MULTIQUIP Mikasa Series User manual

OPERATION AND PARTS MANUAL
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
SERIES
MODEL MRH800DS2
VIBRATORY ROLLER
(YANMAR L100V1AJ1R1AAMK DIESEL ENGINE)
Revision #1 (4/12/11)
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PAGE 2 — MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11)
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
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PAGE 4 — MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11)
TABLE OF CONTENTS
MRH800DS2 Vibratory Roller
Proposition 65 Warning ........................................... 2
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-10
Specifications ................................................... 12-13
Dimensions............................................................ 14
General Information............................................... 15
Components ..................................................... 16-19
Basic Engine.......................................................... 20
Inspection ......................................................... 22-23
Operation.......................................................... 24-27
Maintenance..................................................... 28-32
Troubleshooting ................................................ 33-35
Explanation Of Code In Remarks Column............. 36
Suggested Spare Parts ......................................... 37
Nameplates And Decals................................... 38-39
Axle Assy. ......................................................... 40-41
Base Assy......................................................... 42-43
Front Guard Assy.............................................. 44-45
Side Cover Assy................................................ 46-47
Water Tank Assy. .............................................. 48-49
Hydraulic System Assy. .................................... 50-53
Hydraulic Oil Tank Assy..................................... 54-55
Engine Assy...................................................... 56-57
Electric Device Assy.......................................... 58-59
Clutch (Vibration) Assy...................................... 60-61
Vibrator Assy..................................................... 62-63
Upper Control Arm Assy. .................................. 64-67
Lower Control Arm Assy. .................................. 68-69
Yanmar L100V1AJ1R1AAMK Engine
Cylinder Block Assy.......................................... 70-71
Cylinder Head And Cover Assy ........................ 72-73
Air Cleaner And Muffler Assy ........................... 74-75
Crankshaft, Piston, Camshaft Assy.................. 76-77
Lub. Oil Pump And Governor Assy.................... 78-79
Cooling And Starting Device Assy. ................... 80-81
Fuel Injection Pump And Valve Assy................. 82-83
Fuel Tank Assy.................................................. 84-85
Starting Motor And Dynamo Assy..................... 86-87
Tool, Label And Gasket Set .............................. 88-89
Terms and Conditions of Sale — Parts ................. 90
NOTICE
Specifications and part numbers are subject to change
without notice.
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PAGE 6 — MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11)
SAFETY INFORMATION
Do not operate or service the equipment before reading
the entire manual. Safety precautions should be followed
at all times when operating this equipment.
Failure to read and understand the safety
messages and operating instructions could
result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
The following table shows the potential hazards associated
with the operation of this equipment.
Lethal exhaust gas hazards
Explosive fuel hazards
Burn hazards
Respiratory hazards
Rotating parts hazards
Symbol Safety Hazard
Pressurized fluid hazards
Electric shock hazards
Runover hazards
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MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11) — PAGE 7
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
ALWAYS clear the work area of any debris, tools, etc.
that would constitute a hazard while the equipment is
in operation.
NOTICE
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest phone or keep
a phone on the job site. Also, know the phone numbers
of the nearest ambulance, doctor and fire department.
This information will be invaluable in the case of an
emergency.
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PAGE 8 — MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11)
SAFETY INFORMATION
ROLLER SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
WARNING
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
Never leave the roller unattended with the engine
running. Turn off engine.
Use chock blocks when parking roller on a grade.
Use extreme care when operating near obstructions, on
slippery surfaces, grades, and slide slopes.
When reversing, particularly on the edges and banks
of ditches, as well as in front of obstaces, the operator
must stay in a standing position at a safe distance from
the machine.
When operating near any house/building or pipelines,
always check the effect of machine vibration. Stop work
if necessary.
DO NOT operate the roller with the covers open.
ALWAYS keep the machine away from other personnel
and obstacles. Always keep immediate are free of
bystanders.
NOTICE
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
DO NOT use worn-out hoses or couplings. Inspect daily.
ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel.
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment requires an adequate
free flow of cooling air. NEVER operate this equipment
in any enclosed or narrow
area where free flow of the
air is restricted. If the air
flow is restricted it will cause
injury to people and property
and serious damage to the
equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the engine oil drain plug
while the engine is hot. Hot oil will gush out of the oil
tank and severely scald any persons in the general area
of the roller.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
Always turn the engine off before performing maintenance.
DANGEROUS
GAS FUMES
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MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11) — PAGE 9
SAFETY INFORMATION
NOTICE
NEVER run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
NEVER tip the engine to extreme angles during lifting as
it may cause oil to gravitate into the cylinder head, making
the engine start difficult.
FUEL SAFETY
DANGER
DO NOT add fuel to equipment if it is placed inside truck
bed with plastic liner. Possibility exists of explosion or
fire due to static electricity.
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
DO NOT fill the fuel tank while the engine is running
FUEL
FUEL
or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
BATTERY SAFETY (ELECTRIC START ONLY)
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up
the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
DO NOT charge battery if frozen. Battery can explode.
When frozen, warm the battery to at least 61°F (16°C).
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gases.
If the battery liquid (dilute sulfuric acid)
comes into contact with clothing or skin,
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PAGE 10 — MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11)
SAFETY INFORMATION
rinse skin or clothing immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the equipment.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
TRANSPORTING SAFETY
CAUTION
NEVER allow any person or animal to stand underneath
the equipment while lifting.
NOTICE
Before lifting, make sure that the equipment parts are not
damaged and screws are not loose or missing.
Use lifting equipment capable of lifting the weight of
the roller.
Always make sure crane or lifitng device has been
properly secured to the lifting bail (hook) of the
equipment.
ALWAYS shutdown engine before transporting.
NEVER lift the equipment while the engine is running.
Tighten fuel tank cap securely and close fuel cock to
prevent fuel from spilling.
Use adequate lifting cable (wire or rope) of sufficient
strength.
Use one point suspension hook and lift straight upwards
with sufficient bearing capacity to prevent machine from
tilting or slipping.
DO NOT lift machine to unnecessary heights.
ALWAYS make sure that roller is secured correctly when
transporting on a trailer. Make sure all supports attaching
the roller to the trailer are tight.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
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MRH800DS2 VIBRATORY ROLLER • OPERATION AND PARTS MANUAL — REV. #1 (04/12/11) — PAGE 11
NOTES
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