Kato Imer CARRY 110 Operating Instructions Manual Download

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OPERATING INSTRUCTIONS

TRACKED MINIDUMPER

CARRY 110

serial numbers from nr.:

MD*00030

(Original instructions)

03/17

–

R00

Codice 2050307024

Summary of Contents for CARRY 110

Page 1: ...OPERATING INSTRUCTIONS TRACKED MINIDUMPER CARRY 110 serial numbers from nr MD 00030 Original instructions 03 17 R00 Codice 2050307024 EN ...

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Page 3: ... 14 2 7 2 SELF LOADING SHOVEL 14 2 7 3 TRILATERAL PLATFORM 14 2 7 4 CEMENT MIXER KIT 15 2 7 5 FOOTPLATE 15 2 7 6 USING THE AUXILIARY HYDRAULIC PTO AND SWITCHING VALVE fluid flow rate 26 l min 15 2 7 7 INSTALLING THE SELF LOADING SHOVEL OPTIONAL 16 2 7 8 INSTALLING THE CEMENT MIXER KIT SELF LOADING SHOVEL OPTIONAL 17 2 8 REPLACING THE ACCESSORY 18 2 8 1 REMOVING THE ACCESSORY 18 2 8 2 MOUNTING ACCE...

Page 4: ...3 6 600 HOURS MAINTENANCE AND CHECKS or 2 YEARS 31 3 6 1 HYDRAULIC FLUID CHANGE 31 3 6 2 REPLACING THE DRIVE MOTOR OIL 32 3 6 3 REPLACING THE ENGINE COOLANT 32 3 7 SPECIAL OPERATING CONDITIONS 33 3 8 LENGTHY STORAGE 35 4 TROUBLESHOOTING 36 4 1 TROUBLESHOOTING TABLE 36 4 2 SPARE PARTS 36 5 HYDRAULIC SYSTEM 37 5 1 SPECIFICATIONS 37 5 2 HYDRAULIC SYSTEM DIAGRAM 37 6 ELECRIC SYSTEM DIAGRAM 38 7 TECHNI...

Page 5: ... CE modificata dalla 2005 88 CE emissione acustica ambientale delle macchine ed attrezzature destinate a funzionare all aperto e alla legislazione nazionale che la traspone Dlgs 262 2002 Categoria macchina Dumper annesso I n 18 Procedure applicate per le valutazioni di conformità controllo interno della produzione con valutazione della documentazione tecnica e controlli periodici all VI 1a procedu...

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

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

Page 8: ...uthorised service centres WARNING Scheduled services are required by the Manufacturer Failure to observe this requirement voids the warranty PROGRAMMED SERVICE TABLE HOURS 20 50 200 400 600 800 1000 1200 1400 1600 OPERATION Oil and engine filter change Check replace engine air filter Check and adjust track tension Replace hydraulic circuit filter Change hydraulic fluid ...

Page 9: ...jury May also be used to indicate the potential for damage to the machine or its parts We have made every effort to reduce the risks associated with correct use of the machine and nonetheless we cannot be held responsible for predicting every kind of danger in all unintended operating conditions We have taken every effort to prevent accidents during he machine s operation however we are not liable...

Page 10: ...fety gloves visible clothing safety boots and ear defenders 5 BEFORE STARTING THE MACHINE Since all equipment is hydraulically operated it is EXTREMELY IMPORTANT that the hydraulic fluid be at temperature BEFORE you start working while the fluid is heating up the operator should check the machine s operation and whether it needs servicing Remember the basic principle of hydraulics is flow of hydra...

Page 11: ...icient safety distance between machine and obstacle Leading the machine on foot raise the platform assuring the hook 2 DO NOT OVERLOAD Never overload any cylinder enough to trigger the opening of the safety valve This would cause an excessive rise in the oil temperature lowering the useful life of the hydraulic components 3 SECURE FOOTING FOR SAFE OPERATION Check that the machine footing is level ...

Page 12: ...d Even slight roughness can cause the machine to bump around or tip over DRIVE IN REVERSE THE OPERATOR MUST BE UPHILL OF THE LOAD AT ALL TIMES NEVER STEER on sloping or unstable ground the machine may tip over NEVER DRIVE ACROSS A SLOPE When working on sloping ground always drive uphill or downhill Take great care on icy ground as the machine may skid 1 4 LOADING AND TRANSPORT 1 PRECAUTIONS WHEN L...

Page 13: ...machine always refer to the instruction manual Before ANY service work stop the engine and engage the parking brake to prevent unexpected movements which may cause injury raise the accessory and fit its safety lock NEVER ALLOW ANYONE to work on the undercarriage with the accessory raised if it is not securely locked During maintenance operations mark the control levers with labels These labels can...

Page 14: ...oughly and call for medical treatment immediately During battery servicing remember that charging or discharging generates a highly explosive mixture of hydrogen and oxygen A flame or spark can ignite these gases ALWAYS wear protective glasses and gloves when working with the battery 5 HYDRAULIC SYSTEM MAINTENANCE Before disconnecting a hydraulic line on the machine be sure that the shovel if pres...

Page 15: ...rns due to contact with high temperature parts Do not touch hot parts while the machine is operating or before having given it time to cool down after being switched off use suitable safety equipment if necessary The sign indicates the shearing hazard associated with the bucket Keep your hands away from the bucket arm while the bucket is operating The sign indicates the hazard of being struck by o...

Page 16: ...s A and B 1 Move the engine speed lever to the desired position 2 Check the RH and LH travel levers as follows STRAIGHT TRAVEL FORWARDS travel Push both levers gradually forwards The machine will move off in a forwards direction STOP Move both levers gradually back to the middle position to stop the machine BACKWARDS travel Pull both levers gradually back The machine will move off in a backwards d...

Page 17: ...rom trucks or when driving on sloping ground High speed Set the button to the marked position Drive at high speed on level hard even ground BUTTON C HIGH SPEED LOW SPEED HIGH SPEED BUTTON Driving on slopes LOWER THE ENGINE SPEED DO NOT CHANGE THE TRAVEL SPEED WHEN DRIVING DOWNHILL WHEN DRIVING ON SLOPING GROUND MAKE SURE THAT THE TRACKS ARE IN LINE WITH THE SLOPE AND NOT ACROSS IT NEVER DRIVE ACRO...

Page 18: ...one way lock to facilitate its use with special tools 2 1 7 AUXILIARY SWITCHING VALVE LEVER Lever H Enables and facilitates use of one way tools such as demolition hammers hydraulic drills water pumps cement mixer kit etc by directing the return flow to the tank Move the lever to the position marked for one way use moves in one direction only and to for two way use moves in both directions WITH TH...

Page 19: ...d N turn off Do not run the starter motor for more than 15 sec If the engine does not start after 15 sec allow it to cool down for 2 minutes and try again Turn the key I to OFF before attempting to start the engine again 5 Reduce the engine speed to allow it to warm up STARTING AT LOW TEMPERATURE 1 Repeat the procedure given in point 1 of the paragraph STARTING AT NORMAL TEMPERATURE 2 Turn the key...

Page 20: ... that it is in front of and with its tracks parallel with the ramps Do not operate the control levers except for the travel levers when the machine is on the ramps 5 Keep the centre of gravity of the machine within the area of the loading ramps 6 Make sure the ramps are stable SECURING THE MACHINE FOR TRANSPORT 1 Switch off the engine 2 Fix the tracks and secure the machine to the load bed with ch...

Page 21: ...2 OPERATING INSTRUCTIONS MINIDUMPER CARRY 110 13 2 6 EQUIPMENTS SKIP WITH SHOVEL SKIP TRILATERAL PLATFORM CEMENT MIXER WITH SHOVEL KIT ...

Page 22: ... completely full Raise the shovel and lower speed when unloading so as to avoid material falling out of the shovel and onto the driver s position 2 7 3 TRILATERAL PLATFORM The platform is a multifunctional accessory used for many purposes in construction work greenhousing and civil engineering It is specially designed to tip and hence unload on three sides which is especially useful when unloading...

Page 23: ...om the ground since there is no risk of its hitting the driver s legs When open it allows the operator to drive the machine in the on board position It is fitted with a vibration damper to protect the legs For total operator safety the footplate is equipped with a lock spring loaded which stops it from closing accidentally 2 7 6 USING THE AUXILIARY HYDRAULIC PTO AND SWITCHING VALVE fluid flow rate...

Page 24: ...n locknut 4 Mount the cylinders to the arms RH cylinder to RH arm etc using the provided hex head pins ref D and fully tighten down the pin locknut 5 Fit the hydraulic lines to the cylinders in accordance with their length Route the two L 930 and L 1500 lines into the rear guide ref F welded under the skip Route the hydraulic lines L 2200 mm and L 2550 mm into the guides on the skip now fit the fe...

Page 25: ...nd secure the shovel frame B to the linkage and chassis using the six bolts removed at previous step 4 Fix the shovel frame to the linkage using the four bolts supplied with it C This secures the shovel to the cement mixer so as to facilitate accessory changeovers 5 Fit the hydraulic lines into the guides in the front casing D in the proper positions Connect the lines to the machine s PTO E using ...

Page 26: ... Use steel ropes with a minimum load rating of 300 kg 2 Release the hydraulic snap fittings 3 Remove the four bolts at the front securing the linkage to the machine s chassis 4 Raise and remove the accessory by lifting REMOVING ACCESSORIES WITH REPLACEMENT KIT OPTIONAL 1 Fit the mounts 1 and 2 to the accessory s frame as shown in the figure 2 using the supplied wrench undo the rotating feet until ...

Page 27: ...AL 1 Start the engine and slowly approach the accessory making sure to keep the machine centred relative to the mounts Continue approaching until the two frames are fully coupled 2 Stop the engine With the provided wrench screw the feet in alternately until the accessory frame is resting on the machine s chassis and the supports are free to be completely removed 3 Locate and screw in the four fron...

Page 28: ... 3 Clean any diesel hydraulic fluid and grease off the tracks 4 Do not turn the machine quickly on the tracks 5 If the machine is not used for a long time more than 3 months store the tracks away from direct sunlight and rain 6 When using rubber tracks only operate the machine in the temperature range 25 C to 55 C 2 10 PARKING THE MACHINE At the end of the day s work proceed as follows PARKING THE...

Page 29: ... Every 250 hours of operation before the above service jobs Engine Oil change Air cleaner Replace filter element Travel reducer gear Check oil level Every 600 hours of operation before the above service jobs Hydraulic System Change fluid and clean filter element Travel reducer gear Change reducer casing oil Engine coolant Change coolant The above intervals depend on the conditions in which the mac...

Page 30: ... if worn however if excessively worn the tracks may skid and require greater power from the engines If the remaining tread is less than 5 mm it is advisable to replace the track with a new one 2 EXPOSURE OF THE STEEL CORDS If the steel cords of a rubber track are exposed due to excessive wear or damage replace the track with a new one 3 CUT STEEL CORDS If any of the steel cords are cut replace the...

Page 31: ...ver 2 Change the damaged fuse with a new one We list below the circuits protected by each fuse and their amperages 1 Engine stop solenoid timers hourmeter 30A 2 double speed switch oil and water sensor 10A 3 Generator 10A MAIN FUSE A fuse 2 is located between the positive terminal and the key switch to protect the cabling against short circuits In case of power failure check this fuse and identify...

Page 32: ...e cells weekly in extreme temperatures as acid consumption may be higher in such conditions 4 Topping up the battery acid Keep the acid topped up to just below the filling hole or at least above the level mark add water as necessary If you spill any acid replace it with sulphuric acid at the same concentration as that remaining inside the battery The acid level must never drop below the upper edge...

Page 33: ...emove cap B on top of the tank inside the engine compartment remove the LH side panel and add as much fuel as is required with the provided funnel Make sure to completely tighten down the filler cap afterwards Clean all fuel spills off the machine NEVER REFUEL THE MACHINE WITH THE ENGINE RUNNING DO NOT SMOKE WHEN REFUELLING FUEL SPILLS ONTO HOT SURFACES CAN CATCH FIRE DO NOT INHALE FUEL FUMES REFU...

Page 34: ...eaning cycles after a year or when any part of the cleaner is damaged Check the air cleaner dust indicator If the indicator is in the red zone and after a test reset clean replace the filter element as indicated below CLEANING THE AIR CLEANER ELEMENT 1 Stop the engine 2 Release the three retainers and remove the service cover 1 3 Remove the element 2 from the air cleaner housing 3 Note Carefully r...

Page 35: ...t 2 and fit and secure the service cover 1 with the valve 2 pointing downwards Note Insert a new element When the gasket is correctly seated in the tube it forms a snug fit with the inlet For a better seal press the end of the filter element against the external ring 8 Reset the dust indicator with the reset button 9 If the dust indicator refuses to reset replace the element REPLACING THE AIR FILT...

Page 36: ...3 4 7 COOLANT LEVEL CHECK Maintenance intervals Check Level daily Add coolant to the maximum level mark 1 Open the hatch on the engine compartment s rear panel 2 Slacken off the radiator cap slowly to depressurise it then remove it 3 Check the coolant level and condition Top up to the maximum level mark if necessary Note If the coolant is dirty or foamy change it See the coolant change instruction...

Page 37: ...ed below otherwise go to point 14 3 Fit the cylinder safety and switch off the engine 4 Slacken off the oil filler cap 1 to depressurise the circuit 5 Clean the area to keep dirt out of the filter body 2 6 Place a container under the filter to catch any hydraulic fluid leaks while replacing the filter cartridge Note always observe the established regulations governing the disposal of exhausted oil...

Page 38: ...y part of the cleaner is damaged Refer to point 3 4 5 of this manual for the replacement procedure Note always observe the established regulations governing the disposal of exhausted filters 3 5 3 DRIVE MOTOR REDUCER GEAR OIL LEVEL CHECK Check the condition after 200 hours of operation 1 Orient the reducer so that the drain cap 1 is pointing down 2 Remove the oil level filler cap 2 The oil should ...

Page 39: ...terior of the tank with fresh oil 9 Clean and refit the suction filter 5 filter cover 4 and suction line 10 Clean and refit the drain cap 2 11 Fill the tank with hydraulic fluid See the table in paragraph 3 2 12 Run the engine at low speed for five minutes 13 Operate the control levers to charge the circuit 14 Restore the machine to its initial condition and switch off the engine 15 Check the hydr...

Page 40: ...t Check the condition daily Replacement after 600 hours of operation or two years of service also change the coolant when it is dirty or foamy 1 Place the machine on firm and level ground Stop the engine 2 Slacken off the radiator cap 1 slowly to depressurise the radiator then remove it 3 Open the drain cock radiator 2 and drain the coolant into a container Note observe established regulations gov...

Page 41: ...and minimise wear and degradation of the components EXTREMELY LOW TEMPERATURES 1 Condensation may form in the fuel tank and freeze The ice may block the flow of fuel in the ducts thus stopping the engine This hazard can be reduced by keeping the fuel tank as fully topped up as possible during the cold season If the water in the fuel should condense in the tank drain the tank and fill it with fresh...

Page 42: ...ch off the engine when not working VERY SANDY DUSTY CONDITIONS Particles in the air can accelerate the wear of the machine s components they exercise an abrasive action on moving parts To prevent this lubricate the machine more frequently and service the air intakes and filters more often 1 Take care not to let sand or dust into the hydraulics keep the tank well closed and keep an eye on the filte...

Page 43: ...ir fuel mixture injected into the engine combustion chambers so that the engine s performance may be affcted high altitudes have a lower atmospheric pressure and less oxygen in the air Over 1500 metres above sea level you may have to adjust the fuel injection for the machine to run properly Refer to the Technical Assistance Service for details To reduce the problems attendant on the lower density ...

Page 44: ...ed in track Poor drive motor operation Brake fault Remove jammed material Request assistance service Request assistance service The machine does not steer straight Jamming in tracks Track tension not even on both sides Pump fault Servocontrol fault Drive motor failure Remove jammed material Adjust the tension on both sides Request assistance service Request assistance service Request assistance se...

Page 45: ... NOMENCLATURE PRESSURE Mpa Kgf cm2 Pump P1 P2 21 5 220 Shovel 16 7 170 Dump 16 7 170 AUX PTO Mpa Kgf cm 2 Litres min MAX pressure 16 7 170 MAX capacity 26 5 HYDRAULIC SYSTEM 5 1 SPECIFICATIONS 5 2 HYDRAULIC SYSTEM DIAGRAM P4 P3 P2 P1 1 2 T 2 P 3 2 1 1 ...

Page 46: ... mm Withe Black 0 75 mm Orange 1 5 mm Orange 1 5 mm Brown 1 mm Red 1 5 mm Black 1 5 mm GLOW PLUG LED OIL LED GENERATOR LED WATER TEMPERATURE LED B C R2 HOUR METER KEY SWITCH 10A A Black 35 mm L 500 mm BATTERY 2050309005 Red 35 mm L 1050 mm GLOW PLUG Black 4 mm A11 A13 A14 A15 A16 A12 A1 A5 A6 A19 A20 A23 A24 A25 A26 A28 A29 A30 A33 B2 B10 B9 B1 B8 2030809000 BR A34 Pre risc Start ON OFF CONNECTION...

Page 47: ...EL ENGINES Diesel Sound power level guaranteed LwA 101 dB Sound pressure at operator s ear LpA 85 dB 7 2 DIMENSIONS DIMENSIONS Nomenclature Rubber tracks Track width mm 200 Length of track mm 1450 Width of machine mm 900 Height of machine at controls mm 1300 Turning radius mm 950 Minimum ground clearance mm 160 Skip Volume m3 0 42 Trilateral platform Optional Dimensions length x width x height mm ...

Page 48: ...7 TECHNICAL SPECIFICATIONS MINIDUMPER CARRY 110 40 7 4 DIMENSIONS OF MACHINE KIT SHOVEL CEMENT MIXER SHOVEL PLATFORM ...

Page 49: ...TRACKED MINIDUMPER CARRY 110 PUBLISHED MARCH 2017 KATO IMER S p A ITALY ...

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