Kato Imer CARRY 105 ELECTRIC POWER Operating Instructions Manual Download Page 1

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OPERATING INSTRUCTIONS

TRACKED MINIDUMPER

CARRY 105 ELECTRIC POWER

serial numbers from nr.:

MZ*00010

(Original instructions)

03/17

–

R00

Code 2050407035

Summary of Contents for CARRY 105 ELECTRIC POWER

Page 1: ...OPERATING INSTRUCTIONS TRACKED MINIDUMPER CARRY 105 ELECTRIC POWER serial numbers from nr MZ 00010 Original instructions 03 17 R00 Code 2050407035 EN ...

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Page 3: ...4 CE modificata dalla 2005 88 CE emissione acustica ambientale delle macchine ed attrezzature destinate a funzionare all aperto e alla legislazione nazionale che la traspone Dlgs 262 2002 Categoria macchina Dumper annesso I n 18 Procedure applicate per le valutazioni di conformità controllo interno della produzione con valutazione della documentazione tecnica e controlli periodici all VI 1a proced...

Page 4: ...ntedirectriz 13 Cumplenlesnormasarmonizadas 14 Direccion Data 15 Nombre 16 Puesto GERMAN Ubersetzung 1 EG KONFORMITÄTSERKLÄRUNG Direktive2006 42 EG NachtragII 1A 2 Hersteller 3 Adresse 4 Technische Datei erstellt von Technischer Leiter KATOIMERS p A 5 Adresse 6 Erklärthiermit dassdieMaschine Kategorie TRANSPORTER 7 Typ 8 Seriennummer 9 InstallierteNutzleitung 10 Konformist mitdeneinschlägigenBesti...

Page 5: ...å Garanteradljudeffektnivå 12 Uppfyller villkorensomomnämnsiföljandedirektiv 13 Följandeharmoniseradestandarderhartillämpats 14 Ort Datum 15 Namn 16 Befattning NORSK oversettelse 1 SAMSVARSERKLÆRING ORIGINAL Direktiv2006 42 EF vedleggII 1A 2 Produsent 3 Adresse 4 Tekniskdokumentasjonutarbeidetav TekniskansvarligKATO IMER S p A 5 Adresse 6 Meddetteerklærervi atmaskinkategorien HJULLASTER 7 Type 8 S...

Page 6: ... 16 3 4 LIFTING THE MACHINE 16 3 5 LOADING AND UNLOADING THE MACHINE 17 3 6 SET UPS 18 3 7 USE AND ACCESSORIES 19 3 7 1 LOAD BODY 19 3 7 2 SELF LOADING SHOVEL 19 3 7 4 ASSEMBLY INSTRUCTIONS FOR THE SELF LOADING SHOVEL OPTIONAL 20 3 7 5 PARKING BRAKE 22 3 8 REPLACING THE ACCESSORY 23 3 8 1 RELEASING AND REMOVING THE ACCESSORIES 23 3 8 2 INSTRUCTIONS TO LIFT THE LOAD BODY WITH SHOVEL 25 3 9 PRECAUTI...

Page 7: ... 31 4 8 LONG STORAGE 32 5 PROBLEMS AND SOLUTIONS 33 5 1 PROBLEMS AND SOLUTIONS TABLE 33 5 2 SPARE PARTS 34 6 HYDRAULIC SYSTEM DIAGRAM 35 6 1 TECHNICAL DATA 35 6 2 HYDRAULIC SYSTEM LAYOUT 35 7 TECHNICAL SPECIFICATIONS 36 7 1 GENERAL SPECIFICATIONS 36 7 2 MACHINE DIMENSIONS 36 7 3 MACHINE DIMENSIONS AND USE LIMITATIONS 37 ...

Page 8: ... to carry out the same can lead to the warranty becoming null and void SCHEDULED INTERVENTIONS TABLE HOURS 20 50 200 400 600 800 1000 1200 1400 1600 After operations have been interrupted for a long time INTERVENTION Inspection on the integrity of cables and batteries Brushes inspection Check replace brushes Data download to check battery status Check and adjust belts tension Replace hydraulic pla...

Page 9: ...y hazardous situation which if not avoided could result in minor or moderate injury It may also be used to alert the operator against possible damage to the machine and its components We have made every effort to reduce the risks associated with correct use of the machine and nonetheless we cannot be held responsible for predicting every kind of danger in all unintended operating conditions It is ...

Page 10: ...G THE MACHINE It is ESSENTIAL to conduct warm up BEFORE starting operations in order to run the hydraulic fluid smoothly During the heating phase the operator must check the correct functioning of the machine or the necessity for maintenance Remember the fundamental principle on which the hydraulics is based is the running of oil If you hear a harsh noise it means that there is insufficient lubric...

Page 11: ...d or un a slope check the level of the ground and balance of the machine to prevent slipping or overturning 4 MACHINE OPERATING LIMITS The ground should be level and firm for safe operation If you have to operate the machine on sloping ground endure the tracks are in the same direction of the sloping ground and not perpendicular to it If you have to operate the machine on soft or unlevelled ground...

Page 12: ...ps on the ground may cause the machine to jolt leading to overturning DRIVE IN REVERSE THE OPERATOR MUST ALWAYS BE UPSTREAM THE LOAD NEVER steer on a grade or unstable ground which causes a turnover NEVER travel across a grade When travelling on a grade travel up and down in parallel with the grade Be careful to travel on the frozen ground since the machine tends to skid or fall down 1 4 LOAD AND ...

Page 13: ...ds and or explosive gases may leak out Avoid direct contact with the parts of the cell that are not covered If this should happen wash the affected areas immediately with abundant clean water and soap In the event of electrolyte contact with eyes rinse them with plenty of water for at least 15 minutes and immediately seek medical assistance DANGER In the event of a fire or temperatures higher than...

Page 14: ...e electrical socket and avoid using long cables or extensions that may get in the way Safety extend the power supply cable and avoid placing in such a manner that it may get in the way If using an extension or a multiple socket check that they tolerate the overall amount of electricity required Ensure he machine is well ventilated and check that the ventilation grid is not clogged Avoid connecting...

Page 15: ...prevent any movement that may cause damage to the operator Lift the accessory and introduce the special safety retainer NEVER allow anyone to work on the undercarriage when the accessory is lifted and not properly blocked During maintenance operations mark the control levers with labels These labels can only be removed by aware personnel able to ensure that safety rules are fully observed Before w...

Page 16: ... gauge if necessary If there is no qualified person consult your local distributor 5 PREVENTING FIRE AND EXPLOSIONS Do not expose the vehicle to excessive heat especially during recharging operations The batteries may explode if the vehicle catches fire Keep away fuel lubricants and coolants from any fire or heat Most of them are very flammable Do not use the machine in fire sensitive areas or exp...

Page 17: ... surfaces when using the machine and for a prolonged period of time after the machine has been switched off or use adequate preventive means The sign indicates the risk of shearing by the injury caused by the loading shovel Always keep hands clear of the arm of the loading shovel when this is in operation The signal indicates a hazard of being struck by objects travelling at high speed while the t...

Page 18: ...3 INSERT OFF ON The label indicates the correct sequence to start charging operations 2 Alarm A2000 IF THE DISPLAY SHOWS THE ALARM A2000 IS NECESSARY TO PERFORM THE EQUALIZATION SI L ECRAN AFFICHE LE A2000 D ALARME EST NECESSAIRE D EFFECTUER L EGALISATION SE IL DISPLAY MOSTRA L ALLARME A2000 E NECESSARIO ESEGUIRE L EQUALIZZAZIONE A2000 1 2 1 0 The label indicates that is needed an equalized full r...

Page 19: ...ontains lithium batteries If handled by untrained personnel these may case electric shocks high current short circuit and fires This is why only expert technical personnel authorised by KATO IMER should proceed to remove the batteries It is forbidden to dispose of batteries with normal solid waste As batteries contain materials harmful to the environment and human health they should be collected d...

Page 20: ... B Travel lever left E Parking brake lever C Travel lever right WARNING In some cases there may be a slight delay in switching on and switching off the power supply pump of the hydraulic circuit if these controls are made very quickly This does not mean the vehicle is not working properly On the contrary this protects the system from transient current A B D C E ...

Page 21: ... driving forwards pull it back to steer right in reverse STEER RIGHT Steer reverse LEVER B Steer forwards TURNING IN PLACE Turn to the left Push the RH lever C forwards while pulling the LH lever B back This turns the machine quickly in place towards the left STEER LEFT IN PLACE Forwards LEVER B Reverse Turn to the right Push the LH lever B forwards while pulling the RH lever C back This turns the...

Page 22: ...he shovel move the lever back to raise the shovel and place the material in the load body 3 1 4 PARKING BRAKE LEVER Lever E Inserting the brake move the lever in a vertical position Releasing the brake move the lever in a horizontal position SELF LOADING BUCKET CONTROL LEVER LEVER D Raise Lower CONTROL LEVER LEVER A Raise Lower PARKING BRAKE LEVER Engaged LEVER E Disengaged BY PULLING THIS LEVEL B...

Page 23: ...s on Once the display is turned on the machine will be in TRAVEL mode and ready to be manoeuvred by using the 4 control levers 4 During movement it is possible to set the NORMAL or FAST mode using the special selector The NORMAL mode involves moving at a slower speed compared to the FAST mode The display briefly shows initial E105 than the hour counter is displayed for 5 seconds indicating the tot...

Page 24: ...GES ON THE DISPLAY WHEN RECHARGING THE MACHINE COMPLETE RECHARGE FORESEES A SUBSEQUENT EQUALISATION PHASE THAT MAY TAKE A FEW HOURS WE RECOMMEND WHEN POSSIBLE E G AT NIGHT PERFORM THIS OPERATION TO INCREASE PERFORMANCE AND TO PROLONG THE BATTERIES LIFE HOWEVER COMPLETE RECHARGING MUST TAKE PLACE WEEKLY OR EVERY 15 EFFECTIVE HOURS OF WORK IF IS NOT PERFORMED EQUALIZATION FOR MORE THAN A 31 DAYS OR ...

Page 25: ...n A warm up period is time well spent in preventive maintenance Practice the following warm up procedure before attempting full load operations 1 Allow the motor to warm up at low idle for at least 5 minutes 2 Activate the accessory s cylinder to heat the hydraulic components quicker 3 4 LIFTING THE MACHINE LIFTING PROCEDURE The machine has 4 anchorage points marked by special labels two next the ...

Page 26: ...rs other than the travel lever while machine is on the lading ramps 5 Maintain the machine balance point while travelling over the loading ramp joint areas 6 Make sure the ramps are stable BLOCKING FOR TRANSPORT 1 Stop the motor 2 Engage the parking brake 3 Block the tracks and secure the machine with tie downs CHOOSE AS FLAT GROUND AS POSSIBLE FOR LOADING THE MACHINE WHEN USING LOADING RAMPS BE S...

Page 27: ...3 USER INSTRUCTIONS MINIDUMPER CARRY 105EP 18 3 6 SET UPS TRUCK BED LOAD BODY WITH SHOVEL LOAD BODY ...

Page 28: ...e machine is fitted with a self loading shovel raise the shovel as high as possible and make sure it does not interfere with any structure at the time of unloading 3 7 2 SELF LOADING SHOVEL The self loading machines attached directly to the load body can be used to load debris or excavated material It is strictly FORBIDDEN TO USE IT FOR EXCAVATING PURPOSES To load material Bring the shovel to the ...

Page 29: ...ols 3 7 4 ASSEMBLY INSTRUCTIONS FOR THE SELF LOADING SHOVEL OPTIONAL The assembly of the self loading shovel is an operations that must be conducted in a fully equipped workshop by expert personnel with the necessary tools and equipment Incorrect assembly could cause injury to the operator or damage to the machine 1 Park the machine on the level and clean ground 2 If the machine is already in use ...

Page 30: ...e booms using the M10x40 screws with the designated nuts and washers Check the planarity of the blade and that the booms are properly coupled Lock by tightening the screws fully home 10 Remove the caps on the distributor after cleaning surrounding surfaces from any dirt 11 Position the flexible pipes according to the sequence indicated in the diagram Extend the pipes up to the shovel cylinders mak...

Page 31: ...eth of the driving wheel Activation or deactivation is performed manually by means of the lever E positioned on the control console at the centre of the traction levers When the brake is engaged the lever as it is in a vertical position prevents the operator from using traction levers correctly forcing the operator to release the brake itself before moving the machine 1 E ...

Page 32: ... tie rods once again 9 Remove the pin C after removing the split pin 2 10 Bring the accessory that has been released from its support to the ground and position it on the designated pallet 11 Attach the new accessory using the two rear holes with the lifting equipment with two tie rods Warning Only use original accessories provided by KATO IMER and manufactured for the machine you are using 12 Lif...

Page 33: ...ous behaviour The machine is ready for use again Proceed to clean check the structure lubricate and store the disassembled accessory If any damage to its structure is detected proceed to repair it immediately Following these simple instructions allows to maintain the accessories in conditions suited to use in compliance with safety standards To assemble a new accessory follow the reverse procedure...

Page 34: ...MINIDUMPER CARRY 105EP 25 3 8 2 INSTRUCTIONS TO LIFT THE LOAD BODY WITH SHOVEL USE STEEL CABLES WITH CAPACITY OF AT LEAST 500Kg TO LIFT THE LOAD BODY WITH SHOVEL FASTEN THE LIFTING CABLES IN THE A AND B POINTS B B B A A A ...

Page 35: ...rack shoe 4 Avoid sudden spot turns or pivot turns 5 Do not use for long 3 months or more Store it to avoid direct sunlight or rain 6 Owing to the rubber s features use the machine with temperatures between 25 C and 55 C 3 10 PARKING THE MACHINE At the end of a day s work following steps should be observed as the established machine shut down procedure PARKING THE MACHINE Park on a level surface i...

Page 36: ...c etc Emergency button Make sure that the emergency button is working correctly Motor Maintenance in the workshop inspection and replacement of the brushes if necessary Batteries Maintenance in the workshop Battery inspection Batteries Data download to check battery status Hydraulic system Filter replacement Every 600 Service hours First perform previous service hour items Hydraulic oil Change oil...

Page 37: ... if they are worn However if excessively worn rubber track shoes are likely to be slippery and more travel force is required If the remaining lug is equal to or less than 5 mm high replace it with KATO IMER general spare parts EXPOSURE OF STEEL CORDS If steel cord is exposed because of weary rubber or damage replace it with KATO IMER general spare parts CUTTING THE STEEL CORDS OF THE RUBBER TRACK ...

Page 38: ...oroughly clean the engine Check the integrity of the power supply cable 7 After every use at the end of the day thoroughly clean all accessories load body truck bed self loading shovel etc 4 5 200 HOURS MAINTENANCE AND CHECKS 4 5 1 INSPECTION AND REPLACEMENT OF THE BRUSHES BRUSHES INSPECTION Along with the running of the brushes one needs to check that their length can ensure they operate properly...

Page 39: ...al lowering and turn off the motor 3 Clean the area to keep dirt outside the tank 4 Relieve the internal pressure from the hydraulic tank by loosening the fill plug 1 5 Remove the oil drain plug 2 Drain oil into a container NOTE Always dispose of used oil as established by local regulation 6 CIean the inside of the tank with the clean oil 7 CIean and install the drain plug 2 8 Fill the hydraulic t...

Page 40: ...er foreign matter which may restrict air flow 3 Keep the motor clean of dirt grease and other substance s which inhibit heat dissipation 4 Stop the motor if the machine is not being used SANDY OR DUSTY WORK SITES The presence of large amounts of sand or dust at the work site can contribute to accelerated component wear Indeed the particles that deposit on moving parts act as abrasives This problem...

Page 41: ...it disassemble clean and lubricate the lower 4 8 LONG STORAGE To store the machine from long term follow the next procedures Clean parts of the machine and store indoors If you have to place the machine outdoors choose a flat place and cover the machine Apply grease on the exposed part of the hydraulic cylinder rods During storage operate the machine once a month to maintain films of oil at the lu...

Page 42: ...il filter clogged Pump or coupling damaged Main relief valve pressure too low Control valve damaged Replenish hydraulic oil Conduct maintenance of the oil filter Repair or replace Repair or replace Repair or replace Travel of left right or both sides are inoperable Clogging foreign matter such as stone Bad functioning of the traction motor Remove foreign matter Repair or replace Straight travel de...

Page 43: ... THE BMS MACHINE IN RECHARGE MODE Turn off the machine let it cool and try again A 2244 EXCESSIVELY LOW NETWORK VOLTAGE Check the network voltage A 2248 INTERNAL TEMP OF THE BATTERY CHARGER EXCESSIVELY HIGH Turn off the machine let it cool and try again A 2253 EXCESSIVELY HIGH NETWORK VOLTAGE Check the network voltage A 2000 EQUALIZATION IS REQUIRED Connect the machine in charge until the equaliza...

Page 44: ...EM DIAGRAM 6 1 TECHNICAL DATA Tank level capacity 10 litres System level capacity 12 litres P1 P2 pump flow rate 2x10 litres min 6 2 HYDRAULIC SYSTEM LAYOUT The 2 distributors with 2 elements are used In the standard version fixed crawler and with load body or truck bed with the possibility of fitting a loading shovel or other accessories ENGINE ...

Page 45: ... V from 33 6 to 48 Nominal voltage V 39 6 NOISE LEVEL Sound power level guaranteed LwA 84 dB Noise emission at the operator ear LpA 74 dB 7 2 MACHINE DIMENSIONS DIMENSIONS Description Rubber shoe Shoe width mm 180 Shoe length mm 1120 Machine width mm 690 Machine height at control level mm 1120 Min ground clearance mm 80 Load body Volume m3 0 22 Loading Truck Bed Optional Dimensions Sides closed le...

Page 46: ...7 TECHNICAL SPECIFICATIONS MINIDUMPER CARRY 105EP 37 7 3 MACHINE DIMENSIONS AND USE LIMITATIONS LOAD BODY LOADING SHOVEL TRUCK BED ...

Page 47: ...TRACKED MINIDUMPER CARRY 105 ELECTRIC POWER PUBLISHED MARCH 2017 KATO IMER S p A ITALY ...

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