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Baroness SP05, Service Manual

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machine. Transport on a trailer if you have to
transport the machine a long way.
For the towing method, see the Owner’s
manual.

Important

Going over the limit of towing may lead to the
failure of hydraulic equipment. Also, if the
machine is towed at high speed, the wheel may
cease its motion. Stop towing in case of wheel
lock. Resume towing at low speed after the
pressure has been stabilized.

Neutral

If the machine goes forward or in reverse
without pressing on the forward/reverse pedals,
the neutral is not working. Adjust accordingly.
Refer to the Owner’s manual for adjustment of
the neutral.

Depressurization

Be sure to depressurize the hydraulic system
before inspecting and repairing it.
For depressurizing, move the machine to a level
place. Apply the parking brake and lower the
rake. Then, stop the engine and remove the key.
To depressurize the hydraulic circuit, set the
forward/reverse pedals and all the drives of the
operating machine in the neutral position. To
depressurize the steering circuit, turn the
steering wheel from side to side.

Hydraulic circuit failure

The hydraulic traveling circuit of this equipment
is made up of a closed circuit.
In the event of failure of the hydraulic equipment
of the hydraulic circuit, debris and contaminant
from the faulty hydraulic equipment will circulate
to every part of the circuit. Since this
contaminant causes damage to other hydraulic
equipment, such debris and contaminant must
be removed to prevent further failure of other
hydraulic equipment.
In the event that failure of hydraulic equipment is
found in the hydraulic circuit, remove hydraulic
hoses and piping of the whole hydraulic circuit
and elean them well with kerosene and soon.
Drain all the hydraulic oil from hydraulic tank
and hydraulic equipment other than the
hydraulic hoses and piping and clean well.
We recommend to replace the hydraulic oil,
hydraulic oil filter and defective hydraulic
equipment with new ones.

Hydraulic system

Hydraulic system

Page 5-9

General instructions

Summary of Contents for SP05

Page 1: ...Bunker rake SP05 Service manual Serial No 10151 Vol 1...

Page 2: ...t prior notice for improvement When replacing parts be sure to use genuine Baroness parts or parts designated by Kyoeisha Note that the Baroness product warranty may not apply to defects caused by the...

Page 3: ...air 5 35 Inspection and repair of each section 5 38 Removal and installation of each section 5 39 Electrical system 6 1 Maintenance 6 2 Specifications 6 3 Special tools 6 4 Measurement method 6 4 Adju...

Page 4: ...Contents 2...

Page 5: ...Safety instructions 1 2 Before operating the machine 1 2 When operating or transporting the machine 1 3 Maintenance and storage 1 4 Jacking up the machine 1 5 Safety labels and operation labels 1 5 S...

Page 6: ...that the operators receive training 1 2 3 4 5 6 7 and the following must be thoroughly understood The basic safety precautions for operating a ride on bunker rake Controlling the machine by applying...

Page 7: ...ss the machine is designed to do so Never drive the machine on a slope with an angle of gradient that is greater than that specified or in a place where there is a danger of the machine slipping If in...

Page 8: ...e servicing or adjusting the machine be sure to disconnect the battery To remove the battery disconnect the negative battery cable first To install the battery connect the positive battery cable first...

Page 9: ...close the fuel valve When storing the machine for an extended period of time remove the battery and the ignition key If the machine is going to be stored with the battery still attached disconnect th...

Page 10: ...Safety Page 1 6 Safety labels and operation labels...

Page 11: ...Waste disposal 2 2 Disposal Disposal Page 2 1...

Page 12: ...e sure that waste generated when servicing or repairing the machine is disposed of in accordance with local regulations e g waste oil antifreeze batteries rubber products and wires etc Disposal Page 2...

Page 13: ...e 3 3 List of maintenance standards 3 4 Tightening torques 3 5 Standard tightening torques 3 5 Principal tightening torques 3 8 Jacking up the machine 3 9 Jack up points 3 9 Lubrication 3 10 Grease po...

Page 14: ...859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 1...

Page 15: ...bic Meters Cubic Centimeters m3 m3 cm3 0 7646 0 02832 16 39 Weight Tons Short Pounds Cunces Avdp sh tn lb oz Metric Tons Kilograms Grams ton kg g 0 9078 0 4536 28 3495 Pressure Pounds Sq In Pounds Sq...

Page 16: ...belt tension Adjust the belt tension so that the spring cover is not lifted H PXSB43 Tire pressure Front wheel 70 kPa 0 71 kgf cm2 10 15 psi 21 11 00 10 Rear wheels 40 kPa 0 41 kgf cm2 5 80 psi 25 13...

Page 17: ...sted or has foreign matter such as sand on it Such a screw cannot be fully tightened even if it is tightened by the specified torque The friction on the thread surface increases causing a loss of torq...

Page 18: ...61 96 7 10 71 38 101 97 61 96 88 51 M6 8 11 81 58 112 17 70 81 97 36 14 18 142 76 183 55 123 91 159 32 M8 23 29 234 53 295 71 203 57 256 68 28 38 285 52 387 49 247 83 336 34 M10 45 57 458 87 581 23 3...

Page 19: ...68 1200 1 355 78 19 0 3 4 117 68 1200 1 355 78 25 0 1 137 30 1400 1 581 74 32 0 1 1 4 166 72 1700 1 920 69 38 0 1 1 2 205 94 2100 2 372 61 50 0 2 245 17 2500 2 824 54 Fittings with parallel threads O...

Page 20: ...Three wheel drive Front wheel section K0006100202 10 bolt 20S 29 38 295 71 387 49 256 68 336 34 K0160000492 24 special nut P1 5 180 200 1835 46 2039 40 1593 18 1770 20 K0014120602 12 heat treated bolt...

Page 21: ...r death Use the jack up points identified in this manual when jacking up the machine Only place a jack under the jack up points specified Placing a jack at any other point could result in damage to th...

Page 22: ...ipples are installed in the following positions Grease them every 50 hours 3 4 6 3 4 5 7 1 8 4 2 2 8 8bq62b 001 Grease points_001 Parts Number of grease points Two wheel drive Three wheel drive 1 Forw...

Page 23: ...ulley 8bq62b 004 Grease points_004 1 2 3 Pump neutral lever fulcrum upper part of piston pump 8bq62b 005 Grease points_005 Front wheel axle s rhombic flange unit 8bq62b 006 Grease points_006 Rear whee...

Page 24: ...bq62b 008 Grease points_008 Front blade lever fulcrum 8bq62b 009 Grease points_009 Front blade arm fulcrum 8bq62b 010 Grease points_010 7 8 Maintenance standards and maintenance Page 3 12 Grease point...

Page 25: ...epair 4 3 Cooling system 4 3 Air cleaner 4 4 Fuel tank 4 4 Muffler 4 4 Inspection and repair of each section 4 4 Cooling system 4 4 Air cleaner 4 5 Fuel cock 4 6 Fuel filter 4 6 Fuel pipe 4 6 Engine o...

Page 26: ...p flames away from the battery Batteries emit hydrogen gas and mishandling may ignite it and cause an explosion The electrolytic solution in the battery is sulfuric acid Contact with the electrolytic...

Page 27: ...ng wire 3 Tighten the casing clamp screw 3 1 2 whlybv 003 Adjustment of the choke control_001 1 Casing clamp screw 2 Choke lever 3 Casing wire General inspection and repair Cooling system Air cooled e...

Page 28: ...mage leakage or poor connections and replace the hose stopper and connector part as appropriate 3 4 5 Draining of fuel and cleaning of the fuel tank Important Make sure that fuel is drained outside Dr...

Page 29: ...ments Clean the outer element 1 every 50 hours and replace it every 400 hours Cleaning and replacement need to be done at shorter intervals if the contamination is heavy Replace elements after one yea...

Page 30: ...an air blower Fit them back securely so as not to cause any fuel leakage 1 2 3 4 4zzo6r 001 Cleaning of the fuel cock_001 1 Filter 2 Packing 3 Filter pot 4 Ring 4 5 1 2 Fuel filter Inspection and rep...

Page 31: ...n to the oil pan Recheck the amount of oil 10 to 20 minutes after you have refilled the oil Important Do not mix different kinds of engine oil 1 2 3 4 5 6 1 2 3 4 2rjzcu 001 Inspection of and refillin...

Page 32: ...hole Insufficiently screwing of the cap or a defective seal will fail to maintain negative pressure in the crankcase which may raise the oil level and result in the emission of white smoke or break t...

Page 33: ...level screw in the oil level gauge until it reaches the bottom and then remove to check Start the engine and check for any oil leakage 1 2 3 5 4 zuw5ff 001 Replacement of the engine oil filter_001 1...

Page 34: ...003 Removal of the engine_003 1 Plus battery cable 2 Minus battery cable 3 Battery 4 Bolt Remove the throttle wire 1 choke wire 2 and cleaner hose COMP 3 from the engine Cover to prevent dust from ent...

Page 35: ...ing the fuel pump and fuel hose 9 10 11 3 1 2 o3sknc 008 Removal of the engine_008 1 Fuel hose clamp 2 Fuel pump 3 Fuel hose Remove the nut 4 and high nut 5 in order to make it easier to remove the te...

Page 36: ...k to see if all the parts that were removed for engine repair are now installed as before 14 1 2 Important When installing the engine in the machine take care not to damage the engine fuel hose wiring...

Page 37: ...gine_003 1 Belt 2 Engine pulley 3 Tension pulley 4 Nut 5 High nut 6 Spring cover 7 Spring 8 Pump pulley 9 Bolt 10 Tension ass y 11 Engine fulcrum Tighten the seat mount support fitting 1 with two bolt...

Page 38: ...y cable 1 to the battery Next connect the negative battery cable 2 See Electrical system General repair Battery 11 12 13 4 3 1 2 vmpsh8 008 Installation of the engine_008 1 Plus battery cable 2 Minus...

Page 39: ...Note 5 23 Traveling circuit 5 25 Raise lower circuit 5 28 Steering circuit 5 31 Charge circuit 5 34 General inspection and repair 5 35 Note 5 35 Hydraulic hose piping 5 36 Hydraulic oil 5 36 Bleeding...

Page 40: ...nd or an appropriate block Use BARONESS genuine parts for replacement and accessories Never start the engine in a enclosed room or poisoning by carbon monoxide may occur Never touch the exhaust system...

Page 41: ...b7jb 001 Hydraulic equipment layout_001 1 Piston pump 6 Drive switching valve 2 Wheel motor 7 Check valve 3 Valve module 8 Raise lower cylinder 4 Torque generator 9 Branch fitting 5 Oil cooler Hydraul...

Page 42: ...h the steering wheel inside the front cover Oil cooler This is to cool high temperature oil It is positioned under the left side of the seat in front of the engine Drive switching valve This is to swi...

Page 43: ...If the rake cannot be raised with a manual lever the hydraulic system is likely to be faulty 1 2 quvfjc 001 Manual valve_001 1 Manual lever 2 Coupler General instructions Hydraulic hose Hydraulic hos...

Page 44: ...31b 001 Bite type tube fitting_001 Remove burrs on the inside and outside of the tube with a file or the like of w7s31b 002 Bite type tube fitting_002 Insert the nut and sleeve into the tube Note the...

Page 45: ...nce is suddenly felt then further tighten with the nut for a 1 4 turn 6 7 w7s31b 009 Bite type tube fitting_009 Reference For direct tightening use the fitting body to follow procedures 1 to 5 when us...

Page 46: ...o the seat surface 2 and O ring 1 1 2 jf65lf 003 Adjustable joint_003 1 O ring 2 Seat surface To fit screw in the main body by hand till the washer face touches lightly and turn from that position in...

Page 47: ...d all the drives of the operating machine in the neutral position To depressurize the steering circuit turn the steering wheel from side to side Hydraulic circuit failure The hydraulic traveling circu...

Page 48: ...Low pressure charge In take return Direction Input shaft Output shaft Torque generator Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100B...

Page 49: ...return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine...

Page 50: ...In take return Direction Input shaft Output shaft Torque generator Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pum...

Page 51: ...return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Motor for left rear...

Page 52: ...essure charge In take return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Dra...

Page 53: ...return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine...

Page 54: ...In take return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pum...

Page 55: ...rge In take return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston...

Page 56: ...In take return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pum...

Page 57: ...return Direction Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine...

Page 58: ...auge for low pressure measurement vasdfi 004 K4701000020 Pressure For 0 15 MPa For 0 2 175 60 psi For 0 152 96 kgf cm2 Used mainly for measurement of the pressure on the low side Pressure gauge for ul...

Page 59: ...sed for temporarily blocking fluid of measurement for pressure gauge maintenance inspection repair etc Joint for pressure gauge vasdfi 006 K4701000040 Used as a joint for pressure piping Female connec...

Page 60: ...9000042 Y Used for extension of screw T shape fitting for pressure measurement Special adapter 1013 9 vasdfi 015 K3009000010 Y 2 pieces used for extension of screw T shape fitting for pressure measure...

Page 61: ...justment and so on Note on hydraulic measurement Warning As mentioned in the testing procedure the use of a pressure gauge not meeting the pressure measurement standard may result in damage to the pre...

Page 62: ...round to prevent breakage of the hydraulic system and measuring instrument Screw in the hydraulic fitting by hand till it touches the other side lightly then fasten with a wrench Fit hoses and measur...

Page 63: ...Pressure gauge Torque generator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine Br...

Page 64: ...ke to the rear hook 5 1 2 3 5 vt1bvt 004 In the case of forward side_004 5 Rear hook Start the engine and accelerate to the maximum speed Press on the traveling pedal for forward direction It is consi...

Page 65: ...he like of to the front hook point 7 7 vt1bvt 007 In the case of forward side_008 7 Front hook point Start the engine and accelerate to the maximum speed Press on the reverse pedal and check the press...

Page 66: ...erator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine Branch metal Motor for left...

Page 67: ..._002 1 Valve module 2 Hydraulic measurement port G 3 1 z4kw7w 003 Raise lower circuit_003 1 Valve module 3 Cap 1 4 z4kw7w 004 Raise lower circuit_004 4 Hexagonal wrench Fit the elbow 5 to the hydrauli...

Page 68: ...the raise lower switch to Raise It is considered normal if the pressure gauge 6 reads about 10 MPa 101 97 kgf cm2 when the raise lower cylinder is retracted fully The pressure should be the same when...

Page 69: ...nput shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine Motor for left rear wheel 2 200BS4S...

Page 70: ...essure gauge hose 5 to the PF port 2 of the valve module 1 Measure by inserting the pressure gauge 4 between the input IN 7 of the torque generator 6 and the PF port 2 of the valve module Start the en...

Page 71: ...Valve module 2 PF port 3 Hydraulic hose 4 Pressure gauge for low pressure measurement 5 Pressure gauge hose 6 Torque generator 7 Input IN Hydraulic system Hydraulic system Page 5 33 Measurement metho...

Page 72: ...rator Input shaft Output shaft Valve module Rake raise lower cylinder Raise Lower 3WD circuit 2WD 3WD changeover valve Front wheel motor 2 100BS4S Drain Piston pump Engine Motor for left rear wheel 2...

Page 73: ...repair Note Before inspection and repair Move the machine to a level place Apply the parking brake and lower the rake Then stop the engine and remove the key Clean the machine Be sure to clean parts...

Page 74: ...e circuit looseness abrasion loosening of connecting part weather related deterioration and chemical related deterioration If necessary repair before operating the machine 1 2 3 4 5 6 7 Hydraulic oil...

Page 75: ...15 16 1 2 3 4 5 6 7 Warning When jacking up the machine check the Safety Jack up Jack up all the wheels of the machine and support securely with a jack stand or proper block Check to see that the for...

Page 76: ...f hydraulic equipment Change hydraulic oil regularly 2 3 4 1 2 Change period First time After 100 hours of operation From the second time onward For every 500 hours of operation Specified hydraulic oi...

Page 77: ...ve the hydraulic hoses 2 fitted to the raise lower cylinder 1 Remove the split pin 4 snap pin 5 and washers 6 then remove the hardened flat head pins 3 Remove the raise lower cylinder 1 1 2 3 4 1 2 3...

Page 78: ...e rear cover 1 2 3 4 1 Remove the hydraulic hose 1 fitted to the oil cooler 4 Remove the fitting bolt 3 of the oil cooler bracket 2 Remove the oil cooler 4 together with the oil cooler bracket 2 4 1 3...

Page 79: ...r 1 Remove the hydraulic hose 2 fitted to the valve module Remove the pipe adapter 7 and the adjuster elbow 6 Remove the valve module fitting bolt 3 Remove the valve module 4 1 2 3 4 1 2 3 4 5 6 2 2 1...

Page 80: ...val For belt adjustment refer to Engine Fitting of Engine 1 2 3 4 5 6 7 8 Caution After fitting check for hydraulic oil leakage at each part Refer to the tightening torque list We assume no responsibi...

Page 81: ...er fitting check for hydraulic oil leakage at each part Refer to the tightening torque list We assume no responsibility for problems caused by abnormal tightening tightening with excessive torque or t...

Page 82: ...asher 3 and washer 4 and remove the hydraulic tank cover 5 1 2 3 Remove the drain plug 7 under the hydraulic tank 6 and drain all the hydraulic oil Remove the hydraulic hose 8 fitted to the hydraulic...

Page 83: ...at each part Refer to the tightening torque list We assume no responsibility for problems caused by abnormal tightening tightening with excessive torque or the like of Hydraulic system Hydraulic syst...

Page 84: ...Hydraulic system Page 5 46 Removal and installation of each section...

Page 85: ...imity switch 6 8 Brake pedal switch 6 8 Electrical components 6 8 Safety switches 6 8 Seat switch 6 9 Forward reverse pedal proximity switch 6 9 Brake pedal switch 6 9 Light switch 6 9 Raise lower swi...

Page 86: ...er people away from the machine during work If necessary use appropriate chain blocks hoists or a jack If the machine is lifted up ensure that it is supported by jack stands or appropriate blocks When...

Page 87: ...cal components_001 1 Seat switch 6 Buzzer 11 Fuses 2 Brake pedal switch 7 Forward reverse pedal proximity switch 12 Magnet switch 3 Light switch 8 Key switch 13 Battery 4 Solenoid valve 9 Raise lower...

Page 88: ...ight of the operation panel Raise lower switch The raise lower switch is connected to the solenoid valve in the valve module and is used to switch the solenoid valve This 1 2 3 4 5 6 7 8 9 switch is l...

Page 89: ...xcess of one tenth of the rated current With regard to the maximum recommended charging current follow the battery manufacturer s instructions Caution If the battery gets extremely hot or releases a s...

Page 90: ...1 i7f5hf 001 Interlock system_001 1 Control board 2 i7f5hf 002 Interlock system_002 2 LED indicator lights Electrical system Page 6 6 Measurement method...

Page 91: ...is occupied the parking brake is set and the forward or reverse pedal is depressed interlock system activation condition 2 Be sure to release the parking brake before moving the machine interlock sys...

Page 92: ...nsor mounting plate Brake pedal switch Adjust the brake pedal switch by loosening the nuts 4 so that A is 2 mm 0 079 in or more when the parking brake is not engaged 2 and B is 6 mm 0 24 in or less wh...

Page 93: ...vehicle body earth and also there is battery voltage 12V in working the forward reverse pedal the proximity switch a does not detect the magnet 3 Vcc GND Vout GND Vout Vcc B WR RL YW B L YW B L WR WB...

Page 94: ...B 3 2 1 A B 1 2 3 a A B st96l5 001 Raise lower switch_001 a Raise lower switch lever Solenoid valve The solenoid valve 3 is located behind the front cover and installed in the valve module 2 The sole...

Page 95: ...age Resistance Holding current DC12V 7 6 1 58A Hour meter The hour meter is located in the lower right of the operation panel and indicates the total number of hours the engine has run The number in b...

Page 96: ...side behind the rear cover When the key switch is set to the START position see Key switch_001 the coil in the magnetic switch magnetically attracts the plunger When the plunger comes into close conta...

Page 97: ...oing so could cause a fire or explosion etc 2 3 Caution If the electrolyte overflows neutralize it with bicarbonate etc until the bubbles disappear and wash out with plenty of water Failure to do so c...

Page 98: ...secured by the mounting bracket If it is not tighten the nuts securing the battery until it is firmly secured If the battery is not firmly secured by the mounting bracket the battery could move due t...

Page 99: ...ositive and negative terminals as the old one Installing a battery that has different terminal positions could cause damage to the cables Do not use organic solvents such as benzene thinner or gasolin...

Page 100: ...the battery charger to the battery firmly secure the positive clip to the positive battery terminal and the negative clip to the negative battery terminal Wrong or loose connections could cause a fir...

Page 101: ...he electrolyte gets extremely hot the electrode plates or other parts in the battery could deteriorate resulting in a shorter service life Electrical system Electrical system Page 6 17 General inspect...

Page 102: ...Electrical system Page 6 18 General inspection and repair...

Page 103: ...ion of each section 7 4 Wheel 7 4 Brake 7 5 Steering 7 7 Seat 7 7 Lift arm 7 8 Cover 7 8 Damper 7 9 Inspection and repair of each section 7 10 Tire 7 10 Brake 7 10 Brake wire rod 7 12 Traveling cable...

Page 104: ...nd accessories Never start the engine in a enclosed room for poisoning by carbon monoxide may occur Never touch the exhaust system while the engine is running or right after the engine has stopped Its...

Page 105: ...asdfi 009 K480200044D Used for the hanging pulley when removing the wheel mounting eye Drum removal jig B vasdfi 010 K4802000452 Used for the center hole when removing the wheel mounting eye Main body...

Page 106: ...4 Remove the bolt 5 nut 6 spring washer 7 and washer 8 from the right rhombic flange unit 1 to remove the right rhombic flange unit 1 Remove the bolt 11 from the front wheel bracket 9 and the front w...

Page 107: ...nts of the right and left of the rear part and lift the tire off the ground See Overhaul standard and maintenance Jack up point Remove four heat treated bolts 1 1 lp4z4o 002 Removal of rear wheel_001...

Page 108: ...5 1 2 3 z2sgi8 010 Removal of brake drum_004 1 Drum removal jig A 2 Drum removal jig B 3 Gear puller Remove the wheel mounting eye 1 from the plate 1 z2sgi8 011 Removal of brake drum_005 1 Wheel mount...

Page 109: ...eel Fitting of steering column For fitting follow the opposite procedure of removal 1 2 3 4 5 6 Caution Refer to the tightening torque list We assume no responsibility for problems caused by abnormal...

Page 110: ...m 8 8 2 3 4 1 7 7 6 5 6 5 pk2gk7 001 Removal of rake hanging arm_001 1 2 3 4 5 1 Cylinder 2 Split pin 3 Washer 4 Hardened flat head pin 5 Arm mounting fitting right and left 6 Split pin 7 Hardened fla...

Page 111: ...e of the gas spring 5 fitted to the rear cover 4 Remove the bolts 7 and washers 8 from the seat mount 6 1 2 3 4 3 7 8 2 7 5 6 1 4 3vnwki 002 Removal of rear cover_001 1 Seat 2 Slide handle 3 Cover sto...

Page 112: ...cations for tire pressure Do not pump up a tire more than the specified pressure 1 2 3 Brake A worn brake shoe will increase the amount of brake pedal depression and may cause the pedal to touch the f...

Page 113: ...part Use grease that is exclusively for brakes and never apply onto the shoe friction surface If it adhered on the surface remove it with brake cleaner etc z2sgi8 005 Disassembly and assembly of brak...

Page 114: ...brake lever causes the braking power to be stronger and the brake pedal to feel heavier Adjustment of spring rod Spring contraction by depressing the brake pedal may cause the brake to be weaker Adju...

Page 115: ...dal neutral rod 10 Pump neutral lever 11 Push pull cable 12 Split pin 13 Trunnion lever Throttle wire rod Depending on the frequency of use the lever movement may become slow or the inner wire may cha...

Page 116: ...to the Right angle of the outer wire Inspect and adjust accordingly Inspection of choke wire Check to see if the choke lever 1 moves smoothly 1 F R O N T 1 b95bj2 001 Inspection of choke wire_001 1 Ch...

Page 117: ...ain Adjustment of steering chain A loose steering chain may cause more play for further elongation and too tight a steering chain may cause the handle to be heavy and result in faster abrasion of the...

Page 118: ...Main body Page 7 16 Inspection and repair of each section...

Page 119: ...Removal and installation of each section 8 5 Rake 8 5 Front blade section 8 5 Sand cultivator section 8 5 Finishing brush section 8 5 Cargo box section 8 5 Inspection and repair of each section 8 5 Ra...

Page 120: ...ped Due to its high temperature doing so could cause burns Do not use an open flame near the battery The battery may generate hydrogen gas so improper handling of the battery could cause it to catch f...

Page 121: ...and then tighten the bolt 1 5b7smu 001 A B 1 2 Front blade section_001 1 Bolt 2 Small front blade Install and adjust the connecting shaft and L ball Refer to Specification Adjustment values Attach th...

Page 122: ...aft 7 Nut Finishing brush section Adjust the height of the brush from the ground to suit the bunker conditions by holding the lever The brush height can be adjusted to four levels by adjusting the pin...

Page 123: ...een the rake fulcrum pipe and the fulcrum swing fitting See Removing the rake_001 Front blade section For details on how to remove and install the front blade section refer to the procedure for handli...

Page 124: ...ke hanging arm to ensure that it is not worn 1 2 3 4 5 6 6 6 mafeci 003 Rake_002 6 Hardened flat head pin Inspect the plate spring 7 to ensure that it is not cracked or bent Inspect the spring pin 8 o...

Page 125: ...ce in the L ball of the front blade and the adjusted height of the front blade when raised are within the specified values Refer to Specifications Adjustments 1 2 5b7smu 002 Front blade section_001 1...

Page 126: ...y have not come off Inspect the spring pins 4 and joint pin 6 to ensure that they have not come off Inspect the trapezoidal cultivator fittings 5 to ensure that they are not worn 1 2 3 3 6 2 A A 5 4 4...

Page 127: ...Engine problems 9 2 Traveling problems 9 4 Steering problems 9 5 Work machine and mower unit problems 9 6 Troubleshooting Troubleshooting Page 9 1...

Page 128: ...ctrical components Key switch The magnetic switch has failed Electrical system Electrical components Magnetic switch The starter does not turn Other than because of the above mentioned causes The star...

Page 129: ...cal components The fuel level is low Instruction manual for engine The fuel filter is clogged Engine Inspection and repair of each section Fuel filter The fuel cock is not open Engine Inspection and r...

Page 130: ...the above mentioned causes The engine speed is low The engine does not work properly Maintenance manual for engine The parking brake is set Main unit Inspection and repair of each section Brake wires...

Page 131: ...The viscosity of the hydraulic oil is incorrect Hydraulic system General inspection and repair Hydraulic oil The hydraulic oil cooler does not cool the oil sufficiently Owner s Manual for this machin...

Page 132: ...l inspection and repair Hydraulic oil The viscosity of the hydraulic oil is incorrect Hydraulic system General inspection and repair Hydraulic oil The hydraulic oil cooler does not cool the oil suffic...

Page 133: ...A fork blade has become worn Work machine and mower unit Inspection and repair of each section Rake section The angle or depth of a fork blade has been incorrectly adjusted Work machine and mower uni...

Page 134: ...Troubleshooting Page 9 8 Work machine and mower unit problems...

Page 135: ...Specifications 10 2 Maintenance schedule 10 3 Hydraulic circuit diagram 10 5 Electric wiring diagram 10 6 Consumable parts list 10 7 Reference Reference Page 10 1...

Page 136: ...psi Rear wheels Size 25 13 00 9 Air pressure 40 kPa 0 41 kgf cm2 5 80 psi Brake Internal expanding brake rear wheels Steering system Torque generator power steering Engine Model Vanguard 356447 Type V...

Page 137: ...First time Engine oil filter Fuel filter Spark plugs Valve clearance Cleaning of exterior Main unit Air cleaner outer Every 400 hours or every year whichever comes first Air cleaner inner Every 400 h...

Page 138: ...hours Every 400 hours Every 500 hours Every year Remarks Main unit Cleaning inspection of each part Activation of safety devices Work machin e Tightening of each part Cleaning inspection of each part...

Page 139: ...B A A B R P Drain Piston pump Branch metal B2 B3 B1 S1 S2 T 1 0MPa P1 P2 20 6MPa 4 9MPa Engine Motor for left rear wheel 2 200BS4S B Motor for right rear wheel 2 200BS4S A A B A3 A1 A2 B2 B1 B3 A B G2...

Page 140: ...s Red Yellow Green Blue Black Buzzer Fuse To earth mounting bolt on engine To earth mounting bolt on engine Key switch Solenoid valve Fuse Raise lower switch Proximity switch for forward reverse pedal...

Page 141: ...oe 1 Shoe upper left P741 8008 00 Shoe 1 Shoe lower left P741 8006 00 Shoe 1 Brake wire right K1120145200 Brake wire 1452 1 Brake wire left K1120086210 Brake wire 862 1 V belt K2374200430 Low edge cog...

Page 142: ...SP05 SM USZ 10A 00 S K...

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