 terminal. Never connect the positive terminal to the negative. + 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 Before Servicing @ Post a warning tag during inspection or servicing + Starting the engine or touching any lever inadvertently by any third person while the roller is under inspection or in service may lead to serious personal accident. + Attach the warning tag at @ conspicuous position on the control handle. If necessary, post it additionally around the roller as well ADANGER Do not operate ~12- | |& WARNING: Negligence of these instructions can lead to accidents. 1, BASIC PRECAUTIONS FOR SAFETY | Use proper tools + itis very dangerous to use damaged or deteriorated a 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 + Replace fuel hose and high pressure hydraulic 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. 3x Change any hose found to be abnormal even if it is within its recommended service interval. 1 With the Forward-Neutral-Reverse (F-N-R) lever placed in Neutral, apply parking brake and engage blocking ll Inspect or service your machine with the engine stopped + Use extreme care when servicing the machines with BO| the engine running such as cleaning inside of radiator. HEAT OFF on @ + One man should always be ready to stop engine. Use y if START y care not to touch any lever unless it is necessary. Service personnel should use care to prevent any part of his body or clothing from being caught by moving parts, lH Matters to be observed during replenishment of fuel, oil or grease + There is a risk of slipping on spilled fuel, oil or grease. Wipe it off immediately. Be sure to close the fuel, oil and grease caps securely. Never use fuel for washing. Replenish fuel, oil and grease at a well-ventilated place. + Entry of water into electric system may cause operation error or malfunction. Do not clean the control cover by water or stream. -13-& WARNING: Negligence of these instructions can lead to accidents. 1, BASIC PRECAUTIONS. FOR SAFETY @ Check the coolant level in the radiator + To check the coolant level, shut down the engine and allow the engine and radiator to cool down. Illumination + For inspecting the level of the fuel, oil, coolant and battery electrolyte, use burn-proof illuminations. A Failure to use this type of illumination can result in an A , explosion, 110 During Servicing lm 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. @ 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. Entry of water into electric system may cause operation error or malfunction. Do not clean the control cover by water or steam. @ When repairing the electrical system + For repairing the electrical system or for conducting welding, disconnect the negative cable from the battery to shut off the electricity. @ 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 and hydraulic hoses. An oil or hydraulic fluid spill can cause a fire. ~14- tes& WARNING: Negligence of these instructions can lead to accidents, _1. BASIC PRECAUTIONS FOR SAFETY 1 Be careful of high pressure hydraulic fluid + Bear in mind that the working equipment hydraulic systems are under internal pressure. Do not perform adding, draining, inspection or servicing of the hydraulic systems until the internal pressure has been rélieved. 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. B =) ain @ Use care when inspecting or servicing fan or belts in motion + Secure loose clothing and keep articles away that could 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. I 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. -15-A WARNING: Negligence of these instructions can lead to accidents. [_1. BASIC PRECAUTIONS FOR SAFETY 111 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. © 1355-19026-0 1. Operating Cautions “oro ea ho peas marl efor using he mahi Inco pean can esse ere iy Sat. Mis yor esponsbaly o opeae te mete sally Heopine macho dan aye ge museron ado: rece he Snoe of sping Foto ta salty le the wok st, 3. the sal sav ove pode ‘he warty of SA ey Insists om ot coer re ean re ot ache raofeaionwtout io apeeere 0 SAKN Hany edits. ‘uring roe oats amon ha racine. ‘han naar ero af onan For 2 rckitwih a cans ode town a arp itoring hasan hep, Caring age dayne les ‘uring artpran, pane ck, gs, he eng, as wh ep. ‘en owing open oe lon fe uta vavetsarioa*ed on boon atc te ‘cau pump. lero. 2s th nowt ve (arn ore54- 68) Who th rsa vate i opening, bs care osause to race moos ‘Wt th ood oor, do a star te ei do hal wrk. 2, Staring the Engine ‘hack each is oes machine age sn sera eoerng ble operation ‘Chek ath Reve rest seston in OFF pst, Push sonntne frie ero erat inte cal season de pees! sb 10 scans bebe sarin he ene Tum th ane vacnaSTART™ When gr ha sere. on ean ihe bzzs sound cantons a stg sep be argne an ha ange “testing rune eng ating sina ar up 8. Traveling ‘ing epee, ue ta angie othe sr rotate maine ‘Sctopootasione te onsite sonen te A veto naa “parte ie grtngiat opasbon tH) ‘oh Eon" Fo°F a the rnacie wlan oa reaewan epoch “oth reo, rs i tre oN pan 4, Stopping “Sele Poe real ao engine ow toa spat “Tho erin sped by au up He traveler et Then no ar niche OF 6, Parking Cautions ‘St te ies te lover toe net! on hrc ae enh parking ee in? () I posten - ow a engine a casi runing ta ior aoa Srna ‘Dung aay the macht parkng lexan tp he engin ema he machin ay. ‘tare engoe sepong. te aie te have kena ne mac -16- @ 3998-16499-0 A WARNING Zt AE ‘Do not open the hood with the engine running. Contact with ot parts wil cause burs, -Contact with rotating parts will cause severe lun sss @1472-19010-1 Don't stop the engine during the operation of the F-R lever. @ 2998-96001-1 A_CAUTION USE SPECIFIED FUEL ONLY *Use of other than the specified fuel may resultin damage to the engine. Please refer to the manual for detals senses& WARNING: Negligence of these instructions can lead to accidents. 1, BASIC PRECAUTIONS FOR SAFETY(2, OPERATION __ 2 OPERATION 2.1 Instruments and Controls 2.4.1 Operator's station | @ Forward-Neutral-Reverse (F-N-R) lever @) Horn switch @ Light switch © Vibration switch @ Safety system knob @ Left side cover opening/closing knob @ Throttle lever @ Upper hood opening/closing "T" knob © Starter switch ® Sprinkler cock © Parking lock Lever ® Sprinkler drain @ Control handle lock pin @ Hour meter ~18-2. OPERATION 2.1.2 Instrument / Operating device For safe execution of your job, fully understand the role and function of the systems involved Hour meter The hour meter counts operation time of the machine. Reading on the meter provides standard times for periodical inspections, refiling of oil, servicing, or other, on the machine. Forward-Neutral-Reverse (F-N-R) lever This has three functions; Starting (forward or reverse), stopping and speed changing steplessly. Moving the lever forward or reverse causes the roller O @ Neutral to travel accordingly and placing it in neutral position causes the roller to stop. @ Reverse NOTE: Traveling speed is in proportion to the angle of lever tited bration switch | 1) Vibration is generated when switch @ is set to the ON position. 2) Vibration is shut down if set to the OFF position. IMPORTANT + Do not operate the vibration 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. 192. OPERATION Safety system knob When depressed, it causes the roller to travel stop. Fuse WARNING Be sure to turn off the power (starter switch OFF) before replacing the fuse. The electrical equipment and wiring will be protected from burning. Replace the fuse when it is corroded and covered with white powder or when it is not firmly set in the fuse holder. Replace the fuse with a new one with the same capacity. -20-2. OPERATION Starter switch Starts and stops the engine. HEAT: When the engine is cold, hold the starter switch BO] in the HEAT position for about 10 seconds. The HEAT OFF on @ key will automatically return to the OFF position. | / START Tum the key to the START position to start the \ engine. \ OFF: — 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. ON: The charging circuit and lamp circuit are charged with electricity. Leave the key in this position after the engine has started. START: The engine is cranked and gets started. The moment the engine has started, release the key. It will automatically return to the ON position. | Horn switch Horn sounds with the horn switch ®) pressed. ;7— IMPORTANT Horn is operative with the starter switch in the ON position. Throttle lever Shifts the engine RPM. The engine RPM increases when depress throttle fever all the way down. et IMPORTANT ——, 8 Full throtie Be sure to raise the idling speed of the engine to the highest during work. -21-2. OPERATION Light switch 1) Set the switch @) in the ON position to turn on the light. 2) Set the switch @ in the OFF position to turn off the light. WARNING + The light comes on when the start switch is set in the ON position. * Do not turn on the light while the engine rotates at a low speed. 2.2 Handling Control handle Can be folded for transportation. 4) To fold the control handle: With the lock pin @ pulled back to release the lock, lift the control handle. When the handle is in fully folded position, the pin automatically locks the handle. 2) To set the control handle to the operating position: With the lock pin @ pulled back to release the lock, swing down the contro lever till it comes to the operating position. The lever is automatically locked there. NOTE: When the control handle is folded, the back side of the control handle is the back end of the machine. Watch the control handle when loading the machine or placing it in a yard to prevent the handle from contacting other objects. CAUTION When having folded up the control handle or returned it to the operating position, always check if the lock pin @ is locked. ~22-2. OPERATION IMPORTANT Do not clean the rear of the control cover by high-pressure. Otherwise, it may cause any error of system. Parking lock lever For parking, place the parking lock lever © in (®) position. If the lever is difficult to operate, try to move the roller slightly forward or reverse. For traveling, be sure to return the lever to (®) position. NOTE: If the parking lock lever is hand to lock, propel the machine slightly forward or backward, WARNING + When parked, it is absolutely important that the parking lock lever © is in (©) position. + Never shift the lever to (©) position while the roller is in motion (Do not use it for a service brake). 23ves 2. OPERATION 2.3 Operation 2.3.1 Before starting up [F-N-R lever ] Make sure that F-N-R lever is in neutral, vibration lever @ in OFF and parking lock © in (®) position respectively. © Forward [ Vibration switch ] {Parking lock lever ] WARNING + Make sure that there is no obstruction around, before starting up. + Be sure to place the F-N-R lever in Neutral before starting up. ~242. OPERATION 2.3.2 Starting the engine 1) Place fuel cock in “O" (open) position. > IMPORTANT Placing the fuel cock in O (open) position causes automatic air bleeder to actuate to remove residual air from piping or filter. Wait for 20 seconds before starting the engine. 2) Depress throttle lever all the way down. Stop. 4 CS) Fu throtie 3) With starter switch turned to ON, make sure that oil pressure warning buzzer sounds. If not, locate the cause to correct it 4) If engine is cold, preheat it for about 10 seconds. Oo HEAT OFF on &) 5) Turning starter switch to START position causes engine to start. Releasing the switch as it starts, causes the switch to move back to ON position automatically -25-2. OPERATION 2.3.3. After starting the engine After starting, do not operate the machine immediately but observe following: 1) Warm up the engine for a few minutes. 2) Make sure that color of exhaust is normal and no abnormal noise or odor is noticed. 3) During or immediately after operation, coolant in radiator remains hot and it is dangerous to remove the cap. Be sure to stop engine and allow to cool down before removing the cap carefully. ACAUTION + After engine has started, try not to turn the starter switch. | + If oil pressure warning buzzer continues to sound after engine has started, | stop the engine immediately and check the level of engine oil. + Do not operate starter motor continuously any more than 15 seconds. + If engine fails to start, allow an interval of 30 seconds or longer. 2.3.4 Traveling WARNING * When staring, operate the horn after securing the safety around the machine. | + Pay careful attention to obstacles behind, when driving in reverse in particular. ACAUTION While travelling, do not turn the starter switch OFF. 1) Place parking lock lever @) in (®) position. -26-2. OPERATION | 2) Tilting the F-N-R lever forward or reverse, causes your machine to travel accordingly. AACAUTION Be sure to operate the lever slowly. NOTE: The travel speed can be controlled by the F-N-R lever. 2.3.5 Stopping / Parking WARNING a ~ * Avoid abrupt braking, Leave enough space for braking safety. | * Avoid parking on a grade. + Before leaving the machine, be sure to stop the engine, shift the parking lock | lever to the (©) position, and apply the blocks. Remove the starter key. | 1) Move the F-N-R lever to the neutral position ®, and the machine will stop. CAUTION For normal braking, move the F-N-R lever to the neutral position. @® Reverse 2) Place parking lock lever in (®) position. 3) Run the engine unloaded at idling speed for 2 to 3 minutes. 4) Returning throttle lever all the way causes the engine to stop. 5) Place fuel cock to C (Closed) position. 6) Turn the starter switch to OFF position. -27-2. OPERATION WARNING — When the engine stops on a slope, return the F-N-R lever to the neutral position ®, and set the parking lock lever in the (®) position and apply the blocks to prevent an accident due to the falling of the machine by its own weight. ACAUTION — Whi travelling, do not turn the starter switch OFF. 2.4 Vibratory Operation 1) Vibration is generated when switch © is set to the ON position. 2) Vibration is shut down when switch @ is set to the OFF position. -—— AWARNING | ‘Set the F-N-R lever to the neutral position @ when the engine has stopped. Unexpectedly during the vibratory operation on a slope. This prevents the roller from creeping down the slope. IMPORTANT + While the machine is standing still, do not engage vibration. + If stranded in mire during compaction work, stop the vibration immediately. 2.5 General Rules for Operation 1) While traveling, have the contro! handle pin locked completely. 2) Before lifting up your machine, make sure that the handle is locked with the lock pins. 28 - tne2, OPERATION 2.6 Operation of Unloader Valve For towing your machine with engine stopped, operate unloader valve in the following manner. (Unloader is located underneath hydraulic pump) (Use 17mm spanner) [For towing] (Unloaded) Open the unload valve turning it clockwise by a turn [For normal travel] (Loaded) Close the unload valve turning it counterclockwise. Tightening torque: 5.4 ~ 6.8 Nem WARNING On a slope, chock the wheels and use extreme care when handling the unloader lever and towing the machine. 2.7 Operation of Sprinkier System ACAUTION —— ——— In cold climate, drain water completely after work to prevent freezing. | : \_. Close - Rear wheel 4A SF Eom | IMPORTANT + Before starting sprinkler, check the level of water in tank and top us as necessary. + Be sure to always use fresh water for sprinkling operation. Turning sprinkler cock to OPEN position allows sprinkling operation to start. -29-2. OPERATION Draining procedure 1) Remove drain cap off the tank to permit to drain. oS an 2) Turn cock to OPEN position to drain the hose. [ee i TF Drain cap \ A I How to remove the sprinkler pipe 1) While holding down the bottom of sprinkler pipe mounting bracket by a thumb, pull out the sprinkler pipe. 2) Disconnect the hose attached to the sprinkler pipe. How to remove the sprinkler filter 1) Drain water from the sprinkler tank, 2) Inserting a hand in the sprinkler tank, pull out the filter from the bottom left in the tank. CAUTION + When removing the sprinkler filter, put on clothing and protectors fit to the work. There is a risk of hurting fingers or hand by the feed-water inlet or filter of sprinkler, + Install or remove the sprinkler filter gently. Rough handling could damage it. + If the sprinkler filter is damaged in the tank or damaged it during handling, broken pieces of filter could clog the sprinkler circuit, making it unable to sprinkle water properly. When the filter is damaged, remove the drain cap and clean the inside of sprinkler tank sufficiently. ~ 30{ _ 2. OPERATION 2.8 Adjustment of Scraper Loosen blade mounting bolts ® and adjust the clearance of scraper blade to 2 ~ 3mm, before tightening the bolts again. 2.9 Precautions for Work 2.9.1 Compaction operation @ Do not operate the vibrator on hard location + Do not work the vibrator 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. 1 Change the direction of travel gently + When changing the direction of travel during asphalt mix compaction, slowly shift the F-N-R lever. 2.9.2 When going downhill I Use the F-N-R lever + Run slowly by the operation of the F-N-R lever even if the travel distance is short. MH Use the engine brake + Go downhill by applying the engine brake along with the F-N-R lever operation. 2.9.3 Ona slope @ Working on a sidehill + Work in an uphillidownhill direction, and avoid working on sidehill with the machine inclining sideways. EEA EEE eee Eder EEE ee PaEd EEE Ea PREECE eee ene2! 2. OPERATION : | 10 Applicable Jobs 1) The machines do a variety of jobs as listed below. + Rolling compaction + Vibratory rolling compaction work 2) The roller can be used for the following applications, which can be classified as follows according to the names. : Work + Asphalt road paving + Construction of forestry and farm roads + Dust removal treatment for road + Foundation building + Road improvement + Construction of sidewalk, shoulder and + Embankment construction gutter foundation Dam construction Material to be compacted Asphalt pavement + Soils Crusher run + Slag Cement concrete + Soft rock Sands Layers to be compacted + Surface course, Binder course + Embankment + Base course + Shoulder + Subgrade + Sidewalk 2.11 After Operation 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, of frozen dri 1) 2) 3) 4) ums: 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. Park the machine on a hard and dry surface. If such a place is not available, cover the ground with hard plates. Low temperature will cause a significant reduction of battery efficiency. Cover batteries or take them off from the machine and store in a worm place for the following day's operation. To prevent freezing, drain water from the sprinkler system (See page 30). 32-2. OPERATION IMPORTANT + Insufficient draining of water can cause troubles or damage to the system. + If pressurized water is used for washing the machine, exercise caution no to allow water to penetrate into the exhaust pipe. The engine can break down. 2.42 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. + If the engine stops while self-propelling on the rumps for loading or unloading, return the F-N-R lever to the neutral position immediately. Failure to do so will cause the roller to creep down the rumps. For loading and unloading, use ramps or a proper loading stand. -33-2. OPERATION 2.42.1 Use of a mobile crane 1) Before lifting the roller, check the mobile crane in accordance with the specified check lot, 2) Check the lifting wire ropes to see if they are in good condition and have enough capacity to lift the roller. 3) When lifting, set the stabilizer of the crane on the planking sheet under it. 4) The truck driver who transports the roller must make sure that the parking brake of his truck is applied positively and al tires are chocked. 5) When lifting, the crane operator and other workers must strictly obey hand signals. 6) Engage the wires to the lifting hook of the roller. Conduct loading or unloading slowly keeping the machine well-balanced. 7) Perform loading or unloading slowly being careful not to allows the roller and wire ropes to touch obstruction 8) Loading the machine in the correct position on the truck bed. -— AWARNING | + Exercise sufficient care so that the hook on the crane or wire rope will not strike against the handle or lever. + Lift an object perpendicularly, and avoid transverse, vertical, or slantwise as to prevent danger. 34-2.42.2 Self-propelling 1) 2) 2. OPERATION. 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. WARNING Make certain that rumps and roll surfaces are free from water, oil and mud, etc. If they are noticeable, remove them. 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. Making sure the machine has been loaded in the proper position on the truck, set the F-N-R lever to the neutral position @ and shut down the engine. 2.13 After Loading the Machine When the machine has been located property on the trailer, tie it down as follows: D) Set the parking lock lever to the (®) position. ‘When loading is complete, put wooden biocks at the front and rear of the rolls. Anchor the front and rear of the roller to the truck with wire ropes and suitable ‘two hooks to prevent the machine from moving. When unloading, check to see that the roller has slipped out of place or is floating, before removing ropes etc. which fasten the roller the track. 35 / Wooden block Forward run at _low speed rd Back at i |e. % low speed h >»[_2. OPERATION 2.14 Operation in Cold Weather In cold weather, take the following measures to prevent troubles such as starting difficulty and coolant freeze-up. 2.141 Fuel oil and grease Use fuel and oil with low viscosity. See "Rating" on page 60. 2.14.2 Buttery AwWarNING 1 + Batteries generate explosive gases. Do not use an open flame close to batteries. + The battery electrolyte is corrosive. Keep the electrolyte away from your eyes and skin. If you are affected by the electrolyte, flush with large quantities of water and get medical help. When the temperature decreases, the battery capacity will lower, possibly freezing the electrolyte. Keep the battery in a satisfactory condition at all times, and pay attention to heat insulation for satisfactory start-up on the next morning, The hydrometer atop the battery permits confirmation of the condition of the battery. Green......... Satisfactory White Charging is necessary. Red. Replacement is necessary. 2.14.3 Coolant WARNING Do not bring open flame to the antifreeze or do not smoke when handling it. It is inflammable. ACAUTION Never use methanol-, ethanol- and propanol-base antifreeze. 362. OPERATION | Always mix and use clean water (soft water) and antifreeze liquid (long-life coolant) as cooling water. For the mix ratio, refer to the following table. Ambient temperature Always Amount of anti-freeze 0.62 (0.46 gal) Amount of coolant 0.68 (0.46 gal fae Ratio | 50% Our vehicles are filled with a long-life coolant (non-amine type). The validly of the antifreezer is for two years. Use non-amine type long-life coolant when changing coolant. 2.15 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 60. 2.16 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) Cover the battery after disconnecting the negative cable or take off the battery from the machine and store in a safe place. 4) If the temperature is expected to go down below 0°C, check the specific gravity of the coolant. 5) Completely drain the sprinkler system. 6) With the F-N-R lever placed at the neutral position @, Vibration switch at the OFF position, have the parking lock lever set to the (®) position. 7) Chock the machine. 8) Remove the starter switch key. -37-[_2. OPERATION _ 2.17 During the Storage Period > AWARNING If necessary to operate the machine for anti-corrosive purpose in closed area, | ensure good ventilation keeping windows and doors open to prevent gas [ poisoning. During storage, operate the machine at least once a month to prevent the oil films on the lubricated parts from deteriorating and to change the batteries. 2.18 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, | | | Disconnent with negative cable first An explosion will result. When connecting the terminals, make certain that they are tight. -38- BEE EEE Ce re ea eee reeeCe Cee en eeee Ce Cerro CeCe ere eee CeCe eee eee Cee ea eee Ce ee Hea2. OPERATION 2.18.1 Connection and disconnention of booster cables ‘When jump-starting the engine, connect the booster cable as follows: @ Connection of booster cables 1) Connect one end of the positive booster cable ® to the positive @ terminal of the battery on the machine. 2) Connect the other end of the positive booster cable ® to the positive @ terminal of the booster supply. 3) Connect the negative booster cable ® to the negative © terminal of the booster supply. 4) Connect the other end of the negative booster cable ® to a good earth of the engine block of the machine. 1 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. + Do not allow the positive @ terminal to make contact with negative © terminal when connecting the booster cables. + Wear safety goggles when jump-staring the engine. + Do not allow the machine to make careless contact with the booster supply. + Do not make wrong connections. Connect the negative © cable to the engine block earth far away from the battery, as sparks may occur when connecting. { =39- Booster supply Batteries of the machine Connect to the engine block earth of the machine Batteries of the machine EO) Booster supply Disconnection from the engine block of the machine2. OPERATION : | 7 AcAUTION ~ + 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. + Connect the clips positively. 2.419 Prevention of Engine Trouble due to Water Entering Engine Cylinder (Measures against Water Hammer) For prevention of engine trouble due to water entering the engine cylinders, follow the instruction below. 2491 Preventive measures against water entering When washing the machine, refrain from spraying pressurized water directly on the exhaust outlet. Otherwise, take measures to prevent water entering the outlet by sealing it with a cover, for example. 2.20 Method to Open / Close the Upper Hood / Left Side Cover The operator's manual is stored in the engine room, in front of the spray water tank. Operation manual storage plac: ~40-“2. OPERATION | 2.20.1 How to open the upper hood + Turn the T-type knob atop the upper hood counter- clockwise to release the upper hood lock. | + Pull the T-type knob upward, and open the hood til it touches the stopper. + If you release hand, it will be fixed in the open state by the weight of hood. 2.20.2 How to close the upper hood + Pulling up the hood slightly in the opening direction, slide the upper hood stopper knob toward the rear | of vehicle so that the upper hood stopper lock is released. | + Close the upper hood slowly. When it is closed | completely, turn the T-type knob clockwise to lock the upper hood. | | | 2.20.3 How to open the left side cover + Insert a finger in the knob hole of left side cover, and | slide the knob toward the front of vehicle to release the lock. Pull the cover toward the left of vehicle to | open. 2.20.4 How to close the left side cover + If you close the left side cover till it touches the stopper, the cover is locked. WARNING | Close the hood before starting the engine. 413. PERIODICAL MAINTENANCE 3 PERIODICAL MAINTENANCE 3.1 Precautions 4) Inspection and maintenance Whether or not the inspection service and lubrication are performed at the correct regular intervals exerts significant influence of the occurrence of trouble and service life of the machine. In this manual, typical intervals for inspection and service are given. However, flexibility should be introduced 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 results. Note that supply and replacement of filters, elements, fats, and oils are important. 2) 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. Change oil while its temperature remains high after operation. 6 For a long-term storage, fill the fuel tank, lubricate necessary points and run the machine for more than 20 minutes once a month. 7 _ In 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, a 42PERIODICAL MAINTENANCE 3) Periodical 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 wear, while 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 maintain their perfect function. If any abnormality is detected such as crack, deformation, wear or oil leakage, go ahead and replace them even if itis within scheduled replacement time. EA eee aoe Periodical replacement |] Replacement Ht See eee maintenance part period Pee Master eyindor Seals (ubber paris) 2 years Wheel oylinder Seals (udber parts) 2 years 1 Brake system Brake hose 2 years Brake piping parts ‘Air hose 2 years Operating paris Cable 4 years Orbitrot Seals (rubber paris) 2 years Hydraulic piping parts | Hydraulic hose 2 years 2 Steering system Steering cylinder Seals (rubber parts) 2years Hydraulic pump Seals (uber parts) 4 years Axle Seals (rubber paris) 4 years Travel pum Seals (rubber paris) 4 years 3 Power transmission ane ee 7 system Travel motor Seals (rubber paris) 4 years (inclusive of axte) Hydraulic piping parts | Hydraulic hose 4 years Isolation rubber | teolation rubber itselt 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 yoars | Radiator hose 2 years 6 Cooling system Piping parts |_ Radiator drain hose 4 years 7 Gontrol related parts | Cable parts | cable parts 4 years Intake hose 2 years 8 Intake system Piping parts CAC hose 2 years 8 Flood system Hydraulic piping parts | Fuel hose 4 years 43 -3. PERIODICAL MAINTENANCE _ ACAUTION With a new machine, adjust the drive belt (P.50), change the engine oil (P.51) and adjust the fan belt (P.52) after 20 hours of operation for the first time only. Check the electric wiring at a regular interval not exceeding one month: 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 fed above, if there are some trouble on the parts at periodical inspection or daily check, replace them as soon as possible._3. PERIODICAL 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 item as shown below: Hydraulic oil tank Shockmounts: * Condition’ * Unusual wear + Damage “+ Fuel level | + Oil level and leakage | + Air cleaner clogging Hydraulic system and coupling + Radiator coolant leakage = Oil leakage and level | Parking lock lever A * Function | kK Drum * Loose bolt For servicing the engine, See the separate engine manual.|_3. PERIODICAL MAINTENANCE 3.3 Periodical Maintenance Points For servicing the engine, See the separate engine manual. ~46 —3. PERIODICAL MAINTENANCE Interval | Ret Item Service | Lubricant | arty Hydraulic oif tank | Check oll level, add as necessary Hydraulic ol! | 4 Battery Check hyérometer | 1 eee Air cleaner heck or clean element 1 or daily cq | Fasine rank case | Check allove, ade as necessary, leak Engine oil 1 Fuel tank Check fuel level, add asnecessary, leak _| Diesel ivel 1 Radiator Check coolant level, add as necessary, leak | Coolant 1 ® | Drive batt Check looseness and adjust 2 Air cleaner: Clean or replace element | 1 Gooling fan [ Check for cracks 1 Sorubonours | qq [Ensine crankoase | Change ol Engine oil 1 Engine crank case | Clean element 14 Fan belt ‘Chock looseness and adjust 1 Fuel fter Clean 1 © | Hydraulic oifiter | Replace element | 1 | 80 200, Tg Resicton gears App ase [Grease 2 | Fuel tank Clean { 1 i Every 450, ay [Eur Replace element Hee 1 service hours Radiator Clean inside iz | eee tears | @ | Hydraulic ol tank | Change oil and clean inside Hydraulicoll | 4 | Every yearor | | aftercleaning | € | Aircloaner Replace element fa i Gtimes | Bron 2 veers | gp | Fanbot | Change bert 1 Every 2years_| @ | Radiator ‘Change coolant Coolant 1 @ | Sprinkler pipe lean or change 2 Shock mounts ‘Check cracks 4 “Parking lock lever __| Check conditions - 1 | @ | Sprinkiertank | Clean inside i | 1 | As needed Safety system knob _| Apply grease Grease 1 | Scraper ‘Adjust or replace blade 4 Control handle ‘Apply grease Grease 1 Radiator Clean 1 Electric bulbs Blowout check Beet 47 -L 3.4 Maintenance Procedure ™ For servicing the engine, see the separate engine manual. (1) Every 10 service hours or daily @ | Hydraulic oil tank Filler port 1) Check oil level with level gauge. 2) Level is proper when it is seen in the middle of gauge. 3) Ifinsufficient, replenish through filler port. @ | Battery 1) Check the condition of the battery and replace it as necessary. Check the color of the hydrometer atop the battery to confirm the condition of the battery, ae Satisfactory Charging is necessary. Red.......... Replacement is necessary. 2) Retighten any loosened terminal and coat it lightly with vaseline or grease for prevention of corrosion ® | Aircleaner = See the separate engine manual. 1) After removing dust from cup, wipe the interior to clean. 2) Check the condition of the element. If the element is clogged, clean the element by tapping it lightly or with compressed air blown from inside to remove dust. Air cleaner element AAWARNING ~ 1 Exercise caution not to get a speck of dust in your eye. 48 -3. PERIODICAL MAINTENANCE NOTE: Air cleaner should be renewed every year or after six cleanings. IMPORTANT - + Where operating environment is dusty, cleaning should take place in more frequent interval. * Any element which has been damaged or has hole in it should be replaced with new one. ® | Engine crank case With engine positioned horizontally, Check oil level. Replenish if the level is not in between the marks on gauge. @® | Fuel tank Check fuel level with fuel gauge. WARNING For refueling, park the machine on a level and solid surface. ~49-3. PERIODICAL MAINTENANCE @® | Radiator Coolant filer port Make sure that coolant is up to the neck of filler port. In not, replenish, AAWARNING Try not to remove radiator cap while coolant | is hot. (2) Every 100 service hours @ | Drive belt 1) Checking the tension: Tension of this belt is proper if it slacks 2 to 3mm when depressed at its midway with a force of about 3kq. 2) Adjustment: With pump bracket mounting bolts @ (2 locations) loosened, loosen the nut of adjust bolt © and adjust tension using the bolt, before tightening those loosened bolt and nut again. IMPORTANT With a new machine, V belt tension should be adjusted after 20 hours of operation as an exception for the first time only. @ | Aircleaner ™ See the separate engine manual. 1) After removing dust from cup, wipe the interior to clean. 2) Clean the element by tapping it tightly or with compressed air blown from inside to remove dust. -50-3. PERIODICAL MAINTENANCE WARNING | Exercise caution not to get a speck of dust in your eye. NOTE: Air cleaner should be renewed every year or after six cleanings. IMPORTANT + Where operating environment is dusty, cleaning should take place in more frequent interval. * Any element which has been damaged or has hole in it should be replaced with new one. Cooling fan ™ See the separate engine manual. Check the cooling fan and replace if damage. | Engine crank case | = See the separate engine manual. 1) Replace engine oil. 2) Remove drain plug to allow oil to be drained while oil temperature remains warm after operation. 3) Tighten drain plug and fill oi. AWARNING When draining a hot oil, use care not to get burned. IMPORTANT For a new machine, change oil at 20 operating hours for the first time only. 4) Clean the oil filter by diesel fuel. —51-_3. PERIODICAL MAINTENANCE Fan belt ™ See the separate engine manual. 1) Checking the belt tension: Belt tension is proper if slack is 5 to 10mm when depressed between the pulleys with thumb. 2) Adjustment With nut loosened, turn tension bolt clockwise to Increase tension before tightening the nut securely. NOTE: Change the fan belt every two years or every 500 hours. ;—— IMPORTANT —— With a new machine, V belt tension should be adjusted after 20 hours of operation as an exception for the first time only. @ [Foe itr ; ea ie = See the separate engine manual. 1) With filter cup removed, remove any dust or water accumulated at the bottom. 2) Rinse filter cup and element in fresh Gas oil Filter cuy -52-(3) Every 200 service hours © | Hydraulic oil filter Replace filter cartridge @ | Reduction gears Apply grease to reduction gears for both front and rear roll ® | Fuel tank See the separate engine manual. Clean the inside of the fuel tank and remove the sediment. -53-3. PERIODICAL MAINTENANCE (4) Every 450 service hours ® | Fuel filter = See the separate engine manual. Replace the fuel filter element. Fuel flier mounting bott Retaining \ Filter cup. ® | Radiator ™ See the separate engine manual. Clean the inside of the radiator. NOTE: Change the cooling water every two years. (5) Every 500 service hours Hydraulic oil tank | 1) Remove drain plug of hydraulic oil tank while oil remains warm and drain oil. 2) After cleaning the tank interior, fill the tank with new oil to specified level 3) Start engine and run it for 2 to 5 minutes at idling speed. After making sure that bubbles have _— Oil filter port Level gauge — Drain plug disappeared from oil, stop engine and check the oil level again, WARNING | When draining a hot oil, use care not to get burned. -54-3. PERIODICAL MAINTENANCE (6) As needed Sprinkler pipe 4) Remove the sprinkler pipes from the clamp. 2) Remove the cap of the both ends. 3) Clean inside of the pipe with water and remove the sediment at the holes of the pipes. @) | Shock mounts ‘Check the rubber blocks for cracks, and their mounting bolts for looseness. @ | Parking lock lever | Check the function smoothly, when the lock lever is operated. @ | Sprinkler tank 1) Open the drain cap. 2) Drain the sediment from the tank with water fed from fill hole. ® | Safety system knob Apply grease to pipe. -55-3. PERIODICAL MAINTENANCE | | ® | Scraper Loosen blade mounting bolts ® and adjust the clearance of scraper blade to 2 ~ 3mm, before tightening the bolts again Replace if damaged UH {® | Controt handle Apply grease to control handle and lock pin, B® Radiator | = See the separate engine manual. Clean the fins to eliminate clogging, - 56 -3. PERIODICAL MAINTENANCE ® | Electric bulbs Make sure that the electric bulbs light up or blink by operating switches @) on the control cover. If they do not light up, replace them with new ones. ~57-. PERIODICAL MAINTENANCE 3.5 Consumable Parts Replace the filter element, air cleaner element, or other consumable parts, at times of periodic inspection or maintenance, before their wear limits expire. Take care to replace consumable parts securely so as to use this machine economically. Always use SAKAI genuine parts for replacement. Parts numbers are subject to change for improvements of product. When placing orders for parts, report the machine model and serial number (chassis No.) to our sales agent or specified service factory in order to check the latest part numbers. Replacement period Replacement Consumable part tem PartNo. sentetttn, | “ster ours Remark 2 Year) of operation ee (Hour) Fuel fiter element 4032-93003-0 450 Air cleaner element 4032-93004-0 Every 6 times of cleaning Suction filter element (Hydraulic oll) 4223-62001-0 200 Wash or replace Battery 4916-46000-0 eeiace oe 42B19R required 583. PERIODICAL MAINTENANCE 4032-93003-0 Fuel filter element[_3. PERIODICAL MAINTENANCE are 3.6 Feeding Water and Lubricants 3.6.1 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. 3.6.2 Refill capacity Replenishing F | Capacity in liters (gal) ype I Point j HV520/HV620 Fuel Tank Diesel fuel 4.8 (1.2) Engine oil pan Engine ol | 1.30.3) Hydraulic oil tank Hydraulic oil 10.6 (2.7) Radiator Coolant 1.2 (0.3) Sprinkler tank Water 35 (8.8) 3.6.3 Rating Ambient temp. and applicable viscosity rating bres Service - Applicable classification | -15 ~ 30°C 0 ~ 40°C 5~ 55°C standards Cold Moderate Tropical Engine oil | API grade CD | SAE 10W-30 | SAE 10W-30 | SAE 40 | MIL-L-2104C ISO-vG32_| 1SO-VG32 | ISO-vG68 Hydraulic oll | Wearresistant | Soi t4o | overvii40 | overvitio | ‘80-3448 Grease Lithium type extreme pressure NLGI-2 Ambient temp. -15 ~ -10°C Ambient temp. -10 ~ 55°C Fuel *! Diesel fuel *2 Diesel fuel ASTM + D975 No.1-D ASTM + D975 No.2-D $15 or $500 $15 or $500 Vi: Viscocity Index 1 For EPA regulation: Diesel fuel ASTM + D975 No.1-D S15 ONLY *2 For EPA regulation: Diesel fuel ASTM * D975 No.2-D $15 ONLY - 60 Dias3.6.4 Recommended lubrications 3. PERIODICAL MAINTENANCE Fees Lubricant Eengine oil Hydraulic oil Grease oll Hag eee API-CD VG 46 NLGI-2 MULTIFAK EP CHEVRON _ RANDOHDZ — | (p16 GREASE EP) BP os Bartran HV Energrease LS-EP cw 30 Castrol Spheerol CASTROL (plese! X) Castro! Hyspin AWH nd Shell Alvania SHELL Shell Rimula Rt Shell Tellus $2 V pebsiieisioe EXXON MOBIL Mobil Delvac 1130 | Mobil DTE 10 Excel Mobilux EP CAUTION: 1) Fill the fluid reservoirs with the filters installed. 2) Use recommended fuels and lubricants only. -61-nnn nee reer ee aTeTe a) eae vein | VA Tox] = 286 Tan can | a 5 | ame mei Tk “BRR DE Tag] onan [enn FAA Ya meno | wm | ‘pod | ‘1m J0 40109 zi ‘NOLLAVD HoLMs Nouwuan or 4 OLIME NOH Ossett ous 4Hon ~62- roumstanvis a Sayeed aso vazzne muviw Sunseaud 20 | ey € ai : susneon SV) reins wna 3. PERIODICAL MAINTENANCE 3.7 Electric Wiring Diagram4. SPECIFICATIONS | 4 SPECIFICATIONS (1) HV520 Model HVv520 Mass: Performance: Maximum mass 620 kg (1,365 lbs) Traveling speed 0 ~3.0 km/h (0 ~ 1.9 mile/h) Shippingmass __585kg(1,2901bs)__ | _Gradeabilty 21 degrees Dimensions: ~~ TEngine: Overall length 2,450 mm (96.5") Model KUBOTA E75-E3-NB3 Overall width 640 mm (25.2") (Diese! engine) Overall height 4,175 mm (46.3") Displacement 0.325 (19.8 cu.in) Roll dia. x width 355 mm x 595 mm (14° x 23.4")] Rated output 4.2 KW (6.6 HP) / 2,100 min Wheel base 520 mm (20.5") Max. torque 48.1 Nem /2,000 min* Performance: (13.3 fb / 2,000 rpm) ‘Compaction width 595 mm (23.4") Battery 12V Centrifugal force 9.8 kN (2,205 ibs) 32Ah Frequency 60 Hz (3,600 von) NOTE: Gradeabilty is the calculated valve. It may vary with ground surface conditions. Maximum mass : Fuel=100%, Water=100% Shipping mass : Fuel= 10%, Water= 0% -63-4, SPECIFICATIONS (2) HV620 Model Hv620 ‘Mass: Performance: Maximum mass 640 kg (1,410 lbs) Traveling speed 0 ~ 3.0 km/h (0 ~ 4.9 mile/h) Shipping mass __605 kg (1,338 Ibs) Gradeabilty 21 degrees Dimensions: Engine: Overall length 2,450 mm (96.5") Model KUBOTA E75-E3-NB3 Overall width 695 mm (27.4") (Diesel engine) Overall height 1,175 mm (46.3") Displacement 0.3250 (19.8 cu.in) Roll dia. x width 365 mm x 650 mm (14"x 26.6"}| Rated output 4.2 KW (6.6 HP)/ 2,100 min? Wheel base 520 mm (20.5") Max. torque 48.1 Nem 2,000 min* Performance: (13.3 ft-lb / 2,000 rpm) Compaction width 650 mm (26.6") Battery 12 Centrifugal force 11.8 KN (2,650 Ibs) 32An Frequency 60 Hz (3,600 vprn) NOTE: Gradeabilty is the calculated valve. It may vary with ground surface conditions Maximum mass : Fuel=100%, Water=100% Shipping mass : Fuel= 10%, Waler= 0% -64-SAKAI HEAVY INDUSTRIES, LTD. | Head Office: 1-4-8, Shiba Daimon, Minato-ku, Tokyo, Japan Telephone: Tokyo (03) 3431-9971 Facsimile: Tokyo (03) 3436-6212 Printed in Japan 2016.6.55 D®SAKAI HEAVY INDUSTRIES, LTD.