Sakai R2H-2 Install guide

R2H-2
SHOP MANUAL
3498-66344-0

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.
All information, specifications and illustrations in this publication are based on
the product information available at the time that the publication was written. The
contents may change without prior notice due to modications of the model.

R2H-2○
0
CONTENTS
1. SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words1-001
1-2. General1-001
1-3. Qualications of Operators and Maintenance Personnel 1-002
1-4. Safety Practices and Policies1-002
1-5. Pre Start Inspection1-003
1-6. Safety Instructions1-003
1-7. Starting 1-004
1-8. Operating1-004
1-9. Stopping1-004
1-10. Maintenance1-005
1-11. Transporting the Machine 1-007
2. SPECIFICATIONS
1. SPECIFICATION DATA 2-001
2. TABLE OF STANDARD VALUES
2-1. Engine2-003
2-2. Propulsion2-003
2-3. Hydraulic System2-003
2-4. Steering 2-004
2-5. Brakes2-004
2-6. Capacities 2-004
3. FUEL AND LUBRICANTS SPECIFICATION
3-1. Rating 2-005
3-2. Recommended Lubricants2-005
4. TIGHTENING TORQUE CHART2-006
3. ENGINE AND CONTROLS
1. ENGINE
1-1. Engine Mount3-001
1-2. Engine Exterior3-002
2. CONTROL SYSTEM
2-1. Throttle Control 3-003
2-2. Forward-reverse Control3-004

R2H-2○
0
3. PUMP MOUNT
3-1. Pump Mount3-005
3-1-1. Installation of pump  3-006
4. HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM
1-1. Graphic Symbols for Hydraulic Circuits 4-001
1-2. Hydraulic Circuit Diagram4-003
2. PROPULSION HYDRAULIC SYSTEM
2-1. Propulsion Hydraulic Piping4-004
2-1-1. Propulsion hydraulic piping (Front 1)4-004
2-1-2. Propulsion hydraulic piping (Front 2)4-005
2-1-3. Propulsion hydraulic piping (Rear)4-006
2-2. Hydraulic Component Specications 4-007
2-2-1. Hydraulic pump assembly (propulsion + steering・charge) 4-007
2-2-2. Propulsion hydraulic motor (front)4-009
2-2-3. Propulsion hydraulic motor (rear) 4-011
3. STEERING SYSTEM
3-1. Steering Hydraulic Piping4-013
3-2. Steering Wheel4-014
3-3. Hydraulic Component Specications 4-015
3-3-1. Orbitrol4-015
3-4. Frame (Center Pin)4-016
5. ELECTRICAL SYSTEM
1. ELECTRICAL CIRCUIT
1-1. Electrical Circuit Diagram5-001
2. ELECTRICAL COMPONENTS
2-1. Electrical Component Layout (1)5-002
2-2. Electrical Component Layout (2)5-003
3. ELECTRICAL COMPONENT SPECIFICATIONS
3-1. Fuse Box 5-004
3-2. Combination Meter 5-005
6. DRUM
1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001
2. FRONT DRUM6-003
3. REAR DRUM6-004

R2H-2○
0
7. BRAKE
1. BRAKE PEDAL 7-001
2. BRAKE SYSTEM7-002
8. WATER SPRAY SYSTEM
1. WATER SPRAY PIPING 8-001
9. INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT
1-1. Safety Precautions for Inspection and Adjustment9-001
1-2. Preparation for Inspection and Adjustment 9-001
1-3. Precautions for Inspection and Adjustment 9-001
1-4. Warm-up9-001
1-5. Inspection and Adjustment of Engine Related Items9-001
2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE
2-1. Measurement9-002
2-2. Adjustment9-003
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT
PRESSURE
3-1. Measurement9-004
3-2. Adjustment9-005
4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE
4-1. Measurement9-006
5. MEASUREMENT OF Machine HIGH/LOW SPEED CHANGE CIRCUIT
PRESSURE
5-1. Measurement9-007
6. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE
6-1. Measurement9-008
7. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1. Measurement9-009
7-2. Inspection 9-010
8. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
8-1. Measurement of Propulsion Pump Case Pressure 9-011
9. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
9-1. Measurement of Front Propulsion Motor 9-012
9-2. Measurement of Rear Propulsion Motor9-013
10. ADJUSTMENT OF THROTTLE LEVER LINKAGE
10-1. Adjustment9-014

R2H-2○
0
11. ADJUSTMENT OF F-R LEVER LINKAGE
11-1. Adjustment9-015
10. TROUBLESHOOTING
1. TROUBLESHOOTING
1-1. Safety Precautions for Troubleshooting 10-001
1-2. Important Information for Troubleshooting10-001
1-3. Before Starting 10-002
1-4. Wire Color Code and Number 10-002
2. ELECTRICAL SYSTEM TROUBLESHOOTING
2-1. When Performing Electrical System Fault Diagnosis 10-003
2-1-1. Precautions to take during electrical circuit fault diagnosis10-003
2-1-2. Inspection procedures using a tester 10-004
2-1-3. Inspection of electrical system 10-009
2-2. Engine10-012
2-2-1. Engine will not start (Starter motor does not run) 1/310-012
2-2-1. Engine will not start (Starter motor does not run) 2/310-014
2-2-1. Engine will not start (Starter motor does not run) 3/310-016
2-2-2. Engine will not start (But starter motor runs) 10-018
2-2-3. Engine does not stop running10-018
2-2-4. No charging10-020
2-2-5. Glow plug is not heated (Engine starting performance is bad in cold
weather)10-020
2-2-6. Starter motor runs even when F-R lever is not at neutral 10-020
2-3. Propulsion 10-022
2-3-1. Machine moves neither forward nor backward10-022
2-3-2. Machine speed cannot be changed10-024
2-3-3. Brake cannot be released10-026
2-3-4. Brake does not work10-028
2-4. Water Sprays10-030
2-4-1. Continuous water spray does not operate 10-030
2-4-2. Continuous water spray works, but intermittent water spray does not
operate 10-032
2-5. Lighting 10-034
2-5-1. Head lamp, side marker lamp, tail lamp and license lamp do not
light 1/210-034
2-5-1. Head lamp, side marker lamp, tail lamp and license lamp do not
light 2/210-036
2-5-2. Flood lamp does not light 1/210-036
2-5-2. Flood lamp does not light 2/210-038

R2H-2○
0
2-5-3. High-beam of head lamp does not light10-038
2-5-4. Turn signal light does not blink10-040
2-5-5. Hazard lamp does not light (Turn signal blinks)10-042
2-5-6. Backup lamp does not light 10-044
2-5-7. Stop lamp does not light 10-044
2-5-8. Illumination of combination meter does not turn on 10-046
2-5-9. Combination meter warning lamp or indicator lamp is abnormal 10-046
2-5-10. Tachometer reading is abnormal 10-048
2-5-11. Hour meter is abnormal 10-048
2-5-12. Temperature meter is abnormal 10-050
2-5-13. Fuel meter is abnormal 10-050
2-5-14. Charge warning lamp remains ON 10-052
2-5-15. Oil pressure warning lamp remains ON10-052
2-5-16. Parking brake indicator lamp does not light10-054
2-5-17. Water spray indicator lamp does not light 10-056
2-5-18. Flood lamp indicator lamp does not light10-058
2-5-19. Side marker lamp indicator lamp does not light10-058
2-5-20. Turn signal indicator lamp does not light10-060
2-5-21. Glow (Preheating plug) indicator lamp does not light10-062
2-5-22. Horn does not sound 10-064
2-5-23. Backup buzzer does not sound10-064
3. HYDRAULIC SYSTEM TROUBLESHOOTING
3-1. When Performing Hydraulic System Troubleshooting 10-065
3-2. Propulsion System10-066
3-2-1. Machine moves neither forward nor backward 1/2 10-066
3-2-1. Machine moves neither forward nor backward 2/2 10-067
3-2-2. Machine moves in one direction only (forward or backward)10-067
3-2-3. Slow machine speed or small drive force 1/2 10-067
3-2-3. Slow machine speed or small drive force 2/2 10-068
3-2-4. Machine speed does not change 10-068
3-2-5. Machine does not stop completely with F-R lever in neutral 10-068
3-2-6. Propulsion system is overheating10-069
3-2-7. Abnormal noise from propulsion system10-069
3-3. Steering System10-070
3-3-1. Steering wheel is hard to turn10-070
3-3-2. Steering response is slow10-070
3-3-3. Steering wheel backlash or play is large 10-071
3-3-4. Steering system is overheating 10-071
3-3-5. Abnormal noise from steering system 10-071

SAFETY

1-001
SAFETY
1. GENERAL SAFETY
1-1. Understanding the Safety Symbols and Words
The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol.
DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and
CAUTION are displayed, become alert. Your safety or those around you may be involved.
NOTICE is used to provide important information that is not hazard related.
DANGER: Indicates an imminently hazardous situation or condition which if not avoided
can result in serious personal injury or death.
WARNING: Indicates a potentially hazardous situation or condition which if not avoided
can result in serious personal injury or death.
CAUTION: Indicates a potentially hazardous situation or condition which if not avoided
may result in moderate personal injury or damage to the machine or
personal property.
(NOTICE): Indicates important information about operation or maintenance of the
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.
★: Indicates standard value to judge whether measured value is good or not.
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
• Operators and maintenance personnel must be alert to recognize and avoid potential
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.
• The machine must only be used for its intended purpose as described in the Operator’s
Manual. It must be operated by safety-conscious persons who are fully aware of the risks
involved when operating the machine. Any malfunctions especially those affecting the safety
of the machine must be corrected immediately.

1-002
SAFETY
• The machine is designed specically for the compaction of asphalt or soil road construction
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.
• Operating the machine within the limits of its designated use also involves compliance with
the inspection and maintenance requirements contained in the Operation and Maintenance
Manual.
1-3. Qualications of Operators and Maintenance Personnel
• Work on the machine must be performed by qualified personnel only. Individual
responsibilities of personnel regarding operation, maintenance, repair of the machine must
be clearly stated.
• Define the operator’s responsibilities; the operator should have authority to refuse
instructions that are contrary to safety.
• Do not allow persons being trained to operate or perform maintenance on the machine
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
• Keep the manuals in the container provided on the machine. Manuals must always be
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
and protective equipment and trafc or jobsite regulations.
• Machine operating instructions should also be supplemented with detailed instructions
pertaining to the specic jobsite or work location.
• 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.
• Wear close tting garments and always tie back and secure long hair, also avoid wearing
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.