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Sakai TS160-2, Operating & Maintenance Instructions, Page: 1 / 74

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Summary of Contents for TS160-2

Page 1: ...ad this handbook thoroughly and understand the whole information contained before trying to operate inspect and service your machine OPERATING MAINTENANCE INSTRUCTIONS MODEL 4 Et J No ifirg TS160 2 Fr...

Page 2: ...ting your machine Keep this handbook at hand whenever you do your work The main subjects of this manual are 1 Basic precautions for safety 2 Operation 3 Daily maintenance and 4 Specifications For oper...

Page 3: ...uments and Controls 18 2 1 1 Operator s station 18 2 1 2 Gauges indicator lamps and warning lamps 19 2 1 3 Switches 21 2 1 4 Operating levers and pedals 24 2 1 5 Fuse box 25 2 2 Handling and Adjustafe...

Page 4: ...d 44 2 16 When the Battery Has Discharged 45 2 16 1 Connection and disconnection of booster cables 45 3 PERIODICAL MAINTENANCE 47 3 1 Precautions 47 3 2 Walk Around Checking 49 3 2 1 Tire inflation pr...

Page 5: ...parts or making inquiries about your machine the following information is requested 1 Machine model Indicated on the dashboard in the operator s station MODEL CHASSIS No SAKAI HEAVY INDUSTRIES LTD TO...

Page 6: ...n this manual you must assume responsibility for your own personal safety In this manual and on the machine you will find safety notices Each safety notice starts with a signal word as shown below A D...

Page 7: ...thoroughly Incorrect operation can kill or cause injury It is your responsibility to operate the machine safely Non approved modifications can pose safety related problems Before making any modificat...

Page 8: ...he controls or protruded portions of the machine Do not wear oily clothing According to the type of jobs wear safety goggles or mask 7 7U11 Know the work area in advance Know the terrain geology and c...

Page 9: ...ove the filler caps drain the oil or replace the filters you can get burned Perform this work in accordance with the correct procedures with the machine cooled Adt 41A down To remove the radiator cap...

Page 10: ...do not try to vomit Get medical help immediately 1 2 Preparation for Safe Operation Clean the step operator s station and floor board Do not place parts tools or unnecessary articles on the step opera...

Page 11: ...ithout difficulty when you twist your body for reverse run Secure forward and backward visibilities Adjust the rear view mirrors and under mirrors for good visibility If dirty clean them If damaged re...

Page 12: ...d to be abnormal rectify the fault before traveling again Listen for unusual sounds and check for abnormal temperature rise If abnormal park the machine in a safe location and find the source of troub...

Page 13: ...ions When changing the direction of travel secure the safety on the path in the travel direction At night carefully drive the machine Nighttime driving tends to frustrate the sense of distance Careful...

Page 14: ...ht to the destination When parking Select level and hard ground If necessary to park on a slope block the front of the drums on the downside of the slope When required to park on the public road provi...

Page 15: ...ransportation Follow required regulations Select a transporting route according to the overall width overall height and gross weight of the trailer with the roller loaded 1 8 Handling the Battery When...

Page 16: ...minal For disconnection start with the negative one Do not allow a tool to bridge between the positive terminal and machine body This can generate dangerous sparks Do not connect the booster cable to...

Page 17: ...their intended use only Change safety related parts at regular intervals Replace fuel hose and high pressure hydraulic hoses regularly to prevent fire Replace high pressure hoses of the power steerin...

Page 18: ...ay During service do not allow persons not concerned to enter the work area particularly when grinding or welding operation is performed or heavy hammers are being used Keep your machine clean Spilled...

Page 19: ...ooled down Use care when inspecting or servicing fan or belts in motion Secure loose clothing and keep articles away that could get caught in moving parts Do not let your body or tools make contact wi...

Page 20: ...ntact with machine parts in the vicinity of the engine while engine is running and after has been stopped Contact with hot part will cause burns freit 3998 16505 0 A DANGER Ito Roll Over Prevention Do...

Page 21: ...A WARNING Negligence of these instructions can lead to accidents 1 BASIC PRECAUTIONS FOR SAFETY Bonnet other side...

Page 22: ...perator s station 10 Steering wheel 10 Parking brake switch Horn switch Throttle lever Forward Reverse lever F R lever 0 Lamp switch with liquid spray switch Brake pedal Liquid spray switch Turn signa...

Page 23: ...4 10 xviscomvu in this manual should be based upon the hour meter g gge a gig readings leassaal Tachometer Hour meter Temperature gauge Indicates the coolant temperature Green zone means normal but re...

Page 24: ...go off when the engine has started If any of them lights up while the engine is running this indicates a faulty condition Stop the engine and trace the source of trouble Checking for warning lamp and...

Page 25: ...is position ON The charging circuit and lamp circuit are charged with electricity Let the key stay in this position after the engine has started START The engine is cranked and gets started The moment...

Page 26: ...To disengage the brake be sure to press the button again instead of pulling it When dismounting from the machine press the button to apply the brake without fail CAUTION Never pull the switch UP If t...

Page 27: ...itor display is turned off OFF ON Liquid spray switch Liquid is sprayed when switch is pressed Spraying is shut off if the switch is released While the liquid is being sprayed the spray indication lam...

Page 28: ...or normal braking return the F R lever back to neutral In an emergency depress the brake pedal This provides a quick braking with the F R lever brought to the neutral position N through a mechanical l...

Page 29: ...except for an emergency If used during the compacting operation of asphalt pavement this can cause damage to its surface NOTE Depressing the brake pedal brings the F R lever into neutral N 2 1 5 Fuse...

Page 30: ...disabled or VBolt when troubles have developed in the hydraulic system for propulsion disengage the brake as instructed below Remove the brake release bolts 2 piecese from the Seal washer motor e Rem...

Page 31: ...ystem if the F R lever is not in the neutral position N Ensure that the F R lever is in the Forward neutral position N before starting 0 Neutral 111 0 Reverse 2 3 2 Starting the engine A WARNING Check...

Page 32: ...rt 4 Turning the key to the START position makes the engine start Release the key the moment the engine has started The key will automatically return to the ON position Do not allow the starter key to...

Page 33: ...mperature gauge Pointer falls near the center zone Fuel gauge Pointer falls between the E and F marks Charge lamp Has gone off Engine oil pressure warning lamp Has gone off 3 Check for the color of ex...

Page 34: ...tends to be a blind spot 2 3 5 Stopping and Parking A WARNING Avoid abrupt braking Try to leave enough time for braking Avoid parking on a grade If necessary to park on a grade wheel to prevent unexp...

Page 35: ...the starter switch OFF while the machine is in motion 3 Remove the starter key When dismounting from the machine apply the brake by pressing the parking switch button If necessary to park on a grade...

Page 36: ...at the same time To shut off sprinkling and the indication lamp of monitor display is turned off set the switch to the OFF position Pay attention to the water level in the sprinkler tank If the pump...

Page 37: ...8 sprinkler filter drain cock 0 sprinkler pump drain cock C E and other drain cocks to completely discharge water Open sprinkler pipe drain cock 0 at the front and rear to completely discharge water...

Page 38: ...p drain cock C sprinkler pump drain cock Supplement to draining method Check that all the caps and valves e have been closed Start the sprinkler pump Repeatedly open and close the sprinkler pump drain...

Page 39: ...ts up Spraying is shuts off and the indication lamp of monitor display is turned off when the OFF switch is released ON Open the door left below the operator s seat and the liquid spray control valve...

Page 40: ...ve Turn the valve counterclockwise The nozzle extension width will increase The spraying quantity increases Turn the valve clockwise The nozzle extension width will decrease The spraying quantity decr...

Page 41: ...e speed drops drastically during rolling compaction 2 6 2 When going downhill Use the FR lever Run slowly by the operation of the F R lever even if the travel distance is short Use the engine brake Go...

Page 42: ...ition the following morning caused by muds and other extraneous matter on the drum or frozen drums Remove muds and water from the machine Muds can get into the seals together with water drops on the h...

Page 43: ...hine is facing in the wrong direction allow it to dismount from the ramps and correct the direction For loading and unloading use ramps or a proper loading stand 2 9 1 Use of a trailer equipped with a...

Page 44: ...ve back in the ONLOAD position Locate the machine correctly on the trailer 2 9 2 Self propelling 1 Engage the trailer brake and chock its wheels Fix the ramps so that the machine and trailer are compl...

Page 45: ...ng hook holes Particularly pay attention to sidewise skidding 2 11 Transportation To decide the transporting route check the width of the road height and weight including the roller of the trailer Obe...

Page 46: ...x ratio according the lowest temperature in the job location 33t 26 C 20 C 16 C 11 C Ambient temperature Amount of anti freeze 2 8E 2 5E 2 2k 2 0E 1 7k Amount of coolant 2 8k 3 1E 3 4 3 6E 3 9k Ratio...

Page 47: ...sfactory condition at all times and pay attention to heat insulation for satisfactory start up on the next morning The hydrometer atop the battery permits confirmation of the condition of the battery...

Page 48: ...temperature is expected to go down below 0 C add antifreeze to the coolant Completely drain the sprinkler water Place the F R lever in the neutral position N turn the sprinkler switch off and apply t...

Page 49: ...with the positive terminal Do not allow a metallic item to bridge between the positive terminal and machine body This can generate sparks causing an explosion Loose battery terminals can cause sparks...

Page 50: ...ositive terminal to make contact with the negative terminal when connecting the booster cables Wear safety goggles when jump staring the engine Do not allow the machine to make careless contact with t...

Page 51: ...ter operation For a long term storage fill the fuel tank lubricate necessary points and run the machine for more than 20 minutes once a month In freezing weather add antifreeze to the coolant accordin...

Page 52: ...2 years or 500 hours Piping parts Engine drain hose 4 years 6 Cooling system Piping parts Radiator hose 2 years Radiator drain hose 4 years 7 Control related parts Cable Cable 4 years 8 Intake system...

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Page 55: ...e bead wire is cut bent or significantly deformed When the carcass ply is showing due to excessive wear When damaged portion of the carcass exceeds one thirds of the tire width When a tire has ply sep...

Page 56: ...3 PER OD CAL MAINTENANCE 3 3 Periodical Maintenance Points...

Page 57: ...Grease 2 Every 200 1 Engine oil filter Replace element hours Every 250 hours 0 Wheel hub nut Check looseness 42 Every 450 C Fuel filter Replace element hours 1 0 Hydraulic oil tank Change oil wash ins...

Page 58: ...f it is between H and L marks If necessary add the hydraulic fluid from the fill port Radiator With the cap removed check to see if the coolant level is near the port Add as necessary Use soft water f...

Page 59: ...tighten it sufficiently and thinly apply vaseline or grease to prevent rusting Fuel tank Check the fuel level with the fuel gauge Add as necessary from fill hole 0 To open the filler cap insert the s...

Page 60: ...h the drain plug removed A WARNING When draining a hot oil use care not to get burned 2 Refit the drain plug and fill the crankcase with the engine oil from the fill hole on the cylinder head cover NO...

Page 61: ...ose tighten it Be sure to torque it to the specified value Tightening torque 147 N m A CAUTION Turn the wheel hub nut in the tightening direction during inspection Excessive tightening of the wheel hu...

Page 62: ...e engien at idling for 2 to 5 minutes When the hydraulic oil has become free from air bubbles stop the engine and recheck the oil level Suction filter Take off the hydraulic tank cover Take out and cl...

Page 63: ...ctric bulbs turn signal lamps headlamps and flood lamps light up or blink by operating switches on the operation panel If they do not light up replace them with new ones Fuel tank With the drain plug...

Page 64: ...s Use a needle or the like to clean nozzle hole Refit the filters to the nozzles Air cleaner Unclip and remove the cover and pull out the element Blow compressed air from inside of the element to clea...

Page 65: ...ement Change the element if necessary Sprinkler filter filler port Liquid spray filter Remove the filter case located on the lower right of the driver s station Clean or change the element Gas damper...

Page 66: ...se Interval Consumable Part Part No Annual Replacement per Remark replacement year operation hours Engine oil filter cartridge 4032 17006 0 200 Fuel filter cartridge 4032 12013 0 450 Air cleaner eleme...

Page 67: ...0 4032 12013 0 4703 68005 0 4416 62001 0 Gas damper 4409 91000 0 Engine oil filter cartridge 4032 17006 0 Line filter cartridge hydraulic oil 4213 46001 0 Suction filter element hydraulic oil 4210 68...

Page 68: ...container with flushing oil before filling new oil Be sure to use fuels and greases designated recommended by SAKAI Faulty due to the use of those not designated recommended by SAKAI is out of the sco...

Page 69: ...c oil Oil API CC API GL 4 VG 45 company RPM DELO Universal Rando Oil CALTEX 300 oil Thuban 90 HD 46 BP Vanellus BP Gear Oil BP Energol BP C3 30 EP 90 HLP 46 Esso Lube Esso Gear Oil Nuto ESSO 03 30 GP9...

Page 70: ...uClara BATTERY HMSO N CO ENGINE STOP TACHO FUEL UNI HYD THERMO OIL SOLENOID METER FILTER UN PRESSURE BR FUSE SENSOR SWITCH SWITCH OA 1 S 1 I STARTING MOTOR RR 51 FUSE woRi L9130 LAWW CAUTION Size of...

Page 71: ...ong time or the electricity is used too much the pole plates will be damaged shortening its service life extremely When the battery will not be used for a long time charge it sufficiently leave it in...

Page 72: ...ard reverse 0 14 km h 0 8 7 mile h Vibrating power Gradability Rolling width Minimum turning radius Engine Model Total displacement Rated output Max torque Tank capacity Fuel tank Hydraulic tank Sprin...

Page 73: ...SAKAI HEAVY INDUSTRIES LTD Head Office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone Tokyo 03 3431 9971 Facsimile 03 3436 6212 Printed in Japan 2008 10 105 00...

Page 74: ...l_ri SA A EAVY DS...

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