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Yanmar ViO38-6, User Operation And Maintenance Manual

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Yanmar ViO38-6 User Operation And Maintenance Manual Download Page 148

2  M

AINTENANCE  PRECAUTIONS

CAUTION 

No maintenance operations described in this guide are to be performed with the engine 

running; please refer to the Maintenance Manuel for any other operation. 

2.1 Precautions before maintenance

2.1.1 Removing the residual pressure

Before performing any maintenance operation, remove residual pressure in the hydraulic circuit.

1. Perform the machine's parking operations. 

2.4 Parking precautions, page 76

2. Turn the key to the OFF position to stop the machine's engine, then turn it to the ON 
position. 

Note

The locking lever must be lowered.

3. Handle the following controls several times to remove the residual pressure: 

•  Left command lever (Arm & Rotation of the upper part )

•  Right command lever (Boom & Bucket )

•  Blade lever

•  3rd hydraulic circuit control 

(P.T.O. 1)

4. Set the starter key to OFF position. 

5. Remove the key from the ignition.

The residual pressure in the accumulator is removed and there is no more pressure in the hydrau-
lic circuit.

2.1.2 Place a warning label

WARNING

Do not operate the control lever during servicing. 
Maintenance personnel may be seriously injured. 

Place a "MAINTENANCE IN PROGRESS" label on the machine and on the joysticks. 

131

Summary of Contents for ViO38-6

Page 1: ...USER OPERATION AND MAINTENANCE MANUAL MINI EXCAVATOR ViO38 6 Original manual MUB33ENMA00100 28 09 2017 ...

Page 2: ...de to transform its perfomances beyond the original factory speci fications the warranty expires and the improvements on site under warranty are rejected The use of fuel beyond the specifications required or boosting the machines engines will cancel the warranty All the information illustrations and specifications contained in this manual are based on the la test product information available on p...

Page 3: ......

Page 4: ...d for conformity assessment are NF EN ISO 3744 NF ISO 6395 Notified Body CETIM Centre Technique des Industries Mécaniques 52 avenue Félix Louat BP 80067 60304 SENLIS Cedex FRANCE Net power output 18 5 kW 2200 rpm Measured sound pressure 93 9 dBA Guaranteed sound pressure 94 dBA Name and address of the person established in the European community authorized to compile the technical file and transmi...

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Page 6: ...N Note information about your YANMAR machine here Always use these references for everything to do with your YANMAR machine Model name Machine serial number Serial number of the engine Your YANMAR dealer Address Telephone ...

Page 7: ......

Page 8: ...r user do not forget to pass on the manual at the same time YANMAR provides its customers with products that conform to the regulations and indus trial standards that apply in their respective countries If you are using a YANMAR machine that you have bought from a foreign company you should be aware that certain safety mecha nisms may be missing from the machine Consult your dealer to find out whe...

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Page 10: ...e operator of this machine must be competent and trained in its use WARNING Never try to operate or repair the machine if you have not read and understood all the applicable warnings and usage instructions contained in this manual and on the safety signals on this machine Physical injury may be caused if the safety instruc tions are not respected WARNING Never modify the design of the machine or i...

Page 11: ... lights 15 5 1 2 Clock 17 5 1 3 Time counter 17 5 1 4 Diesel gauge 17 5 1 5 Cooling fluid temperature indicator 18 5 1 6 Preheating light 18 5 1 7 Navigation keys 19 5 1 8 Information and error icons 19 5 2 Switches 21 5 2 1 Start key 22 5 2 2 Headlight switch 22 5 2 3 Horn 23 5 2 4 Windscreen wiper switch and windscreen wiper 23 5 2 5 Ventilation switch 23 5 2 6 Engine rate setting 24 5 2 7 Engin...

Page 12: ...nical quick hitch CSERI 56 B Operating instructions 57 1 Basic precautions 59 1 1 Comply with your workplace s safety rules 59 1 2 Put the safety mechanisms in place 59 1 3 Wear suitable clothing and protective equipment 59 1 4 Do not drive under the influence of alcohol drugs or medication 60 1 5 Provide adequate ventilation when working in an enclosed space 60 1 6 Protect plants from hot air and...

Page 13: ...s for using optional accessories 78 2 7 Precautions for the battery 79 3 Precautions for the engine 80 4 Checks before starting the machine 81 4 1 Overall visual inspection 81 4 2 Checking and topping up the level of cooling fluid 82 4 3 Checking and topping up the engine oil level 83 4 4 Checking and topping up the fuel level 84 4 5 Checking and topping up the hydraulic oil level 85 5 Checks afte...

Page 14: ... machine 115 15 4 Slinging the machine 117 16 Detecting anomalies 118 16 1 Phenomena that do not constitute faults 118 16 2 Detecting anomalies 118 16 2 1 Engine 119 16 2 2 Electrical equipment 120 16 2 3 Machine structure 121 17 If the battery is discharged 122 17 1 Precautions for connecting and disconnecting the starter cables 122 17 2 Connecting the starter cables 122 17 3 Starting the engine ...

Page 15: ...tation crown 144 6 3 Maintenance every 15 days 145 6 3 1 Checking the air conditioning heating system 145 6 4 Non periodic maintenance 145 6 4 1 Fuse replacement 145 6 4 2 Top up the windscreen washer fluid 146 6 4 3 Replacing the windscreen wiper 146 6 4 4 Accessory state check 146 6 5 Rubber track maintenance 146 6 5 1 Checking the condition of the tracks 146 6 5 2 Track replacement 147 6 5 3 Te...

Page 16: ...ing ViO38 6 Canopy 169 2 Lifting Cabin 170 Appendices 171 A List of error codes displayed on the operator display station 172 B Control sheets to be photocopied 174 C Notes 179 D Lashing record 180 Index 181 ...

Page 17: ......

Page 18: ...e CHAPTER COVERED IN THIS PART 1 APPLICATIONS AND REGULATIONS 2 IDENTIFICATION PLATES 3 WARNING LABELS 4 IDENTIFICATION OF IMPORTANT PARTS 5 DESCRIPTION OF THE DRIVING POSITION 6 OPERATION OF THE AIR CONDITIONING 7 COVERS 8 HEATING VALVE 9 OPTIONS ...

Page 19: ...2 ...

Page 20: ...using this machine check the requirements applicable to its use concerning the driving permits Respect all applicable laws See your dealer for questions about usage permits 1 4 Lifting Using the machine as a hoist is subject to the Machinery Directive 2006 42 EC for mem bers of the European Community and to the legislations specific to each country for states outside the EC YANMAR CONSTRUCTION EQU...

Page 21: ...thout operator equipped with a standard bucket and tanks topped off 5 Weight of the machine with operator 75 kg 6 Serial number and engine power 7 Machine serial number 2 2 Engine serial number plate The engine s serial number plate is located on the top of the lifting arm lever cover and on the adhesive label lo cated inside the bonnet Never remove this plate for any reason 2 3 EPA information pl...

Page 22: ... and intervention request When you order spare parts or call for an inervention tell your dealer the model name the serial number of the machine and the serial number of the engine and the number of hours displayed on the time counter 1 Time counter ...

Page 23: ...see whether all the messa ges are in the correct location and are legible If an adhesive label is missing damaged or illegible replace it straight away In the same way if an adhesive label is on a part that has been replaced add a new adhesive label to the new part Contact your YANMAR dealer to obtain new adhesive labels The part code number is clearly indicated on each label ...

Page 24: ...3 Warning labels 7 3 1 Location of the warning adhesive labels ...

Page 25: ...3 Warning labels 8 ...

Page 26: ...3 Read the user manual 2 Usage precautions page 64 2 1 5 Accessing the machine page 67 4 Do not remove the protective casings while the machine is running 2 2 9 Radiator ventilator page 135 5 Pressurised elements Do not unscrew while the liquid is hot 1 8 Avoid removing the caps when the temperatures are high page 61 6 Hot surfaces 4 3 Checking and topping up the engine oil level page 83 7 Transpo...

Page 27: ...ite 6 2 1 Greasing the pin and rotation crown page 144 14 This sticker describes the operation of the machine controls and their location relative to the operator seat Options 5 3 Joysticks and pedals page 26 15 Filler holes for various reservoirs on the machine and track tension system 3 Recommended greases and fluids page 136 6 5 Rubber track maintenance page 146 6 6 Steel track maintenance page...

Page 28: ...e 67 19 Fusebox 5 8 Fuses page 34 20 To switch to 2nd gear press the switch on the blade lever The 2nd gear indicator lights on the LCD monitor 5 2 10 2nd gear switch page 25 21 Interference between the bucket and the machine 10 2 Compatible accessories page 102 22 Circuit breaker This switch is used to disconnect the battery directly 9 2 Circuit breaker page 49 ...

Page 29: ...hen using with a bucket or an accessory page 100 Lifting capacities F Lifting capacities page 167 25 Before transporting the machine check the total height of the load 15 3 Tying down the machine page 115 26 The air conditioning system contains fluorinated greenhouse gases 1 15 Air conditioning system page 63 27 Reflective strips make the machine more visible in the dark 23 Cabin s emergency exit ...

Page 30: ...ont D Rear 1 Blade 2 Boom cylinder 3 Bucket 4 Axes 5 Bucket link 6 Arm 7 Bucket cylinder 8 Arm cylinder 9 Boom 10 Locking lever 11 Sprocket wheel 12 Support roller 13 Track roller 14 Idle wheel 15 Canopy 16 Boom headlamp 17 Boom base 18 Boom rotation cylinder 19 Track 20 Blade cylinder 13 ...

Page 31: ...Driver s seat 2 Left command lever 3 Locking lever 4 Foot rest 5 Side movement pedals 6 Boom rotation pedal 7 Slide movement levers 8 Right command lever 9 Operator display station 10 Blade lever 11 Engine rate control 12 Start key 13 Switches 14 Cup holder 15 Options ...

Page 32: ...oblem occurs when starting a light co mes on and the alarm sounds WARNING When an indicator light comes on and the alarm sounds during operation stop the engine immediately and follow the steps recommended in this manual 1 Indicator lights 2 Clock 3 Time counter 4 Diesel gauge 5 Cooling fluid temperature indicator 6 Menu change 7 Information and error icons 8 Indication of functions 9 Keys F1 to F...

Page 33: ...ate the presence of information such as maintenance indications Press F4 to view the details d Hydraulic oil temperature gauge This indicator lights only at startup and it does not have any function on this machine e Travel speed indicator Increased speed This indicator shows that the 2nd gear is engaged f Battery charge warning alert If the battery is not correctly charged the warning light will ...

Page 34: ...n the engine is running the time counter per manently records the time even if the machine is not being used The time counter records 1 for one hour without considering the engine rotation speed The decimal to the far right records 1 for 0 1 hours 6 minutes 5 1 4 Diesel gauge Full Empty The diesel gauge operates when the starter key is in ON position It indicates the level of diesel in the tank Wh...

Page 35: ...ant reaches the limit 2 during working then slow the engine down and wait for it to return to normal When the engine is cold top up with cooling fluid following the procedure described in chapter 4 2 Checking and topping up the level of cooling fluid page 82 5 1 6 Preheating light When the start switch is in the ON position and pre heat the symbol appears on the monitor screen hold the key in the ...

Page 36: ...ed the date and time settings will be reset 7 Operator LCD display station interfaces page 90 Maintenance notice This icon indicates on the basis of the machine s accumulated hours of use that the maintenance period for an maintenance object has been reac hed Required maintenance must be performed after referring to the main tenance section of this manual When the maintenance has been performed th...

Page 37: ...p up with cooling fluid following the pro cedure described in chapter 4 2 Checking and topping up the level of cooling fluid page 82 Engine stop icon If the control panel displays this icon alternately with another icon stop the engine immediately Take the necessary corrective measures Error icon This icon indicates an error other than those described above Refer to the list of error codes to iden...

Page 38: ...1 Start key 2 Horn 3 2nd gear switch 4 Engine rate setting 5 Windscreen wiper switch and windscreen wiper 6 Headlight switch 7 Eco mode switch 8 Engine slow down switch 9 Ventilation switch for cab 10 Interior lighting switch for cab 11 Engine stop switch ...

Page 39: ...tch is in the ON position and preheat the symbol appears on the monitor screen hold the key in the ON position until the symbol is no longer displayed START position startup Turn the key to START position to start the engine Re lease the key after the engine starts and it will return it self to ON position WARNING To protect the starter and battery Do not keep the ignition key more than 10 seconds...

Page 40: ...ORTANT Do not press the washer command when the washer tank is empty as this may damage the pump Using windscreen wipers on a dry windscreen may damage the glass Only use the wind screen wipers when the windscreen is wet The windscreen wiper blade may freeze in cold weather Do not try to activate it if it is fro zen as this may damage the windscreen wiper motor 5 2 5 Ventilation switch Use this sw...

Page 41: ...the engine speed knob ON Auto idler activated The indicator light is on OFF Auto idler deactivated The light is off 5 2 8 Eco mode switch This switch is used to reduce fuel consumption by reducing the engine rate ON eco mode activated The indicator light is on OFF eco mode deactivated The light is off 5 2 9 Engine stop switch 1 STOP 2 Normal If the engine does not stop when the ignition key is set...

Page 42: ...D monitor 1 2nd gear switch Press the second gear switch again to return to normal speed The light goes out 5 2 11 Interior lighting switch ON The lighting is activated OFF The lighting is desactivated Auto At the opening of the door a timer switches the interior lights on for 15 seconds The interior light auto matically turns off when the cabin door is closed ...

Page 43: ...e driving position 26 5 3 Joysticks and pedals 1 Locking lever 2 Right command lever 3 Proportional roller P T O 1 4 Left command lever 5 Travel levers and pedals 6 Blade lever 7 Protection of pedals 8 Boom rotation pedal ...

Page 44: ... hand side WARNING Make sure the security system is operating when accessing the machine or leaving the operator s seat WARNING The movement relationship between the command lever mechanism and the equipment movements thay produce are described in detail in this manual To avoid any accidents due to handling errors it is prohibited to modify the hydraulic circuit when reconnecting the hydraulic cyl...

Page 45: ...et auger etc ope rate only the proportional roller 5 3 4 Left command lever The left hand joystick is used to control the arm movements and the rotation of the upper part Handling the arm 1 Left command lever Rotation of the upper part 1 Left command lever When you release the lever it returns to neutral position and the respective movements stop Por the machines with a 4th hydraulic circuit this ...

Page 46: ...elves with the content of this manual before carrying out a task WARNING Before handling the travel levers check whether the machine is in normal or reverse po sition The machine is in the normal position when the blade is on the same side as the work equipment If the machine is in the reverse position the displacement levers must be handled in re verse to move forward and backward Normal position...

Page 47: ... To turn right do the same thing with the left travel lever To make a rotating turn of the machine to the left 1 Position the travel levers in the neutral position 2 Push the right travel lever forward and pull the left travel lever rearward To make a rotating turn of the machine to the right reverse the operation of the levers 5 3 6 Blade lever 1 Blade lever Use this lever to command the blade Pu...

Page 48: ...ion pedal Use this pedal to pivot the boom to the left or right A Rotate right press right B Rotate left press left N If the pedal is released it returns to the neutral po sition and the boom keeps its position 5 4 Power socket The intake works when the ignition key is in the ON position Appliances up to 12V 120W 10A may be connected 1 Lid 2 Power socket IMPORTANT Always close the lid if the plug ...

Page 49: ...on when you are working on the machine adjust it before you start Always fasten your safety belt and adjust it before starting the machine Seat position adjustment Pull the lever 1 to move the seat forward and back Pull the strap to adjust the seat back hinge Suspension adjustment 1 Turn the key to the ON position to turn on the po wer circuit and the charging circuit 2 The seat suspension 4 can b...

Page 50: ...s possible 3 Remove the three screws securing the rear of the seat support 4 Raise the seat via the front and use the rod to lock it in the raised position Closing the cover 1 Raise the seat slightly to release the rod 2 Lower the seat 3 Reinstall the five screws and tighten to secure the seat support 5 7 Location for the tools and user manual 5 7 1 Toolkit The toolkit location is on the left hand...

Page 51: ...uipment and the electrical cabling against a surge In case of a bad contact or if the electrical system does not work when the key is on replace the faulty fuse with a fuse in good condition 6 4 1 Fuse replacement page 145 The general supply fuses are located beside the bat tery under cover R The fusebox is underneath the driver s seat 1 Storage box cover 2 Fusebox 3 General supply fuses ...

Page 52: ...wiper motor Cab headlight Rear light E 15 Cabin power supply F 15 Windscreen wiper G 30 Heating Air conditioning H 5 Interior lighting Radio I 10 J 5 Operator display station 2 K 5 L 5 Immobilizer Starter M 5 Engine N 5 P T O 1 Movement alarm Eco mode O 15 Quick hydraulic hitch P 30 Power socket Seat pump Q 30 Headlights R 10 Safety relay S 20 Spare fuses T 30 U 10 V 5 Electronic Control Unit ECU ...

Page 53: ... Safety relay D 5 Engine 2 E 30 Power socket Seat pump F 20 Headlights G 20 Cabin power supply 2 H 20 Windscreen wiper I 5 Starter J 5 Options 2 Immobilizer K 5 Options 1 Immobilizer L 30 Heating Air conditioning M 5 Fleet management system SMART ASSIST N 5 O 10 Engine 1 Engine Electronic Control Unit ECU P 5 Operator display station Q 5 Cabin power supply 1 R 10 Options 1 S 20 Spare fuses T 30 U ...

Page 54: ...ducts in the ash tray 5 10 Cabin CAUTION The upper and lower parts of the windscreen can be opened The opening and clo sure of the windscreen must be secured with the safety levers in order to avoid any sudden unplanned closure which may cause injuries Do not pass your hand or head through the open door or windscreen 1 Upper windscreen 2 Side door 3 Lower windscreen CAUTION Place the locking lever...

Page 55: ...open the door To close the door Slam the door and turn the key clockwise to lock it From the interior Pull the interior handle to open the door b Locking the door The door lock is used to hold the door open during the machine operation 1 Cylindrical lock 2 Handle To lock the door 1 Open the door 2 Push the door against the outer side of the cabin for engaging the cylindrical lock To unlock the doo...

Page 56: ...ckwards until it positions itself under the ceiling WARNING Open the windshield carefully to avoid bump ing your head 3 Lock it is using the safety lock located to the right and left of the ceiling A Safety lock Closure of the upper part of the windscreen 1 Grasp the handles and push the levers to the right and left of the window until you hear a click for them to unlock A Handle 2 Slowly lower th...

Page 57: ...the ceiling 1 Lift the lower part of the windscreen using both hands 2 Store it in the compartment provided on the rear left hand side of the cab Note Immobilise it by inserting it into the safety mechanisms Closure of the lower part of the windscreen 1 Press the upper part of each lock to take the wind screen out of its compartment 2 Put the lower part of the windscreen in its place 3 Lower the l...

Page 58: ...driving position 41 5 11 Headlights WARNING The headlight becomes very hot when it is operating Never touch it with your bare hands before it has cooled down to avoid any risk of burning Boom headlamp Cab headlight Options ...

Page 59: ... contact your dealer Use under abnormal conditions may damage the installation Every week run the air conditioning at least once for a few minutes this will help to keep the installation in good condition 1 Operating switch 2 Ventilator switch 3 Temperature switch A Grill 1 Activate the operating switch IMPORTANT Only start up the air conditioning after starting the machine to avoid overloading th...

Page 60: ...tion of the air conditioning 43 Air recycling 1 Air recycling lever The exterior air is cooled down or heated and in troduced into the cab The cab air is cooled down or heated up then re expelled into the cab ...

Page 61: ...and topping up of the va rious levels should be done when the engine is stopped and the temperatures are brought back down Opening the cover 1 Handle 2 Key 1 Insert the starter key into the lock 2 Turn the key counterclockwise 3 Pull the exterior handle to open the bonnet Closing the cover 3 Rod 1 Lift the the rod to release it 2 Close the cover 3 Press on it until you hear a click 4 Turn the key ...

Page 62: ...terior handle 2 Key 1 Insert the starter key into the lock 2 Turn the key counterclockwise 3 Pull the exterior handle to open the bonnet 4 Lock the cover using the rod Closing the cover a Rod 1 Lift the cover slightly and press the rod to release it 2 Close the cover 3 Press on it until you hear a click 4 Turn the key clockwise to activate the lock ...

Page 63: ...se it 2 Secure the rod in its stowage space 3 Close the cover 7 4 Rear cover According to the machine configuration the rear cover conceals either the windscreen was her tank the condenser for the air conditioning system or a storage space Opening the cover 1 Handle 2 Key 1 Insert the starter key into the lock 2 Turn the key counterclockwise 3 Pull the exterior handle to open the bonnet Closing th...

Page 64: ...pping the heating function do the following 1 Heating valve 1 Perform the machine s parking operations 2 Stop the engine by turning the key from ON position to OFF position 3 Open the bonnet with the ignition key 4 Turn the valve in the locked position to stop the heating function 5 Close the engine bonnet Note To restore the heating function reverse the process 47 ...

Page 65: ...onal PTO The adjustable proportionality allows better P T O flow control by combining a knob with the proportional roller 1 Proportional roller 2 Knob 3 Position holding button To use the adjustable proportionality system 1 Operate the accessory with the proportional roller 2 Set the maximum hydraulic circuit speed with the knob Turn the button clockwise to increase the flow rate Turn the button c...

Page 66: ... the corresponding joystick comes on 3 The accessory operation is maintained and the ac cessory is operated at the rate set by the knob 4 Press the position holding button again to return the pressure to its starting level CAUTION Do not use the position holding with bucket tilting you would risk damaging the machi ne s hydraulic circuit 9 2 Circuit breaker The machine can be fitted when this opti...

Page 67: ...aries according to machine configuration WARNING Do not perform lifting operations without the lifting equipment listed below being installed on the machine 13 Load lifting page 110 1 Arm valve 2 Boom valve 3 Blade valve 4 Lifting Tables 5 Overload switch 6 Lifting ring ...

Page 68: ...ackle eye and whose WLL1 is equal to or greater than the load to be lifted 9 3 2 Safety valves The safety valves must be installed with the ring These flaps are installed on the machine s boom rocker arm and blade cylinders to avoid the equipment falling to the ground if the hoses break 9 3 3 Overload switch When the operator wishes to perform handling it is essential for the overload switch to be...

Page 69: ... air conditioning page 42 9 5 Quick hitch The machine can be fitted when this option is requested CAUTION Before any connection or disconnection of the hydraulic hoses remove the residual pres sure from the hydraulic circuit 2 1 1 Removing the residual pressure page 131 Connecting 1 Insert the adapter into the receiver A slight click indicates that the connection is successful The ball is released...

Page 70: ...re that the bucket or accessory is compatible with the capabilities of your machine 10 2 Compatible accessories page 102 the bucket or accessory mounting operation is performed on a level and stable ground the bucket or accessory is properly positio ned to be installed on the machine WARNING Check the condition of the interface between the quick hitch and the accessory cleanli ness shocks It is fo...

Page 71: ...ve the ground 3 Be equipped with the wrench supplied with the accessory 4 Slide the spanner from right to left along the cam to insert the lug of the spanner into the cam bore 5 Detach the cam using the spanner as a lever to re lease the accessory DANGER By pressing the key the bucket or accesso ry detaches and comes into contact with the ground Take care not to get your hands or feet crushed by t...

Page 72: ...accessory hooks on the buc ket or accessory pin 5 Slowly raise the boom to lift the accessory This lets you position the accessory correctly in the quick coupler Note Lift the accessory high enough to allow the bucket cylinder to move through its full range of travel 6 Extend the bucket cylinder fully to lock the quick coupler system Note You should hear a click when the quick cou pler system lock...

Page 73: ...completely free the quick hitch from the bucket or accessory Mounting the accessory 1 Place the accessory on a stable flat surface 2 Clean all the parts Note Make sure the locking pins are retracted into the quick hitch If the pins are in the extended position a Be equipped with the wrench supplied with the accessory and insert it into the quick hitch hole b Turn the key 1 to disengage the bucket ...

Page 74: ...ER START UP 6 CHECKS AFTER USE 7 OPERATOR LCD DISPLAY STATION INTERFACES 8 USING THE MACHINE IN COLD WEATHER 9 RUBBER TRACKS 10 HANDLING THE BUCKET 11 HANDLING OF ACCESSORIES 12 ACCESSORY CHANGE BY DIRECT COUPLING 13 LOAD LIFTING 14 IMPLEMENTING THE 3RD HYDRAULIC CIRCUIT 15 TRANSPORTING THE MACHINE 16 DETECTING ANOMALIES 17 IF THE BATTERY IS DISCHARGED 18 TOWING THE MACHINE ...

Page 75: ...58 ...

Page 76: ...harmful en vironment The machine must therefore not be used in such environments 1 2 Put the safety mechanisms in place Make sure that all covers and all housings are properly installed in their respective posi tions If any of them are damaged repair them immediately The use of safety mechanisms such as locking lever s must be mastered and understood by the machine s operator 5 3 1 Locking lever p...

Page 77: ...e engine in an enclosed space open the windows and doors to let air circulate Never let the engine idle unnecessarily and never leave the engine running when you are not using the machine Provide respirators based on working conditions to ensure the machine operator works safely 1 6 Protect plants from hot air and exhaust fumes The silencer and radiator release hot air and exhaust fumes at high te...

Page 78: ...rised personnel must not enter this area 1 8 Avoid removing the caps when the temperatures are high The engine coolant engine oil and hydraulic oil are hot and pressurised after the engine stops Removing caps draining coolant or oil or replacing a filter under these conditions risk causing burns Before you remove the cap from the hydraulic oil tank shut down the engine then gently turn the cap to ...

Page 79: ...fy your machine you must contact your dealer 1 12 Precautions for optional parts and tools Any modifications that are not approved by YANMAR may cause safety risks If the equipment you want to add to your machine is not listed by YANMAR you must contact your dealer YANMAR cannot be held responsible for any physical injuries accidents failure or damage to the machine due to any unauthorised modific...

Page 80: ... that you do not slip on the pieces of glass that have fallen at your feet on the cab floor 1 15 Air conditioning system The air conditioning system contains fluorinated greenhouse gases The characteristics of these gases are indicated on the sticker affixed to the machine and are listed below 3 1 Location of the warning adhesive labels page 7 A C YANMAR Contains fluorinated greenhouse gases xx xx...

Page 81: ... pipes high voltage lines or other elements contact the responsible companies to locate them exactly and to avoid damaging them Examine the field and the ground and decide on the best way to work When working on the street make sure the worksite is secure If you have to use the machine under specific conditions water snow etc 2 3 7 Working in an area covered with snow page 73 2 3 9 Working in a su...

Page 82: ... starting the machine page 81 Keep the headlights and mirrors clean To clean the cab exterior Be sure to keep three points of support with the machine when cleaning the external elements e g mirrors Use the support points identified in the illustra tion opposite If 3 points of stable support are not accessible for cleaning or maintenance of the external ele ments use adapted equipment in order to ...

Page 83: ...falling objects FOPS and protection against side tipping TOPS Never modify any of these structures elements The protection structures mounted on the machine comply with the recommendations of ROPS ISO 12117 2 2008 FOPS ISO 10262 2000 For the specifications of these structures refer to the table below Type ROPS TOPS Weight in conformity with CE standards 4804 kg 2 1 4 Check the position of the blad...

Page 84: ...If the handles or the track is dirty or covered with oil wash them off CAUTION Make sure that you do not bang your head against the rearview mirror when you climb into or out of the cab 2 1 6 Fasten your safety belt and adjust the rearview mirror s The operator s seat is fitted with a safety belt Always fasten your safety belt and adjust it before starting the machine WARNING The seat belt must be...

Page 85: ... Alert people nearby using the horn or any other si gnal before starting the machine DANGER If a person is in the machine s danger zone it may be struck by the machine s moving parts or be wedged between the machine s lower and upper parts which can result in se rious injury or death 2 2 2 Movement and accessories When moving the machine keep the bucket bet ween 40 and 50 cm above the ground with ...

Page 86: ...s or a damp metal plate even with a slight tilt Drive the machine carefully at low speed to prevent it slipping WARNING The machine may lose its balance and tip over when rotating the upper part or when the equipment is working on a slope Do not pivot the upper structure with a load in the bucket If the rotation cannot be avoi ded provide a bank to keep the machine as horizontal as possible Then t...

Page 87: ...pply excessive force to the cylinder s stop piece and may reduce the equipment s life span Main tain safe room for manoeuvre Do not use the bucket s dropping force Do not use the bucket s dropping force to dig the ground as with a pick or harvester This may apply excessive force to the rear of the machine and shorten its life span In addition this may cause a serious accident Do not strike the bla...

Page 88: ... cylinder Place the blade at the back if it is not in use Do not lift loads without a suitable fastening de vice it is strictly forbidden to wrap a sling around your machine s accessory or suspend it to a bucket tooth Do not hang a load without the kit s lifting facilities 9 3 Lifting Kit page 50 2 3 2 Dangerous tasks Digging from the top is dangerous as there is a risk of rock falls or landslides...

Page 89: ...o close to an electrical line If the machine is to enter into contact with a cable the operator must not leave his seat Warn all personnel on the ground to stay far enough away from the machine To determine the voltage of the wires on the work site contact the electricity production company concerned Voltage V Minimum safety distance m Electricity lines 50000 3 50000 5 WARNING This table is provid...

Page 90: ... 5 Raise the lock lever 6 Turn the key to OFF position to switch off the engine and disconnect the electrical circuit Remove the key from the ignition 2 3 6 Working on a slope Make sure that the machine does not lose its ba lance and tip over when rotating the upper structure or when rotating equipment on a slope Do not pivot the upper structure with a load in the bucket If the rotation cannot be ...

Page 91: ...ound When you are working in an area with a high risk of rock fall wear a helmet and remain under the canopy or in the cab 2 3 9 Working in a submerged area Before you use the machine in a submerged area examine the condition of the ground and the depth and flow of the water The maximum depth of water in which the machine may be used is located up to the centre of the carrying roll IMPORTANT When ...

Page 92: ...rself on the ground with the lower part of the bucket and not with the teeth The angle between the boom and the arm must be 90 to 110 If both tracks are stuck 1 Place a log or piece of wood under the tracks 2 Push the bucket into the firm ground 3 Retract the arm as if to dig and move forward with the side movement levers to get out of the mud 2 3 11 Working in an area with reduced visibility When...

Page 93: ... the uphill side of the slope at the tracks Stopping the engine 1 Release the right and left side movement levers in neutral position to stop the machine 2 Turn the switch to the left to decrease the engine speed IMPORTANT Stopping the engine after a rotation at high speed risks reducing its life span Do not stop the engine suddenly except in an emergency If the engine is overheating do not stop i...

Page 94: ... a serious accident 2 5 Precautions for the accessories CAUTION An accessory that is not adapted to the machine may imbalance it When you mount or remove an accessory follow these precautions 1 Place the machine on flat firm ground 2 Stop the engine 3 Keep the parts clean and well greased 4 Never mount any accessories that exceed the maximum accepted dimensions 5 Do not stay beneath a suspended lo...

Page 95: ...e pivoting accessory and a nearby object and may strike the accessory against the object To avoid this type of accident stop the rotation as soon as possible Because of the increase in the inertia the accessory will fall a greater distance away after it has been stopped in the air There will be major unplanned drift for the accessory Check that the arm and the boom are correctly mounted If this is...

Page 96: ...ammable Keep the battery away from all flames and sparks If you accidentally swallow any of the battery s electrolyte drink a large quantity of water milk or fresh eggs and consult a doctor immediately Before inspecting or handling the battery switch off the engine and turn the starter switch to OFF Make sure that you do not cause a short circuit by touching the battery terminals with a tool If a ...

Page 97: ...efore despatch Otherwise there is a risk that its performance will be affected and its life span shortened When running in the machine make sure to Preheat the engine by running it on idle for 5 minutes after starting it Do not run the machine with a heavy load or at a high speed Do not start accelerate or stop the engine suddenly Do not change direction too suddenly Note Observe these precautions...

Page 98: ...re are no oil leaks from the hydraulic system the hydraulic oil tank the pi pes and seals 5 Check that there are no traces of grease or leaks from the hydraulic pipes 6 Check that there are no cracks wear or play on the bolts and there are no oil leaks on the track rollers runners sprockets and rollers 7 Check that the bolts have not broken or come loose 8 Check the proper operation and the condit...

Page 99: ...markers 1 maxi 2 mini If the level is below the min marker 1 Take the cap off the tank 2 Top up to the maximum marker 3 Close the tank again 4 Close the engine bonnet IMPORTANT If the tank is empty check for leaks and the water level in the radiator If the level of water in the radiator is low top it up in the radiator then in the tank WARNING Only remove the radiator cap to top up the radiator Re...

Page 100: ... oil level is above marker H remove the ex cess quantity of oil via the drainage cap P then check the level again Note Do not pour the excess engine oil onto the ground or the road F Filler hole Once the engine oil is at the appropriate level close the bonnet again Select the oil according to the temperature If you start the engine at temperatures below 0 C use an SAE 10W an SAE 10W 30 or SAE 15W ...

Page 101: ...c Top up through the filler hole keeping an eye on the gauge located on the tank Only use the recommended diesel EN 590 Minimum cetane index 45 1 Cover B 2 Cap 3 Diesel gauge Temperatures C Quantity prescribed L 20 10 0 10 20 30 Diesel N 2 D 41 N 3 D N 3 D S WARNING If you spill any fuel wipe it up with a cloth 1 Tank vent 5 Close the tank again 6 Close cover B Note If the cap vent holes are plugg...

Page 102: ...he oil level varies according to the oil temperature Before start up the oil level must be on or around the central point of the gauge scale oil temperature 10 to 30 C During normal operation the oil level must be around the upper limit marker on the oil gauge scale oil temperature 50 to 80 C 4 If the oil level is below the minimum marker top up as follows a Open cover B using the starter key b Op...

Page 103: ...VG46 40 in the tank 22 the rest IMPORTANT Do not mix different types of oils If you need to top up the oil with an oil of a different brand or type from the oil left in the tank remove the remaining oil completely Replacing the hydraulic oil The hydraulic oil must be replaced every 1000 hours Contact your dealer ...

Page 104: ...ture handle it gently Do not accelerate suddenly if the engine is not hot After the engine starts do not use the machine immediately but respect the following procedure 1 Run the engine on idle and check that the engine oil pressure alarm light is off 2 Check that the gauges and the screen correspond to the following statuses 1 Diesel gauge normal 2 Cooling fluid temperature indicator normal 3 Tim...

Page 105: ...ccessory make sure it does not hit the ground or the machine IMPORTANT Check that there is no abnormal noise in the hydraulic circuit 6 Check the colour of the exhaust gas the noise and the vibrations of the machine 7 Raise the locking lever to ensure that no handling of the equipment and no rotation of the upper structure is possible with the joysticks 8 Unlock the locking lever and activate the ...

Page 106: ...Check whether the radiator vents are clogged Clean or replace the fuel filter cartridge regularly Clean the electrical equipment particularly the starter and the alternator to avoid any dust deposits If the machine is used in mud snow or sand Clean the machine Check there are no cracks or damage Check that no nuts or screws are missing Apply grease to all equipment axes that have been submerged in...

Page 107: ...nfirm the selection by pressing F4 7 1 Indication of functions This section of the menu indicates the functions of buttons F1 to F4 Return to previous menu Reset the selected value Move the cursor over the object to the left of the one selected Displays the details of an information notice maintenance notice for example Move the cursor over the object to the right of the one selected Stop the buzz...

Page 108: ...enance interface 1 Displays the maintenance inter val screen 2 Displays the maintenance histo ry screen 1 Maintenance object icon 2 Maintenance object name 3 Time accumulated since the pre vious maintenance 4 Maintenance interval This interface allows you to check the mainte nance periods and cumulative elapsed time since the last maintenance for each maintenance object Information icon appears on...

Page 109: ...ss The display returns to the maintenance interface and a confirmation sound is emitted Changing the maintenance interval To change the maintenance interval follow this procedure 1 Select the maintenance interface 2 Select the maintenance object using F4 3 Press the F2 key to select the first digit Note To select the thousands hundreds or tens di gits repeatedly press F2 4 To edit the highlighted ...

Page 110: ...achine use for the selected month The number of operating hours is shown approximately by a number of chips under the cor responding date and a time span 0 5 2 0h 2 0 4 0h 4 0 8 0h 8 0h Hours of machine use for the selected day The hours of machine operation are displayed as follows 1 Number of hours in the morning 2 Number of hours in the afternoon 3 Total operating hours for the day ...

Page 111: ...und parameter Adjusts the monitor to emit a confirmation sound when a button is pres sed The buzzer sounds when the settings are changed or when a mal function is detected can not be removed Brightness setting Adjusts the brightness of LED visual indicators and the LCD screen when the work light is in operation 7 5 Configuration interface This interface allows you to change the settings shown in t...

Page 112: ... these pages and respect these safety instructions before starting up the machine 2 1 Precautions before starting the engine page 64 95 1 Set the engine speed switch setting between idle and full throttle positions 2 Turn the key to the ON position a Keep the key in the ON position to warm up the engine until the warm up icon no longer appears on the screen b When the glow plug icon no longer appe...

Page 113: ...nd and park the machine on these boards to avoid the tracks freezing on the ground 2 Drain the water built up in the fuel system by turning the evacuation tap to avoid and freezing 3 Cover the battery or place it in a warm place and reinstall it on the machine the next morning 8 4 When cold weather is over When the exterior temperature increases replace the engine oil and the fuel 3 Recommended gr...

Page 114: ... to the ground Simple operation Resistance Traction power excellent good ordinary The rubber tracks have certain advantages that are inheritent to the material s unique pro perties It is essential that you perfectly understand the properties of the rubber tracks and comply with the handling and operating precautions for these tracks to extend their life span and get the most out of them 9 3 Rubber...

Page 115: ...ly change the speed You risk wearing or damaging the track Never rotate on ground with a significant difference in level Climb a step at a right angle to avoid the tracks coming off Gently lower a machine that has been raised from the ground with the equipment We recommend not to handle materials that become oily once crushed soya wheat grains compressed colza oil yeast etc After use clean the mac...

Page 116: ...gnificant difference in level there is a spacing between the tracks and the rollers 1 Track 2 Track roller when you carry out side movement in reverse there is another spacing between the tension roller and the track 3 Idle wheel when the machine is moving although the tracks have been blocked to the side by an obstacle when the idler pulley and the rollers are not ali gned with respect to the tra...

Page 117: ... before using the machine for exca vation levelling operations or in working conditions with the accessories Depending on the machine configuration arm length presence of a counterweight and working conditions the operator must make sure that the equipment and accessories selection is made according to the nature of the task to be carried out and according to the machine s stability limits the tot...

Page 118: ...ion Weight handled Weight of equipped quick hitch Weight of the accessory hammer empty bucket Bucket load capacity x material density This operation is reminded by a sticker affi xed in the cab interior and visible from the driver s compartment Compare the result with the maximum weight under condition of use with bucket shovel or with accessories Weight of quick hitch and accessories hammer empty...

Page 119: ...ith a full bucket forming a dome in accordance with ISO standard 7451 For particular operations or with materials of different densities partial bucket filling due to fluid products such as mud larger buckets may be used In this case it is the responsibility of the user to ensure that the machine stability limit is not exceeded The machine could tip over which could cause serious physical injuries...

Page 120: ...CC00500 Mechanical wedge CSERI Quick hitch GCSMS03A Bucket Retro bucket GCS03AT0600 Ditching bucket GCS03AC1200 Swivel ditching bucket GCS03AP1000 Loading bucket GCS03AT0600 GCS03AC1200 GCS03AP1000 Hydraulic hammer ACD00500 Mechanical cam ACB Morin Quick hitch Module M1 Bucket Retro bucket GMO13R0650 Ditching bucket GMO13C1400 ...

Page 121: ...the machine install the buc ket in the reverse position 12 2 1 Loading bucket page 109 10 1 Machine stability when using with a bucket or an accessory page 100 10 4 Digging trenches 1 Parallel To increase the effectiveness of the machine place an appropriate bucket to dig a trench and position the tracks in parallel on each side of the trench to be dug To dig a wide trench dig on the two sides the...

Page 122: ... area make sure that the water does not reach the body of the hammer Note The hammer can only operate within the following temperature range 5 C 45 C To avoid damaging the structure of the hammer and minimize vibration the operator must be smooth when using the tool Be sure to set the engine speed if you are using a hammer Once the work requiring the hammer is finished set the hammer vertically wi...

Page 123: ...pply plenty of grease to the part in the new tool guide 6 Manually fit the flat end of the tool into the guide 7 Push and turn the tool in order to position it parallel to the pin housing 8 Use a lever to press the pin stop and make it fit into place 9 Insert the pin until the pin stop returns to its position Note There are different forms of tools that can equip the hammer Contact your dealer If ...

Page 124: ... 2 Place the accessory at about 5 cm above the ground 3 Stop the engine 4 Clean all the parts 5 Remove the swivel pin from the A bore and the swivel pin from the B bore IMPORTANT Protect the various elements from dirt and dust Take care not to damage seals on each bushing side Check the good state of o rings Replace it if damaged 107 ...

Page 125: ...d stable ground the bucket or accessory is properly positioned to be installed on the machine 1 Clean and lubricate the bores 2 Put the o rings in place 3 Align the arm bore with the bore A Add shims to compensate for play if necessary 4 Insert the swivel pin into the bore A 5 Align the pin bore with the bore B Add shims to compensate for play if necessary 6 Insert the swivel pin into the bore B 7...

Page 126: ... and T with hydraulic hoses 2 12 2 1 Loading bucket IMPORTANT Protect the various elements from dirt and dust Take care not to damage seals on each bushing side 1 Arm 2 Bucket link 1 Clean and lubricate the bores 2 Put the o rings in place 3 Align the pin bore with the bucket A bore Add shims to compensate for play if necessary 4 Insert the swivel pin into bore A 5 Lift the equipment and align the...

Page 127: ... of the lifting accessories used are compatible with the load being lifted 2 See the load tables for your machine so you do not exceed these limits during the lifting operation 3 Install a device that can oppose the accidental release of the load on the machine s lifting ring with latch hook shackle eye and whose WLL3 is equal to or greater than the load to be lifted 4 Attach the load to be handle...

Page 128: ...control CAUTION Do not operate the controls of the 3rd circuit if there are no installed accessories 14 1 1 3rd circuit selector Use this valve located under the mat to select the 3rd hydraulic circuit in single or dual effect A 3rd circuit dual effect B 3rd circuit single effect with direct tank return 111 ...

Page 129: ... hydraulic tool s hoses Hydraulic oil rate at nominal engine speed 1 Specifications page 163 14 3 Precautions for using the accessory Follow the procedures described in the user manual provided by the accessory s manufacturer Hydraulic hammer single action accessory Set the return pipe selector valve to the position for a single action accessory The hammer works when the proportional roller is ope...

Page 130: ...re the ramps are sufficiently wide long and thick to hold the machine so that you can load it and unload it safely If the ramps flex excessively consolidate them with wedges Install the ramp safely on the truck deck so that they do not become detached Clean grease oil and any other slippery deposits from the ramps and remove the mud from the tracks to avoid the machine sliding sideways on the plat...

Page 131: ...to idle position 6 Direct the machine towards the ramp plates at low speed and load the machine onto the truck Do not use levers other than the side movement levers when travelling across the ramp plates 15 2 Immobilising the machine on the truck Once the machine is in a suitable position on the truck immobilise it as follows a Wedge 1 Lower the blade to the ground Fold the bucket and the arm to t...

Page 132: ...e total height of the load 2 Working dimensions page 164 1 Check the condition of the transport vehicle surface If the surface is greasy it must be cleaned before installing the machine on the transport vehicle Note If the transport vehicle surface is steel provide a non slip mat or spacers to prevent the machine tracks from slipping 2 Check the WLL4 of the tie down points of the transport vehicle...

Page 133: ...ee the machine tie down The driver must ensure that the angles α and β are determined so that there is no de flection of the tie down accessories a Correctly position the hooks on the tie down points b Be alert to where tie down accessories pass they should not rest on sharp edges or have knots present when tying down c Make sure to load balance the various tie downs and do not overload them ...

Page 134: ...e to the maximum limit 3 Place the equipment in the longitudinal axis of the machine 4 Place all the equipment cylinders to maximum extension except the rotation cylinder 5 Stop the engine put the levers in the locked position and check that you have left nothing around the operator s seat before leaving the machine A Front side B Back side a Lifting holes at each end 3 Warning labels page 6 Lift ...

Page 135: ...et Thermal shock for the side movement motor If during cold weather the hydraulic oil temperature rises to over 60 C in relation to the exte rior temperature during an unloading operation without movement after the engine starts the machine may not pivot because of a thermal shock This is not a fault The rotation cylinder extends during excavation The rotation cylinder may extend in certain situat...

Page 136: ...lectric circuit The starter works correctly but the engine does not start Lack of fuel Top up the fuel tank Air in the fuel circuit Repair the air leak Evacuate the air from the fuel circuit Defective fuel injection pump or in jector performance altered Replace the pump or the injector Inadequate compression Check and repair Blown fuse Replace the fuse Stop solenoid damaged Broken filament Check a...

Page 137: ...mum engine speed does not provide enough power to the lights Defective electric circuit Check the play and the proper connection of the terminals Repair if necessary Defective alternator or regulator Check and repair When the engine is running the lamp is very bright and burns out frequently Defective regulator Replace the regulator Battery leak Defective battery Replace the battery The starter sp...

Page 138: ...t rotate smoothly The rotation brake is not unlocked Unlock the rotation locking lever Insufficient quantity of grease Check and lubricate Defective rotation brake valve Check and repair Defective rotation motor Check and repair The hydraulic oil temperature is too high Insufficient quantity of hydraulic oil Fill the hydraulic oil to the required level Overload Reduce the load The machine does not...

Page 139: ... positive terminal on the other machine The capacity of the starter cables and the size of the clips must be adapted to the size of the battery Check that there is no damage cracks or corrosion on the starter cables and clips The machines batteries must have the same capacity 17 2 Connecting the starter cables BS backup battery BP battery broken down MP machine engine broken down 1 Set the start s...

Page 140: ...ing the starter cables After starting the engine on the machine that has broken down disconnect the starter cables in reverse order to the connection procedure BS backup battery BP battery broken down MP machine engine broken down 1 Remove the clip of the black starter cable B from the engine block of the machine that has broken down 2 Remove the clip of the black starter cable B from the negative...

Page 141: ...on one machine to the positive terminal on the other machine A polarity reversal may damage the alternator When the battery is charging remove all the plugs to release the gases generated If the battery overheats the electrolyte temperature exceeds 45 C stop the operation Stop the charging operation as soon as the battery is charged If you continue the following faults may occur battery overload r...

Page 142: ...tuck in the mud and cannot get out on its own or when it is towing a heavy ob ject attach the sling as shown opposite 1 Shackles 2 Slings 3 Lifting holes Minimum capacities of the coupling devices to use WLL6 t Shackles 8 Slings 8 When towing a machine with another machine use a metal cable that is powerful enough for the machine s weight Never tow the machine on a slope Never use a deformed or da...

Page 143: ...126 ...

Page 144: ...VERED IN THIS PART 1 PERIODIC INSPECTIONS AND UPKEEPS 2 MAINTENANCE PRECAUTIONS 3 RECOMMENDED GREASES AND FLUIDS 4 FIRST MAINTENANCE 5 LIST OF PERIODIC INSPECTIONS AND MAINTENANCE OPERATIONS 6 MAINTENANCE BY THE OPERATOR 7 MAINTENANCE BY THE DEALER ...

Page 145: ...128 ...

Page 146: ...ulic oil Aspiration filter Hydraulic oil return filter 1st time Operation of the accumulator Greasing Greasing points Rotation pin and crown Chassis Bearing rollers and bearings idler wheels Track tension Electrical equipment Headlights horn travel alarm Dashboard and indicators System state Engine Water separator GO filter Air filter dusty atmosphere every 250 h Engine oil 1st time 7 Oil filter 1...

Page 147: ...upkeeps 130 Scheduled maintenance points of the machine lubrication filters Hydraulic oil Engine oil Hydraulic oil return filter Travel gears Greasing points Air filter Fuel filter Oil filter Dependent on technical modifications ...

Page 148: ...ine s engine then turn it to the ON position Note The locking lever must be lowered 3 Handle the following controls several times to remove the residual pressure Left command lever Arm Rotation of the upper part Right command lever Boom Bucket Blade lever 3rd hydraulic circuit control P T O 1 4 Set the starter key to OFF position 5 Remove the key from the ignition The residual pressure in the accu...

Page 149: ...e or dispersed part fragments are dangerous and may cause slipping Any water that gets into the electrical system may cause it to malfunction leading to defec tive operation of the machine This also risks causing short circuits that may cause a fire or electric shock Do not spray any vapour directly onto the sensors or connectors Do not use harsh chemicals to clean the machine as these affect the ...

Page 150: ... the following chapters IMPORTANT Do not mix different types of oils If you need to top up the oil with an oil of a different brand or type from the oil left in the tank remove the remaining oil completely 2 2 2 Tools Use tools that are adapted to the planned task The use of damaged worn or inappropriate tools is very dangerous and there is a risk that the machine will be damaged 2 2 3 Parts Use Y...

Page 151: ...der the machine Before you carry out any maintenance or repairs under the machine place the accessory on the ground or in its lowest position DANGER Park the machine on flat firm ground If the machine is not stable do not carry out any maintenance under the machine 2 2 6 Lighting Use flameproof lighting when checking the fuel oil cooling water or battery electrolyte If you do not there is a risk o...

Page 152: ...0 Soldering If you need to solder respect the following points Disconnect the battery cabling negative terminal then positive terminal Ground the machine no more than 1 metre away from the part to be welded Make sure there are no seals or bearings between the soldered part and the earthed part Do not earth near the axes of the equipment or the hydraulic cylinder 2 2 11 Waste processing Always drai...

Page 153: ...ferent types of oils If you need to top up the oil with an oil of a different brand or type from the oil left in the tank remove the remaining oil completely Components Fluid Temperatures C Quantity prescribed L 20 10 0 10 20 30 Thermal engine Engine oil SAE 10W CD 7 3 SAE 10W 30 CD SAE 15W 40 CD Travel gears Box oil SAE 90 GL 4 0 5 by reducer Hydraulic circuit Hydraulic oil ISO VG46 40 in the tan...

Page 154: ...filter element replaced Replace the side movement reducer oil Greasing the pin and rotation crown Replace the hydraulic fluid return filter element Contact your dealer 4 2 After the first 250 hours of service Replace the fuel filter Contact your dealer 1 Periodic inspections and upkeeps page 129 137 ...

Page 155: ...T These are frequencies for example the operations to be carried out every 50 hours must be carried out at 50h 100h 150h 200h etc Certain intervals may vary if a hydraulic hammer is used Refer to the corresponding notes Note If a hydraulic hammer is used the re turn filter must be replaced after 100 or 150 hours of service for a new machine then according to the diagram opposite The hydraulic oil ...

Page 156: ...cking and topping up the fuel level page 84 Engine oil 4 3 Checking and topping up the engine oil level page 83 Cooling fluid 4 2 Checking and topping up the level of cooling fluid page 82 Tracks 6 5 Rubber track maintenance page 146 Radiator vents Check Alternator belt Tension check Decanter separator 6 1 6 Cleaning the separator decanter page 143 Operation of the accumulator Check Electrical cir...

Page 157: ...t Travel gears Oil replacement Decanter separator Replacement Alternator belt Replacement Intake and exhaust valves Play adjustment Cylinder head block Bolt re tightening Fuel pump Check Bearing rollers and bearings idler wheels Greasing Air conditioning heating system Cleaning EGR valve Cleaning Every 2000h Cooling fluid Replacement Injectors and injection pressure Inspection and calilbration Fue...

Page 158: ... hit with any oil Also check that the time counter the headlights the alarm and the lights are working correctly If an element is not working or you think it is defective shut down the machine s engine immediately and contact your dealer 6 1 2 Checks after using the machine After each use several checks must be carried out according to how the machine is used refer to chapter 6 Checks after use pa...

Page 159: ...fore using the machine or after use in the rain on soft ground or in muddy water Proceed as follows 1 Lower the bucket and the blade to the ground 2 Stop the engine 3 Clean the greasing connectors indicated by the arrows on the figures 4 Grease them with a grease pump 5 Wipe off the excess grease with a cloth or equivalent ...

Page 160: ...e the fuel inlet tap 4 Loosen the drain valve to drain the separator 5 Unscrew the separator bowl to remove it 6 Remove the bowl Note Remove the bowl carefully to avoid spilling any fuel If you spill any fuel wipe it up with a cloth 7 Empty into the container Take care not to lose the ring 8 Remove the filter and replace with a new filter 9 Clean the ring and the inside of the bowl with clean fuel...

Page 161: ...that there are no oil leaks from the hydraulic hose connectors 6 1 9 Visual inspection of the fuel hoses Visually check that the fuel does not leak from the fuel hose connectors Also check that the hoses are not damaged If there are any faults contact your dealer The fuel hoses must be changed every 2 years or every 2000 hours of service Contact your dealer 6 2 Maintenance every 50 hours 6 2 1 Gre...

Page 162: ...ORTANT Do not put anything in the condenser compartment This will block the passage of air on this exchanger and damage the air conditioning unit s performances or even damage the cooling system particularly the compressor 5 In the event of a malfunction to the air conditioning heating system contact your dealer 6 4 Non periodic maintenance 6 4 1 Fuse replacement 1 Set the starter key to OFF posit...

Page 163: ...er or refer to the manufacturer user manual supplied with the accessory 6 5 Rubber track maintenance 6 5 1 Checking the condition of the tracks The wear to the rubber tracks depends on the working conditions and the nature of the ground Regularly check the wear and tension of the tracks Note A new track must be checked for the first time after 30 hours Height of the fixing nuts If height A is redu...

Page 164: ... Not yet to be repaired If a crack appears between the track attachment in serts repair it if the length of the crack reaches 60 mm If the interior steel cable is exposed repair the track immediately even if the crack is a small one If the length of the crack is less than 30 mm or if the depth of the crack is less than 10 mm you do not need to repair the track To find out whether the track must be...

Page 165: ...e of them must commission the machine according to the signals given by the other person Be sure to perform the track tension verification on a firm and even surface It is strictly forbidden to be positioned under the machine for the duration of the operation 3 Check the tension The play H between the external rolling surface of the second track roller on the tightener roller and the internal surf...

Page 166: ...rm the track tension verification on a firm and even surface It is strictly forbidden to be positioned under the machine for the dura tion of the operation 4 Using the grease pump inject grease with the grea ser so that the play H is between 8 13 mm 5 Proceed with the track tensioning To check that the tension is correct put the machine down and move it gently forwards and backwards 6 Check the te...

Page 167: ...ipment by activating the command lever WARNING Do not support the machine with the accessory on ly The command levers may move or hydraulic oil may spill accidentally and cause the machine to fall When the machine is checked or adjusted by two people one of them must commission the machine according to the signals given by the other person Be sure to perform the track tension verification on a fir...

Page 168: ...uipment by activating the command lever WARNING Do not support the machine with the accessory only The command levers may move or hy draulic oil may spill accidentally and cause the machine to fall When the machine is checked or adjusted by two people one of them must commission the machine according to the signals given by the other person Be sure to perform the track tension verification on a fi...

Page 169: ... sure to perform the track tension verification on a firm and even surface It is strictly forbidden to be positioned under the machine for the dura tion of the operation 4 Using the grease pump inject grease with the grea ser so that the play H is between 125 135 mm 5 To check that the tension is correct put the machine down and move it gently forwards and backwards 6 Check the tension again If it...

Page 170: ...hine with the equipment by activating the command lever WARNING Do not support the machine with the accessory only The command levers may move or hydrau lic oil may spill accidentally and cause the ma chine to fall When the machine is checked or adjusted by two people one of them must commission the ma chine according to the signals given by the other person Be sure to perform the track tension ve...

Page 171: ...take and exhaust valves Play adjustment Fuel pump Check Battery electrolyte Density check Cylinder head block Bolt re tightening Every 2000h Fuel hose coolant hose Verification and replacement Cooling fluid Replacement Injectors and injection pressure Inspection and calilbration Non periodic Cooling system Cleaning It is important to entrust the machine to a deal at the intervals indicated so that...

Page 172: ...ING IMPORTANT The conservation and storage of the machine must comply with standard NF ISO 6749 Earth moving equipment conservation and storage of October 1987 The following chapters take part of the standard mentioned above but are not exhaustive Refer to the standard for any additional information ...

Page 173: ...156 ...

Page 174: ...cient performance characteristics and is appropriate for the machine s storage temperatures 3 Recommended greases and fluids page 136 If necessary top up the water 4 2 Checking and topping up the level of cooling fluid page 82 WARNING Do not open the bonnet during machine operation Verification and topping up of the various levels should be done when the engine is stopped and the temperatures are ...

Page 175: ...ation and recommissioning instructions as well as the conservation date must be placed in an impermeable envelope with a label and secured to the machine at a visible location To protect the machine against rainwater trap it to avoid accumulation of water that can promote corrosion of metal parts The locking lever s must be in locked in a position to avoid any possibility of the machine being acti...

Page 176: ...machine to working order Before using the machine again after a storage period of two months do the following 1 Remove the protections on the hydraulic cylinder rods 2 Apply a large quantity of oil or grease to the moving part 3 Drain the water from the fuel tank from the engine oil casing and from the hydraulic fluid tank by removing the drainage caps 4 Leave the machine to warm up after you star...

Page 177: ...160 ...

Page 178: ...161 E Technical data CHAPTER COVERED IN THIS PART 1 SPECIFICATIONS 2 WORKING DIMENSIONS 3 NOISE EMITTED BY THE MACHINE 4 VIBRATIONS EMITTED BY THE MACHINE ...

Page 179: ...162 ...

Page 180: ... 43 65 Maximum excavation force bucket arm kN 32 1 18 1 Travel Speed high low km h 4 5 2 7 Maximum slope 30 Rotation speed rpm 9 5 Average pressure on the ground standard track kg cm 0 34 0 35 0 35 0 36 Hydraulic pump rate L min 37 0 x 2 variable rate pump 26 2 geared pump 10 8 geared pump Maximum hydraulic circuit pressure MPa P1 P2 22 1 P3 21 6 P4 3 9 Engine YANMAR 3TNV88 ESBV Type 3 cylinders w...

Page 181: ...imensions of the additional accessories and equipment installed on the machine may modify the working dimensions and must therefore be taken into account before using the machine Unit mm A 590 O 4510 B 540 Q 4980 C 640 R 5110 D 85 S 3190 E 135 T 980 F 1550 U 2550 G 775 V 3070 H swing 2120 1900 Y 3330 I 375 Z 4720 K 2460 AA 320 L 325 AB 300 M 1480 AC 1250 N 2160 AD 1550 ...

Page 182: ...stant acoustic pressure measured with frequency weighting C Measurements carried out machine in static position machine running at nominal power LwA determined and guaranteed according to Directive 2000 14 CE amended by Directive 2005 88 CE LpA LAeq measured and guaranteed according to standard NF ISO 6396 1997 These values are declared in accordance with Directive 2006 42 CE and do not correspond...

Page 183: ...uits on the gravel storage area approximate speed 4km h 2 6 mi h clockwise turn Hydraulic hammer Operation of hydraulic rock breaker for 20 seconds on a steel plate of 100x50x5cm placed on the ground Note These values are declared in accordance with Directive 2006 42 CE and do not corres pond to exposure values over 8h of work The following provisions should be taken in order to transmit the minim...

Page 184: ...he load handled does not exceed the maximum weight allowed 10 1 Machine stability when using with a bucket or an accessory page 100 IMPORTANT The data in these tables represent the lifting capacity according to standard ISO 10567 They correspond to 75 of the maximum static load before tipping or to 87 of the hydraulic lifting force The data marked with show the hydraulic limits of the lifting forc...

Page 185: ...168 ...

Page 186: ...LIFTING VIO38 6 CANOPY Machine with canopy and rubber tracks A Tilt from the rotation axis B Attachment point height Housing overload alarm value setting Hydraulic capacity limits of the lifting force 169 ...

Page 187: ...170 2 LIFTING CABIN Machine with cab and rubber tracks A Tilt from the rotation axis B Attachment point height Housing overload alarm value setting Hydraulic capacity limits of the lifting force ...

Page 188: ...Appendices Additional informations A List of error codes displayed on the operator display station B Control sheets to be photocopied C Notes D Lashing record 171 ...

Page 189: ...Engine management ECU fault EEPROM Maintenance required 00 0000630 12 CAUTION EEPROM Maintenance required 00 0000638 02 WARNING Engine fault Maintenance required 00 0000638 03 WARNING Rack actuator Maintenance required 00 0000638 04 WARNING Rack actuator Maintenance required 00 0000638 07 WARNING Rack actuator Maintenance required 00 0000639 12 CAUTION CAN communication fault Maintenance required ...

Page 190: ...enance required 28 000096 02 CAUTION Fuel sensor fault Maintenance required 28 000096 04 CAUTION Fuel sensor fault Maintenance required 28 000100 00 WARNING Abnormal engine oil pressure 16 Detecting anomalies page 118 28 000167 01 CAUTION Insufficient battery charge 16 Detecting anomalies page 118 28 000639 12 WARNING CAN communication fault Maintenance required 28 520777 02 CAUTION Failure of the...

Page 191: ...he Rotation pin and crown Greasing 6 2 1 Greasing the pin and rotation crown page 144 Control sheet Maintenance every 50 hours Number of hours of service hours Parts Operations Done by the Rotation pin and crown Greasing 6 2 1 Greasing the pin and rotation crown page 144 Control sheet Maintenance every 50 hours Number of hours of service hours Parts Operations Done by the Rotation pin and crown Gr...

Page 192: ...n levers Verification and adjustment Dealer Air filter 10 Cleaning GO filter Replacement Control sheet Maintenance every 250 hours Number of hours of service hours Parts Operations Done by the Rotation pin and crown Greasing Side movement and acceleration levers Verification and adjustment Dealer Air filter 10 Cleaning GO filter Replacement Control sheet Maintenance every 250 hours Number of hours...

Page 193: ...asing Rotation reducer Replenish engine oil Travel gears Replenish engine oil Engine oil 11 Replacement Oil filter11 Replacement Dealer Radiator vents Cleaning Side movement and acceleration levers Verification and adjustment Hydraulic oil return filter Replacement GO filter Replacement Air filter Replacement Control sheet Maintenance every 500 hours Number of hours of service hours Parts Operatio...

Page 194: ...g Engine oil Replacement Oil filter Replacement Aspiration filter Cleaning or replacement depending on the filter Dealer Radiator vents Cleaning Belt Replacement Side movement and acceleration levers Verification and adjustment Air filter Replacement Hydraulic oil return filter Replacement Battery electrolyte Density check GO filter Replacement Intake and exhaust valves Verification and adjustment...

Page 195: ...nding on the filter Radiator vents Cleaning Dealer Belt Replacement Side movement and acceleration levers Verification and adjustment Hydraulic oil return filter Replacement Battery electrolyte Density check GO filter Replacement Cooling fluid Replacement Fuel pump Verification and adjustment Cooling system Cleaning Fuel hose coolant hose Verification and replacement Intake and exhaust valves Veri...

Page 196: ...C Notes 179 ...

Page 197: ...he machine on the transport vehicle 2 Check the location and condition of the machine tie down points 3 Tie down the machine at the points provided for that purpose and that are indicated on the machine DANGER Blocking of turret provided by the brake Additional accessories bucket arm etc Rigging Tension in lashing accessories Measure the loading height Grip on truck bed frost snow DEVICE Weight of...

Page 198: ...id 18 82 136 Covers 33 44 D Daily 141 Dashboard 15 Detecting anomalies 118 Diesel gauge 17 Dimensions 164 Door 37 38 E Engine 4 119 163 Adjustment 24 Precautions 80 Shutdown 24 73 76 Starting 22 Error 172 Exit 63 F Fuel 84 Gauge 17 Purge 144 Type 136 Fuses 34 145 G Greasing 129 133 136 142 144 H Headlights 22 41 Heating 47 Heating valve 47 Horn 23 Hydraulic circuit 163 PTO 1 28 48 111 Hydraulic ha...

Page 199: ... Machine 66 Operator 59 Q Quick hitch 52 102 Mechanical 53 54 56 R Rotation Boom 31 Cabin 28 Running in 80 S Safety valves 51 Seat 32 Slinging 117 Soldering 135 Specifications 163 Switch 14 21 2nd gear 25 Eco mode 24 Engine slow down 24 Headlights 22 Lighting 25 Stopping the engine 24 Ventilation 23 Windscreen wiper Windscreen washer 23 T Technical data 161 Tie down 115 180 Time counter 17 Toolkit...

Page 200: ...Electricity lines 72 Muddy area 75 Reduced visibility 75 Submerged area 74 Unstable ground 74 183 ...

Page 201: ...MINI EXCAVATOR http www yanmar eu ...

Page 202: ...USER OPERATION AND MAINTENANCE MANUAL MINI EXCAVATOR ViO38 6 ...

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