Sakai R2-4 Install guide
R2-4
SHOP MANUAL
3498-6634A-0
Introduction
This manual provides important information to familiarize you with safe operating
and maintenance procedures for your SAKAI roller. Even though you may be
familiar with similar equipment you must read and understand this manual before
operating or servicing this unit.
Safety is everyone’s business and it is one of your primary concerns. Knowing the
guidelines presented in this manual will help provide for your safety, for the safety
of those around you and for the proper operation and maintenance of the machine.
Improper operation is dangerous and can result in injury or death.
Sakai Heavy Industries cannot foresee all possible circumstances or varying
conditions to which the operator, serviceman or machine may be exposed to that
might lead to a potential hazard. Therefore, the warnings and cautions listed in
this manual and those placed on the machine are not intended to be all inclusive
and liability for personal injury or damage to equipment or property cannot be
assumed.
the product information available at the time that the publication was written. The
R2-4 ○
0
0-001
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-002
1-002
1-003
1-6. Safety Instructions1-003
1-7. Starting 1-004
1-004
1-9. Stopping1-004
1-005
1-007
2. SPECIFICATIONS
A
1-1. R2-42-001
1-2. R2-4 2-004
1-3. R2H-4 2-007
1-4. R2H-4 2-010
S
2-1. Engine2-013
2-013
2-3. Hydraulic System2-013
2-4. Steering 2-014
2-5. Brakes2-014
2-014
N
3-1. Rating 2-015
3-2. Recommended Lubricants2-015
2-016
R2-4 ○
0
0-002
3. ENGINE AND CONTROLS
1. ENGINE
3-001
1-2. Engine Exterior3-002
S
3-003
3-004
T
3-005
3-1-1. Installation of pump 3-006
4. HYDRAULIC SYSTEMS
4-001
4-003
4-004
4-004
4-005
4-006
4-007
4-008
propulsion + steering・charge 4-008
4-010
4-012
4-014
2-2-5. Block A 4-015
2-2-6. Block B 4-016
3. STEERING SYSTE
4-017
3-2. Steering Wheel4-018
4-019
4-019
4-020
R2-4 ○
0
0-003
5. ELECTRICAL SYSTEM
1. K
5-001
5-003
S
5-004
5-005
4. WIRING HARNESSES
5-006
5-008
5-010
5-012
5-014
4-6. Floor Board Harness 5-016
4-7. Engine Harness5-018
4-8. Starter Switch Harness 5-019
5-020
4-10. Lighting Switch Harness5-021
4-11. Hazard Switch Harness5-022
4-12. F-R Lever Switch Harness5-023
4-13. Backup Buzzer Switch Harness5-024
4-14. Foot Brake Switch Harness 5-025
4-15. ENGINE WARNING Lamp Harness 5-026
5-027
4-17. Water Spray Harness 5-028
5-029
5-030
5-031
S
5-1. Fuse Box 5-032
5-033
6. DRUM
6-001
-46-003
-4 6-004
R2-4 ○
0
0-004
-46-005
-46-006
7. BRAKE
7-001
7-002
8. WATER SPRAY SYSTEM
8-001
9. INSPECTION AND ADJUSTMENT
T
9-001
9-001
9-001
1-4. Warm-up9-001
1-5. Inspection and Adjustment of Engine Related Items9-001
9-002
2-2. Adjustment9-003
E
9-004
3-2. Adjustment9-005
E
9-006
E
9-007
E
9-008
9-009
E
9-010
7-2. Inspection 9-011
E
9-012
E
9-013
9-014
R2-4 ○
0
0-005
R
9-015
9-017
E
11-1. Adjustment9-018
10. TROUBLESHOOTING
G
10-001
1-2. Important Information for Troubleshooting10-001
1-3. Before Starting 10-002
G
10-003
10-003
2-1-2. Inspection procedures using a tester 10-004
2-1-3. Inspection of electrical system 10-009
10-011
10-011
10-012
2-3. Engine10-019
10-019
10-021
10-023
2-3-3. No charging10-023
2-3-4. Glow plug is not heated
10-025
2-3-5. Starter motor runs even when F-R lever is not at “N”
and parking brake is not applied 10-025
2-3-6. Engine speed does not change when operating throttle lever10-027
10-029
10-029
10-031
2-4-2. Brake cannot be released10-031
10-031
10-033
2-4-4. Speed cannot be changed 10-033
2-5. Water Spray10-035
10-035
R2-4 ○
0
0-006
does not operate10-037
2-6. Lighting10-039
2-6-1. Head lamp, side marker lamp, tail lamp and license lamp
10-039
2-6-1. Head lamp, side marker lamp, tail lamp and license lamp
10-041
10-041
10-043
2-6-3. High-beam of head lamp does not light10-043
2-6-4. Turn signal lamp does not blink10-045
10-047
2-6-6. Backup lamp does not light 10-047
2-6-7. Stop lamp does not light 10-049
2-6-8. Illumination of combination meter does not light 10-051
10-051
2-6-10. Tachometer reading is abnormal 10-053
2-6-11. Hour meter is abnormal 10-053
2-6-12. Temperature meter is abnormal 10-055
2-6-13. Fuel meter is abnormal10-055
10-057
2-6-15. Water spray indicator lamp does not light 10-057
2-6-16. Flood lamp indicator lamp does not light10-059
2-6-17. Side marker lamp indicator lamp does not light10-059
10-061
2-6-19. Turn signal indicator lamp does not light10-063
2-6-20. Horn does not sound10-065
2-6-21. Backup buzzer does not sound10-065
G
10-066
10-067
10-067
10-068
10-068
10-068
10-069
10-069
10-069
10-070
3-2-7. Abnormal noise from propulsion system10-070
R2-4 ○
0
0-007
3-3. Steering System10-071
3-3-1. Steering wheel is hard to turn10-071
3-3-2. Steering response is slow10-071
3-3-3. Steering wheel backlash or play is large 10-072
3-3-4. Steering system is overheating 10-072
3-3-5. Abnormal noise from steering system 10-072
SAFETY
1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
can result in serious personal injury or death.
can result in serious personal injury or death.
may result in moderate personal injury or damage to the machine or
personal property.
machine that may cause damage, breakdown, or shortened service life of
the machine if you fail to observe or important point to maintain of quality in
maintenance works.
Items that indicate the weight of a part or equipment and require attention in wire
selection and operating posture for slinging operation.
N•m
In the assembly operation, tightening torque in locations that require particular
attention.
1-2. General
hazards. They should also have comprehensive training, the required skills and necessary
tools to perform the job safely.
• The machine was built in accordance to the latest safety standards and recognized safety
rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or
nearby personnel and may cause damage to the machine or other property.
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.
★
1-002
SAFETY
materials. Use of the machine for other purposes such as towing other equipment is
considered contrary to the designated use. The manufacturer cannot be responsible or held
liable for any damage resulting from such use. The risk for such use lies entirely with the
user.
1-3. Qualications of Operators and Maintenance Personnel
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
instructions that are contrary to safety.
without constant supervision by an experienced person.
• Work on the electrical system of the machine must be done only by an experienced person
or under the guidance of a skilled electrician and according to electrical engineering rules
and regulations.
• Work on the frame, brakes, hydraulic and steering systems must be performed by skilled
personnel with special knowledge and training for such work.
1-4. Safety Practices and Policies
available at the site where the machine is being used.
• The operator or user of the machine must be aware of all applicable or legal and mandatory
regulations relevant to accident prevention and environmental protection. These regulations
may also deal with handling of hazardous substances, the required proper personal safety
• Always be sure the persons working on the machine have read the operating instructions
and all safety precautions before beginning work. Reading safety instructions after work has
already begun is too late.
jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up
in the machinery or rotating parts.
• Use protective equipment as required by the circumstances or by law.
1-003
SAFETY
legible.
• Stop the machine immediately in the event of any malfunction. Report any malfunction
immediately to the supervisor or other person of authority.
• Never perform service or maintenance on the machine unless the drums or tires are
adequately blocked, articulation lock bar and pin is in the locked position and the parking
brake is applied.
manufacturer’s approval.
• Always perform the recommended routine inspections and adjustments according to the
prescribed intervals.
1-5. Pre Start Inspection
• Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly
performed. Repair or replace any malfunctioning, broken or missing parts before using the
• Always clean up any spilled fuel.
repairs have been made and warning tags have been removed by authorized personnel.
mounting hardware is tight.
slipping.
• Know how to shut-down or stop the machine immediately in case of emergency.
• Know the capabilities and limitations of the machine such as speed, gradeability, steering
and braking.
• Be aware of the dimensions of the machine such as height, weight especially for
transporting.
1-6. Safety Instructions
• Take all necessary precautions to ensure that the machine is used only when in a safe and
reliable condition.
• Avoid any operational mode that might compromise safety.
functional.
• Always use the hand rails and steps to get on and off your machine maintaining 3-point
1-004
SAFETY
1-7. Starting
• Start the machine only from the driver’s seat and always wear the seat belt.
• Watch that the warning lights and indicators during start-up and shutdown are working in
accordance with operating instructions.
• Watch that no one is in danger before starting and when moving the machine.
traveling with the machine.
1-8. Operating
• Always make sure that there are no obstructions or persons in your line of travel before
starting the compactor in motion.
• Never climb on and off the machine while it is in motion.
• Always remain seated with the seat belt fastened when traveling, compacting or loading or
unloading the machine.
• Use caution and be very observant when operating in close quarters and congested areas.
compatible with these regulations.
• Never carry passengers.
• Know and use the hand signals for particular jobs and who has the responsibility for
signaling.
cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine
stability.
• Avoid side hill travel. Always operate up and down the slope. Always keep the propulsion
when passing under overhead power lines.
• Never allow anyone to stand in the articulation area of the machine when the engine is
running.
• Always look in all directions before reversing the direction of travel.
dark.
can kill.
1-9. Stopping
• Always park the machine in a safe area on solid and level ground. If this is not possible,
always park at a right angle to the slope and block the drums or tires.
• Lock all lockable compartments.
1-005
SAFETY
1-10. Maintenance
machine or it’s safety devices or any work related to maintenance, inspection or repair,
• Ensure that the maintenance area is safe and secure.
• If the machine is shut down for maintenance or repair work
it must be secured against inadvertent starting by removing
the starter key and attaching a warning sign to the starter
switch.
• The machine must be parked on stable and level ground
with the drums or tires blocked to prevent inadvertent
movement.
• Immediately after the engine has stopped, the exhaust
and other lubricants and components will be very hot.
Fluids can be under pressure, removing the radiator cap
Wait until the machine has cooled down.
• Use care when attaching and securing lifting tackle to
individual parts and large assemblies being removed
or repositioned for repair purposes to avoid the risk of
accident. Use lifting devices that are in perfect condition and
loads.
• Always use the proper tools and workshop equipment in
good condition when performing maintenance or repairs on
the machine.
• Always use specially designed safety ladders and working
machine parts as a climbing aid.
• Keep all steps, handles, handrails, platforms and ladders free from mud, dirt, grease, ice or
snow.
carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free
cleaning rags.
connections chafe marks or damage after cleaning.
• Repair or replace defective parts immediately.
• Whenever possible, avoid servicing or maintenance when the engine is running unless the
drums or tires are adequately blocked, the articulation lock bar is in the locked position and
the parking brake is applied.
Always clean up any spilled fuel.
• Ensure safe operation, optimum performance of the machine and its warranty by using only
genuine SAKAI replacement parts.
1-006
SAFETY
from reputable manufacturers.
or when welding on the compactor.
necessary to connect a jumper cable or battery charger. Fumes can
ignite from a spark and may explode.
trouble occurs in the electrical system.
specially trained person according to electrical engineering principles.
connections or burnt or scorched wires must be repaired or replaced immediately.
machine.
operations.
• Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of
or other damage which may affect their function or strength.
pressure. The hydraulic system remains pressurized even after the engine has stopped.
• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece
of cardboard and always wear gloves and safety glasses.
from a pin hole leak can cause severe injury or death.
with the technical requirements.
other chemical substances. Be careful especially when these items are hot as there is a risk
of burning or scalding.
only in adequately ventilated premises. Before starting the engine in an
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