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 ○

0-001

CONTENTS

1. SAFETY

1. GENERAL SAFETY

1-1. Understanding the Safety Symbols and Words1-001

1-2. General1-001

 1-002

1-002

1-003

1-6. Safety Instructions1-003

1-7. Starting 1-004

1-004

1-9. Stopping1-004

1-005

 1-007

2. SPECIFICATIONS

A

1-1. R2-42-001

1-2. R2-4  2-004

1-3. R2H-4 2-007

1-4. R2H-4  2-010

S

2-1. Engine2-013

 2-013

2-3. Hydraulic System2-013

2-4. Steering 2-014

2-5. Brakes2-014

 2-014

N

3-1. Rating 2-015

3-2. Recommended Lubricants2-015

2-016

R2-4 ○

0-002

3. ENGINE AND CONTROLS

1. ENGINE

3-001

1-2. Engine Exterior3-002

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 Wheel4-018

 4-019

4-019

4-020

R2-4 ○

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 Harness5-018

4-8. Starter Switch Harness 5-019

5-020

4-10. Lighting Switch Harness5-021

4-11. Hazard Switch Harness5-022

4-12. F-R Lever Switch Harness5-023

4-13. Backup Buzzer Switch Harness5-024

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



-46-003

-4 6-004

R2-4 ○

0-004

-46-005

-46-006

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-up9-001

1-5. Inspection and Adjustment of Engine Related Items9-001



9-002

2-2. Adjustment9-003



E

9-004

3-2. Adjustment9-005

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 ○

0-005

R

 9-015

9-017

E

11-1. Adjustment9-018

10. TROUBLESHOOTING

G

 10-001

1-2. Important Information for Troubleshooting10-001

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. Engine10-019

10-019

10-021

 10-023

2-3-3. No charging10-023

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 lever10-027

10-029

 10-029

 10-031

2-4-2. Brake cannot be released10-031

10-031

10-033

2-4-4. Speed cannot be changed 10-033

2-5. Water Spray10-035

10-035

R2-4 ○

0-006



does not operate10-037

2-6. Lighting10-039

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 light10-043

2-6-4. Turn signal lamp does not blink10-045

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 abnormal10-055

 10-057

2-6-15. Water spray indicator lamp does not light 10-057

2-6-16. Flood lamp indicator lamp does not light10-059

2-6-17. Side marker lamp indicator lamp does not light10-059

10-061

2-6-19. Turn signal indicator lamp does not light10-063

2-6-20. Horn does not sound10-065

2-6-21. Backup buzzer does not sound10-065

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 system10-070

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