Sakai R2-4 Shop Manual 3498-6634A-0 – PDF DOWNLOAD

Sakai R2-4 Shop Manual 3498-6634A-0 – PDF DOWNLOAD

FILE DETAILS:

Sakai R2-4 Shop Manual 3498-6634A-0 – PDF DOWNLOAD

Language : English
Pages :234
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sakai R2-4 Shop Manual 3498-6634A-0 – PDF DOWNLOAD

1 SAFETY
1 GENERAL SAFETY
1-1 Understanding the Safety Symbols and Words 1-001
1-2 General 1-001
1-3 Qualifications 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
1-1 R2-4 2-001
1-2 R2-4 ROPS 2-004
1-3 R2H-4 2-007
1-4 R2H-4 ROPS 2-010
2 TABLE OF STANDARD VALUES
2-1 Engine 2-013
2-2 Propulsion 2-013
2-3 Hydraulic System 2-013
2-4 Steering 2-014
2-5 Brakes 2-014
2-6 Capacities 2-014
3 FUEL AND LUBRICANTS SPECIFICATION
3-1 Rating 2-015
3-2 Recommended Lubricants 2-015
4 TIGHTENING TORQUE CHART 2-016
R2-4 ○0
0-002
3 ENGINE AND CONTROLS
1 ENGINE
1-1 Engine Mount 3-001
1-2 Engine Exterior 3-002
2 CONTROL SYSTEMS
2-1 Throttle Control 3-003
2-2 Forward-reverse Control 3-004
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 (1) 4-004
2-1-2 Propulsion hydraulic piping (2) 4-005
2-1-3 Propulsion hydraulic piping (3) 4-006
2-1-4 Propulsion hydraulic piping (R) 4-007
2-2 Hydraulic Component Specifications 4-008
2-2-1 Hydraulic pump assembly (propulsion + steering・charge) 4-008
2-2-2 Propulsion hydraulic motor (F) 4-010
2-2-3 Propulsion hydraulic motor (R) 4-012
2-2-4 Valve 4-014
2-2-5 Block A 4-015
2-2-6 Block B 4-016
3 STEERING SYSTEM
3-1 Steering Hydraulic Piping 4-017
3-2 Steering Wheel 4-018
3-3 Hydraulic Component Specifications 4-019
3-3-1 Orbitrol 4-019
3-3-2 Valve 4-020
R2-4 ○0
0-003
5 ELECTRICAL SYSTEM
1 Precautions for wor k
1-1 Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in
Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses 5-001
2 SYSTEM CIRCUIT DIAGRAM
2-1 Electrical Circuit Diagram 5-003
3 ELECTRICAL COMPONENTS
3-1 Wiring Harness Layout (1) 5-004
3-2 Wiring Harness Layout (2) 5-005
4 WIRING HARNESSES
4-1 Main Harness (1) 5-006
4-2 Main Harness (2) 5-008
4-3 Main Harness (3) 5-010
4-4 Frame Harness (F) 5-012
4-5 Frame Harness (R) 5-014
4-6 Floor Board Harness 5-016
4-7 Engine Harness 5-018
4-8 Starter Switch Harness 5-019
4-9 Control Switch Harness 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
4-16 DPF Harness 5-027
4-17 Water Spray Harness 5-028
4-18 Combination Lamp Harness (F,L) 5-029
4-19 Combination Lamp Harness (F,R) 5-030
4-20 Sub Power Harness 5-031
5 ELECTRICAL COMPONENT SPECIFICATIONS
5-1 Fuse Box 5-032
5-2 Combination Meter 5-033
6 DRUM
1 PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001
2 DRUM
2-1 Drum (F) (R2-4) 6-003
2-2 Drum (F) (R2H-4) 6-004
R2-4 ○0
0-004
2-3 Drum (R) (R2-4) 6-005
2-4 Drum (R) (R2H-4) 6-006
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 of propulsion motor (F) 9-008
6-2 Measurement of propulsion motor (R) 9-009
7 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE
7-1 Measurement 9-010
7-2 Inspection 9-011
8 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE
8-1 Measurement of Propulsion Pump Case Pressure 9-012
9 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE
9-1 Measurement of Propulsion Motor (F) 9-013
9-2 Measurement of Propulsion Motor (R) 9-014
R2-4 ○0
0-005
10 ADJUSTMENT OF THROTTLE LEVER
10-1 Adjustment of Potentiometer 9-015
10-2 Adjustment of Operating Force 9-017
11 ADJUSTMENT OF F-R LEVER LINKAGE
11-1 Adjustment 9-018
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
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 Diagnosis Trouble Code 10-011
2-2-1 Description of diagnostic trouble code (DTC) 10-011
2-2-2 Table of the diagnostic trouble code (DTC) 10-012
2-3 Engine 10-019
2-3-1 Engine will not start (Starter motor does not run) 1/2 10-019
2-3-1 Engine will not start (Starter motor does not run) 2/2 10-021
2-3-2 Engine will not start (But starter motor runs) 10-023
2-3-3 No charging 10-023
2-3-4 Glow plug is not heated
(Engine starting performance is bad in cold weather) 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
2-4 Propulsion System 10-029
2-4-1 Machine moves neither forward nor backward 1/2 10-029
2-4-1 Machine moves neither forward nor backward 2/2 10-031
2-4-2 Brake cannot be released 10-031
2-4-3 Brake does not work 1/2 10-031
2-4-3 Brake does not work 2/2 10-033
2-4-4 Speed cannot be changed 10-033
2-5 Water Spray 10-035
2-5-1 Continuous water spray does not operate 10-035
R2-4 ○0
0-006
2-5-2 Continuous water spray works, but intermittent water spray
does not operate 10-037
2-6 Lighting 10-039
2-6-1 Head lamp, side marker lamp, tail lamp and license lamp
do not light 1/2 10-039
2-6-1 Head lamp, side marker lamp, tail lamp and license lamp
do not light 2/2 10-041
2-6-2 Flood lamp does not light 1/2 10-041
2-6-2 Flood lamp does not light 2/2 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
2-6-5 Hazard lamp does not light (Turn signal blinks) 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
2-6-9 Combination meter warning lamp or indicator lamp is abnormal 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
2-6-14 Charge warning lamp remains ON 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
2-6-18 Parking brake indicator lamp does not light 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
3 HYDRAULIC SYSTEM TROUBLESHOOTING
3-1 When Performing Hydraulic System Troubleshooting 10-066
3-2 Propulsion System 10-067
3-2-1 Machine moves neither forward nor backward 1/2 10-067
3-2-1 Machine moves neither forward nor backward 2/2 10-068
3-2-2 Machine moves in one direction only (forward or backward) 10-068
3-2-3 Slow machine speed or small drive force 1/2 10-068
3-2-3 Slow machine speed or small drive force 2/2 10-069
3-2-4 Machine speed cannot be switched 10-069
3-2-5 Machine does not stop completely with F-R lever in “N” 10-069
3-2-6 Propulsion system is overheating 10-070
3-2-7 Abnormal noise from propulsion system 10-070
R2-4 ○0
0-007
3-3 Steering System 10-071
3-3-1 Steering wheel is hard to turn 10-071
3-3-2 Steering response is slow 10-071
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

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