Multiquip R2000H User Manual 2

OPERATION AND PARTS MANUAL

MODEL R2000H

RIDE-ON STATIC ROLLER

(

Honda GX240K1QAE2

Revision #4 (07/24/08)

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

ENGINE)

PROPOSITION 65 WARNING

PAGE 2 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

NOTES

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 3

TABLE OF CONTENTS

Multiquip R2000H — Ride-On Static Roller

Proposition 65 Warning ............................................. 2

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Specifications (Roller) ............................................... 6

Specifications (Engine) ............................................. 7

Dimensions ............................................................... 8

Safety Message Alert Symbols ............................ 9-10

Rules For Safe Operation .................................. 11-13

Operation and Safety Decals .................................. 14

General Information ........................................... 15-16

Roller Components ............................................ 18-19

Engine Components ............................................... 20

Inspection ........................................................... 21-22

Initial Start-Up ......................................................... 23

Operation ........................................................... 24-25

Maintenance ...................................................... 26-28

Preparation For Long-Term Storage ...................... 29

Troubleshooting (Roller).......................................... 30

Troubleshooting (Engine) ........................................ 31

Explanation Of Code In Remarks Column .............. 32

Suggested Spare Parts ........................................... 33

Name Plate and Decals ..................................... 34-35

Brake Assembly ................................................. 36-37

Steering Assembly ............................................. 38-39

Chassis and covers Assembly ........................... 40-41

Battery Assembly ............................................... 42-43

Rear Drum Assembly ......................................... 44-45

Drive Assembly .................................................. 46-47

Transmission Assembly...................................... 48-49

Water System Assembly .................................... 50-51

Honda GX240K1QAE2 Engine

Air Cleaner Asssembly ....................................... 52-53

Camshaft Asssembly ......................................... 54-55

Carburetor Asssembly ....................................... 56-57

Control Asssembly ............................................. 58-59

Crankcase Cover Asssembly ............................. 60-61

Crankshaft Asssembly ....................................... 62-63

Cylinder Barrel Asssembly ................................. 64-65

Cylinder Head Asssembly ..................................66-67

Fan Cover Asssembly ........................................ 68-69

Flywheel Asssembly ........................................... 70-71

Fuel Tank Asssembly ......................................... 72-73

Ignition Coil Asssembly ...................................... 74-75

Starter Motor Assembly .....................................76-77

Control Box Assembly ........................................ 78-79

Muffler Asssembly .............................................. 80-81

Piston Asssembly ............................................... 82-83

Recoil Starter Asssembly ................................... 84-85

Engine Labels .................................................... 86-87

Terms and Conditions of Sale ................................. 88

NOTE

Specification and part number are subject to change without notice.

PAGE 4 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Effective:

January 1

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■

View Parts Diagrams

■

Order Parts

■

Print Specification Information

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax.

Domestic (US) Customers dial:

1-800-6-PARTS-7 (800-672-7877)

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at:

parts@multiquip.com.

To obtain an MQ Account, contact your District Sales Manager for more information.

internet

Use the on

Standard orders

and qualify for a 5% Discount

for all orders which include

complete part numbers.*

Fax

your order in and qualify for a 2% Discount

Standard orders

for all orders which include

complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers

their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

should contact

When ordering parts, please supply:

❒❒

❒

❒❒

Dealer Account Number

❒

❒❒

❒

Dealer Name and Address

❒❒

Shipping Address (if different than billing address)

❒

❒❒

❒

Return Fax Number

❒❒ ❒❒

❒

Applicable Model Number

❒❒

❒

Quantity, Part Number and Description of Each Part

❒❒

All orders are treated as

Standard Orders

and will ship the same day if received prior to 3PM PST.

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 5

Specify Preferred Method of Shipment:

❒❒

✓

UPS/Fed Ex

■

Priority One

■

Ground

■ Next Day

■

Second/Third Day

✓ DHL ✓

Tr u ck

R2000H — SPECIFICATIONS (ROLLER)

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retemaiDlloR

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-HR

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yticapaCslloRtnorF

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m049(.ni73

).mm117(.ni82-tnorF

)mm318(.ni23-raeR

805(.ni02-tnorF

).mm

)mm016(.ni42-raeR

).mm38(.ni52.3-HR

).mm922(.ni9-HL

).mm38(.ni52.3

).mm44(.ni57.1-HL

).gK411sretil8.65+8.65(.sbl052snollag51+51

deepSlevarT)esreverdnadrawrof.xam(hpm6.5

aM)seerged51(%72

evirD

PAGE 6 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

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niahcnoissimsnartcit

R2000H — SPECIFICATIONS (ENGINE)

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R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 7

R2000H — DIMENSIONS

Figure 1. R2000H Roller Dimensions

SNOISNEMID.3ELBAT

.FER

NOITPIRCSED

RETTEL

AthgieHllarevO).mm5921(.ni15

BhtdiWllarevO).mm049(.ni73

ChtgneLllarevO)

DthgieHemarFtnorF).mm318(.ni23

EthgieHleehWgnireetS).mm9121(.ni84

FthgieHemarFrewoL).mm234(.ni71

GhtgneLesaBleehW).mm0721(.ni05

NOISNEMID

).MM(.NI

.mm4581(.ni37

PAGE 8 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

R2000H — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in

injury to yourself and others.

This Operation and Parts Manual has been developed to provide

NOTE

complete instructions for the safe and efficient operation of the

Multiquip Model R2000H

Roller. Refer to the engine manufacturer's instructions for data relative to its safe operation.

Before using this roller, ensure that the operating individual has read and understands all instructions in this manual.

Static

HAZARD SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and

odorless, and can cause death if inhaled. NEVER operate this equipment in a confined

area or enclosed structure that does not provide ample free flow air.

Explosive Fuel

GASOLINE is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or

combustible fluids. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent.

DANGER: You WILL be KILLED or

SERIOUSLY injured if you do not follow directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you do not follow directions.

CAUTION: You CAN be injured if you

do not follow directions.

Potential hazards associated with MQ R2000H vibration roller operation will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols.

Burn Hazards

Explosive Fuel

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. Never operate the engine with heat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 9

R2000H — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF switch in

the OFF position, and remove the ignition key when the machine is not in use.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Respiratory Hazard

ALWAYS wear approved respiratory

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual to help prevent damage to your roller, other property, or the surrounding environment.

This roller, other property, or the surrounding environment could

NOTE

be damaged if you do not follow instructions.

PAGE 10 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

RULES FOR SAFE OPERATION

■

DANGER:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the R2000H Roller:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed boots and other protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or pump.

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact

hot

with

■

The engine of this roller requires an adequate free flow of cooling air. Never operate the roller in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the roller or engine and may cause injury to people and property. Remember the roller's engine gives off DEADLY gases.

components can cause serious burns.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

ALWAYS check the machine for loosened threads or bolts before starting.

■

ALWAYS wear proper respiratory (mask) hearing and eye protection equipment when operating the roller.

■

ALWAYS refuel in a well-ventilated area, away from sparks and open flames.

■

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool.

DO NOT

could result from fuel vapors, or if fuel is spilled on a hot engine.

■

NEVER operate the roller in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

smoke around or near the machine. Fire or explosion

bodily

harm or even death.

■

Topping-off to filler port is dangerous, as it tends to spill fuel.

■

Refer to the technical questions or information.

■

NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

Honda Engine Owner's Manual

for engine

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 11

■

NEVER Run engine without air cleaner. Severe engine

damage may occur.

■

ALWAYS read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

■

ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using roller.

■

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■

DO NOT operate this roller with hydrostatic oil temperature higher than 180 degrees fahrenheit.

■

NEVER leave the roller unattended, turn off engine and place parking brake lever in upright position.

■

CAUTION must always be observed while servicing this roller. Rotating parts can cause injury if contacted.

■

DO NOT leave roller with engine running.

■

If the roller must be stopped on an incline (grade), remove the ignition key and

front

and

■

NEVER drive the roller on unshored trenches or near steep,

place chock blocks (not provided) under

rear

drums.

unsupported banks. The vibration caused by the roller could cause a cave-in.

■

ALWAYS use extreme care when operating near obstructions, on slippery surfaces, grades and side slopes.

■

ALWAYS wear slip resistant safety shoes or boots.

■

Unauthorized equipment modifications will void all

■

Maintenance Safety

■

the

■

warranties.

■

When working on slopes, avoid

sidehill travel

. Operate up

■

and down travel only. Remember, the danger of sliding on and/or tripping on steep slopes is always present.

RULES FOR SAFE OPERATION

Start the roller only when seated in the operator’s position. Check all hydraulic components and fittings for wear. Before starting engine, ensure that there is smooth movement

of the travel lever, throttle and parking brake.

ALWAYS check

leakage before starting engine. High Temperatures – Always stop engine and allow the

engine to cool before adding fuel, oil or performing service and maintenance functions. Contact with cause serious burns.

NEVER disconnect any

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.

NEVER lubricate components or attempt service on a running machine.

ALWAYS allow the machine a proper amount of time to cool

before servicing. Keep the machinery in proper running condition. Fix damage to the machine immediately and always replace

broken parts, or missing decals. Dispose of hazardous waste properly. Examples of potentially

hazardous waste are used motor oil, fuel and fuel filters. DO NOT use food or plastic containers to dispose of

hazardous waste. DO NOT pour waste, oil or fuel directly onto the ground,

down a drain or into any water source.

hydraulic oil, engine oil

, and fuel levels for

hot

"emergency or safety devices"

components can

■

ALWAYS wear

■

When malfunctions occur, always remove the ignition key and place a "

seat belts

DO NOT OPERATE

" sign in the operator's

seat.

■

If a malfunction occurs with the travel lever mechanism, speed and direction will be impossible to control. Immediately stop the roller and correct the problem.

■

If the steering system operates improperly, immediately stop the engine and apply the parking brake.

■

In the event of hydraulic hose or line failure, promptly return the travel lever to the “neutral” position, stop the engine and set the parking brake.

PAGE 12 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

RULES FOR SAFE OPERATION

Loading and Transporting

DANGER :

DANGER! ALWAYS LOAD AND UNLOAD THE ROLLER ON LEVEL, HARD GROUND OR PAVEMENT.

result from improper loading, lifting or unloading. Use extreme caution!

■

The roller has an operating weight of approximately 2,063 lbs. (938 Kg). Use lifting equipment capable of lifting this weight.

■

ALWAYS check the roller's lifting hooks. Before lifting or transporting the roller, lock the frame with the locking bar that is provided. Make sure the hooks are secure and tight before lifting the machine.

■

When driving the roller onto a transporting vehicle or trailer, use ramps or other suitable material of sufficient strength to support the roller.

■

Remove mud, oil, ice, snow or any other slippery materials from the ramps and bed of the vehicle to avoid accidents.

■

After loading, apply the parking brake.

■

Use a chain, binders or other suitable means to firmly secure the roller before transporting.

■

Only use the lifting points for the roller that are clearly marked

lifting point

as “

”.

Serious injury or death can

Emergencies

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

always

know the location of the

keep a phone on the job site

and

fire department

fire extinguisher

first aid kit

. This

■

NEVER apply chains through the articulating section of the roller. The chain could cause damage by scoring the hydraulic steering cylinder.

■

NEVER stand below roller when it is being lifted.

DANGER :

DO NOT allow personnel to

near any suspended machine

or death may result.

stand under

. Serious injury

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 13

Machine Safety Decals

OPERATION AND SAFETY DECALS

The R2000H information. The illustration below and on the next page shows these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

static roller

is equipped with a number of safety decals. These decals are provided for operator safety and maintenance

PAGE 14 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

R2000H — GENERAL INFORMATION

The R2000H roller has been designed for asphalt application and compaction of granular soils used in site preparation. Use the machine only for the purpose intended and by experienced personnel who understand this operating manual and all safety decals. Typical applications for this roller are driveways, patch work and road repairs.

POWER PLANT

The R2000H roller is powered by a Honda GX240K1QAE2, aircooled, gasoline engine rated at 7.1 hp @3,600 rpm. The engine features a side-mounted muffler designed to direct engine exhaust away from the operator. In the event of low oil, this engine has a built in " oil level reaches an unsafe operating level.

SPRINKLER SYSTEM

A 21 gallon (79.5 liters) water tank with a gravity feed spray bar is provided for wetting the roll for asphalt pavement rolling.

The water system is fully adjustable from the operator’s position by adjusting the valve in the floor.

Water can be added to the front and rear rollers. Thirty gallons (250 lbs.) of water can be added to the front rollers, 51 gallons (427 lbs.) to the rear roller.

oil alert system

" that will shut down if the engine

NEVER! stand under, or get onto the roller while it is being lifted or moved.

ONLY! use approved certified lifting devices capable of lifting at least 4,000 lbs. (1,814 Kg.).

When lifting of the roller is required, only use the provided

eyes

to lift the roller. Using other sections of the roller for lifting

purposes may cause severe damage to the roller.

DO NOT operate this roller on

Danger

CAUTION

Danger

slippery

wet

surfaces.

lifting

Before starting an asphalt rolling job, be sure all spray bar holes are clear of dirt or foreign matter and are working. Always use clean fresh water in the water tank. To prevent rust and foreign debris from clogging the spray bar holes, drain and flush water tank and spray bars every 30 days.

LIFTING THE ROLLER

When lifting of the roller is required, attach a suitable hook or shackle to the lifting points (4) are marked by a lifting hook decal. Make sure the lifting device is capable of lifting 4,000 lbs. (1,814 Kg.).

lifting eye

of the roller. These

DANGER:

Before operating the roller, make sure that personnel and obstacles are free from the roller’s path. Serious injury or even death can result!

The forward-reverse control lever operates the hydrostatic pump which governs the roller speed and direction of travel. The speed in which movement of this lever is made is directly related to the

amount of pressure that is applied to the travel lever in each direction. Travel speed is infinitely variable from 0 to 4 mph. The neutral position of this lever will cause the roller to stop.

This roller is (ROPS). The possibility exists of the roller tipping over causing severe bodily harm , even death, if side-side operation is used (Figure 3). DO NOT use this roller for side to side applications.

OPERATING ON SLOPES

Special care must be taken when operating the roller on hills or slopes. There exist the possibility of serious injury to the operator and severe damage to the roller in the event of a roll over. ALWAYS operate the roller up and down hills rather than from side to side. For safe operation hillside slopes should not exceed 15 degrees (27 % grade). See Figure 2 below.

not offered

Figure 2. Recommended Slope

with a

Rollover Protection Structure

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 15

R2000H — GENERAL INFORMATION

Tipping (Rollovers)

NEVER! operate the roller on side slopes (Figure 3). The

possibility exist that the roller could tip over (roll over), thus causing bodily harm even death and serious damage to the equipment.

In the event the roller does tip over, if at all possible, try to shut down the engine by turning the ignition key to the Extreme care must be taken to prevent damage to the engine. When the roller has been tipped over, oil from the engine crankcase can flow into the combustion chamber, which can severely damage the engine the next time it is started.

IMMEDIATELY after a unit has tipped over upright the unit as soon as possible to prevent oil from leaking into the combustion chamber.

CAUTION:

WARNING:

Figure 3. Tipping (Rollover)

OFF

position.

To prevent damage to the engine after a

rollover, the roller must NOT be started.

NEVER start a roller after a rollover. CONTACT your nearest authorized Multiquip

dealer for instructions or servicing.

This roller is intended to be used on flat surfaces only. DO NOT use this roller near open trenches, hollow spaces or rocks that be below surface.

NOTE

DANGER:

NEVER! operate the roller on

slopes

causing injury to personnel and severe damage to the equipment.

This roller is

Protection Structure

possibility exists of the roller tipping over causing severe bodily harm , even death, if side-side operation is used (Figure 3). DO NOT use this roller for side to side applications.

. The roller may tip over

not offered

with a (ROPS). The

side

Rollover

PAGE 16 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

NOTE PAGE

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 17

R2000H — ROLLER COMPONENTS

Figure 4. Roller Components

PAGE 18 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

R2000H — ROLLER COMPONENTS

1. Engine – The MQ R2000H ride-on roller uses an 7.1 HP Honda GX240K1QAE2 air cooled, 4-stroke, single cylinder gasoline engine. This engine uses unleaded gasoline.

2. Steering Wheel — Use this wheel to steer the roller.

3. Parking Break Lever — Pull the lever upward to set the parking break. To release the parking break, press and hold the button on top of the lever and push lever downward.

4. Transmission Control Lever — Push the lever to make the roller travel in a forward direction, pull the lever

backward

Maximum travel speed is 5.6 MPH (9.0 KPH). Center position is neutral, no travel.

5. Documentation Box — Maintain and store Operation, Parts, and Engine manuals in this box.

6. Operator's Seat — of both front rear drum edges during start the roller unless seated in the operator's seat.

7. Water Tank/Cap — Remove filler cap and fill with clean fresh water. Water tank capacity is 21 gallons (79.5 liters). If water level is low, add water as necessary.

8. Rear Lifting Point – Attach a crane or suitable lifting device to this point when lifting of the roller is required.

9. Rear Scrapper – This adjustable rear scrapper blade helps prevent the buildup of material between the drum and frame.

10. Rear Roller – This roller is a 32-inch wide with beveled edges (no vibration). The beveled edges help prevent asphalt marring.

11. Front Lifting Point – Attach a crane or suitable lifting device to this point when lifting of the roller is required.

12. Front Scrapper – This adjustable rear scrapper blade helps prevent the buildup of material between the drum and frame.

13. Front Roller Water Plug – Remove this plug to add water (ballast) to the front drum. This plug is located on each side of the split front roller.

14. Front Roller Zerk Fitting – Grease this fitting as recommended in the maintenance section of this manual.

15. Steering Zerk Fitting – Grease this fitting as recommended in the maintenance section of this manual.

to make the roller travel in a reverse direction.

A contoured seat that provides visibility

operation.

forward

at all times

NEVER!

steel drum

16. Access Panel – Lift this -panel to gain access to the

17. Sprinkler Valve Lever – A gravity feed spray bar is

18. Front Roller – This roller is a

19. Rear Roller Water Plug – Remove this plug to add

transmission assembly and battery. A. Transmission – This roller uses a hydrostatic

pump which provides hydraulic pressure to the hydraulic drive system. Fill the pump reservoir with hydrostatic transmission fluid. Fill with Mobil 300, GM Dextron B or Ford MCZ-41A type transmission fluid.

Free Wheel Engagement Pin

The hydrostatic transmission is equipped with a free wheel engagement pin, which, when actuated, allows the oil to circulate freely within the roller, thereby permitting the roller to be moved without the engine running. This engagement pin is only to be used in the event the roller is disabled.

This pin is located on the side of the hydrostatic transmission underneath the acess cover. It is actuated by pushing the pin inward and placing the locking clip over the pin to keep it in place.

B. Battery – Provides +12VDC to the electrical

system. Replace only with recommended type battery, see specification Table 1.

provided on the front and rear of the roller for the wetting

Pull

of the roll for asphalt pavement.

start

Push

drum

edges help prevent asphalt marring.

water (ballast) to the rear drum. This plug is located on the chain-side of the roller. It is shown here for clarity only.

NOTE

the flow of water to the gravity feed system.

the lever

with beveled edges (no vibration). The beveled

downward

Tie-Down Transport Points –

Attach a chain or suitable tie-down

device to these points when transporting of the roller is required.

upward on the lever

stop

the flow of water.

split

28-inch wide

steel

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 19

R2000H — ENGINE COMPONENTS

Figure 5. Engine Controls and Components

INITIAL SERVICING (ENGINE)

The engine (Figure 5) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1. Fuel Filler Cap/Fuel tank – Remove this cap to add unleaded gasoline to the fuel tank. Make sure cap is tightened securely. DO NOT over fill. Fuel tank capacity is

1.59 gallons (6.0 liters). Use unleaded gasoline. For additional information refer to Honda engine owner's manual.

DANGER

6. Choke Lever – Used in the starting of a cold engine, or in cold weather conditions. The choke enriches the fuel mixture.

7. Air Cleaner – Prevents dirt and other debris from entering the air intake system. Remove wing-nut on top of air filter cannister to gain access to filter element.

NOTE

Operating the engine without an air filter, with a damaged air filter, or a filter in need of replacement will allow dirt to enter the engine, causing rapid engine wear.

8. Spark Plug – Provides spark to the ignition system. Set

Adding fuel to the tank should be done only when the engine is stopped and has had an opportunity

to cool down. In the event of a fuel spill, DO NOT attempt to start the engine until the fuel residue has been completely wiped up, and the area surrounding the engine is dry.

2. Throttle Lever – Used to adjust engine RPM speed (lever

advanced forward

FAST

3. Engine ON/OFF Switch – ON position permits engine

starting, OFF position stops engine operations.

4. Recoil Starter (pull rope) – Manual-starting method. Pull

the starter grip until resistance is felt, then pull briskly and smoothly.

5. Fuel Valve Lever – OPEN to let fuel flow, CLOSE to stop

the flow of fuel.

PAGE 20 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

SLOW

, lever back toward operator

spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch) Clean spark plug once a week.

9. Muffler – Used to reduce noise and emissions.

10. Ignition Switch– Use this switch to start and stop the engine.

11. Circuit Breaker– Protects the battery charging circuit. See Honda owner's manual for additional information.

WARNING

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operating. NEVER operate the engine with the muffler removed.

R2000H — INSPECTION

CAUTION

NEVER operate the roller

in a confined area or enclosed area structure that does not provide

free flow of air

ample

ALWAYS wear approved eye and hearing protection before operating the roller.

NEVER place hands or feet inside the guard rings while the engine is running. ALWAYS shut the engine down before performing any kind of maintenance service on the roller.

Before Starting

1. Read safety instructions at the beginning of manual.

roller

2. Clean the filter and carburetor.

3. Check the air filter for dirt and dust. If air filter is dirty, replace air filter with a new one as required.

, removing dirt and dust, particularly the air

3. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick.

4. If the oil level is low (Figure 7), fill to the edge of the oil filler hole with the recommended oil type (Table 4). Maximum oil

capacity is 400 cc.

Reference manufacturer engine

NOTE

Figure 7 Engine Oil Dipstick (Oil Level)

manual for specific servicing instructions.

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4. Check carburetor for external dirt and dust. Clean with dry compressed air.

5. Check fastening nuts and bolts for tightness.

Engine Oil Check

Explosive Fuel

1. To check the engine oil level, place the roller on secure level ground with the engine stopped.

2. Remove the filler dipstick from the engine oil filler hole (Figure 6) and wipe it clean.

Figure 6. Engine Oil Dipstick (Removal)

CAUTION

Fuel Check

1. Remove the gasoline cap located on top of fuel tank.

2. Visually inspect to see if fuel level is low. If fuel is low, replenish with unleaded fuel.

3. When refueling, be sure to use a strainer for filtration. DO NOT top-off fuel. Wipe up any spilled fuel.

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Motor fuels are highly flammable and can be dangerous if mishandled. DO NOT smoke while refueling. DO NOT attempt to refuel the roller if the engine is

hot! or running

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 21

R2000H — INSPECTION

Water System Check

1. Check the water tank, located under the operator's seat, to see if filled (Figure 8). Add water if necessary. The water tank has a capacity of approximately 21 gallons (79.5 liters).

Figure 8. Water Tank Check

2. Water can also be added to the front and rear rollers. To fill, remove pipe plug from the roller side plate and position roller so that the hole is at the top. The right side cover must be removed to fill the rear roller. Replace plugs and side cover after filling. Thirty gallons (250 lbs.) of water can be added to the front rollers and 51 gallons (427 lbs.) of water can be added to the rear roller.

Battery Check

A 12-volt DC battery (Figure 9) is shipped dry, and will require a proper electrolyte level for operation.

ALWAYS be sure that the battery cables are properly connected to the battery terminals as shown below. Generally

RED

the the battery, and the BLACK cable will be connected to the negative terminal of the battery.

WARNING

cable will be connected to the positive terminal of

Figure 9. Battery

If the battery cables are connected incorrectly, electrical damage will occur causing damage to the roller's electrical circuits. Pay close attention to the polarity of the battery when connecting the battery.

3. Protect water from freezing by adding antifreeze or draining water tank when not in use. Use only clean water in water tank.

PAGE 22 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

R2000H — INITIAL START-UP

CAUTION:

DO NOT attempt to operate the roller until the

Safety, General Information and Inspection sections have been read and understood.

1. Sit down in the operator's seat.

2. Before starting engine, make sure the immediate area is free of obstructions and debris that may lay in the roller's path.

3. Make sure that the roller's transmission control lever (Figure

10) is placed in the

neutral position

2 Rotate the

and set to ensure optimum operating speeds.

NOTE

throttle lever

slow

for starting. The engine governor speed is factory

Figure 12. Throttle Lever

(Figure 12) halfway between

The CLOSED position of the choke lever enriches the fuel mixture for starting a COLD engine. The OPEN position provides the correct fuel mixture for normal operation after starting, and for restarting a warm engine.

fast

Figure 10. Transmission Control Lever

NOTE

Starting the Engine

1. Place the engine position.

fuel valve lever

NEVER operate the roller with the access cover open. Keeping the cover closed will prevent dirt and debris from entering into the transmission and drivetrain assemblies. ALWAYS keep the

access cover closed for normal operation.

(Figure 11) to the "ON"

3. Place the position.

Choke Lever

(Figure 13 in the "

Figure 13. Choke Lever

CLOSED

Figure 11. Engine Fuel Valve Lever

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 23

4. Insert the ignition key into the ignition (Figure 14), place key

start

in the

5. If the engine does not start, repeat steps 1 through 4 or consult the troubleshooting guide contained in this manual.

6. Let the engine warm for 3 to 5 minutes before using roller.

Check for fuel and oil leaks, and noises that would associate with a loose guard and/or covers.

7. If necessary return the choke knob to the full position.

OPERATION

1. Release the parking brake by pushing down on the parking brake lever.

position, when engine starts release key.

Figure 14. Ignition Switch

3. The speed of the roller is directly proportional to the amount of pressure being applied to the lever in each direction. Travel speed is between 0 and 4 mph (6.4 kph). The transmission control lever may be moved forward or reverse at any engine speed. However, it should not be moved rapidly as damage to the drive train may result.

4. Further adjustment of travel speed can be made by changing engine throttle setting. Maximum speed is attained with maximum engine speed and full forward or reverse lever

position. Maximum power is attained with lever just out of neutral position and maximum engine speed

OPEN

WARNING

R2000H — OPERATION

Figure 15. Traveling Forward

Transmission control lever must be in neutral position when starting engine. NEVER engage transmission abruptly because this places unnecessary high loads on all drive line components.

2. To make the roller move in a transmission control lever forward as shown in Figure 15. Make sure lever is securely place into notch.

PAGE 24 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

forward direction

, move the

WARNING

The roller in the " transmission system will not hold the roller in a "stopped" condition.

NOTE

parking brake

To transmission control lever toward the cannot be slowed or stopped using the hydraulic braking system, use the slow and then stop the roller.

must be used to hold the

stopped

slow

neutral position

" condition. The

stop

roller, move the

. If roller still

parking brake

Water Sprinklers Control

1. If the application requires the wetting of a surface, open

water valve

the (Figure 16) to spread the proper amount of water onto the roller drum at the desired rate that will wet both the front and rear rollers.

located at the bottom of the roller floor

R2000H — OPERATION

Figure 16. Water Sprinkler Valve (ON)

Normal Shut-Down

1. Place the engine throttle lever in the idle position. Let the

engine idle for 3-5 minutes.

2. If the water valve is open, close it (Figure17)

Figure 17. Water Sprinkler Valve (OFF)

Place position

the transmission lever (Figure 18) in the

neutral

5. Turn the ignition key (Figure X) to the OFF position remove key. Store key in a safe place.

6. Place the engine position.

7. To prevent the roller from moving, place chock blocks under each roller drum

Figure 19. Parking Brake Lever (Set)

Figure 20. Ignition Switch (OFF)

fuel valve lever

(Figure 20) in the OFF

Figure 18. Transmission Control Lever (Neutral)

Place

the parking brake lever (Figure 19) in the This will lock the rear roller drum in place, and prevent the roller from moving. Whenever the operator's seat is vacated, place the transmission lever in neutral, and set the parking brake

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 25

set position

8. Clean the entire roller with warm water and mild soap. Pay close attention to the scrapper bar and spray bar holes, making sure that no dirt or debris is present. Dirt and debris can cause the sprinkler system to get clogged.

Emergency Shut-Down

1. Turn the ignition key (Figure20) to the OFF position.

2. Place the engine position.

fuel valve lever

(Figure 11) in the OFF

R2000H — MAINTENANCE

Read carefully and follow the maintenance instructions in this

Hydrostatic Transmission

section. Always check the engine and transmission lubrication before using the roller.

WARNING

1. Even minute amounts of foreign matter will cause major damage. If the reservoir screen is damaged, it must be replaced immediately.

Before servicing or performing maintenance,

off

make sure that the engine is brake is in the

disconnected

, the transmission control lever is

neutral

position, and the spark plug is

and secured away from the

, the parking

spark plug.

Lubrication

Refer to the lubrication chart below for proper lubrication of roller.

2. The fluid will last under normal operating conditions, for the life of the transmission. If overheating or water contamination occurs, the oil will change from its normal reddish color to black or milky and must be replaced.

3. To drain the fluid, remove the plastic reservoir and the 3/816 hex head vent-plug from the top of the cast iron body.

CAUTION

Follow the engine's manufacturer manual for engine lubrication.

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4. To refill, reassemble the hex head vent-plug and the plastic

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reservoir to the transmission. Refill through the reservoir with clean fluid. With the transmission control lever in full forward or reverse position, rotate the input pulley several times to flush the internal mechanism of the transmission and re-

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drain. Refill through the reservoir with an approved transmission fluid.

The threads connecting the reservoir to the aluminum body are left-handed. Turn transmission upside down to drain.

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5. Prior to running the roller, the transmission fluid level should not be above the cold mark. Overfilling reduces the expansion are in the reservoir and fluid will spill out at operating temperatures.

6. Proper cooling is essential to both the performance and life of the transmission. Cooling is dependent on the fan and the fins on the body. Keep the fan tightened and replace it if the blades become broken. Keep the cooling fins clean.

WARNING

Cleaning the transmission with high pressure water spray or live steam may force water into the reservoir. A few drops of water in the system will result in excessive oil expansion, loss of oil

through the vent hole in the reservoir, and a loss of power at operating temperature. A shield or cover should be placed over the reservoir cover during cleaning operation or in other situations where water maybe introduced into the unit.

PAGE 26 —R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08)

R2000H — MAINTENANCE

Transmission Control Lever Adjustment

If the roller tends to creep when the control lever is in neutral, perform the following. Refer to Figure 21 for location of components.

Figure 21. Control Lever Adjustment Points

1. Place the unit where there is ample clearance fore and aft.

2. Open the cover, place the control lever to neutral position, and remove cotter pin from rod.

3. Start engine and allow to run at idle speed.

4. Move control lever in reverse until roller just starts to move backwards.

Brake Adjustment

1. The brake should be adjusted so that it takes 70 ± 5 lbs. of force applied at the end of the lever to fully actuate it.

2. To adjust brake, turn the knob located at the top of the brake lever clockwise (toward the operator) to tighten the brake.

3. Turn the knob counterclockwise (away from the operator) to loosen the brake.

Steering Adjustment

1. The roller chain of the steering mechanism must be kept clean, lightly oiled and properly tensioned.

2. Adjust the turnbuckle to allow 1/16" deflection to the slack side of the chain when in the straight position.

Drive Chains

1. The drive chains must be kept clean, lightly-oiled, and properly tensioned.

2. When wear of the side bars, rollers or sprockets become noticeable, they should be replaced promptly.

3. Clean all dirt from the chain with solvent and re-oil lightly.

Drive Chains Tension Adjustment

5. Carefully hold the control lever in place and turn the engine off.

6. Without disturbing setting of control lever/transmission arm, add washers on rod between cotter pin hole and grid tube and replace cotter pin.

7. Return control lever to neutral position.

8. Check position of guide tube rod in arm slot. If not centered, remove end of link from arm, loosen lock nuts, adjust length by screwing ends in or out until ball stud drops in arm in centered position.

9. Tighten all nuts.

10. Restart engine and make sure transmission output sprocket does not move, at all engine speeds.

1. Move the roller slowly in the reverse direction until the slack side of the chain is toward the rear of the roller.

2. Put the control lever in the neutral position and shut the engine off and apply parking brake.

3. Loosen the two bolts that hold the idler plate forward (into the chain) using a pry bar.

4. Retighten the two mounting bolts.

5. Start the engine and move the roller in the forward direction, 5 to 10 feet.

6. Move the control lever to the neutral position and turn the engine off.

7. Proper chain tension is approximately 0.2 to 0.4-inch deflection with approximately 5 lbs. of force applied to the center of the span between the sprockets toward the front of the roller.

8. If the tension is still incorrect, readjust.

R2000H RIDE-ON STATIC ROLLER — OPERATION & PARTS MANUAL — REV. #4 (07/24/08) — PAGE 27

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