Sakai SV204 Series Installation and operation manual

DIC212
VIBRATING
ROLLER
K
From SV204D →1SV65 - 30101
SV204T →1SV65 - 30101
SV204TB →1SV65 - 30101
SV204TF →1SV65 - 30101
Series
Read this handbook thoroughly and understand the whole information
contained before trying to operate, inspect and service your machine!
No. 3498-36540-0
OPERATING &
MAINTENANCE
INSTRUCTIONS
M
O
D
E
L
S
V
2
0
4
S
e
r
i
e
s
DIC212
VIBRATING
ROLLER
K
From SV204D →1SV65 - 30101
SV204T →1SV65 - 30101
SV204TB →1SV65 - 30101
SV204TF →1SV65 - 30101
Series
Read this handbook thoroughly and understand the whole information
contained before trying to operate, inspect and service your machine!
No. 3498-36540-0
OPERATING &
MAINTENANCE
INSTRUCTIONS
M
O
D
E
L
S
V
2
0
4
S
e
r
i
e
s

PREFACE
PREFACE
This operator’s manual serves as a guide for the use of your SAKAI SV204 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 PRECAUTIONS FOR SAFETY ........................................................ 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 ..................................................................... 10
1.5 During Operation ................................................................................. 11
1.6 Loading and Unloading ....................................................................... 14
1.7 Transportation ..................................................................................... 14
1.8 Handling the Battery............................................................................ 15
1.9 Towing................................................................................................. 16
1.10 Before Servicing .................................................................................. 17
1.11 During Servicing .................................................................................. 19
1.12 Safety Decals ...................................................................................... 22
2 OPERATION................................................................................................. 24
2.1 Instruments and Controls .................................................................... 24
2.1.1 Operator’s station ........................................................................ 24
2.1.2 Gauges, indicator lamps and warning lamps............................... 25
2.1.3 Switches ...................................................................................... 28
2.1.4 Operating levers / pedals............................................................. 31
2.1.5 Unloader valve............................................................................. 32
2.1.6 Fuse box ...................................................................................... 33
2.2 Handling and Adjustments .................................................................. 34
2.2.1 Handling the DPF ........................................................................ 34
2.2.2 Seat adjustment........................................................................... 38
2.2.3 Fusible link................................................................................... 39
2.2.4 Accessory soket........................................................................... 39
2.2.5 Scraper adjustment and replacement.......................................... 40
2.2.6 Disengaging the brake when towing............................................ 41
2.3 Operation............................................................................................. 42
2.3.1 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 ....................................................................... 46
2.3.6 Stopping the engine..................................................................... 47
2.3.7 Check after stopping the engine .................................................. 47
2.4 Vibratory Operation ............................................................................. 48
2.5 Precautions for Work........................................................................... 49
2 5.1 Compaction operation.................................................................. 49

CONTENTS
2.5.2 When going downhill.................................................................... 49
2.5.3 On a slope ................................................................................... 49
2.6 Applicable Jobs ................................................................................... 50
2.7 After Operation .................................................................................... 51
2.8 Loading and Unloading ....................................................................... 51
2.8.1 Use of a trailer equipped with a winch ......................................... 52
2.8.2 Self-propelling.............................................................................. 53
2.9 After Loading the Machine .................................................................. 53
2.10 Transportation ..................................................................................... 53
2.11 Operation in Cold Weather.................................................................. 54
2.11.1 Fuel oil and grease ...................................................................... 54
2.11.2 Coolant ........................................................................................ 54
2.11.3 Battery ......................................................................................... 55
2.12 When the Cold Season is Over ........................................................... 56
2.13 For a Long Storage Period .................................................................. 56
2.14 During the Storage Period................................................................... 56
2.15 When the Battery Has Discharged ...................................................... 57
2.15.1 Connection and disconnection of booster cables ........................ 57
3 PERIODICAL MAINTENANCE..................................................................... 59
3.1 Precautions ......................................................................................... 59
3.1.1 Lifting the machine on a hoist ...................................................... 61
3.2 Walk-around Checking ........................................................................ 62
3.2.1 Tire inflation pressure check........................................................ 63
3.2.2 Checking for external injury to a tire ............................................ 63
3.3 Periodical Maintenance Points ............................................................ 64
3.4 Maintenance Procedure ...................................................................... 67
(1) Every 10 hours or daily................................................................. 67
(2) Every 50 hours ............................................................................. 68
(3) Every 250 hours ........................................................................... 70
(4) Every 500 hours ........................................................................... 73
(5) Every 1000 hours ......................................................................... 76
(6) Every 1500 hours ......................................................................... 78
(7) Every 3000 hours ......................................................................... 78
(8) As required ................................................................................... 79
3.5 Consumable Parts............................................................................... 82
3.6 Feeding Water and Lubricants ............................................................ 84
3.7 Electric Wiring Diagram....................................................................... 86
4 SPECIFICATIONS........................................................................................ 88
(1) SV204D ............................................................................................... 88
(2) SV204T ............................................................................................... 89
(3) SV204TB ............................................................................................. 90
(4) SV204TF ............................................................................................. 91

– 1 –
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 nameplate of the left side of the operator’s seat.
(2) Machine serial number
SV204D →1SV65 – ◯◯◯◯◯
SV204T →1SV65 – ◯◯◯◯◯
SV204TB →1SV65 – ◯◯◯◯◯
SV204TF →1SV65 – ◯◯◯◯◯
(3) Engine serial number

– 2 –
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 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).

– 3 –
SAFETY NOTICES
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.
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.
WARNING
☆Making alterations to the machine.
Please do not make alterations to the machine without permission for safety reaseons.
We shall not be held responsible for injures, death or breakdowns caused by alterations.
☆Basic precautions for safe operation of your machine are described beginning on page 4.
☆To operate and work with your machine, you must be qualified.

1 BASIC PRECAUTIONS FOR SAFETY
– 4 –
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
■Understand the intended use of the machine
• This machine is developed and manufactured mainly for rolling compactions of road
constructions and repairing. 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.
■Obey the worksite rules
• Follow noise standards and worksite rules such as matters forbidden or to be attended to,
and working procedures.

1 BASIC PRECAUTIONS FOR SAFETY
– 5 –
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

1 BASIC PRECAUTIONS FOR SAFETY
– 6 –
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.

1 BASIC PRECAUTIONS FOR SAFETY
– 7 –
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 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.

1 BASIC PRECAUTIONS FOR SAFETY
– 8 –
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.

1 BASIC PRECAUTIONS FOR SAFETY
– 9 –
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 : 496 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.
• Be sure to wear the seatbelt during operation.
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 ROPS-CAB)
• 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.

1 BASIC PRECAUTIONS FOR SAFETY
– 10 –
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.
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.

1 BASIC PRECAUTIONS FOR SAFETY
– 11 –
WARNING: Negligence of these instructions can lead to accidents.
■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.
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.
■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.

1 BASIC PRECAUTIONS FOR SAFETY
– 12 –
WARNING: Negligence of these instructions can lead to accidents.
■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 roller 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.
■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.

1 BASIC PRECAUTIONS FOR SAFETY
– 13 –
WARNING: Negligence of these instructions can lead to accidents.
■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
■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

1 BASIC PRECAUTIONS FOR SAFETY
– 14 –
WARNING: Negligence of these instructions can lead to accidents.
■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.
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.