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MAINTENANCE

MINIDUMPER

CARRY 107

3 MAINTENANCE

3.1 MAINTENANCE INTERVALS

Check point

Item

When required

Tracks

Check and ad just tension

Battery

Cleaning and level check of electrolytic liquid

Gears with greaser

Grease lubrication

Daily (every 8 hours of work)

Engine Oil

Check the oil level

Hydraulic oil tank

Check the hydraulic oil level

Fuel tank

Check the fuel level

Machine checking

General daily check of conditions of machine

Every 50 hours of work (Before performing the previous services)

Engine

Clean the air cleaner element

Diesel engine

Drain water in the fuel tank

Every 200 hours of work (Before performing the previous services)

Engine

Change the oil

Engine

Clean the fuel sedimentor

Air filter

Change the air cleaner element

Hydraulic system

Change the strainer

Every 600 hours of work (Before performing the previous services)

Hydraulic oil

Oil change

The intervals given depend on the environment in which the machine is used, very dusty environments for

example require more frequent cleaning of the air cleaner

3.2 RECOMMENDED LUBRICANT TABLE

Position

Quantity

Specifications

HONDA ENGINE

GX270

Max. 1.1 litres

SAE 10W-30

YANMAR ENGINE

L100 AE

Max. 1.65 litres

SAE 20W40

HYDRAULIC OIL

Total quantity 22 litres

Tank capacity 16 litres

LONG LIFE

HYDRAULIC OIL

ISO NO. 46

LUBRICATE THE

FITTING.

Lithium grease EP-2

Содержание CARRY 107

Страница 1: ...OPERATING INSTRUCTIONS TRACKED MINIDUMPER CARRY 107 107 E serial numbers from nr CARRY 107 MC 00430 CARRY 107 E MC 00430 Original instructions 03 17 R00 Code 2050207044 EN ...

Страница 2: ......

Страница 3: ...ING SHOVEL 14 2 7 3 PLATFORM 14 2 7 4 CONCRETE MIXER KIT 15 2 7 5 FOOTBOARD 15 2 7 6 USE OF THE AUXILIARY POWER PORTS 15 2 7 7 USE OF THE AUXILIARY POWER PORTS HI FLOW OPTIONAL 15 2 7 8 GRADER BLADE USER INSTRUCTIONS OPTIONAL ACCESSORY 16 2 7 9 USING THE GRADER BLADE AS A SNOW PLOUGH OPTIONAL ACCESSORY 16 2 7 10 INSTRUCTIONS FOR SELF LOADING SHOVEL ASSEMBLY OPTIONAL 17 2 7 11 ASSEMBLY INSTRUCTIONS...

Страница 4: ...CHECKS AND MAINTENANCE EVERY 200 HOURS 32 3 6 1 HYDRAULIC OIL REPLACEMENT 32 3 6 2 CLEANING THE FUEL SEDIMENTOR GASOLINE MOTOR 32 3 6 3 AIR FILTERING ELEMENT REPLACEMENT 33 3 6 4 HYDRAULIC SYSTEM STRAINER REPLACEMENT 33 3 7 CHECKS AND MAINTENANCE EVERY 600 HOURS OR AFTER ONE YEAR 33 3 7 1 HYDRAULIC OIL REPLACEMENT 33 3 8 UNUSUAL OPERATING CONDITIONS 34 3 9 LONG TIME STORAGE 35 4 TROUBLE SHOOTING 3...

Страница 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 procedur...

Страница 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...

Страница 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...

Страница 8: ...vice centres WARNING The scheduled Maintenance coupons are specified by the Manufacturer The failure to perform them may invalidate the guarantee SCHEDULED MAINTENANCE TABLE HOURS 20 50 200 400 600 800 1000 1200 1400 1600 OPERATION Engine oil filter replacement Hydraulic system strainer replacement Air cleaner replacement Track tension checking and adjustment Hydraulic system strainer and hydrauli...

Страница 9: ... injury 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 lia...

Страница 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...

Страница 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 ...

Страница 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...

Страница 13: ...e 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 only be removed by aware personnel able to ensure that safety rules are fully observed 2 CLEANING THE MACHINE Keep the machine clean Remove al dirt and grease and check the m...

Страница 14: ... flame or spark can ignite these gases ALWAYS wear protective glasses and gloves when working with the battery 6 HYDRAULIC SYSTEM MAINTENANCE Before disconnecting a hydraulic line on the machine be sure that the shovel if present is on the ground the tool holder is in the lowered position the engine is off the pressurised air has been relieved from the hydraulic tank the control levers are moved r...

Страница 15: ...ign indicates the danger of burns 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 t...

Страница 16: ...2 INSTRUCTIONS FOR USE MINIDUMPER CARRY 107 7 2 INSTRUCTIONS FOR USE 2 1 MACHINE CONTROLS C B A G D F E H D A C B F H E D A C B H E CARRY 107 BASE CARRY 107 PLUS CARRY 107 E ...

Страница 17: ... forwards to travel forward and left pull the right lever towards you to reverse and turn left Right turn Push the left lever 2 forwards to travel forward and right pull the left lever towards you to reverse and turn right SPOT TURN Spot left turn Push the right lever B forwards and at the same time pull the left lever A backwards This operation causes a quick left turn Spot right turn Push the le...

Страница 18: ...le for machines fitted with extensible track Utilizzare il meccanismo di espansione contrazione seguendo le procedure qui sotto riportate 1 Use the spanner mechanism following the procedures described below 2 Increase engine rpm 3 Move the Spanner Lever forwards or backwards to extend or retract the track Track extension Push the lever forwards Track retracting Pull the lever backwards 2 1 7 USING...

Страница 19: ...e engine With recoil starter turn the engine switch to the ON position Pull the starter grip lightly until resistance is felt then pull briskly CAUTION Do not allow the starter grip to snap back against the engine Return it gently to prevent damages to the starter With electric starter where equipped Turn engine switch to the START position and hold it there until the engine start NOTE Do not use ...

Страница 20: ...HE STARTER CABLE SHEATH 15 54 RED YELLOW BLACK 15 30 50 GREEN WHITE 30 1 KEY SWITCH BLACK CHARGE WARNING LAMP OIL PRESSURE WARNING LAMP 2 2 6 FUEL SEDIMENTER The fuel tank is equipped with a sedimentation and draining system for water found in the fuel Any water or other impurities that deposit in the transparent sedimenter 1 are drained through the valve 2 Check and drain out any water and impuri...

Страница 21: ...be run straight onto the loading ramps Never operate control levers other than the travel levers while the machine is on loading ramps 5 Maintain the machine balance point within the loading ramp area 6 Make sure the ramps are stable FIXING FOR TRANSPORT 1 Switch off the engine 2 Fasten the tracks and secure the machine to the truck using chains or steel cables RAMP WIDE RAMP MAX ANGLE 15 WEDGES U...

Страница 22: ...2 INSTRUCTIONS FOR USE MINIDUMPER CARRY 107 13 2 6 ATTACHMENTS BUCKET BUCKET WITH SHOVEL GRADER BLADE KIT PLATFORM CONCRETE MIXER KIT WITH SHOVEL CONCRETE MIXER KIT ...

Страница 23: ...ing shovel is linkable to the bucket and to the deck it can be used only to load debris or moved material IT IS ABSOLUTELY FORBIDDEN TO DIG To load Position the shovel on the ground Operate the machine approaching it slowly to heap until filling up completely Lift the machine by reducing the speed when material unloading begins in order to avoid material out of the accessory and on the driver seat...

Страница 24: ...TROL LEVE R SELF LOADIN SHOVEL REVO L UTION VALVE VAT ADJUSTMENT SHOVEL POS ITION FOR CONVEYOR US E 2 7 5 FOOTBOARD The footboard is hinged to the driving frame In the closed position it allows safe driving from the ground avoiding the danger of contact with the driver s legs In the open position the operator can drive on board A shock absorbing system reduces the vibrations transmitted to the low...

Страница 25: ...s free to rock during operation Remove the pins B from seat 1 and fit them into seat 2 The rocker allows the blade to pass over small obstacles such as protruding manhole covers during operation thus avoiding impact stress to the machine and operator The springs return the blade to its working position once the obstacle has been passed Adjust the height of the blade with lever F ref 2 1 The blade ...

Страница 26: ... bucket guides then fit the female quick coupling on the pipe L 1100 mm and the male quick coupling on the pipe L 1300 mm using the special seal washers 6 Fit the cylinders on the bucket using the screws E and self locking nuts DO NOT LOCK the nuts fully home the cylinder must be free to turn 7 Fit the shovel taking care to avoid play in the coupling with the arms 8 Fit the pipe cover F on the bac...

Страница 27: ...crews provided 3 Connect pipe 2 in position A of the union tee on the valve and in position B on the shovel distributor Connect the sheathed pipes 3 L 3600 in position C and pipe 4 L 3400 in position D on the distributor 4 Lock the pipes 3 e 4 together with the already existing concrete mixer pipes to brackets F and G and to clamps H and I Divide the mixer and shovel pipes after WARNING clamp H ma...

Страница 28: ... A and B from the manifold and connect them to the hydraulic junction Connect hoses 5 and 6 from the hydraulic junction to the manifold Make sure the hoses are securely installed Repressurise the hydraulic circuit ref 3 4 2 For information on operating the Hi flow PTO refer to 2 7 67 Reinstall the machine s front housing 2 7 13 PARKING BRAKE The parking brake is mounted on the frame of the right t...

Страница 29: ...rsons For the bucket with shovel and concrete mixer kit the use of a hoisting device or special gantry is necessary ref 2 8 3 2 8 4 2 8 5 To install a new accessory reverse the sequence of the operations carried out 2 8 2 ACCESSORY FITTING AND CLAMPING PROCEDURE Position the accessory in the boom taking care to insert the accessory rear pins in the special brackets of the boom D Insert the couplin...

Страница 30: ... CONCRETE MIXER KIT USE STEEL CABLES WITH MINIMUM CAPACITY of 300 Kg A A B B B B A A B B A A CONCRETE MIXER KIT WITH SHOWEL TO LIFT THE CONCRETE MIXER KIT WITH SHOWEL HOOK THE LIFTING CABLES AT POINTS A AND B BUCKET WITH SHOVEL TO LIFT THE BUCKET WITH SHOVEL HOOK THE LIFTING CABLES AT POINTS A AND B ...

Страница 31: ...ASING THE BOOM FRAME FROM THE ACCESSORY AND THE MINIDUMPER FROM THE GANTRY 8 7 INSERT THE RESTING PINS AND LOCK THEM TURNING 90 MOVE FORWARDS SLOWLY LIFTING THE BOOM FRAME AT THE SAME TIME TO TAKE THE PINS ABOVE THE SPECIAL RESTS 6 3 5 2 QUICK COUPLINGS ON THE SHOVEL OVERTURN THE ACCESSORY AND DISCONNECT THE FLUID POWER PIPES THROUGH THE SPECIAL QUICK COUPLINGS 1 4 QUICK COUPLINGS ON THE MACHINE R...

Страница 32: ...TURE 3 1 8 RAISE THE BOOM FRAME UNTIL COUPLING THE ACCESSORY 2 MOVE BACKWARDS SLOWLY UNTIL THE ACCESSORY RESTS ON THE BOOM FRAME 4 LOWER THE ACCESSORY COMPLETELY 6 5 MOVE OUT OF THE GANTRY AND LOWER THE ACCESSORY OVERTURN THE ACCESSORY AND CONNECT THE FLUID POWER PIPES THROUGH THE SPECIAL QUICK COUPLINGS 7 COUPLE THE CLAMPING SYSTEM REMOVE THE RESTING PINS QUICK COUPLINGS ON THE MACHINE QUICK COUP...

Страница 33: ...ROM THE GANTRY 8 7 INSERT THE RESTING PINS AND LOCK THEM TURNING 90 MOVE FORWARDS SLOWLY LIFTING THE BOOM FRAME AT THE SAME TIME TO TAKE THE PINS ABOVE THE SPECIAL RESTS 5 6 3 1 4 2 RAISE THE SHOVEL TO THE END OF ITS STROKE LOWER THE ACCESSORY COMPLETELY RELEASE THE CLAMPING SYSTEM A DISCONNECT THE FLUID POWER PIPES THROUGH THE SPECIAL QUICK COUPLINGS REMOVE THE CONTROL PANEL TAKING OFF THE TWO LO...

Страница 34: ...RED WITH THE STRUCTURE 3 1 8 6 MOVE BACKWARDS SLOWLY UNTIL THE ACCESSORY RESTS ON THE BOOM FRAME 4 RAISE THE BOOM FRAME UNTIL COUPLING THE ACCESSORY 2 COUPLE THE CLAMPING SYSTEM REMOVE THE RESTING PINS RAISE THE ACCESSORY AND POSITION THE TWO PIPE STOPPER BRACKETS ON THE MACHINE FRAME FIT THE CONTROL PANEL USING THE TWO LOCKING KNOBS A CONNECT THE FLUID POWER PIPES THROUGH THE SPECIAL QUICK COUPLI...

Страница 35: ...LA LEVA DI RIBALTAMENTO D RIF 2 1 POTREBBE CAUSARE SERI DANNI ALLA STRUTTURA TOGLIERE IL PERNO DI BLOCCAGGIO E SOLLEVARE LE GAMBE FISSANDOLE NUOVAMENTENELLA POSIZIONE PIÙ ALTA MANOVRANDO LA LEVA F RIF 2 1 SOLLEVARE LA LAMA FINCHÉ L ACCESSORIO NON SI APPOGGIA SUL TELAIO PORTATREZZI 1 2 4 3 POSITION THE MACHINE ON SOLID FLAT TERRAIN AND RAISE THE BLADE TO ITS MAXIMUM HEIGHT WITH LEVER F REF 2 1 PLAC...

Страница 36: ...lic oil or grease from the track shoe surface 4 Avoid fast turns on the tracks 5 If the machine is not to be used for a long time 3 months or more store the tracks avoiding direct sunlight or rain 6 Owing to the characteristics of the rubber use the machine at a temperature between 25 C and 55 C 2 10 PARKING THE MACHINE At the end of the day s work follow the procedure described below PARKING THE ...

Страница 37: ...r in the fuel tank Every 200 hours of work Before performing the previous services Engine Change the oil Engine Clean the fuel sedimentor Air filter Change the air cleaner element Hydraulic system Change the strainer Every 600 hours of work Before performing the previous services Hydraulic oil Oil change The intervals given depend on the environment in which the machine is used very dusty environm...

Страница 38: ...ore engine power is required If the remaining lug is 5 mm or less replace it with a brand new one 2 EXPOSURE OF STEEL CORDS If the steel cords of a rubber track shoe are exposed due to excessive wear or damage replace it with a brand new one 3 BREAKS OF RUBBER TRACK SHOE STEEL CORDS When a steel cord break is detected replace the track shoe immediately If you leave it as it is and continue working...

Страница 39: ... level line in the battery is reached Check the cells once a week in extreme temperatures battery fluid consumption may be higher 4 Topping Up Keep the fluid level immediately below the openings for topping up or in any case above the level indicated by the level line adding water when necessary If part of the electrolytic fluid has been spilled replace it with sulphuric acid in the same concentra...

Страница 40: ...e necessary fuel using the funnel provided After filling up make sure that the fuel filler cover is closed properly Clean any surfaces involved by fuel spilling when filling up GASOLINE ENGINE DIESEL ENGINE A HOT OIL AND COMPONENTS CAN CAUSE PERSONAL INJURY DO NOT ALLOW HOT OIL OR COMPONENTS TO CONTACT SKIN DO NOT OVERFILL THE CRANKCASE TO AVOID ENGINE DAMAGED ENGINE DAMAGE CAN RESULT NEVER OPERAT...

Страница 41: ...lement when it has been cleaned five times at the most 3 5 2 FUEL TANK CLEANING AND DRAIN DIESEL ENGINE Refer to the instructions of the engine handbook for engine tank drain and cleaning operations Note always dispose of drained fluids as established by local regulations 3 6 CHECKS AND MAINTENANCE EVERY 200 HOURS 3 6 1 HYDRAULIC OIL REPLACEMENT Refer to paragraph of chapter 3 4 and the instructio...

Страница 42: ...the tool holder pistons and if present those of the loader shovel and track extension fully retracted and switch off the engine 2 Raise the tool holder and engage the lock to prevent accidental lowering and switch off the engine 3 Clean the area to keep dirt out of the tank 4 Loosen the oil filler cap 1 to relieve the tank pressure 5 Remove the drain plug 2 and drain all the oil from the system in...

Страница 43: ...oncrete asphalt or mat surface EXTREME HEAT Like extreme cold extreme heat requires that precautions be taken with respect to the battery and lubrication 1 High temperatures necessitate the use of lubricants which are both more viscous and which resist deterioration at higher operating temperatures Refer to the Lubrication Section and lubricate the machine using the lubricants recommended for the ...

Страница 44: ...n polished or machined surfaces coat the area with grease or lubricant to repel water 3 Keep bearings and their surrounding surfaces well lubricated to prevent the entry of water 4 Never use saltwater in the cooling system Internal corrosion will occur and all parts will have to be replaced 5 Hose down the machine periodically when working in saltwater If necessary use an oil soaked cloth to clean...

Страница 45: ...he drive is not working on one or both sides Foreign matter such as stone has got caught Engine failing Remove foreign matter Ask for service Straight travel defective Something trapped Different track tension Defective pump Defective travel levers Engine or braking valve failure Remove foreign matter Adjust tensions on both sides Ask for service Ask for service Ask for service Bucket lifting powe...

Страница 46: ...AULIC SYSTEM DIAGRAM 4 ELEMENTS The 4 element control valve is used In the base version fixed track with only loading bucket dumper or deck with no possibility to install the loader shovel or takeoff for auxiliary equipment for any attachments TRIPLE SUCTION OIL PUMP SINGLE SUCTION OIL PUMP P1 P2 P3 P1 P2 P3 TOOL HOLDER CYLINDER TRACTION MOTORS BRAKE VALVES TRACTION 2 SPEED R H TRACTION L H BRAKE ...

Страница 47: ...ER TRACTION MOTORS BRAKE VALVES TRACTION MOTORS BRAKE VALVES TRACTION 2 SPEED R H TRACTION L H TRACTION 2 SPEED R H TOOL HOLDER TRACTION L H BRAKE TOOL HOLDER ENGINE MANIFOLD OIL TANK FILTER JOINT ENGINE OIL TANK FILTER JOINT SHOWEL SHOWEL HYDRAULIC SYSTEM DIAGRAM 5 ELEMENTS HI FLOW TRIPLE SUCTION OIL PUMP SINGLE SUCTION OIL PUMP P1 P2 P3 AUX P1 P2 P3 AUX DEVIATOR DEVIATOR SHOWEL CYLINDERS TOOL HO...

Страница 48: ...L TRACTION 2 SPEED R H SHOWEL CYLINDERS TOOL HOLDER CYLINDER TRACTION MOTORS BRAKE VALVES SPANNER SPANNER CYLINDERS TRACTION L H TOOL HOLDER TOOL HOLDER ENGINE MANIFOLD P1 OIL TANK FILTER JOINT P2 P3 BRAKE P1 P2 P3 ENGINE OIL TANK FILTER JOINT HYDRAULIC SYSTEM DIAGRAM 6 ELEMENTS HI FLOW TRIPLE SUCTION OIL PUMP SINGLE SUCTION OIL PUMP P2 P3 AUX TRACTION L H SHOWEL TRACTION 2 SPEED R H SHOWEL CYLIND...

Страница 49: ... Diesel Guaranteed sound power level LwA 100 dB 108 dB Sound pressure level at the operator s ear LpA 83 dB 88 dB 6 2 MACHINE DIMENSIONS DIMENSIONS Description Rubber track shoes Track width mm 200 Track length mm 1250 Machine width Retracted track mm 760 Extended track mm 1060 Machine height to controls mm 1320 Slewing radius mm 910 Minimum ground clearance mm 100 Bucket volume m3 0 33 Loading pl...

Страница 50: ...ax Flat and compacted Asphalt Forward travel NO m sec 1 0 87 Backward travel NO m sec 0 87 0 74 Flat and compacted Complete cycle Loading Self load Shovel Unloading Forward travel Backward travel YES m sec 1 07 0 8 Equivalent acceleration For hand arm vibrations Method of measurement according to ISO5349 GROUND ACTION CARGE UNIT Eq Ac Flat and compacted Asphalt Forward travel NO m sec 3 25 Backwar...

Страница 51: ...6 SPECIFICATIONS MINIDUMPER CARRY 107 42 6 5 OVERALL DIMENSIONS BUCKET SHOVEL CONCRETE MIXER SHOVEL PLATFORM GRADER BLADE ...

Страница 52: ...TRACKED MINIDUMPER CARRY 107 PUBLISHED MARCH 2017 KATO IMER S p A ITALY ...

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