Yanmar ViO80-1A User Operation And Maintenance Manual Download

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Control sheet: Maintenance every 1000 hours / Every year

Number of hours of service

hours

Parts

Operations

Done by

the

Rotation pin and crown

Greasing

Rotation reducer

Oil replacement

Travel gears

Oil replacement

Hydraulic oil

Replacement

Bearing rollers and bearings, idler wheels

Greasing

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

Fuel injection valve

Verification and adjustment

Cylinder head block

Bolt re-tightening

EGR valve

Cleaning

Heating system

Air conditioning

Verification and adjustment

189

Summary of Contents for ViO80-1A

Page 1: ...USER OPERATION AND MAINTENANCE MANUAL EXCAVATOR ViO80 1A Original manual MUB11ENMA00202 12 01 2016 ...

Page 2: ...e 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 lat est product information available on pu...

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Page 4: ...sessment are NF EN ISO 3744 NF ISO 6395 produced by SNCH 11 route de Luxembourg L 5230 Sandweiler LUXEMBOURG Net power output 39 3 kW 1900 rpm Measured sound pressure 97 8 dBA Guaranteed sound pressure 98 dBA Name and address of the person established in the European community authorized to compile the technical file and transmit it in whole or part to the public authorities in response to a reaso...

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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 ...

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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 ap plicable warnings and usage instructions contained in this manual and on the safety signals on this machine Physical injury may be caused if the safety instructions are not respected WARNING Never modify the design of the machine or i...

Page 11: ...ge 17 5 1 3 Cooling fluid temperature indicator 17 5 1 4 Time counter 18 5 1 5 Displaying the fuel consumption 18 5 1 6 Navigation keys 18 5 1 7 Information and error icons 19 5 2 Switches 20 5 2 1 Start key 21 5 2 2 Headlight switch 21 5 2 3 Horn 22 5 2 4 Windscreen wiper switch and windscreen wiper 22 5 2 5 Engine rate setting 22 5 2 6 Side movement switch 22 5 2 7 Engine slow down switch 23 5 2...

Page 12: ...0 9 9 Anti starter with key 50 9 10 Fleet management system 51 9 11 SMART ASSIST 51 9 12 Radio 52 9 13 Quick hitch 52 9 14 Centralized greasing system 53 9 15 Mechanical quick hitch 54 9 15 1 Mechanical quick hitch ARDEN EQUIPMENT 55 9 15 2 Mechanical quick hitch RETROMATIC MORIN 57 9 15 3 Mechanical quick hitch CSERI 58 9 16 Quick hydraulic hitch CSERI 59 9 16 1 Dismantling the accessory 60 9 16 ...

Page 13: ...uring the machine 78 2 3 6 Working on a slope 78 2 3 7 Working in an area covered with snow 78 2 3 8 Working on unstable ground 79 2 3 9 Working in a submerged area 79 2 3 10 Working in a muddy area 79 2 3 11 Working in an area with reduced visibility 80 2 4 Parking precautions 81 2 5 Precautions for the accessories 82 2 6 Precautions for using optional accessories 82 2 7 Precautions for the batte...

Page 14: ...ssory 117 15 Using the particle filter 119 15 1 Auto regeneration 119 15 2 Assisted regeneration 119 15 3 Launching the regeneration 120 15 4 Manual regeneration of the particulate filter 120 16 Transporting the machine 122 16 1 Loading unloading the machine 122 16 1 1 Precautions for loading unloading the machine 122 16 1 2 Procedure 123 16 2 Immobilising the machine on the truck 124 16 3 Tying d...

Page 15: ...e commands 150 6 1 4 Checking the seat 150 6 1 5 Greasing points 151 6 1 6 Using the centralized greasing system 152 6 1 7 Cleaning the separator decanter 152 6 1 8 Purging the fuel tank 153 6 1 9 Checking the hydraulic hoses 153 6 1 10 Visual inspection of the fuel hoses 154 6 2 Maintenance every 50 hours 154 6 2 1 Greasing the pin and rotation crown 154 6 3 Maintenance every 15 days 154 6 3 1 Ch...

Page 16: ...3 1 Specifications 175 2 Working dimensions 176 3 Noise emitted by the machine 177 4 Vibrations emitted by the machine 178 F Lifting capacities 179 1 Lifting ViO80 1A 181 2 Lifting ViO80 1A With rear counterweight 182 Appendices 183 A List of error codes displayed on the operator display station 184 B Control sheets to be photocopied 187 C Notes 192 D Lashing record 193 Index 195 ...

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Page 18: ...OVERED 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 USING THE ELECTRIC FUEL FILLING PUMP 9 OPTIONS ...

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Page 20: ...ements 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 EQUIPMENT EUROPE S A S declines all re...

Page 21: ...acture of the machine 4 Transport weight Machine weight without 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 Nev...

Page 22: ...l for an inerven tion 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 2 3 EPA information plate The EPA information plate is attached to the engine Never remove this plate for any reason ...

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: ...essing the machine page 72 2 Usage precautions page 70 4 Do not remove the protective casings while the machine is running 2 2 9 Radiator ventilator page 142 5 Pressurised elements Do not unscrew while the liquid is hot 1 8 Avoid removing the caps when the temperatures are high page 67 6 Hot surfaces 4 3 Checking and topping up the engine oil level page 87 7 Level of engine cooling fluid 4 2 Check...

Page 27: ...l page 89 13 Transporting the machine 16 Transporting the machine page 122 14 Using the electric fuel filling pump 8 Using the electric fuel filling pump page 45 15 Using a grease pump grease the pin and the rotation crown at the greasers indicated with arrows on the figure opposite 6 2 1 Greasing the pin and rotation crown page 154 16 Using the electric fuel filling pump 8 Using the electric fuel...

Page 28: ...lters 1 Periodic inspections and upkeeps page 137 6 1 5 Greasing points page 151 20 Tension check 6 5 3 Tension check page 157 6 6 3 Tension check page 161 21 Fusebox 5 7 Fuses page 33 22 Opening of the upper part of the windscreen 5 8 Cabin page 37 23 Cabin s emergency exit 1 14 Cabin s emergency exit page 69 24 Manual regeneration of the dust particle filter DPF 25 Exhaust gas temperature icon 5...

Page 29: ... bucket or an accessory page 103 Lifting capacities F Lifting capacities page 179 28 A low ash oil must be used as engine oil 15 Using the particle filter page 119 29 Interference between the bucket and the machine 10 2 Compatible accessories page 105 30 Always fasten your safety belt and adjust it before starting the machine 2 1 6 Fasten your safety belt and adjust the rearview mirror s page 72 3...

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

Page 31: ...ional PTO P T O 2 6 Locking lever 7 Foot rest 8 Side movement pedals 9 Protection of pedals 10 Boom rotation pedal 11 Proportional roller P T O 1 12 Horn 13 Operator display station 14 Right command lever 15 Start key 16 Air conditioning heating switch 17 Control panel 18 Blade lever 19 Engine rate control 20 Adjustable proportionality P T O 2 21 Cup holder 22 Windscreen washer tank ...

Page 32: ...m 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 Fuel consumption 8 Information and error icons 9 Indication of functions 10 Keys F1 to F4 For the advanced features on the op...

Page 33: ... 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 Reduced speed This indicator lights only at startup and it does not have any function on this machine f Battery charge warning alert If the batte...

Page 34: ...tion is affected by the level of machine tilt 5 1 3 Cooling fluid temperature indicator C cold H hot It indicates the temperature of the engine cooling fluid The normal temperature is close to zone 1 dur ing normal operation If the temperature of this coolant 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...

Page 35: ...hours 6 minutes 5 1 5 Displaying the fuel consumption The current fuel consumption is calculated from the amount of fuel used by the machine and is displayed on the operator display station The display of fuel consumption can be stopped by changing the settings on the operator display station 7 operator LCD display station interfaces page 94 5 1 6 Navigation keys 1 Keys F1 to F4 2 Indication of fu...

Page 36: ...must be reset from the maintenance interface 1 Periodic inspections and upkeeps page 137 Exhaust gas temperature icon When launching the regeneration an icon representing the temperature of the exhaust gas is displayed on the operator display station to warn of the emis sion of high temperature gas Note This icon does not indicate a malfunction of the machine It indicates that the temperature of t...

Page 37: ...ches 1 Horn 2 Start key 3 Engine slow down switch 4 Eco mode switch 5 Side movement switch 6 Manual regeneration 7 Windscreen wiper switch and windscreen wiper 8 Headlight switch 9 Engine rate setting 10 Interior lighting switch 11 Engine stop switch ...

Page 38: ...Keep the key in this po sition while the engine is running 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 se conds in the START position If the engine does not start move the ignition key to the OFF positi...

Page 39: ...t 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 Engine rate setting Turn the switch to the...

Page 40: ... off 5 2 8 Eco mode switch This switch is used to reduce fuel consumption by reduc ing 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 to OFF set this switch to STOP After stopping the engine make sure you put the engine stop switch to the NORM...

Page 41: ...ion of the DPF the mo nitor displays the DPF regeneration icon Immediately conduct a manual regeneration of the DPF 5 3 Joysticks and pedals 1 Locking lever 2 Right command lever 3 Adjustable proportional PTO P T O 1 4 Left command lever 5 Adjustable proportional PTO P T O 2 6 Travel levers and pedals 7 Protection of pedals 8 Boom rotation pedal 9 Blade lever 15 4 Manual regeneration of the partic...

Page 42: ...ight and left hand command levers may be moved WARNING Place the locking lever s in locked position as soon as you leave the 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 hyd...

Page 43: ...roportional roller Adjustable proportional PTOAdjustable proportional PTO The adjustable proportionality allows better P T O flow control by combining a knob with the proportional roller 1 Proportional roller 2 Knob To use the adjustable proportionality system 1 Operate the accessory with the proportional roller 1 2 Set the maximum hydraulic circuit speed with the knob 2 Turn the button clockwise ...

Page 44: ...ion is maintained and the ac cessory is operated at the rate set by the knob 2 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 5 3 4 Left command lever The left hand joystick is used to control the arm movements and the rotation of the upper pa...

Page 45: ...rtional roller Adjustable proportional PTOAdjustable proportional PTO The adjustable proportionality allows better P T O flow control by combining a knob with the proportional roller 1 Proportional roller 2 Knob To use the adjustable proportionality system 1 Operate the accessory with the proportional roller 1 2 Set the maximum hydraulic circuit speed with the knob 2 Turn the button clockwise to i...

Page 46: ...ing the machine must familiarise themselves 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 mov...

Page 47: ... travel lever to rotate forward or pull the right travel lever to turn backwards 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 t...

Page 48: ... 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 posi tion and the boom keeps its position 5 4 Power socket 1 Lid 2 Power socket The power sockets work when the ignition key is in the ON position Appliances up to 12V 120W 10A may be connected IMPORTANT Always close the lid if the pl...

Page 49: ...just 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 lever 2 to push the seat and the two side consoles back and forwards together Pull lever 3 to adjust the seat back Suspension adjustment The seat suspension 4 can be adjusted according to the weight of the driver Firm...

Page 50: ...ving position 33 5 6 Location for the tools and user manual 5 6 1 Toolkit The location for the toolkit is between the cab and cover B 5 6 2 User manual The location for the user manual is under the dri ver s seat A User manual ...

Page 51: ...ng 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 155 The fusebox is underneath the driver s seat 1 Storage box cover 2 Fusebox 3 General supply fuses 4 Power fuse options ...

Page 52: ...tronic Control Unit ECU 2 E 20 EGR valve F 20 Air conditioning G 20 Engine Electronic Control Unit ECU Engine Electronic Control Unit ECU Engine H 5 Operator display station I 30 Power socket J 20 Radiator ventilator K 30 Boom headlamp L 5 Engine Electronic Control Unit ECU 1 M 5 Movement alarm N 10 P T O Quick hydraulic hitch O 10 Safety relay P 5 ECU2 Acc Q 5 Engine R 20 Windscreen wiper S 10 Sp...

Page 53: ...ing relay Bougies de préchauffage C 80A Starter Power fuse options Symbol Fuse capacity Circuit name A 5A B 2A C 10A D 2A E 5A Rotating headTILTROTATOR F 5A Quick hydraulic hitch Medium pressure hydraulic line Continuous pressure hydraulic line G 10A Centralized greasing system Options H 2A I 5A Anti theft mechanism Options ...

Page 54: ...per windscreen 3 Side door 4 Lower windscreen WARNING Place the locking lever s in locked position to avoid any unplanned operation of the joysticks when handling the windscreen 5 8 1 Cab side door 1 Exterior handle 2 Key 3 Interior handle a Opening and closing of the door From the exterior To open the door 1 Insert the key into the lock 2 Turn the key anti clockwise to unlock the door 3 Pull the ...

Page 55: ...e 5 8 2 Upper windscreen Opening of the upper part of the windscreen 1 Grasp the handles A and push the levers to the right and left of the window until you hear a click for them to unlock A Handle 2 Remount the top part of the windscreen and drag it backwards until it positions itself under the ceiling WARNING Open the windshield carefully to avoid bumping your head Closure of the upper part of t...

Page 56: ...d left of the lower windscreen towards the inside 2 Lift the lower windscreen 3 Hold it in place by pushing the locking levers to wards the outside A Lever Closure of the lower part of the windscreen 1 Push the locking levers on the right and left of the lower windscreen towards the inside 2 Lower the lower windscreen 3 Hold it in place using the locking levers Hold it in place by pushing the lock...

Page 57: ...arrows 2 Tighten the pressure lock to hold the window in the position you want 3 To close the window loosen the pressure lock A Handle B pressure lock 5 9 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 58: ...if the air conditioning is ineffective stop it immediately switch to OFF and 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 sets the ventilator speed 3 Temperature control switch allows sett ing the desir...

Page 59: ...led into the cab 4 Adjust the air output by turning the air vents It is useful to start up the ventilator to create an over pressure inside the cab in this way it will be more difficult for dust to enter the cab when you are working A Grill IMPORTANT Only start up the air conditioning after starting the machine to avoid overloading the ther mal motor on start up ...

Page 60: ...e done when the engine is stopped and the temperatures are brought back down Opening the cover 1 Insert the starter key into the lock 2 Turn the key anti clockwise 3 Pull the exterior handle to open the bonnet 4 Lock the cover using the rod 1 Exterior handle 2 Key Closing the cover 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 Tu...

Page 61: ...k the cover using the rod Closing the cover 1 Cover B 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 7 3 Cover R The battery and the electric pump fuel filler are under bonnet R Opening the cover 1 Open the bonnet with the ignition key 2 Pull the handle to unlock the safety mechanism The...

Page 62: ...Unscrew the aspiration suction cap 4 Dip the aspiration suction into the volume of diesel to be aspirated 5 Open cover B using the starter key Open cap on the fuel tank 1 Cover B 2 Fuel tank 3 Diesel gauge 6 Switch the pump on by pressing the on off button Note the tank is equipped with a level sensor automa tic shutdown of the pump 7 Remove the suction strainer from the Diesel volume 8 Close the ...

Page 63: ...the lifting equipment listed below being instal led on the machine 13 Load lifting page 115 9 3 1 Lifting ring An appropriate ring is required to suspend a load with the machine For more details contact your dealer The lifting ring welded to the tie rod must be installed with safety valves Check whether the ring and the ring mounting base are damaged If you detect any da mage ask your dealer to in...

Page 64: ...e audible signal sounds the operator must promptly put the load being handled down on the ground because it could well topple the vehicle 1 Overload box IMPORTANT Activating the load indicator box does not stop the operator from making sure that the load to be handled does not exceed the value indicated on the load table It is forbidden to handle the loads without turning on the overload box 1 Wor...

Page 65: ...olition Handling logs The protection structures mounted on the machine comply with the recommendations of ISO 10262 of 2000 FOPS 9 5 Cab headlight The machine can be fitted when this option is requested The kit includes a LED light an electrical harness and its support The cabin is equipped with lights that are adjustable in two directions vertical and horizontal to optimize the illumination of th...

Page 66: ...itch located in the cab on the right of the driver s seat To attach the flashing light 1 Remove the protective cap from the pin s tip 2 Insert the tip of the flashing light in the pin and tighten the nut located at the base of the flashing light 9 7 Keypad immobilizer The machine can be fitted when this option is requested The theft deterrent keypad consists of an immobilizer box and a keypad inst...

Page 67: ...e left will light up 2 Then turn the starter key within 60 seconds 9 9 Anti starter with key The machine can be fitted when this option is requested The immobilizer key consists of an immobilizer box and a key reader installed in the cockpit For more information consult the instructions supplied with the device 1 To start the engine insert the MED electronic key into its housing remove it and star...

Page 68: ...ry control box cannot be turned off Do not use in areas where the use of mobile phones is prohibited hospitals air ports mining operation area Do not enter a potentially explosive area with your machine your box may re sult in an explosion or fire resulting in serious physical injury Hazardous areas are indicated by signage on the work area observe these to avoid any accidents DANGER If you have a...

Page 69: ... 2 1 1 Removing the residual pressure page 139 Connecting 1 Insert the adapter into the receiver A slight click indicates that the connection is successful The ball is released from the adapter groove located on the receiver 2 Turn the adapter on the receiver to secure the connection Note Before each use clean the receiver surfaces Disconnecting To disconnect turn the adapter to align the ball wit...

Page 70: ...t is not ad visable to change them A switch in the cockpit allows to launch the lubrication of the machine swivel points To refill the centralized greasing system connect the grease pump on the filling connector nipple B 3 Recommended greases and fluids page 144 CAUTION Do not plug the hole at the top of the tank in order not to block the filling DANGER In case of over filling the tank can burst a...

Page 71: ...nstalled on the machine WARNING Check the condition of the interface between the quick hitch and the accessory cleanli ness shocks It is forbidden to operate the bucket or accessory if improperly locked in quick hitch be cause in the case of improper installation it may fall during use 9 15 Mechanical quick hitch IMPORTANT Use YANMAR original parts as recommended in the parts catalogue IMPORTANT B...

Page 72: ...ith the wrench supplied with the ac cessory and insert it into the quick hitch hole 4 Turn the key 1 to disengage the bucket or acces sory locking pin DANGER By pressing the key the bucket or accessory de taches and comes into contact with the ground Take care not to get your hands or feet crushed by the bucket or accessory 5 Remove the key and store it 6 Retract the bucket cylinder to disengage t...

Page 73: ...ck hitch 1 5 Remove the key and store it 6 Place the arm equipped with the quick hitch on the accessory to engage the accessory hooks on the bucket or accessory pin 7 Rotate the quick hitch slowly lifting the boom to fully engage the quick hitch to the bucket or accessory 8 Manoeuvre the bucket or accessory to low height from the ground to see if it is locked in the quick hitch Note Check that the...

Page 74: ... the key the bucket or accessory de taches and comes into contact with the ground Take care not to get your hands or feet crushed by the bucket or accessory 5 Remove the key and store it 6 Manoeuvre the arm to disengage the tool s quick hitch Mounting the accessory 1 Place the accessory on a stable flat surface 2 Clean all the parts 3 Place the arm equipped with the quick hitch on the accessory to...

Page 75: ...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 76: ...ned to be installed on the machine 1 Quick hydraulic hitch 2 Quick hitch control unit Quick hydraulic hitch When the locking pins retract a indicator pin is visible in the quick hitch When the locking pins are removed the indicator pin retracts and is no longer visible A Locking pins B Fastening hooks C Indicator pin Quick hitch control unit Use the control box located in the cab to install or rem...

Page 77: ... warning light does not come on or if the alarm does not sound stop the current operation and contact your dealer 4 Hold switch 2 in the locked position until the locking pins are completely retracted The green light comes on The control rod is visible C 5 Take the boom to disengage the accessory hooks on the bucket pin or accessory 6 Move the quick hitch away from the accessory 7 Turn the switch ...

Page 78: ... the quick hitch slowly lifting the boom to fully engage the quick hitch to the bucket or accessory The control rod must be visible from the driving position 6 Hold switch 2 in the locked position until the locking pins are completely released Note The locking pins engage on the bucket or accessory to lock it The green light comes on The control rod is not visible DANGER Make sure that the control...

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Page 80: ...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 USING THE PARTICLE FILTER 16 TRANSPORTING THE MACHINE 17 DETECTING ANOMALIES 18 IF THE BATTERY IS DISCHARGED 19 TOWING THE MACHINE ...

Page 81: ...64 ...

Page 82: ... harmful en vironment and thus the machine must 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 83: ...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 84: ... The fuel and oil must be stored in a place that re sponds to applicable safety regulations Unauthorised personnel must not enter this area 1 8 Avoid removing the caps when the temperatures are high The engine coolant is hot and under pressure after stopping the machine The removal of the cap or draining the coolant in such conditions may cause burns When you remove the radiator cap shut down the ...

Page 85: ...dify 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 modif...

Page 86: ...indow with a new one 1 14 Cabin s emergency exit If the cab door will not open break the glass with the hammer provided in the cab to be able to exit the cab in an emergency The emergency exit is indicated by a safety sticker Remove the pieces of glass that remain in the win dow frame to avoid any cutting risk Make sure that you do not slip on the pieces of glass that have fallen at your feet on t...

Page 87: ...a ble materials around the engine may catch fire Clean these materials from the machine Dirt oil and snow on the cab floor the levers handles or steps are slippy and dangerous Clean them completely Proceed to the checks 4 Checks before starting the machine page 85 Keep the headlights and mirrors clean To clean the cab exterior Be sure to keep three points of support with the machine when cleaning ...

Page 88: ...ection against side tipping TOPS Never modify any of these structures elements The protection structures mounted on the machine comply with the recommendations of ISO 12117 2 of 2008 ROPS and 10262 of 2000 FOPS For the specifications of these structures refer to the table below Type ROPS TOPS Weight in accordance with ISO standard 6016 11525 2 1 4 Check the position of the blade Check the position...

Page 89: ...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 90: ...ch can result in se rious injury or death 2 2 2 Movement and accessories When moving the machine keep the bucket be tween 40 and 50 cm above the ground with the boom and arm folded If you need to use the command levers when mov ing do not make any sudden movements when oper ating them Move the machine at low speed and slow down when turning on hilly terrain Avoid driving over obstacles if possible...

Page 91: ...ping 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 avoided provide a bank to keep the machine as horizontal as possible Then turn the upper structure Braking when descending on a slope When going downhill you can automatically stop th...

Page 92: ...nt force to dig the ground with the bucket s teeth in contact with the ground This may apply excessive force to the rear of the machine and shorten its life span Do not use the hydraulic cylinder to the end of its run a play This may apply 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 D...

Page 93: ... that the bucket and blade do not come into contact Support the blade on both sides When you use the blade as a support press the blade down on both sides Pay attention to the blade during excavation When carrying out a deep excavation on the ground in front of the blade make sure that the blade does not come into contact with the boom cylinder Place the blade at the back if it is not in use Do no...

Page 94: ... your machine s load can reach the minimum distances indicated in the table below Follow these procedures to prevent any accident or injury Wear shows with rubber or leather soles Use a signaller to warn the operator when the machine is too 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 ...

Page 95: ...the starter key to ON position 3 Use the joysticks to lower the boom and place the accessory or load on the ground 4 Raise the lock lever 5 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 bal ance and tip over when rotating the upper structure or when r...

Page 96: ...rea 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 you come out of the water if the ...

Page 97: ...uck 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 working in a dimly lit area switch on the lights and front headlights and provide ad ditional lighting if necessary Stop all work when fog snow or rain hi...

Page 98: ...the blade to the ground 5 Pull the locking levers back 1 Locking lever 2 Left hand side 6 Turn the key to OFF position to switch off the engine and disconnect the electrical circuit 7 Remove the key from the ignition WARNING Do not touch the command levers before switching off the engine or else the equipment or the machine may move suddenly and cause a serious accident 2 4 Parking precautions IMP...

Page 99: ...he machine the inertia of the upper struc ture will increase and continue to rotate over a long distance once the rotation lever has been released This may give the operator a false impression of the distance to be respected between the 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...

Page 100: ...flammable 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 ...

Page 101: ...efore despatch Oth erwise 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 precaution...

Page 102: ...ere are no oil leaks from the hydraulic system the hydraulic oil tank the pipes and seals 5 Check that there are no traces of grease or leaks from the hydraulic pipes 6 Check that there are no brakes 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 85 8 Check the proper operation and the con...

Page 103: ...min and max markers A expansion flask 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...

Page 104: ...hole If the 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 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 40 ...

Page 105: ...er B using the starter key b Take the cap off the tank c Top up through the filler hole keeping an eye on the gauge located on the tank Only use the recommended diesel ISO 8217 DMX EN 590 96 Minimum cetane index 45 1 Cover B 2 Cap Temperatures C Quantity prescribed L 20 10 0 10 20 30 Diesel N 2 D 115 0 N 3 D N 3 D S WARNING If you spill any fuel wipe it up with a cloth 1 Event 6 Close the tank aga...

Page 106: ...round 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 Open the hydraulic oil tank opening cap c Top up through the filler hole keeping an eye on the gauge...

Page 107: ...ISO VG46 60 0 in the tank 52 0 the rest IMPORTANT Do not mix different types of oils If you need to top up the oil with a different make 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 108: ... correspond to the following statuses 1 Diesel gauge normal 2 Cooling fluid temperature indicator normal 3 Time counter normal 4 Engine oil pressure alert indicator off 5 Battery charge warning alert off 6 Water temperature alarm light off 7 Warning light Alert light off 3 Set the engine speed switch setting between idle and full throttle positions Run the engine about 5 minutes with no load at th...

Page 109: ...f the upper structure is possible with the joysticks 8 Unlock the locking lever and activate the joysticks to check that everything is operating normally 9 If you observe the slightest anomaly during this procedure contact your dealer 6 Check the colour of the exhaust gas the noise and the vibrations of the machine ...

Page 110: ...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 111: ...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 112: ...ime accumulated since the previous 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 the screen indicating that the maintenance period for an object has been reached IMPORTANT The maintenance time accumulator must be re set after the maintenanc...

Page 113: ... 4 To edit the highlighted number press F3 to increase the value by 1 until you reach the desi red value 5 Press F4 to complete the process The display returns to the maintenance interface and a confirmation sound is emitted 7 4 Machine usage management interface This interface allows you to check the machine hours of operation over a period of 90 days Hours of machine use for the selected month T...

Page 114: ...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 Fuel consumption Sets the fuel consumption display on the operator display station 7 5 Configuration interface This interface all...

Page 115: ...the machine 2 1 Precautions before starting the engine page 70 1 Place the acceleration switch in full throttle position 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 appears on the screen turn the key to the START position to start the engine c Release the key aft...

Page 116: ...d 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 greasing oil and the fuel 3 Recommended g...

Page 117: ... same way as steel tracks Use the rubber tracks moderately according to the conditions at the work site and the type of work 9 2 Rubber track warranty The rubber tracks are not guaranteed for repair and replacement if they are damaged fol lowing careless use by the user lack of check of the track tension or incorrect maintenance use of the tracks on surfaces or terrain likely to damage them ...

Page 118: ...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 do not recommend that you use the machine to handle materials that become oily once crushed soya wheat grains compressed colza oil yeast etc After use clean the mach...

Page 119: ...nificant difference in level there is a spacing between the tracks and the rollers 1 Track 2 Tightener 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 aligned with respect to the t...

Page 120: ...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 total weight of the quick hitch the accessories used bucket hydraulic hammer and the load handled does not exceed the maximum weight allowed DANGER Any exc...

Page 121: ...sity This operation is reminded by a sticker af fixed 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 bucket Please refer to the stickers or C E and manufacturer s plates affixed on the accessories mounted on your machine C E stic...

Page 122: ... injuries and ex tensive material damage 10 1 Machine stability when using with a bucket or an accessory page 103 Do not use accessories that are not listed in this chapter The user must ensure that the ac cessory is compatible with the capabilities of the machine and the task at hand If in doubt contact the accessory manufacturer or dealer Mounting without quick hitch Bucket Retro bucket G70800 G...

Page 123: ... 4 4 Bucket Retro bucket GMO40R0600 GMO40R0800 Ditching bucket Swivel ditching bucket Loading bucket GMO40R0600 GMO40R0800 Hydraulic hammer DMS530 DMS530 Mechanical wedge CSERI Quick hitch SW08 SW08 Bucket Retro bucket GCS08DT0800 GCS08DT1000 GCS08CT0600 GCS08CT1000 Ditching bucket GCS08DC1600 GCS08DC1800 GCS08CC1500 Swivel ditching bucket GCS08DP1700 Loading bucket GCS08DT0800 GCS08DT1000 GCS08CT...

Page 124: ...cket Retro bucket GMO40R0600 GMO40R0700 Ditching bucket Swivel ditching bucket Loading bucket GMO40R0600 GMO40R0700 DMS530 DMS530 HCSW08 HCSW08 GCS08DT0800 GCS08DT1000 GCS08CT0600 GCS08CT1000 GCS08DC1600 GCS08DC01800 GCS08CC01500 GCS08DP01700 GCS08DT0800 GCS08DT1000 GCS08CT0600 GCS08CT1000 GCS08DC1600 GCS08DC1800 GCS08CC1500 Hydraulic hammer DMS530 DMS530 Hydraulic corner CSERI Quick hitch Hydraul...

Page 125: ...ylinder and the bucket arm and the angle between the arm cylinder and the arm is 90 For maximum effectiveness handle the arm within the range illustrated opposite 45 forward and 30 back Do not move the equipment to the end of the cylin der run To dig at a level above the machine install the bucket in the reverse position 12 2 1 Loading bucket page 113 10 1 Machine stability when using with a bucke...

Page 126: ... 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 127: ... you must Pull out the tool and after pushing the piston as high as possible using a tube grease it thoroughly and reassemble the tool This prevents oxidation of the piston end Shelter the hammer in a confined area that is protected from the weather Tool change 1 Park the machine preferably on a stable flat and level surface 2 Place the accessory at about 30 cm above the ground in horizontal posit...

Page 128: ... 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 111 ...

Page 129: ...ccessories page 105 the bucket or accessory mounting operation is performed on a level and 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 ...

Page 130: ... 1 Connect the coupled hoses from the hammer to the machine connections 14 Implementing the 3rd hydraulic circuit page 116 2 In the absence of quick hitchs remove the plugs from the hoses on the machine and drain the oil accumulated in the hoses Always drain the machine s oil into a safe container and never directly onto the ground 3 Connect ports A and P then ports B and T with hydraulic hoses 2 ...

Page 131: ...rt the swivel pin into bore A 5 Lift the equipment and align the arm bore with the bucket B bore holding the bucket about 5 cm of the ground Add shims to compensate for play if necessary 6 Insert the swivel pin into bore B 7 Put the bolts in place on axes A and B 8 Grease the hinged parts 12 2 1 Loading bucket IMPORTANT Protect the various elements from dirt and dust Take care not to damage seals ...

Page 132: ...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 handled with the lifting accessory 5 Pass the lifting accessory in the lifting device and lock the device 6 Turn the overload housing switch to ON ...

Page 133: ...14 IMPLEMENTING THE 3RD HYDRAULIC CIRCUIT 14 1 Description 1 3rd circuit selector 2 3rd hydraulic circuit control CAUTION Do not operate the controls of the 3rd circuit if there are no installed accessories ...

Page 134: ...over B 2 Turn the valve lever to select single or dual effect 2 3rd circuit selector A 3rd circuit dual effect B 3rd circuit single effect with direct tank return 14 2 Mounting the accessory WARNING Before performing any maintenance operation remove residual pressure in the hydraulic circuit 2 1 1 Removing the residual pressure page 139 Always drain the machine s oil into a safe container and neve...

Page 135: ...proportional roller to operate the accessory 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 operated ...

Page 136: ...could reduce engine performance YANMAR engines are equipped with a continuous regeneration system which filters harmful substances using a DPF and to perform the regeneration without interrupting the operation of the machine The soot accumulated in the DPF contains mainly metal components it accumulates in large amounts within the filter but it can not be burned in the DPF It is necessary to perfo...

Page 137: ...r on the DPF emit a smell diffe rent from that of conventional engines When regeneration is underway engine noise may change if the engine is idling with no load When regeneration is in progress auxiliary regeneration mechanisms can emit noise during their operation 15 4 Manual regeneration of the particulate filter To perform a manual regeneration 1 Park the machine in a well ventilated place 2 T...

Page 138: ...or display station stops displaying the exhaust gas temperature icon WARNING You can stop the regeneration of the DPF by performing one of the following Lower the locking lever to unlock the machine controls Turn the engine speed setting switch to the high positron Press the manual regeneration switch Set the starter key to the OFF position ...

Page 139: ...erges Use adequate power ramps with hooks at their extremities Make sure 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...

Page 140: ...tes are at the same level 4 The angle between the ground and the ramp plates must be less than 15 1 Ramps 2 Wedge 3 Stops Note Determine the spacing between the ramp plates based on the centre of the track runners 5 Engine rate setting Turn the switch to the left to decrease the en gine speed 6 Direct the machine towards the ramp plates at low speed and load the machine onto the truck Do not use l...

Page 141: ...e to the ground 2 Fold the bucket and the arm to the maximum then lower the boom to wedge the arm on a wooden block 3 Turn the key to OFF position to switch off the engine and disconnect the electrical circuit Remove the key from the ignition 4 Lock the control levers with the locking lever 1 Locking lever 2 Left hand side Note The hydraulic brake locks the rotation motor ...

Page 142: ...indicated on the machine 3 Warning labels page 6 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 WARNING Before starting the machine transportation check the total height of the load 4 Working Load L...

Page 143: ...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 the machine as follows 1 Hook the shackles to the suspension holes at ...

Page 144: ...rmal 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 situations o...

Page 145: ...ectric 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 an...

Page 146: ...attery leak Defective battery Replace the battery The starter speed is too low Defective electric circuit Check and replace the electric circuit Battery insufficiently charged Recharge the battery Defective starter motor Check and repair 17 2 2 Electrical equipment Problem Cause Solution Positioning the starter switch to START does not launch the starter motor Defective electric circuit Check and ...

Page 147: ...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 148: ...itive 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 18 2 Connecting the starter cables BS backup battery BP battery broken down MP machine engine broken down 1 Set the start switc...

Page 149: ...ing the starter cables After starting the engine on the machine that has broken down disconnect the starter ca bles 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 negativ...

Page 150: ...on as the battery is charged If you continue the follow ing faults may occur battery overload reduction in the battery electrolyte battery failure The battery must only be handled once the cables have been disconnected except for checking the level of electrolyte and the specified electrolyte density measurement Connecting To connect start with the positive terminal 18 5 Charging the battery Disco...

Page 151: ...hine gets stuck in the mud and can not get out on its own or when it is towing a heavy object attach the sling as shown opposite 1 Shackles 2 Slings Minimum capacities of the coupling devices to use WLL6 t Shackles 13 Slings 13 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 damag...

Page 152: ...OVERED 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 153: ...136 ...

Page 154: ...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 155: ...s and upkeeps 138 Scheduled maintenance points of the machine lubrication filters Hydraulic oil Engine oil Hydraulic oil return filter Travel gears Greasing points Air filter Fuel filter Dependent on technical modifications ...

Page 156: ...n 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 Stop the engine by turning the key from ON position to OFF position 5 Remove the key from the ignition The residual pres...

Page 157: ...apour directly onto the sensors or connectors Do not use harsh chemicals to clean the machine as these affect the visual and technical characteristics of the machine components These products may also deteriorate the rigidity of the tank Do not spill any water onto the dashboard Do not spray water directly at high pressure onto the radiator or the oil radiator Do not point the pressure washers on ...

Page 158: ...enance manual 2 2 4 Dismantling the accessory If the scheduled task requires the dismantling of the accessory remove it carefully by following the in structions described in this manual 12 1 Dismantling the accessory page 111 Reinstall it carefully and follow the instructions de scribed in this manual 12 2 Mounting the accessory page 112 2 2 5 Working under the machine Before you carry out any mai...

Page 159: ...the electric current when working on the electrical circuit repair welding 2 2 8 Hoses Do not fold the high pressure hoses Do not strike them against any hard objects Damaged or incorrectly bent hoses pipes and ducts explode easily under high pressure never re use them Fuel and oil leaks may cause a fire 2 2 9 Radiator ventilator WARNING Never touch the moving radiator ventilator or the ventilator...

Page 160: ... 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 drain the machine s oil into a safe container and never directly onto the ground When you get rid of toxic waste such as fuel oil cooling water solvents filters...

Page 161: ...erent types of oils If you need to top up the oil with a different make 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 CJ 4 11 2 SAE 10W 30 CJ 4 SAE 15W 40 CJ 4 Travel gears Box oil SAE 90 GL 4 1 1 by reducer Hydraulic circuit Hydraulic oil ISO VG46 60 0 in the tank 5...

Page 162: ...rvice Have the engine oil and the engine oil filter element replaced Replace the side movement reducer oil Have oil in the rotation gears replaced Greasing the pin and rotation crown Replace the hydraulic fluid return filter element Contact your dealer 145 ...

Page 163: ... These are frequencies for examplen 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 164: ...hoses page 153 Fuel hoses 6 1 10 Visual inspection of the fuel hoses page 154 Fuel tank 4 4 Checking and topping up the fuel level page 88 Engine oil 4 3 Checking and topping up the engine oil level page 87 Cooling fluid 4 2 Checking and topping up the level of cooling fluid page 86 Tracks 6 5 Rubber track maintenance page 156 Radiator vents Cleaning Alternator belt Tension check Decanter separato...

Page 165: ...ternator belt Replacement Intake and exhaust valves Play adjustment Fuel injection valve Verification and adjustment Cylinder head block Bolt re tightening Fuel pump Check Control filters Replacement Bearing rollers and bearings idler wheels Greasing Every 2000h Cooling fluid Replacement Injectors and injection pressure Inspection and calilbration Fuel hose coolant hose Verification and replacemen...

Page 166: ...operations 149 Windscreen wiper 6 4 4 Replacing the windscreen wiper page 156 Tracks 6 5 Rubber track maintenance page 156 Non periodic Fuses 6 4 1 Fuse replacement page 155 Windscreen washer for cab 6 4 3 Top up the windscreen washer fluid page 156 ...

Page 167: ... are 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 us...

Page 168: ...ound 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 If your machine is equipped with a central lubrication system 6 1 6 Using the centralized greasing system page 152 ...

Page 169: ...sure proper greasing pump opera tion or if the machine needs an additional lubrication Press the switch in the cab Press the button located under both switches for 2 seconds until the LED on the right comes on Note To access the timer remove the cap located below the grease tank The lubrication cycle is shortened and the lubrication starts normally Once the lubrica tion is carried out the lubricat...

Page 170: ...bonnet 6 1 8 Purging the fuel tank DANGER Keep all sparks flames or cigarettes away 1 Cover 2 Drain plug 1 Pivot the upper structure so that the drainage cap under the fuel tank is opposite the blade between the two tracks 2 Loosen the screws and rotate the bottom cover 3 Place a container to catch the fuel residue under the drainage tap 4 Remove the drainage cap to purge the water and dirt left i...

Page 171: ...3 Maintenance every 15 days 6 3 1 Checking the air conditioning heating system 1 Run the air conditioning 6 Operation of the air conditioning page 41 2 Check the amount of dirt on the air conditioning heating aspiration filters If necessary contact your dealer to replace them 3 Check the operation ventilation and speeds of the heating evaporator and the ventilation on the condenser 4 Check the amo...

Page 172: ...6 4 2 Replacing a bulb Wait several minutes after the engine has been stopped before changing a bulb Boom headlamp 1 Unscrew the headlight support 2 Unscrew the four screws on the unit Make sure that you do not lose the part of the unit that contains the glass 3 Clip the ends of the holding spring to release the bulb connector assembly 4 Replace the burnt out bulb with an identical new one 5 Inser...

Page 173: ... 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 reduced by wear the traction power reduces If A is lower than or equal to 5 mm replace the track 1 Track roller 2 Track If the track steel c...

Page 174: ...n 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 replaced repaired or you can continue to use it ...

Page 175: ...ion 3 Check the tension The play H between the external rolling surface of the second track roller on the tightener rooler and the internal surface of the track must be 20 25 mm 1 Greaser b Track roller c Track If the tension is incorrect follow the procedures given in the following chapters to increase or release the track tension IMPORTANT Perform a task with a relaxed track link may derail the ...

Page 176: ...ser b Track roller c Track 5 Proceed with the track tensioning To check that the tension is correct put the machine down and move it gently forwards and back 6 Check the tension again If it is still not correct ad just it again 7 Re install the cover The tension may be adjusted until the distance A is reduced to 0 If the voltage is still insuf ficient the track must be replaced due to excessive we...

Page 177: ...nt 9 Re install the cover IMPORTANT The rubber track does not resist grease Wipe the grease off completely as it may reduce the life time of the rubber tracks 6 5 5 Releasing the tension WARNING Do not loosen the greaser by more than one turn If it is loosened suddenly the high pressure grease in side may escape or the valve may be ejected which may cause serious injury When you check whether the ...

Page 178: ...procedures given in the following chapters to increase or release the track tension IMPORTANT Perform a task with a relaxed track link may derail the track or cause premature wear of the undercarriage 6 6 Steel track maintenance 6 6 1 Checking the condition of the tracks The wear to the track pins and pegs depends on the working conditions and the nature of the ground Check the track tension regul...

Page 179: ...nsufficient after being adjusted the pin and the peg must be re placed Contact your dealer for repair If the tension is weak even after grease is injected the track must be replaced Contact your dealer 1 Prepare a grease pump 2 Loosen the two screws and rotate the bottom cover to access the lubrication nipple a Cover 3 Raise the machine with the equipment by activating the command lever 4 Using th...

Page 180: ...ay cause serious injury When you check whether the grease has escaped do not look inside the greaser but check that the track is released Do not place your face hand legs or body in the direc tion of the greaser It is very dangerous to remove the grease using procedures other than those described here If the track cannot be relaxed ask your YANMAR dealer to intervene 5 Tighten the greaser Tighteni...

Page 181: ...ke and exhaust valves Play adjustment Air conditioning Check 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 interv...

Page 182: ...nce by the dealer 165 7 1 Maintenance of the particle filter To service the DPF contact your YANMAR dealer Particle filter cleaning every 3000h and replacement every 9000h Catalytic converter replace every 9000h ...

Page 183: ...166 ...

Page 184: ...NING 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 185: ...168 ...

Page 186: ...ient performance characteristics and is appropriate for the machine s storage temperatures 3 Recommended greases and fluids page 144 If necessary top up the water 4 2 Checking and topping up the level of cooling fluid page 86 WARNING Do not open the bonnet during machine operation Verification and topping off of the various levels should be done when the engine is stopped and the temperatures are ...

Page 187: ...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 188: ...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 189: ...172 ...

Page 190: ...173 E Technical data CHAPTERS COVERED IN THIS PART 1 SPECIFICATIONS 2 WORKING DIMENSIONS 3 NOISE EMITTED BY THE MACHINE 4 VIBRATIONS EMITTED BY THE MACHINE ...

Page 191: ...174 ...

Page 192: ...rward Rotation of the boom mm 2470 2130 Boom rotation angle left right 57 60 Maximum excavation force bucket arm kN 63 5 40 8 Travel Speed high low km h 4 5 2 5 4 1 2 3 Maximum slope 30 Rotation speed rpm 9 0 Average pressure on the ground standard track kg cm 35 1 35 5 Hydraulic circuit Hydraulic pump rate L min 70 3 x 2 variable rate pump 53 2 x 1 variable rate pump 19 0 x 1 geared pump Maximum ...

Page 193: ...160 B 750 R 6960 7290 C 840 S 4440 4790 D 60 T 1940 1590 E 120 U 3800 4130 G 1135 1265 10 V 4150 4500 H swing 2470 2130 2520 2170 Y 4680 4910 I 460 Z 6790 7020 K 2710 AA 390 L 480 AB 450 N 2890 AC 1870 P 6410 6450 AD 2270 10 With rear counterweight ...

Page 194: ...nstant 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 correspon...

Page 195: ...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 196: ...e of a counterweight and working conditions the operator must make sure that the total weight of the quick hitch the accessories used bucket hydraulic hammer and the load handled does not exceed the maximum weight allowed 10 1 Machine stability when using with a bucket or an accessory page 103 IMPORTANT The data in these tables represent the lifting capacity according to standard ISO 10567 They co...

Page 197: ...180 ...

Page 198: ... 1A Machine with cab and rubber tracks A Tilt from the rotation axis B Attachment point height Hydraulic capacity limits of the lifting force Maximum load raised by the machine Housing overload alarm value setting 181 ...

Page 199: ... REAR COUNTERWEIGHT Machine with cab and rubber tracks A Tilt from the rotation axis B Attachment point height Hydraulic capacity limits of the lifting force Maximum load raised by the machine Housing overload alarm value setting ...

Page 200: ...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 183 ...

Page 201: ...00 0000628 12 WARNING Engine management ECU fault FlashROM Maintenance required 00 0000630 02 WARNING 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 ...

Page 202: ...ult sub CPU fault Maintenance required 00 522727 12 CAUTION Engine management ECU fault sub CPU fault Maintenance required 00 522727 12 CAUTION Engine management ECU fault sub CPU fault Maintenance required 00 522728 12 WARNING Engine management ECU fault map information error Maintenance required 28 000096 02 CAUTION Fuel sensor fault Maintenance required 28 000096 04 CAUTION Fuel sensor fault Ma...

Page 203: ...top Maintenance required E1 033024 01 CAUTION Abnormal voltage of the management computer power supply bottom Check the battery or perform the maintenance E1 033024 11 CAUTION Abnormal voltage of the management computer power supply bottom Check the battery or perform the maintenance ...

Page 204: ...otation pin and crown Greasing 6 2 1 Greasing the pin and rotation crown page 154 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 154 Control sheet Maintenance every 50 hours Number of hours of service hours Parts Operations Done by the Rotation pin and crown Greasi...

Page 205: ...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 206: ...ement 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 Fuel injection valve Verification and adj...

Page 207: ...placement 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 Fuel injection valve Verification and...

Page 208: ...aler 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 Fuel injection valve Verification and adjustment Cooling system Cleaning Fuel hose coolant hose Verification and replacement Intake and exhaust valves V...

Page 209: ...192 C Notes ...

Page 210: ...e 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 211: ...194 ...

Page 212: ...nservation 169 Cover B 44 Cover R 44 Covers 43 D Daily maintenance 150 Detecting anomalies 127 Diesel type 144 Diesel gauge 17 Dismantling Accessories 60 111 Door 37 Driver s seat 32 Driving the machine on a slope 74 E Engine oil 144 F fuel type 144 Fuses 33 35 G Greasing Greasing points 151 H Headlights 40 Horn 22 Hydraulic oil Replenishment 89 type 144 Verification 89 I Interior lighting switch ...

Page 213: ...commissioning 171 Right hand cab window 40 Rubber track maintenance 156 Rubber tracks 100 Running in 84 S Safety signals xi Soldering 143 Specifications 175 Start key 21 Steel track maintenance 160 Stopping the engine 80 Storage 170 T Technical data 173 tension 157 Tie down 193 Time counter 18 Towing the machine 134 Transporting the machine 122 Travel Levers 29 U Use Maintenance 139 use of equipme...

Page 214: ...EXCAVATOR http www yanmar eu ...

Page 215: ...EXCAVATOR ViO80 1A USER OPERATION AND MAINTENANCE MANUAL ...

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