off-road rubber track dumper bfk808 · 2013. 10. 17. · this machine fits into the off-road rubber...

CHIKUSUI CANYCOM, INC.90-1 Fukumasu, Yoshii-machi,Ukiha gun, Fukuoka, Japan 839-1396

Tel.(09437)5-2195 Fax.(09437)5-4396

Read and understand this manual completely before attempting

to operate, maintain, and inspect this machine.

Keep this manual with care so that it may be consulted in oper-

ating, maintaining, or inspecting this machine.

WARNING

Off-road Rubber Track Dumper

BFK808

OPERATOR'S MANUAL

3659 6701 000

NOTICE TO THE USER

Thank you for purchasing our product.Please read and understand the comments of this manual for proper operation beforeusing this machine.

The user must know that this machine can be potentially dan-

gerous. Always follow the instructions in this manual when oper-

ating, maintaining, or inspecting the machine.

WARNING

Driving this machine on a public road (or its equivalent) may be

illegal. CHIKUSUI CANYCOM, INC. does not bear responsibility

for accidents or violations of local regulations.

WARNING

Do not remodel the machine. Do not remove the safety cover

when operating, or they may cause serious accidents.

WARNING

NOTICE TO THE UNDERTAKER

NOTICE TO THE LEASER (RENTER)

This machine fits into the off-road rubber track dumper category

specified by the Enforcement Ordinance of the Labor Safety

and Hygiene Law. This product is a off-road rubber track

dumper with a maximum authorized payload of than 1.2 ton.

For operation of this product, however, completion of special

training is required. Also, in the case of off-road rubber track

dumpers, it is mandatory to conduct daily inspections, periodic

voluntary inspections, and specific voluntary inspections.

Records of periodic voluntary inspections should be kept for

three years.

CAUTION

When leasing this machine to another undertaker or individual,

explain the method of handling clearly to him or her and instruct

him or her to read this manual without fail before using the

machine.

CAUTION

CONTENTS

1. INTRODUCTION 1

1.1 Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Safety Instruction in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Warning Labels Attached to This Machine . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. WARRANTY AND AFTER-SALES SERVICE 4

3. RULES FOR SAFE OPERATION AND WORK 5

5. SPECIFICATIONS 10

5.1 Specifications for This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.2 Contents of Tool Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. NAME AND FUNCTION OF COMPONENTS 9

6. OPERATION 12

6.1 Preparations for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.1.1 Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.1.2 Inspection & Refilling Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.3 Operation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7. MAINTENANCE 20

7.1 Regular Inspection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.2 Oil/Grease/Lubricant/Fluid List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.3 Consumables (Service Parts) List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267.4.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267.4.2 Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277.4.3 Power Package Oil (Oil for Hydraulic Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.5 Lubrication and Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.5.1 Roller, Upper Roller, and Idler Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.5.2 Each Sliding Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.6 Supply of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.6.1 Battery Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.7 Cleaning .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.7.1 Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.7.2 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.7.3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.8.1 V Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.8.2 Travelling Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337.8.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337.8.4 Side Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347.8.5 Deadman's Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347.8.6 Crawler Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357.8.7 Belt Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.9 After-Use Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.4 Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.5 Dump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196.5.1 Deck Lifting/Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9. TROUBLESHOOTING 40

9.1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10. TRANSPORTATION OF/WITH THIS VEHICLE 44

<Guarantee certificate>

Attached to the end of this manual.

* Receive the guarantee certificate together with a receipt after you have received

instructions for handling of this machine.

<Appendix>

"Instruction manual for engine"

* Be sure to read it together with this manual.

8. STORAGE (LONG TERM) 38

8.1 Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398.3.1 Fuel Cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398.3.2 Cleaning Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398.3.3 Replacing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1

– 1 –

1. INTRODUCTION

1.1 PURPOSE OF THIS MANUAL

The purpose of this manual is to provide the user with appropriate information in detail about how to operate,maintain, and inspect this machine.This manual has been prepared for people who use this machine for the first time.

1.2 CONTENTS

This manual gives information by dividing it into the following chapters.

1. INTRODUCTION

This chapter explains the purpose and contents of this manual and warning terms used in this manual.It also includes the description of warning labels attached to this machine.

2. WARRANTY AND AFTER-SALES SERVICE

This chapter describes the warranty and after-sales service for this machine.

3. RULES FOR SAFE OPERATION AND WORK

This chapter describes the general safety rules which the user must observe when operating and working.

4. NAME AND FUNCTION OF COMPONENTS

This chapter explains the names and functions of the component parts.

5. SPECIFICATIONS

This chapter describes the specifications of this machine. It also describes the details about the tool bag.

6. OPERATION

This chapter explains the preparations before operation, operating procedure, and how to use the con-trol devices.

7. MAINTENANCE

This chapter gives information about maintenance such as regular inspection, supplying oil, grease,lubricant, and fluids, cleaning, adjustments, and after-use maintenance.

8. STORAGE (LONG-TERM)

This chapter gives information about the storage (long-term storage) of this machine.

9. TROUBLESHOOTING

This chapter describes the troubleshooting on this machine.

10. TRANSPORTATION OF/WITH THIS VEHICLE

This chapter explains the procedures and precautions for transporting this machine.

– 2 –

Lower section of load-carrying deck body

1 INTRODUCTION

1.3 SAFETY INSTRUCTION IN THIS MANUAL

In this manual, safety information is classified into the following four categories according to the degree ofhazard (seriousness of possible accidents). Read and understand the contents below and always observe thesafety instructions in this manual.

1.4 WARNING LABELS ATTACHED TO THIS MACHINE

The warning labels shown below are attached to this machine. When warning labels have come off or becomedifficult to see, order new ones from a dealer by the part numbers shown below labels and attach them.

Category Meaning

Indicates an extremely hazardous situation which will result in death or serious

injury if the user does not follow appropriate instructions.

Indicates a potentially hazardous situation which could result in death or serious

injury if the user does not follow appropriate instructions.

Indicates a potentially hazardous situation which could result in injury to the user

or damage to the machine if the user does not follow appropriate instructions.

Used to emphasize information which needs particular attention.

CAUTION

WARNING

DANGER

N O T E

1

– 3 –

INTRODUCTION

Product model

Serial number

BFK808

CONCERNING THE TERM (PERIOD) OF SUPPLY OF REPAIR PARTS

The term (period) of supply of repair parts for this product shall be seven years after manufacturing is discon-tinued.

– 4 –

2 WARRANTY AND AFTER-SALES SERVICE

2. WARRANTY AND AFTER-SALES SERVICE

CONCERNING WARRANTY

Our company guarantees this product based on the guarantee certificate. For more information, refer to the guar-antee certificate attached to the end of this manual.

CONCERNING AFTER-SALES SERVICE

Please feel free to consult with the store of purchase or with our company's sales department in regard to serviceorders or in case trouble or questions arise during the course of using the unit.At such times, please be prepared to report the product model and product's serial number shown in the modellabel, as well as the names of the manufacturer and model of the engine installed. (For the names of the manufac-turer and model of the engine installed, refer to Chapter 5 "SPECIFICATIONS" in this manual. Page 11)

<Location of model label> <Model label>

CHIKUSUI CANYCOM. INC JAPAN

Location of label

SAFETY PRECAUTIONS BEFORE OPERATION

PROTECTIVE CLOTHING

Make it a rule to wear clothes suitable for driving and opera-tion. Do not be lightly dressed or do not wear sandals, etc. incarrying out driving and operation.

PRE-WORK CHECK

Carry out the daily pre-check before starting the machine.Repair or replace defective parts before use.

FUEL HANDLING

When handling fuel or grease, never bring fire (cigarette fire,etc.) to it. Also, be very careful of fire when charging the bat-tery or servicing the engine.

A FELLOW PERSON OR PERSONS MUST NOT RIDE ON THE VEHICLE.

This product is designed to allow only person to ride on it.Operation involving a fellow rider or riders is extremely dan-gerous, because movements of the center of gravity, etc.occur. Never allow a person or persons other than the opera-tor to ride on this vehicle.

– 5 –

3RULES FOR SAFE OPERATION AND WORK

3. RULES FOR SAFE OPERATION AND WORK

This chapter shows the general safety precautions to be observed during driving or operation. Try to carry outdriving or operation safely by being sure to follow the safety instructions in other chapters as well.

PRECAUTIONS WHEN DRIVING THE VEHICLE

PROHIBIT QUICK STARTING, ACCELERAT-ING,TURNING AND BRAKING

Avoid quick starting, sudden accelerating, sharp turns andbraking. Always drive safely. Before driving ensure the areaaround the machine is safe. On soft and wet ground never trysudden or sharp turning or stops, as this may cause themachine to slip or turnover.

OBSERVE SAFE SPEED

Drive at safe speeds in accordance with the road gradient,road surface conditions, and load.

ENGINE BRAKE ON DOWN HILL

When driving down a slope, stop once before going downand set the auxiliary speed shift lever to the "LOW" position.Use engine brake for deceleration. If stopping operation isdone without sufficient deceleration, the vehicle body couldrise and this is dangerous.

DO NOT DRIVE ACROSS SLOPES

On slopes go straight up or down within the limits ofmachine gradeability. Driving across slopes is dangerous.Also, on steep slopes, do not operate the side clutch lever.When it is unavoidable to operate the side clutch lever on asteep slope, operate it quickly and reliably while taking carenot to reverse the turn.

– 6 –

3 RULES FOR SAFE OPERATION AND WORK

PROHIBIT RECKLESS DRIVING

Do not drive when drinking alcoholic drinks or when yourphysical conditions are bad.Also, do not let unauthorized young people drive themachine.

PRECAUTIONS WHEN LOADING

DO NOT OVERLOAD

Do not load the machine with a load which exceeds the maxi-mum working capacity stipulated in the specification for thismachine.

CARE FOR TOTAL WEIGHT

When crossing a wooden bridge, etc., make sure that the totalof this product's machine weight and amount of load does notexceed the limit weight for a wooden bridge, etc. Then, passit carefully at a constant speed.

BE CAREFUL ABOUT THE AMOUNT OF LOADON SLOPES

On slopes from 15 to 20 , the load weight must be 600 kgor less. On steep slopes exceeding 20 , do not use thismachine. When it is used unavoidably, do not load thenachine with any loads.

PUT LOAD ON THE VEHICLE PROPERLY

Luggage must be placed evenly and fixed on the load-deck toprevent weight unbalance and then fix the load with a rope.In addition, be careful about the height of the load and takecare to ensure a good field of view.

– 7 –

3RULES FOR SAFE OPERATION AND WORK

FOLLOW GUIDE'S INSTRUCTIONS IN DAN-GEROUS PLACES

In places with a poor view and on narrow roads and roadswith a large gradient or with a lot of ups and downs, drive thevehicle after ensuring the safety completely in accordancewith the instructions given by a guide.

400 kg

15°-20°

3

ALWAYS APPLY BRAKES ON SLOPES

Avoid parking on slopes. If parking on a slope is unavoid-able, apply brakes and block stoppers.

SAFETY CONFIRMATION WHEN PARKING

When parking always apply brake and stop engine.Always remove key.

PRECAUTIONS WHEN SERVICING

DO NOT SERVICE WHEN THE ENGINE ISRUNNING

Do not service the vehicle while the engine is running.Always do service work after stopping engine.

PRECAUTIONS FOR VENTILATION

When operating the engine indoors make sure that there isenough ventilation to prevent poisoning due to exhaust gas.

– 8 –

RULES FOR SAFE OPERATION AND WORK

PRECAUTIONS WHEN PARKING

DO NOT PARK IN DANGEROUS PLACES

Park the machine on stable, flat ground. Avoid parking indangerous places.

NAME AND FUNCTION OF COMPONENTS

NAMES OF COMPONENTS

• Throttle lever .............................................This lever increases and decreases the engine speed.

• Side clutch lever ........................................This lever is used to change the direction. The machine turns to adirection to which the lever is pulled. Also, when the right and leftside clutch levers are pulled at the same time, the machine makes asudden stop at once.

• Travelling clutch lever ...............................This lever connects and disconnects motive power from the engineto the transmission. When the lever is tilted forward, a state of"travelling" is created. When it is tilted backward, a state of "stop-ping" is created.

• Parking brake lever ....................................This lever makes the machine parked securely. When the lever istilted forward, a state of "OFF (brake released)" is created. Whenit is tilted backward, a state of "ON (brake operated)" is created.

• Deadman's clutch pedal .............................This pedal connects and disconnects motive power from the engineto the transmission. When the pedal is pressed on, a state of "trav-elling" is created. When it is released, a state of "stopping" is cre-ated. This pedal is connected with the travelling clutch.

• Speed change lever ....................................This lever is used to select the travelling speed. To change thespeed, set the travelling clutch lever at "STOP" position and thestate of the machine stopping, and then, change the speed.

• Horn switch ...............................................When the horn switch is pressed, the horn sounds. This switch isused to give a warning when driving or give a signal for work, etc.

• Dump lever ................................................This lever is used to "raise" and "lower" the load-carrying deckbody.

Dump lever

Throttle lever

Speed change lever

ReverseChoke lever

Deadman's clutch pedal

Horn switch

Engine start switch

Forward

Travelling clutch leverParking brake lever

Side clutch lever

4NAME AND FUNCTION OF COMPONENTS

– 9 –

5 SPECIFICATIONS

– 10 –

5. SPECIFICATIONS

5.1 SPECIFICATIONS FOR THIS MACHINE

Use this product properly after understanding the specifications

for this product.

N O T E

BFK808M O D E L560

7.85(800)

2445

970

1860

975

680

160

515

1360

915

305

Mitsubishi GM291

80 59

296(296)

5.9/2000(8.0/2000)

4.4/1800(6.0/1800)

35.3/1400(3.6/1400)

Electric starter

Gasoline

320(235)

6000(6.0)

1200(1.2)

26A19R

12/26

Electronic ignition

BP5ES

kg

KN(kg)

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

cm3(cc)

M A C H I N E W E I G H T

MAXIMUM PAYLOAD CAPACITY

OVERALL LENGTH

O V E R A L L W I D T H

OV E R A L L H E I G H T

GROUND CONTACT LENGTH OF CRAWLER

C R AW L E R T R E A D

MINIMUM GROUND CLEARANCE

LOAD DECK FLOOR HEIGHTMA

CH

INE

DIM

ENSI

ON

SLO

AD D

ECK

DIM

ENSI

ONS INSIDE

DIMEN-SIONS OF LOAD DECK

LENGTH

W I D T HHEIGHT

Values shown in [ ] are dimensions when the safety rollover protection bar is installed.

EN

GI

NE

Air-cooled 4-cycle OHV gasoline

kW/min-2

(ps/rpm)

kW/min-2

(ps/rpm)

N.m/min-2

(kg.m/rpm)

g/kW.h(g/PS.h)

V/AH

M O D E L

T Y P E

CYLINDER (BORE STROKE)

TOTAL DISPLACEMENT

MAXIMUM OUTPUT

R A T E D O U T P U T

MAXIMUM TORQUE

STARTING SYSTEM

F U E L U S E D

RATE OF FUEL CONSUMPTION

FUEL TANK CAPACITY

ENGINE OIL CAPACITY

B A T T E R Y T Y P E

BATTERY CAPACITY

IGNITION METHOD

ITEM NUMBER OF SPARK PLUG

5SPECIFICATIONS

– 11 –

BFK808M O D E L1.6

3.3

5.1

1.5

3.0

4.7

1.5

25

3000(3.0)

Belt tension method

Gear slide

Dog clutch / wet type disc brake

Wet type disc brake

230 42 72

Hydraulic dump

Bucket

Gear pump

1500(1500)

112(6.7)

13.7(140)

60 200

63

about 5.0

about 4.0

1700(1.7)

km/h

km/h

km/h

km/h

km/h

km/h

m

degree

min-1(rpm)

cm3/s( /min)

MPa(kg/cm2)

mm

degree

sec

sec

TRAV

ELLI

NG

PER

FORM

AN

CE

TRAV

ELLI

NG

SPE

ED

FORW

ARD

REV

ERSE

PO

WE

R T

RA

NS

-M

ISS

ION

DE

VIC

ED

UM

P D

EV

ICE

HYDR

AULI

C PUM

PPE

RFOR

MANC

E

F IRST SPEED

SECOND SPEED

THIRD SPEED

FIRST SPEED

SECOND SPEED

THIRD SPEED

MINIMUM TURNING RADIUS

G R A D E A B I L I T Y

AMOUNT OF TRANSMISSION OIL

MAIN SPEED SHIFT TYPE

STEERING DEVICE TYPE

B R A K E T Y P E

C R A W L E R

D U M P S Y S T E M

L OA D D E C K T Y P E

C L U T C H T Y P E

*We reserve the right to change the specifications without prior notice.

T Y P E

RATED REVOLUTION

RATED DISCHARGE

RELIEF SET PRESSURE

CYLINDER (BORE × STROKE)

MAXIMUM TIPPING ANGLE

T I P P I N G T I M E

LOWERING TIMEHYDRAULIC OIL CAPACITY

1

2

3

1

1

1 set

Operator's manual (This document)

Instruction manual for engine

Engine tools For engine maintenance and repair

No. Part name Quantity Remarks

5.2 CONTENTS OF TOOL BAG

6.1 PREPARATIONS FOR OPERATION

6.1.1 Fuel Handling

1. Remove the lock clip for the engine cover.

2. Lift the handle of the engine cover with a hand and openthe engine cover.

Make sure that the engine cover does not fall down.

3. Check the fuel gauge visually. When the amount of fuel isinsufficient, open the fuel tank cap and supply fuel.

Fuel to be used: GasolineFuel tank capacity: 6.0 lit.

– 12 –

6 OPERATION

6. OPERATION

• Before reading this chapter, be sure to read "RULES FOR SAFE OPERATION AND WORK" in chapter 3( Pages 5 to 8).

• Concerning the operation and control, be sure to follow the instructions given in this chapter. If you do nothave a complete understanding of the operating and control system or safety devices, never operate themachine based on your own judgment.

• Petrol (gasoline) fuel is flammable. Neverrefuel or service the fuel system while smok-ing or when near open flames or sparks.

• Never refuel the machine when the engine isrunning.

• After stopping engine, the engine becomeshotter. Therefore fuel must be handled withgreat care when refueling. Do not spill fuel outof filler cap.

DANGER

N O T E

Lock clip

Fuel gauge

Fuel tank cap

2. Remove the lubricating plug (with level gauge).

3. Check the amount of engine oil (level). When the amount ofengine oil falls short of the specified value (level), supplyengine oil.

Engine oil level: Nick line on the level gauge(On the upper side)

– 13 –

6OPERATION

6.1.2 Inspection & Refilling Engine Oil

1. Open the lubricating plug for engine oil.

Lubricating plug

Nick line (On the upper side)

6

3. Set the speed change lever at the "Neutral" position.

4. Set the fuel cock for the engine at the "Open" position.

– 14 –

OPERATION

6.2 STARTING

1. Set the travelling clutch lever at the "Stop" position.

2. Set the parking brake lever at "ON" position.

5. Pull the choke lever to set it at the "Completely closed ( )"position.

When the engine is warm, it is not necessary topull the choke lever.

6. Set the throttle lever on the main body at an intermediateposition between "Low speed" and "High speed".

Reference:The throttle lever on the main body is connected to the throttle lever on the engine side through a throttle wire.

Parking brake lever Travelling clutch lever

open

Fuel cock

close

N

Choke lever

Throttle lever

Low speed

High speed

N O T E

– 15 –

6OPERATION

9. Return the choke lever to the "Completely open ( )" position and perform warming-up for three to five minutes.

•When the engine is not started, do not turn theself-star ting motor for five seconds or more continuously. Return the key to the operationposition and wait for about ten seconds, and then, restart the engine.

•Avoid frequent starting with the self-starter as muchas possible. When the self-starting motor isstarted, try to operate it continuously for a while to charge the battery.

•When the engine cannot be started with the self-starter (e.g. , the battery being dead), turn the keyswitch to the "Operation (ON)" position, and then, start the engine by using the starter knob.

•During the first one week (about 40 to 50 hours) after purchase, as a running-in period, perform operation moderately in such a way that excessiveload is not applied.

When the engine is turning, never turn the key switch to the "Start" position. If done, it may causethe self-starting motor to be damaged.

When starting the engine by using the starter knob:7. Grip the starter knob and pull it with vigor.

8. When the engine is started, return the starter knob slowly to the original position while holding it.

7. Insert the engine key and turn it to the "Start" position.

8. Move the throttle lever to the "Low speed" postion.

N O T E

CAUTION

Engine key

Starting

High speed

Low speed

Choke lever

Starter knob

6

4. Set the parking brake lever at the "OFF" position.

5. Press on the deadman's clutch pedal gradually and start the machine.

6. Stop the machine, and then, perform the steps 1 to 3 shown above. (For the procedure for stopping the machine, refer to 6.4 "STOPPING PROCEDURE". Page 18)

– 16 –

OPERATION

6.3 OPERATION PROCEDURE

1. Check the area around the machine for safety.

2. Make sure that the travelling clutch lever is in the "Stop" posi-tion and the parking brake lever is in the "ON" position.

3. Set the speed change lever at any arbitrary forward or backward gear position reliably. (For the travelling speed in eachgear position, refer to Chapter 5 "SPECIFICATIONS".

Page 10)

Parking brake leverTravelling clutchlever

F3 F2 F1

R3 R2 R1

Parking brake lever

Deadman's clutchpedal

F3 F2 F1

R3 R2 R1

DANGER

When speed changing (changing of gears) is doneincompletely, there could be a possibility of themachine being out of gear, thus creating a very dan-gerous condition. When it is difficult to engage thegears, do not do it forcibly. Instead, press on thedeadman's clutch pedal a little, and then, engage thegears properly.

N O T E

If the deadman's clutch pedal is pressedon quickly, the engine may stop.

(When changing the speed)

CAUTION

Speed changing cannot be done while travelling.Before speed changing is done, be sure to stop themachine completely.

– 17 –

6OPERATION

When making a turn to the left:7. Gradually pull the left side clutch lever toward this side.

The turn radius can be changed arbitrarily according to theforce (amount) to pull the slide clutch lever. When the sideclutch lever is pulled lightly, a gentle turn is made. When itis pulled strongly, a quick turn is made.

When making a turn to the right:7. Gradually pull the right side clutch lever toward this side.

The turn radius can be changed arbitrarily according to theforce (amount) to pull the slide clutch lever. When the sideclutch lever is pulled lightly, a gentle turn is made. When itis pulled strongly, a quick turn is made.

(When making a turn)

Side clutch lever (Left)

Side clutch lever (Right)

When the right and left side clutch levers areoperated at the same time, the machine makesa sudden stop. Therefore, do not operate them at the sametime except in case of an emergency.

Quick turns are dangerous because they couldcause the operator to be thrown out of themachine or cause the machine to turn over.

DANGER

CAUTION

OPERATION

4. Turn the engine key switch to the "Stop (OFF)"position to stop the engine.

5. Pull out the key.

If the key switch is left in the "ON" position, a current continues to flow from the battery toeach circuit, causing the battery to go dead.

If the key switch is left in the "ON" position, a current continues to flow from the battery to each circuit, causing the battery to go dead.

6. Close the fuel cock.

66.4 STOPPING PROCEDURE

1. Set the throttle lever at the "Low speed" positionto decelerate speed of the machine.

2. Move the foot off the deadman's clutch pedal toreturn it to the original position.

3. Set the parking brake lever at the "ON" position.

In case of an emergency, pull the travellin gclutchlever and parking brake lever toward this side atthe same time, or pull both the right and left sideclutch levers toward this side at the same time. The machine will make a sudden stop. For inform- taion, the machine may rise on slopes, and there-fore, take great care.

Engine key

Stopping

Deadman's clutch pedal

Low speed

High speed

– 18 –

CAUTION

N O T E

N O T E

safety of the surrounding area.

Dump operation on steep slopes is very dangerousbecause it makes the machine unstable. When dumpoperation is unavoidably performed on a downhill road, use the machine by putting a forest tree, etc. on thetravelling section to make the machine horizontal.

When the load-carrying deck body is lowered in theloaded condition, lower it slowly with the engine speeddecreased in order not to apply shocks to the machine.

6.5.1 Deck Lifting/Lowering

• Dump operation should be carried out with theengine started without fail.

• The load-carrying deck body goes up or down asshown in the figure.

(When lifting the load-carrying deck body)1. Release the lock plate for the dump lever.

2. Tilt the dump lever to the "Up" position.

3. When the load-carrying deck body goes up to the upperlimit, a relief sound (whizzing sound) is made. Therefore, return the dump lever to the neutral positionquickly.

(When lowering the load-carrying deck body whichhas been lifted)

1. Release the lock plate for the dump lever.

2. Tilt the dump lever to the "Down" position.

3. When the load-carrying deck body goes down to the lowerlimit, return the dump lever to the neutral position quickly.

– 19 –

6OPERATION

6.5 DUMP OPERATION

• When checking the area under the load-carryingdeck body, etc. with the load-carrying deck bodyraised, support the load-carrying deck body reliablyby using the load-carrying deck body drop preven-tion safety prop which is installed on the main body, in order to prevent dangers.

• When the dump is operated, be sure to cofirm the

Dump lever

Load-carrying deckbody drop preven-tion safety prop

Dump lever

up

down

Lock plate

Dump lever

Release

DANGER

WARNING

CAUTION

N O T E

7 MAINTENANCE

– 20 –

7. MAINTENANCE

7.1 REGULAR INSPECTION CHART

Proper inspection/maintenance will prevent accidents and breakdowns. To maintain the machine's normalfunction and ensure daily safe operation, carry out the regular inspection according to the chart below.The regular inspection consists of the yearly, monthly and daily pre-operation checks.

The chart below includes inspections which require technical

knowledge or specified tools and measuring instruments. As to

difficult inspections for the user, consult the dealer or one of our

service centers.

N O T E

Item Content RemarksTiming

Pre-o

p

Yearl

yMo

nthly

Eng

ine

Bod

y

Starting

Eng.speed

Exhaust

Air cleaner

Tightening

Valve clearance

• Check if engine starts smoothly and makes abnormal noise.

• Check if engine speed is proper at idling and unloaded max. speed. Check for smooth operation.

• Accelerate engine and check for axle lever drag, engine stall, and knocking.

• After warming up engine, run engine from idling to high speed and check exhaust gas color and noise.

• Check for gas leak from muffler, exhaust pipe, etc.

• Check case for crack and deformation, looseness at lid or connecting pipe.

• Check element for dirt and damage.

• Check cylinder head and manifold retaining bolts/nuts for looseness.* This check is not necessary if no gas or water leak is found at these areas.• Check valve clearance.* This check may be omitted if there is no abnormal noise due to abnormality in the valve clearance and the engine is turning smoothly.

Smooth start. No abnor-mal noise.

Proper engine speed. Smooth and continuous engine operation.

No drag, engine stall, or knocking

Normal exhaust gas color/noise

No gas leak

No crack or deformation in case. No looseness at lid and pipe.

No severe dirt. No damage.

No looseness

Proper valve clearance

Request dealer for inspection.

Cleaning/Replacement: Page 30


7MAINTENANCE

– 21 –


Pre-o

p

Yearl

yMo

nthly

Bod

y

Eng

ine

Fuel system

Compre-ssing pressure

Engine mount

Lubricating system

• Check compression pressure.* This check is dispensable if no abnormality is found in engine operation and exhaust condition at idling and acceleration.

• Check engine base for crack and deformation.

• Check bolts and nuts for looseness or missing parts.

• Check rubber vibration isolator for damage and deterioration.

• Check oil amount and contamination.

• Check head cover, oil pam, and pipes for oil leak.

• Check fuel tank, injection pump, hose, pipe, etc. for fuel leak.

• Check fuel hose for damage and deterioration.

• Check fuel filter element for dirt and clogging. • Check the injection pressure of the injection nozzle and check the injection nozzle for abnormality in the spray condition.* This inspection may be omitted if there is no abnormality in the rotation condition and exhaust condition during idling and during acceleration.

Proper pressure

No crack or deformation

No looseness or missing parts

Proper amount. No severe dirt.

No damage or deterioration

No severe oil leak.

No fuel leak

No damage or deterioration

No noticeable dirt or clogging

Proper injection pressure. Normal spray.

Request dealer forinspection.

Inspection/Replacement: Page 26

Cleaning: Page 32


7 MAINTENANCE

– 22 –


Pre-o

p

Yearl

yMo

nthly

Ele

ctri

cal

Eng

ine

Charging apparatus

Battery

Wiring harness

V belt

Travellingclitch

Pow

er tr

ain

Dri

ving

sys

tem

Transmission

Side clutch

Sprocket, idler, roller, upper roller

Crawler

• By using an ammeter, check the charging apparatus for abnormality of the function.

• Check electrolyte amount.

• Check terminal for looseness and corrosion.

• Check connection for looseness.

• Check wiring harness for damage.

• Disengage the clutch in the idling condition and check for abnormal nnoise. At the same time. check the state of clutch disengagement by changing gearsin the transmission.

• Check appearance for damage and dirt.

• Engage the clutch gradually to check the state of starting.

• Drive machine with speed change lever set at forward or reverse position. Then, check operating condition and check for gear disengagement, abnormal noise and overheat.

• Check oil amount in case.

• Check oil contamination.

• Check oil leakage in around case .

• Drive machine and check if side clutch lever works properly with no noise when it is operated.

• Operate lever and check if play and pulling allowance are proper.

• Operate lever and check rod, link, bearing section, and connection for play and check each pin for rusting.

• Check for crack, deformation, and wear.

• By driving the vehicle, check for abnormal noise in the shaft section and abnormal generation of heat.

• Check bolts and nuts for looseness and check if they are missing.

• Check for oil leak from the area around the shaft section.

• Check steel cord for cutoff and damage.

• Check rubber for chip, deterioration, and wear.

• Check if core bar is missing and check it for breakage.

• Check crawler tension.

Normal operation

Proper amount

No looseness or severe corrosion

No looseness

No damage

No damage and grease deposit

Smooth engagement without slipping

Normal operation. No gear disengagement, abn-ormal noise or overheat.

No abnormal noise and complete clutch disengagement

Proper amount of oil

No noticeable contamination

No oil leak

Proper operation with no noise

Proper play and pulling allowance

No play or rusting

No crack, deformation, or noticeable wear

No abnormal noise or abnormal generation of heat

No looseness or no missing bolts and nuts

No oil leak

No cutoff or noticeable damage

No noticeable chip, deterioration, or wear

No missing core bar

No looseness or excessive tension


Inspection/Refilling:　 Page 30

Adjustment: Page 33

Adjustment: Page 33

Inspection: Page 32

Inspection/Replacement: Page 27Inspection/Replacement: Page 27

Adjustment: Page 35

Adjustment: Page 34

7MAINTENANCE

– 23 –

• Check each section for crack, deformation, and wear.

• Check tension bolts for deformation and corrosion.

• Check for crack, deformation, and damage.

• Check rod/link/wires for damage and looseness at connection.

Item RemarksTiming

Pre-o

p

Yearl

yMo

nthlyContent

Drivi

ng sy

stem

Bra

ke

Crawler tension bolt

Vahicle body

Parking Brake

Rod, link, andwires

Power package

Load-deck(Bucket)

Loa

ding

sys

tem

Hyd

raul

ic s

ystm

• Check package body for oil leak.

• Put machine in a horizontal place and check oil amount.

• Check oil for contamination.

• Check breather for clogging.

• Check if brackets are fitted properly, and check bolts and nuts for looseness and check if they are missing.

• Check joint with hose and seal section for oil leak.

• Operate package and check for abnormal vibration, noise, and overheat in the no-load and loaded conditions.

• Load package and check discharge amount and discharge pressure during loading.*This inspection may be omitted if no abnormality is found in the inspection in the previous paragraph.

• Check bolts for looseness and check if they are missing.

•Raise and lower the load-deck and check pins attaching the frame to load- deck, dump cylinder attaching pins, etc. for play.

• Drive machine and check brake to see how effective it is.

• Check if machine can be maintained in the stopped condition on inclined floor surface in no load state.• Operate lever repeatedly and check pulling force and return condition.

• Repeatedly operate brake, and check connection for looseness and play and check for damaging split pins.

No deformation andcorrosion

No crack, deformation, or damage

Proper brake effect

Proper brake effect

Normal pulling force or return condition

No damage or looseness

No looseness or play at connection and no damaging split pin

No crack, deformation, and wear in each section

No looseness and no missing bolts

No noticeable play in each pin section

No oil leak

Proper oil amount

No noticeable contamination in oil

No clogging

No abnormal vibration, noise, and overheat

Within the criteria

No oil leak

Proper fitted condition. No loose or missing bolt and nut.

Adjustment: Page 33

Adjustment: Page 33

Inspection/Refilling: Page 28

Inspection/Refilling: Page 28


7 MAINTENANCE

– 24 –

7.2 OIL/GREASE/LUBRICANT/FLUID LIST

Item

Fuel

Engine oil

Transmission oil

Battery fluid

Timing Recommendation Amount Reference page

Power package oil(For hydraulic dump)

Roller, upper roller, and idler wheel

Each sliding section

As necessary.

Add: Check daily andadd as necessary.Replace: 1st: 50 operating hours 2nd or later: every 100 operating hours

Replace: 1st: 50 operating hours 2nd or later: every 500 operating hours

Check every 100 operatinghours and add as necessary.

Every six months* No need for greasing for the first 6 months after purchase Every six months* No need for lubrication for the first 6 months after purchase Check every month andadd as necessary.

gasoline

10W30(SD or higher grade)

Gear oil: API class GL4 or higher, and suitable for wet type disc brake

ISO : VG32Turbine oil ( ) JIS : #90

Chassis grease

Gear oil ( ) API class GL4 or 5SAE class #80

Distilled water

Page 10

Page 27

Page 26

Page 28

Page 29

Page 29

Page 31

For details, refer to the instruction manual for engine.

7MAINTENANCE

– 25 –

7.3 CONSUMABLES (SERVICE PARTS) LIST

Rubber products, such as hydraulic hose, are consumableswhich age even if they are not used. Replace them with newones every two years or when they are damaged.

N O T E

Item Part No. Quantity Refernce pageReplacement timing

Air cleaner element

Fuel filter

V-belt

Brake lining(Steel plate)

Battery

Crawler

Parts, other than the above, which seem to require replacement as a result of inspection

08521300045 (E/G - intermediate)

08520000077 (Intermediate - T/M)

08521300033(E/G - P/P)

73104012000

34070501000

36592011000

Every one year (Or after cleaning is done six times)

Check every 100 operating hours and replace as necessary.

Replace if malfunctioning.




Consult the dealer (or one of our service centers).

1

1

2

2

2

2

1

1

(The entire set is replaced.)

Request dealer forreplacement.



Page 34

Page 32

– 26 –

7 MAINTENANCE

7.4 LUBRICATION

Insufficient or improper lubrication not onlycauses the machine to fail to achieve smoothturning but also causes it to break down, short-ening the life of the engine. Therefore, fill themachine with the right amount of designatedgood quality oil on a regular basis.

N O T E

7.4.1 Engine Oil

Inspection/Refilling1. Open the lubricating plug for engine oil.

2.Visually check the amount (level) of engine oil andcheck the engine oil for dirt.When the level shownbelow is not reached and when the engine oil is verydirty, supply or replace engine oil.

Engine oil level: Nick line on the level gauge(On the upper side)

Oil to be used: Page 24

3. Replace the lubricating plug.

Replacement1. Prepare a suitable pan to collect drainded oil.

2. Remove the oil drain plug and drain oil from thecrankcase.

CAUTION

Hot oil can cause burns.

N O T E

Properly dispose of drained oil.

3. Replace the oil drain plug.

4. Open the refueling cap and pour the designated oil.(Refer to "Inspection/Refilling" shown above.)

Lubricating plug

Nick line (On the upper side)

Oil drain plug

– 27 –

7MAINTENANCE

Dump operation should be carried out with the engine started without fail.

Inspection/Refilling

N O T E

1. Lift the load-carrying deck body. ( Page 19)

2. Support the load-carrying deck body reliably by using the load-carrying deck body drop prevention safety prop. ( Page

19)

3. Stop the engine.

4. Remove the safety cover.

5. Remove the lubricating oil plug.

6. Visually check the amount of oil and check the oil for dirt.When the amount of oil is insufficient (i.e., oil has not reached the oil checking port) and when the oil is very dirty, supply orreplace oil.


7. Replace the lubricating plug.

8. Replace the safety cover.

CAUTION

Hot oil can cause burns.

N O T E



4. Open the refueling cap and pour the designated oil.(Refer to "Inspection/Refilling" shown above.)

Replacement1. Prepare a suitable pan to collect drainded oil.2. Remove the oil drain plug and drain oil.

Reference:When the lubricating plug is removed,oll can bedrained more easily.

7.4.2 Transmission Oil

7 MAINTENANCE

– 28 –

7.4.3 Power Package Oil (Oil for Hydraulic Dump)

When the amount of oil decreases, air entersthe hose and cylinder, making the tipping of thedump bad. Therefore, check oil every 100 oper-ating hours.

1. Stop the machine in a horizontal place. (Put the load- carrying deck body in a lowered condition.)

2. Remove the lubricating oil plug (with oil checking rod).

3. Check the amount of oil visually. When the amount ofoil is insufficient, open the refueling cap and supply oil.

4. Replace the lubricating oil plug.

5. Start the engine and circulate oil.

Replacement1. Prepare a suitable pan to collect drainded oil.2. Remove the oil drain plug and drain oil.

N O T E



4. Open the refueling cap and pour oil.(Refer to "Inspection/Refilling" shown above.)

Inspection/Refilling

N O T E

N O T E

When the engine is started and the load-deckis raised, knocking occurs initially because airis contained. After two or three repetitions,however, a normal state is achieved.

Oil to be used: Page 24Amount of oil: 1.7lit

Refueling cap

Drain Plug

Grease to be used: Page 241. Apply grease to the areas indicated in the figures by

using a commercially available manual grease pump or pneumatic grease pump.

Reference:When a manual grease pump is used, strike it five to sixtimes. When the pump handle becomes heavy halfway, stop greasing at once. When a pneumatic grease pumpis used, a few seconds are enough.

2 Travelling clutch lever fulcrum

3 Parking brake lever fulcrum

4 Travelling clutch tension arm fulcrum

5 Hydraulic tension arm fulcrum

6 Dump lever fulcrum

Grease the areas shown below.


1 Intermediate fulcrum of side clutch

2 Load-carrying deck body fulcrum(One-way dump --- One place)

– 29 –

7MAINTENANCE

Insufficient or improper greasing and lubrication cancause seizure or rust, making it difficult to achievesmooth turning and operation. Therefore, carry outgreasing and lubrication periodically.

7.5.2 Each Sliding Section

Lubricate the areas shown below.Oil to be used: Page 24

1 Side clutch lever fulcrum

Upper roller

Roller

Idler wheel

Load-carring deck body fulcrum

N O T E

7.5 LUBRICATION AND GREASING

7.5.1 Roller, Upper Roller, and Idler Wheel

Two other places

7

7.7 CLEANING7.7.1 Air Cleaner Element

Make sure to clean the air cleaner element on a regular basis (every 100 hour operation). A severely contami-nated aer cleaner element will badly affect engine start-ability, power and life.

Cleaning/Replacing1. Open the engine cover. ( page 12)

2. Remove the air cleaner cover.

3. Remove the inside air cleaner element.

4. Clean the air cleaner element by referring to the attached"Instruction manual for engine".

– 30 –

MAINTENANCE

7.6 SUPPLY OF WATER7.6.1 Battery Fluid

Inspection/Refilling1. Lift the load-carrying deck body. ( Page 19)

2. Check the amount of battery fluid visually. If necessary,supply battery fluid.

Amount of battery fluid: Between the reference lines(Upper and lower)

Battery fluid: Distilled water

Battery

Air cleaner cover

N O T E

– 31 –

7MAINTENANCE

Degree of burning

Damage BreakageWear, car-bon deposit

7.7.2 Spark Plug

Inspection1. Remove the spark plug cap.

Do not pull on the cable when removing thespark plug cap. Always hold the cap body.

N O T E

2. Remove the spark plug using a plug wrench.

3. Check the plug for the following points and clean orreplace it as necessary. (Specifications for spark plug :

Page 10)• Presence or absence of breakage of the insulator• Worn electrode• Carbon deposit • Damage to and breakage of gasket• Degree of burning of insulator in spark section

Cleaning1. Clean the spark plug using a wire brush or plug cleaner.

2. Grind the electrode with sandpaper to adjust the gap asspecified.

Standard clearance : 0.7 mm

3. Replace the spark plug.

Ignition plug capIgnition plug

7

2. Visually check the V belt for damage. If any damage isfound, replace the V belt.

ReplacementRequest dealer for replacement.

– 32 –

MAINTENANCE

7.7.3 Fuel Filter

1. Make sure that the fuel cock is in the "Close" position.

2. Remove the strainer cup. Then, remove deposits in the cupand remove dirt adhering to the filter nut. (Clean the fuelfilter by referring to the attached "Instruction manual forengine".

When the filter net is holed, replace it with a new one.

7.8 ADJUSTMENT

7.8.1 V Belt

Inspection1. Remove the safety cover.

Safety cover

(Engine V belt)

(Transmission V belt)

N O T E

7.8.3 Parking Brake

– 33 –

7MAINTENANCE

7.8.2 Travelling Clutch


2. Support the load-carrying deck body reliably by using theload-carrying deck body drop prevention safety prop. ( Page 19)

3. Stop the engine.

4. Remove the cover.

5. Set the travelling clutch lever at the "Stop" position and put the

6. Loosen the locknut for the brake wire.

7. Turn the adjusting nut to adjust the parking brake wire.

clutch wire in a free condition.

6. Loosen the locknut for the clutch wire.

7. Turn the adjusting nut and adjust the clutch wire.

• When the travelling clutch disengagement is bad:Turn the adjusting nut in the direction of (b).

•When the V belt slips:Turn the adjusting nut in the direction of (a).

8. After adjustment, tighten the locknut securely.


2. Support the load-carrying deck body reliably by using theload-carrying deck body drop prevention safety prop. ( Page 19)

3. Stop the engine.


5. Set the parking brake lever at the "OFF" position and put thebrake wire in a free condition.

Cover

Locknut

Adjusting nut

Clutch wire

Cover

Locknut

Adjusting nut

Parking brake wire

N O T E

When the effectiveness of the brake hasdecreased even a little, make the followingadjustment immediately, trying to ensuresafety at all times.

7

When the amount of play has become large inthe side clutch lever, adjust it with the turnbuckle. The adjustment of play is little necessary except when the transmission is removed and installed and when the rods are overhauled. When theturning is faulty, first adjust the brake adjust bolt for the transmission shown on page 35.


2. Loosen the locknut for the turnbuckle.

3. Adjust the side clutch lever play by turning the turnbuckle.

Side clutch lever play:5 to 10 mm (in the lever grip section)

Reference:The amount of play in the lever decreases when the turnbuck-

le is turned in the direction in which the rod contracts.

4. After adjustment, lock the turnbuckle securely with thelocknut.

7.8.5 Adjustment of Deadman's Clutch Pedal


2. Loosen the locknut for the turnbuckle. Then, adjust thedeadman's clutch pedal by means of the turnbuckle insuch a way that the travelling clutch touches the stopper with the deadman's clutch pedal pressed on asshown in the left figure.

3. After adjustment, tighten the locknut.

– 34 –

MAINTENANCE

• When the effectiveness of the brake is bad:Turn the adjusting nut in the direction of the arrow, adjustthe brake in such a way that with the brake in the "OFF"position, the spring connecting the transmission with thebrake wire stretches by about 3 to 5 mm.

8. After adjustment, tighten the locknut securely.

7.8.4 Side Clutch

Adjustment of slide clutch lever play

sefety cover

Locknut

Adjusting nut

Parking brake wire

Locknut Locknut

Turnbuckle

Side clutch rod

Turnbuckle

N O T E

Locknut

Stopper

Turnbuckle

Deadman'sclutch pedal

Side clutch rod

7MAINTENANCE

– 35 –


Lock nut

6. Turn the brake adjust bolt in the direction of (a).

7. After adjustment, be sure to tighten the locknut.

7.8.6 Crawler Tension

When the crawler is new, initial elongation adjust-ment is required. Looseness is arising by fittingwith the sprocket as the travel distance increases .Crawler tension which is not normal causesdetracking or the crawler life to be shortenednoticeably.

1. Place the vehicle body in a horizontal place.

2. Lift the crawler on one side parallel to the ground byjacking-up or other means.

N O T E

3. Loosen the locknut for the crawler tension bolt.

4. By turning the crawler tension bolt, adjust the clearancebetween the crawler and the roller [as shown in (a)] toabout 15 to 20 mm.

Adjustment of Brake Adjust Bolt for Transmission

When the side clutch disengagement is improper(i.e., when the side clutch gear is disengaged andthe crawler does not stop), adjust the side clutch with the brake adjust bolt for the transmission.


2. Support the load-carrying deck body reliably by using the load-carrying deck body drop prevention safety prop. ( Page 19)

3. Stop the engine.


5. Loosen the locknut for the brake adjust bolt.

N O T E

Adjust bolt

Adjust bolt

Cover

7 MAINTENANCE

– 36 –

•


2. With the travelling clutch lever set at the "Travelling" posi-tion, set the spacing (a) between the travelling V belt andthe belt stopper at about 5 to 6 mm and the spacing (b) at about 10 to 20 mm.

With the travelling clutch lever set at the "Travelling"position, secure 5 mm or more for the clearancebetween the belt stopper and other V belts.

7.8.7 Belt Stopper

• One of the causes of incomplete disengagementthe clutch is poor adjustment of the belt stopper. When the belt stopper is removed in the belt repla-cement, etc., adjust the belt stopper as shown below.

Engine pulley

Belt stopper

Travelling clutch lever set at "Travelling" stateTension pulley

Package pulley

Belt stopper

Intermediate pulley

Tension pulley

Transmission pulley

Tension pulley

Travelling clutch lever set at "Stop" state

N O T E

N O T E

7MAINTENANCE

– 37 –

7.9 AFTER-USE MAINTENANCE

(Normal use)

• Remove all dirt, water and foreign objects fromthe body. Do not use water to wash the engine andoperation panel. Water will damage parts andcause rust built up.

• When the vehicle is left outdoors, it is effective toput a waterproof cover, etc. on it.

(In cold season)

• Remove all dirt, water and foreign objects fromthe body. Any remaining dirt will freeze and cause malfunctions. Place the vehicle on a concrete floor,dry firm ground or wooden blocks. (In extremelycold districts, it is effective to place sleepers, etc., at right angles to the vehicle body, under thecrawlers.)

If the vehicle freezes do not operate,do not force movement. Melt ice with(hot) water or wait until the vehicle isnot frozen. Please take special notethat our company will not take theresponsibility for any failures caused byforced movements.

• When the vehicle is left outdoors, it is effective toput a waterproof cover, etc. on it.

N O T E

8.1 VEHICLE BODY

1. Loosen the crawler tension bolt. ( Page 35)

2. Clean the external surface with an oil-soaked cloth and lubri-cate the rotating sliding sections.

3. Place plates, etc. under the crawler.

4. Set the travelling clutch lever at the "Stop" position and theparking brake lever at the "OFF" position.

5. Remove the engine key.

8.2 BATTERY

When disconnecting the battery cables, discon-nect the minus (-) one first, and then, disconnectthe plus (+) one. When connecting the batterycables, connect the plus (+) one first, and then,connect the minus (-) one.

1. Remove the battery from the body (vehicle).

2. Check the battery fluid level and add fluid as necessary. ( Page 30)

3. Store the battery in a dry area with low temperature.

Notice:Although the battery could be used without any recharges forapproximately 6 months, it would be recommended torecharge before discharge for the battery's longer life.

CAUTION

– 38 –

8 STORAGE (LONG TERM)

8. STORAGE (LONG TERM)

When storing the vehicle for a long time, appropriate maintenance is required for future use. After performing theafter-use maintenance ( Page 47), follow the instructions below.

Do not store the vehicles, battery, or fuel near open flames or in

a high temperature area. Doing so may cause accidental fires.

DANGER

Do not store the vehicle in a damp or dusty place. Be sure to

put a cover (vinyl sheet, etc.) on the vehicle after the engine

has become cool.

N O T E


Locknut

Battery

8.3.2 Cleaning Air Cleaner Element

1. Open the engine cover.( Page 12)

2. Remove the air cleaner element and thoroughly cleanit.( Page 30)

8.3.3 Replacing Engine Oil

1. Drain all engine oil and refill engine with new engine oil.( Page 26)

– 39 –

8STORAGE (LONG TERM)

8.3 ENGINE

For details of the long-term storage of theengine, refer to the attached "Instructionmanual for engine".

1. Turn the fuel cock to CLOSE to stop fuel supply.

N O T E

Reference:

All the illustrations on this page show the Kubota EA8 type engine.

8.3.1 Fuel Cock

Fuel Cock

Air Cleaner

Oil Drain Plug

9 TROUBLESHOOTING

– 40 –

9. TROUBLESHOOTING

• If any malfunction or abnormal operation is found, immediately stop using the machine and make an appropri-ate repair referring to the troubleshooting chart shown below. If the malfunction is not listed in the chart or thesuggested repair does not solve the problem, consult your dealer or one of our service centers.

• Some repair contents require specialized service knowledge. Request your dealer or one of our service centersfor such repairs.

9.1 TROUBLESHOOTING CHART

Area Malfunction Possible cause Corrective action

Engine

Engine does not start or is hard to start.

Engine stalls soon.

Engine stops abruptly.

Improper idling(Irregular engine speed)

• Lack of fuel• Entry of air into fuel

• Insufficient capacity of battery (Poor starting of self-starting motor)

Replenish. ( Page 12)

Replenish battery fluid. ( Page 30)

Charge battery.

Replace battery. ( Page 38)

• Detachment or disconnection of battery terminal (In the case of the self-starter engine)

• Engine oil insufficiency or poor quality

• Others (Other than the above)

Repair. (Ask dealer to repair.)


Try to start the engine again in accordance with the procedure shown in 6.2 "Starting" in Chapter 6 of this manual. When starting is impossible, ask dealer to repair.

• The fuel cock is not opened.

• Insufficient fuel

Open the fuel cock.



Consult dealer

• No fuel

• Burn due to insufficient or deteriorated engine oil

Check and add oil. ( Page 26)

9TROUBLESHOOTING

– 41 –


Engine

Poor power or acceleration

Abnormal noises or vibrations are made in or around the engine.

Rapid engine oil consumption

Engine overheating

Rapid fuel consumption

Excessive black smoke (Abnormal exhaust)

White smoke or blue smoke comes out. (Abnormal exhaust)

• Engine oil leak

• Insufficient engine oil

Adjust

Consult dealer

Reduce loading.

Throttle lever scratches.

• Looseness of V belt

• Improper adjustment of throttle

• Excessive loading

• Deterioration of engine mount

• Others

• Fuel leak from fuel system

• Clogged air cleaner

• Clogged air cleaner

• Improper fuel

• Poor compression

• An excessive amount of engine oil is put in.

• Oil viscosity is too low.

• Worn cylinder or piston ring

Replace (Consult dealer)

Consult dealer

Check and repair.


Check and repair. (Consult dealer)

Clean or replace. ( Page 30)

Clean or replace. ( Page 30)

Replace fuel. ( Page 12)


After checking, adjust oil volume. ( Page 29)

Replace oil with proper oil




• Breakage or rusting of throttle wire

• Deformation or malfunction of throttle lever

9 TROUBLESHOOTING

– 42 –


Crawler

Brake

Crawler does not turn smoothly.

The mchine does not move even when the clutch is let in.

Clutch disengagement is bad.

The V belt slips when the clutch is let in.

Abnormal noise is made near the transmission.

Gears cannot be shifted.

Gears disengage.

The side clutch has play.

Turning cannot be done smoothly.

Not effective

• Gears are not changed (shifted) reliably.

• Application of the brake is effective.

• V belt has come off or is too loose.

• Failure of transmission

• Improper adjustment





• Damaged gear or worn bearing

• Improper adjustment of clutch

• Damaged gear or worn bearing

• Gears are not changed (shifted) reliably.

• Worn gear


• Worn steel plate

• Oil penetrates within brake drum.


• Loosened adjusting nut

Change (Shift) gears reliably.

Release the brake.

Put the V belt on or adjust it.

Consult dealer

Consult dealer

Consult dealer

Consult dealer

Adjust( Page 33)

Adjust( Page 33)

Adjust( Page 33)

Adjust( Page 34)

Adjust( Page 34)

Adjust( Page 43)

Adjust( Page 33)

Change (Shift) gears reliably.

Reduce loading.

Replace steel plate. (Request dealer to replace.)

Reduce loading.

Replace oil seal. (Consult dealer)

Power train

9TROUBLESHOOTING

– 43 –


Dump device

Dump does not operate. • Power package oil is improper.

• Oil leak from hydraulic system

Lubricate.

Check and repair.

Idler wheel, roller, and upper roller

Discontinuous noises are made.

Abnormal generation of heat

Replace defective parts. (Request dealer to replace.)

Replace defective parts. (Request dealer to replace.)

Idler wheel upper roller

roller

10 TRANSPORTATION OF/WITH THIS VEHICLE

– 44 –

10. TRANSPORTATION OF/WITH THIS VEHICLE

When loading and unloading the machine onto or from truck, follow the procedures below.

1. Prepare running boards with enough strength (durable to hold both machine and driver's weight), width (morethan 1.2 times as wide as the crawler), length (more than three times as long as the height), and abrasive sur-face. Place the boards as shown below so that the boards firmly keep their positions even when the machinerides on them.

2. Securely hook the running boards to truck so that there is no difference in height between the boards and thetruck's load-deck.

3. During loading and unloading, the operator should get off this machine and perform the operation.

• Do not allow any one to come near the machine, truck, and

running board while loading or unloading the machine.

• Do not turn on the running boards. The machine may drop

off the running boards.

• When going up the running board, travel slowly in first gear,

forward. When going down the running board, travel slowly in

first gear, backward.

DANGER

When the machine is loading on the place between the truck

and the running board, beware of the machine's center of gravi-

ty because it may move suddenly.

CAUTION

MORE THAN 3 TIMES AS LONG AS HEIGHT

Hei

ght

off-road rubber track dumper bfk808 · 2013. 10. 17. · this machine fits into the off-road rubber...

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