YANMAR C12R-A C30R-2A C50R-3B OPERATION & MAINTENANCE MANUAL - PDF DOWNLOAD

CRAWLER CARRIERS OPERATION & MAINTENANCE MANUAL (GB) Models: C12R-A

Published: 18/04/2007

C30R-2A

C50R-3B

p/n°: LGBBFC-00000

AMMANN - YANMAR THANK YOU FOR PURCHASING YANMAR CONSTRUCTION MACHINERY INTRODUCTION •

Read this manual carefully to learn how to operate and service your machine correctly.

•

Failure to do so could result in personal injury or equipment damage.

•

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

•

This machine is of metric design, and consequently the measurements in this manual are also metric.

Use only metric hardware and tools as specified.

•

Right and left-hand sides are determined by facing in the direction of forward travel.

•

Warranty is provided as a part of Yanmar’s product support program for customers who operate and maintain their equipment as described in this manual. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements under warranty may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

•

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. Ammann-Yanmar reserves the right to modify the information and illustrations in this manual without notice. For additional information, contact your authorized Ammann-Yanmar distributor.

•

The images in this book are provided as a rough guide and may vary according to the models.

CAUTION •

Never attempt to operate or service this machine until you have first read and understood all of the applicable Safety instructions that are set forth in this Manual.

•

The failure to comply with all relevant Safety instructions could result in bodily injury.

•

To assure that this Manual will be conveniently available to future users, always return it to storage compartment, when it is not being used.

REFERENCE INFORMATION Write the correct information for your YANMAR machine in the spaces below.

Always use these numbers when referring to your YANMAR machine.

Model name

:

Serial Number

:

Engine Serial Number

:

Your YANMAR Machine Dealer

:

Address

:

Phone

:

CONTENTS 1. Introduction ..................................................................................................................... 9 2. Safety information ........................................................................................................ 10 3. Product overview and regulation ................................................................................ 11 3.1 3.2

Intended uses ..................................................................................................................... 11 Operation license ................................................................................................................ 11

4. Ordering replacement parts and service call ............................................................. 12 4.1 4.2 4.3 4.4

Location of machine serial number plate ............................................................................

Location of engine serial number plate ...............................................................................

Location of the EPA identification plate ..............................................................................

Ordering replacement parts and service calls ....................................................................

12 12 12 12

SAFETY 5. Basic precautions ......................................................................................................... 15 6. Operating precautions ................................................................................................. 20 6.1 6.2 6.3 6.4 6.5 6.6 6.7

Break in period ...................................................................................................................

Precautions before starting the engine ...............................................................................

Precautions when traveling ................................................................................................

Precautions when working ..................................................................................................

Precautions for parking .......................................................................................................

Precautions for transportation ............................................................................................

Precautions for the battery .................................................................................................

20 20 21 23 25 25 27

7. Precautions for servicing ............................................................................................ 28 7.1 7.2 7.3

Precautions before servicing .............................................................................................. 28 Replacing essential parts periodically ................................................................................ 28 Precautions during servicing .............................................................................................. 31

8. Safety messages (warning labels) .............................................................................. 34 8.1 8.2 8.3

Location of warning labels C12R-A .................................................................................... 35 Location of warning labels C30R-2A .................................................................................. 39 Location of warning labels C50R-3B .................................................................................. 42

OPERATION 9. Identification of important parts ................................................................................. 49 9.1 9.2 9.3 9.4 9.5 9.6

Overview of the machine C12R-A ......................................................................................

Controls and switches C12R-A ...........................................................................................

Overview of the machine C30R-2A ....................................................................................

Controls and switches C30R-2A .........................................................................................

Overview of the machine C50R-3B ....................................................................................

Controls and switches C50R-3B .........................................................................................

49 50 51 52 53 54

10. Description of operator’s area for C12R-A ............................................................... 55 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

Monitor ................................................................................................................................

Switches .............................................................................................................................

Control levers and pedals ...................................................................................................

Engine hood .......................................................................................................................

Storage compartment for the operation & maintenance manual ........................................

Fuses ..................................................................................................................................

Fuel cap ..............................................................................................................................

Wagon support ...................................................................................................................

55 57 58 62 63 63 65 66

11. Description of operator’s area for C30R-2A ............................................................. 67 11.1 11.2 11.3 11.4 11.5 11.6

Monitor ................................................................................................................................

Switches .............................................................................................................................

Control levers and pedals ...................................................................................................

Engine hood .......................................................................................................................

Storage for tools and the operation & maintenance manual ..............................................

Fuse box and fusible link ....................................................................................................

67 69 71 74 75 75

11.7 11.8

Operator’s seat ................................................................................................................... 76 Dump deck support stopper ................................................................................................ 77

12. Description of operator’s area for C50R-3B ............................................................. 78 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12

Monitor ................................................................................................................................

Switches .............................................................................................................................

Control levers ......................................................................................................................

Engine hood ........................................................................................................................

Side cover ...........................................................................................................................

Battery cover .......................................................................................................................

Cabin ..................................................................................................................................

Storage for tools and the operation & maintenance manual ...............................................

Fuse box .............................................................................................................................

Fuel cap ..............................................................................................................................

Operator’s seat ...................................................................................................................

Wagon stopper ...................................................................................................................

78 81 85 87 88 88 89 92 92 93 94 96

13. Operating Instructions for C12R-A ............................................................................ 97 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17

Checking before starting the engine ................................................................................... 97 Operating and checking instructions before starting up the engine .................................. 106 Starting up the engine ....................................................................................................... 107 Operating and checking instructions after starting the engine .......................................... 108 Traveling ........................................................................................................................... 109 Steering (turning the machine) ......................................................................................... 111 Stopping the machine ....................................................................................................... 112 Dumping the wagon .......................................................................................................... 113 Precautions for working .................................................................................................... 114 Precautions for going up and down a slope ...................................................................... 115 Removal of wagon flaps ................................................................................................... 116 Parking the machine ......................................................................................................... 117 Inspection requirements after completing operation ......................................................... 118 Stopping the engine .......................................................................................................... 118 Inspection requirements after stopping the engine ........................................................... 119 Locking ............................................................................................................................. 119 Handling the rubber crawlers ............................................................................................ 120

14. Operating Instructions for C30R-2A ........................................................................ 124 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 14.13 14.14 14.15 14.16 14.17

Checking before starting the engine .................................................................................

Operating and checking instructions before starting up the engine ..................................

Starting up the engine .......................................................................................................

Operating and checking instructions after starting the engine ..........................................

Traveling ...........................................................................................................................

Steering ............................................................................................................................

Stopping the machine .......................................................................................................

Dumping ...........................................................................................................................

Precautions for working ....................................................................................................

Precautions for going up and down a slope ......................................................................

Removal of wagon flaps ...................................................................................................

Parking the machine .........................................................................................................

Inspection requirements after completing operation .........................................................

Stopping the engine ..........................................................................................................

Inspection requirements after stopping the engine ...........................................................

Locking .............................................................................................................................

Handling the rubber crawlers (for machines equipped with rubber) .................................

124 129 130 132 133 134 135 136 136 137 139 140 140 141 141 141 142

15. Operating Instructions for C50R-3B ........................................................................ 146 15.1 15.2 15.3 15.4

Checking before starting the engine .................................................................................

Operating and checking instructions before starting up the engine ..................................

Starting up the engine .......................................................................................................

Operating and checking instructions after starting the engine ..........................................

146 152 154 155

15.5 15.6 15.7 15.8 15.9 15.10 15.11 15.12 15.13 15.14 15.15 15.16 15.17 15.18

Traveling ...........................................................................................................................

Steering ............................................................................................................................

Stopping the machine .......................................................................................................

Dumping the wagon ..........................................................................................................

Swinging the wagon (for the swing wagon type) ..............................................................

Precautions for working ....................................................................................................

Precautions for going up and down a slope .....................................................................

Removal of wagon flaps ...................................................................................................

Parking the machine .........................................................................................................

Inspection requirements after completing operation .........................................................

Stopping the engine ..........................................................................................................

Inspection requirements after stopping the engine ...........................................................

Locking .............................................................................................................................

Handling the rubber crawlers ............................................................................................

156 158 159 160 161 162 162 163 164 165 165 165 166 166

16. Transportation .......................................................................................................... 170 16.1 16.2 16.3

Loading and unloading the machine ................................................................................. 170 Precautions for loading the machine ................................................................................ 171 Suspending the machine (only for C12R-A and C30-2A) ................................................. 172

17. Care in cold weather and long-term storage ......................................................... 173 17.1 17.2

Preparing for cold weather ............................................................................................... 173 Long-term storage ............................................................................................................ 175

18. Troubleshooting ....................................................................................................... 176 18.1 18.2 18.3 18.4

Phenomena that are not breakdowns ...............................................................................

Precautions for operation in water ....................................................................................

If the battery is overdischarged ........................................................................................

Troubleshooting (depending on model) ............................................................................

176 176 176 177

MAINTENANCE 19. Precautions for servicing ........................................................................................ 183 20. Basic servicing practices ........................................................................................ 184 20.1

Filter .................................................................................................................................. 184

21. Fueling, oiling and greasing based on temperature range ................................... 185 21.1 21.2

Fuel and oil ....................................................................................................................... 185 Cooling water .................................................................................................................... 185

22. Standard tightening torque for bolts and nuts ...................................................... 186 22.1

Torque table ..................................................................................................................... 186

23. Maintenance table .................................................................................................... 187 23.1

List of periodic inspection and servicing ........................................................................... 187

24. Procedures of maintenance for C12R-A ................................................................. 190 24.1 24.2 24.3 24.4 24.5 24.6 24.7 24.8 24.9 24.10 24.11 24.12 24.13 24.14 24.15 24.16

Checking the rubber crawlers ...........................................................................................

Replacing the rubber crawler ............................................................................................

Adjusting the fan belt tension ...........................................................................................

Adjusting the drive belt tension .........................................................................................

Checking, cleaning and replacing the air cleaner element ...............................................

Draining the water and deposits from the fuel tank ..........................................................

Cleaning the fuel filter element (with water separator) .....................................................

Replacing the fuel filter element .......................................................................................

Replacing the pre-filter .....................................................................................................

Replacing the engine oil and the engine oil filter ..............................................................

Replacing the hydraulic oil and cleaning the suction filter ................................................

Replacing the hydraulic oil return filter .............................................................................

Adjusting the steering clutches .........................................................................................

Adjusting the steering brakes ...........................................................................................

Adjusting the travel pedal .................................................................................................

Adjusting the F/R lever .....................................................................................................

190 191 193 193 194 196 196 197 198 199 201 202 203 203 203 204

25. Procedures of maintenance for C30R-2A ............................................................... 205 25.1

Checking the rubber crawlers ........................................................................................... 205

25.2 25.3 25.4 25.5 25.6 25.7 25.8 25.9 25.10 25.11 25.12 25.13 25.14 25.15 25.16

Replacing the rubber crawler ............................................................................................

Adjusting the fan belt tension ............................................................................................

Checking, cleaning and replacing the air cleaner element ...............................................

Draining the water and deposit in the fuel tank .................................................................

Checking the water separator ...........................................................................................

Cleaning the water separator element ..............................................................................

Cleaning / replacing the fuel filter element ........................................................................

Replacing the engine oil and the engine oil filter ..............................................................

Replacing the oil in the hydraulic oil tank and cleaning the suction filter ..........................

Replacing the return oil filter .............................................................................................

Checking and replenishing the transfer case oil ...............................................................

Replacing the transfer case oil .........................................................................................

Checking and cleaning the oil filter in the transfer case ...................................................

Replacing the final case oil ...............................................................................................

Greasing the final drive .....................................................................................................

206 208 208 210 210 211 211 212 213 214 215 215 216 217 217

26. Procedures of maintenance for C50R-3B ............................................................... 218 26.1 26.2 26.3 26.4 26.5 26.6 26.7 26.8 26.9 26.10 26.11 26.12 26.13 26.14 26.15

Checking the rubber crawlers ...........................................................................................

Checking the rubber crawler tension ................................................................................

Replacing the rubber crawler ............................................................................................

Adjusting the fan belt tension ............................................................................................

Checking, cleaning and replacing the air cleaner .............................................................

Draining the water and deposits from the fuel tank ..........................................................

Checking the water separator ...........................................................................................

Draining and cleaning the water separator .......................................................................

Cleaning / replacing the fuel filter element ........................................................................

Replacing the engine oil and the engine oil filter element ................................................

Replacing the hydraulic oil and cleaning the suction filter element ..................................

Replacing the return filter ..................................................................................................

Replacing the line filter element ........................................................................................

Replacing the travel reduction gear oil .............................................................................

Checking and replenishing the windshield washer fluid (for cabin) ..................................

218 219 220 222 222 224 224 225 226 228 229 231 232 232 233

SPECIFICATIONS 27. Specifications ............................................................................................................ 237 27.1 27.2 27.3 27.4 27.5 27.6

Specifications ....................................................................................................................

Model view and working range for C12R-A ......................................................................

Model view and working range for C30R-2A ....................................................................

Model view and working range for C50R-3B ....................................................................

Noise emitted by the machines .........................................................................................

Vibrations emitted by the machines ..................................................................................

237 238 239 240 241 242

28. Options ...................................................................................................................... 243 28.1

Options ............................................................................................................................. 243

29. Hydraulic and wiring diagrams ................................................................................ 244 29.1 29.2

Hydraulic diagrams ........................................................................................................... 244 Wiring diagrams ................................................................................................................ 247

NOTES 30. Maintenance .............................................................................................................. 253 31. Notes .......................................................................................................................... 257

1 Introduction

1

Introduction This Operation and Maintenance Manual for the YANMAR machine is designed to provide you with important information and suggestions necessary for using the machine with safety and efficiency.

Please be sure to read through the manual before using the machine, to make yourself familiar with the procedures and instructions for operating, inspecting and servicing. Keep in mind that failure to observe the precautions given in the manual or using any procedures not prescribed in the manual may cause a serious accident.

WARNING Improper use of the machine may lead to hazards which can result in death or serious injury. Personnel engaged in operating and maintaining the machine are required to familiarize themselves with the contents of the manual before setting about their job.

•

Do not attempt to operate the machine before making yourself familiar with the contents of the manual.

•

Personnel responsible for using the machine must keep the manual at hand and review it periodically.

•

If the manual should be lost or damaged, promptly order a new copy from the dealer.

•

When you transfer the machine to another user, always transfer the manual as well.

•

We at YANMAR provide customers with products in compliance with all applicable your country's regulations and industrial standards. If you are using a YANMAR machine purchased abroad, the machine may lack some safety devices. Please consult your dealer to confirm whether or not that machine is in compliance with all applicable your country's regulations and industrial standards.

•

Some machine specifications may differ from those which are described in this manual because of improvements in its design and performance. If you have any questions about the contents of the manual, don't hesitate to contact your dealer.

•

Important safety instructions have been presented throughout this manual, and have been summarized in PART : SAFETY. Be sure to review these pages and pay heed to those safety instructions before proceeding to operate the machine.

9

2 Safety information

2

Safety information The following Signal Words have been used in this Manual and on the Safety Signs to indicate the seriousness of the hazards that could be encountered by failing to comply with the applicable Product Warnings, as follows:

DANGER Could result in death or catastrophic bodily injury.

WARNING Could result in bodily injury.

CAUTION Could result in property damage.

IMPORTANT The signal Word "IMPORTANT" has been utilized in this Manual to denote those User Directions that must be followed to assure the safe operation and maintenance of the machine.

•

WARNING : The operator of this machine must be competent and trained for its use.

•

WARNING : Never attempt to operate or service this machine until you have first read and understood all of the applicable Product Warnings and User Directions that are set forth in this Manual and on the Safety Signs that are affixed to this machine.

The failure to comply with all relevant Safety Instructions could result in bodily injury.

•

WARNING : Never modify the design of this machine or its engine; never remove or disable any of the installed safety guards or devices; and never use any unauthorized attachments in the operation of this equipment.

The implementation of any unauthorized design modifications or the use of unauthorized attachments could result in bodily injury.

Furthermore, since those actions would expressly violate the terms of Yanmar's Product Warranty, the applicable Warranty would also be voided.

10

3 Product overview and regulation

3

Product overview and regulation 3.1

Intended uses

These machines are intended mainly for the materials carrying operation on rough terrain.

3.2

Operation license

Before you operate this machine, confirm the licensing requirements that are applicable to the operation of this machine.

Comply with all applicable laws.

Ask your dealer about licensing requirements.

WARNING It is prohibited to transport persons with this machine.

WARNING Refer to your AMMANN-YANMAR dealer for more information.

11

4 Ordering replacement parts and service call

4

Ordering replacement parts and service call 4.1

Location of machine serial number plate

Never remove the plate for any reason.

C12R-A

C30R-2A

C50R-3RA

4.2

Location of engine serial number plate

The engine serial number plate is located on the top of the cylinder head cover. Never remove the plate for any reason.

4.3

Location of the EPA identification plate

The EPA identification plate is fixed on the engine. Never remove the EPA identification plate for any reason.

4.4

MODELE / MODELL / MODEL NO. MACHINE / MASCHINE NO. MOTEUR / MOTOR / ENGINE POIDS / GEWICHT / WEIGHT ANNEE DE FABRICATION / BAUJAHR / PRODUCTION YEAR

F G E

Ordering replacement parts and service calls

When ordering replacement parts or calling for service, let your dealer know the model designation, the machine serial number, and the engine serial number on the machine serial number plate as well as the reading of the hourmeter.

• Machine serial number plate

08710-84106

12

SAFETY WARNING Never attempt to operate or service this machine until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual.

The failure to comply with all relevant Safety Instructions could result in bodily injury.

13

14

5 Basic precautions

5

Basic precautions WARNING It is the user's responsibility to determine if an application presents any dangerous phenomena, for example: toxic gases, ground conditions requiring special precautions and measures to be taken to eliminate or reduce risks.

Follow safety rules at your workplace •

The operation and servicing of this machine is restricted to qualified persons.

•

When operating or servicing the machine, follow all the safety rules, precautions and procedures.

•

Any work performed by a team or with a signal person should be conducted in accordance with signals agreed on beforehand.

DANGER The machines are not equipped to operate in explosive environments.

Install safety devices •

Make sure that all guards and covers are installed in their correct position. If any of them are damaged, repair them immediately.

•

The proper use of all safety devices, such as lock lever, should be well understood by the machine operator.

•

Never remove the safety devices. Always make sure that they operate properly. Incorrect operation of the safety devices could cause serious bodily injury.

Fasten the seatbelt •

For your safety, a rollover protection structure (ROPS) and a falling object protective structure (FOPS) with a safety belt are installed. (Depending on model)

•

Always fasten the seatbelt and adjust snugly before you operate the machine.

•

The seatbelt must be replaced after an accident.

•

In addition the seat and seat mounting must be checked by your dealer after an accident has occurred.

•

If the seat and seat mounting are damaged, they must be replaced.

15

5 Basic precautions

Wear proper clothing and safety items •

Do not wear loose clothing or jewelry that can be caught on the control levers and other machine parts. Also avoid wearing working clothes stained with oil as they can ignite.

•

Be sure to wear a helmet, safety goggles, safety shoes, a mask, gloves and other protective items, as appropriate.

Take particular precautions when generating metal debris, when striking metal objects with a hammer or when cleaning components with compressed air.

•

Also make sure there are no persons near the machine.

Alcohol •

Never operate the machine while you are under the influence of alcohol or when you are ill or feel unwell as this results in accidents.

Provide adequate ventilation when working in an enclosed area •

Engine exhaust fumes are harmful to the human body and their inhalation is extremely hazardous. When starting the engine in an enclosed area, open the windows and doors for ventilation.

•

Also do not idle the engine unnecessarily or leave the engine running while the machine is not in use.

Caution for the protection of plants from hot air •

Hot air is exhausted from the muffler and the radiator. If this hot air hits plants directly, they will die.

•

Give a cover board to protect plants from the hot air when working near the arranging fence or plant.

Keep fuel and oil away from sources of ignition •

Open flames can ignite fuel, oil, hydraulic oil or antifreeze solutions, which are flammable and dangerous.

Special attention must be paid to the following matters: •

Keep flammable materials away from lighted cigarettes or matches, or any other sources of ignition.

•

Never refuel while the engine is running. Smoking during refueling must be strictly prohibited.

•

Firmly tighten the caps on the fuel and oil tanks.

•

Store fuel and oil in a cool and well-ventilated place where they are not subjected to direct sunlight.

•

Fuel and oil must be stored in a place which meets all applicable safety regulations. Unauthorized persons should not be allowed entry.

16

5 Basic precautions

Avoid removing filler caps while temperatures are high •

The engine coolant, engine oil and hydraulic oil are hot and under pressure immediately after the machine stops operation.

•

Removing caps, draining coolant or oil, or replacing a filter at such a time may cause burns. Allow temperatures to cool down and follow the procedures in this manual.

•

When removing the radiator cap, stop the engine and allow the coolant to cool down, then turn the cap slowly to relieve all pressures.

•

Before removing the cap from the hydraulic oil tank, stop the engine and turn the cap slowly to relieve all pressure to prevent oil from spouting out.

Avoid harmful asbestos dust •

Air containing asbestos dust is carcinogenic and is hazardous to humans. Inhalation of the air may cause lung cancer. When handling materials that may contain asbestos, keep in mind that:

•

Compressed air must not be used for cleaning.

•

Water must be used to clean the machine to prevent asbestos from scattering in the air.

•

You must work on the windward side when operating the machine in a place where there may be asbestos dust.

•

You should wear breathing apparatus as necessary.

Prevent crush injuries by the implements •

Keep hands, arms and all other parts of your body away from all the moving parts, particularly between the implements and the machine and between the hydraulic cylinder and the implements, as pinch points are created in those areas.

Keep a fire extinguisher and first aid kit handy •

The workplace must be provided with a fire extinguisher.

Read instructions on the label to familiarize yourself with how to use it.

•

Keep a first aid kit in a prescribed place.

•

Advise what to do in the event of fire or accidents.

•

Indicate who to contact in an emergency and keep their telephone number in a prominent place.

17

5 Basic precautions

Always lock your machine when leaving the operator's seat

(1)

•

When leaving the operator's seat, be sure to place the lock levers in the lock position, to prevent accidental machine movement which could result in bodily injury.

•

When you leave the machine:

(3) (6)(7) (2) (4) (5)

1) Place the travel levers in the neutral position.

2) Run the engine at low idling speed.

3) Place the lock levers in the lock position.

4) Lower the wagon completely.

5) Lock the dump lever.

6) Stop the engine 7) Be sure to take the starter switch key out of the starter switch.

Avoid unauthorized modifications Precautions for installing optional parts and attachments •

Modifications not recommended by YANMAR may cause safety hazards.

•

When you wish to modify your machine, contact your dealer. The implementation of unauthorized modifications or the use of unauthorized attachments could result in bodily injury, since those actions would also violate, the terms of YANMAR's Warranty, it would be voided.

•

When installing or using optional attachments, read the operating instructions for the attachments and the Manual Sections relating to the installation of attachments.

•

Use only attachments authorized by YANMAR. The use of unauthorized attachments may affect not only the safety of the machine but also the proper operation and life of the machine.

•

The use of unauthorized attachments would also violate the terms of YANMAR's Warranty, so that it would be voided.

Caution for cabin glass (for cabin) •

If the glass of the cabin should be broken by accident, it is very dangerous since the operator’s body might contact the implement directly.

•

Immediately stop working to replace the broken glass with a new one.

18

5 Basic precautions

Emergency escape from operator’s cab (for cabin) •

If the door of the cabin should not open, break the window glass with a hammer which is provided inside the cabin to escape from the operator’s cab in an emergency.

•

Remove the broken pieces of the window glass from the window frame to prevent any injury by those broken pieces. Besides, watch your step not to slip on the broken pieces of the window glass which dropped around your feet.

19

6 Operating precautions

6

Operating precautions 6.1

Break in period

The machine should not be subjected to severe stresses and loads during the initial break in period although it has been prepared well and stringently inspected before shipping.

Otherwise the machine's performance may be affected and its service life shortened. Thus it is essential to break in the machine for the first approx. 100 service hours (reading of the hourmeter).

In breaking in the machine: •

You should warm up the engine by idling for 5 minutes before starting operations.

•

You should not operate the machine under heavy loads or at high speed.

•

You should not start and accelerate the engine too abruptly, or stop it too abruptly.

•

You should not change travel direction too abruptly.

The safety instructions for operation and maintenance that are presented in this Manual are applicable to each of the intended tasks. Never misuse this machine by violating the applicable safety instructions or by attempting to perform unintended tasks, because of the danger of serious bodily injury.

6.2

Precautions before starting the engine

Ensure the safety of your workplace •

Before starting the machine, check to see if there are any hazards in your working area.

•

Examine the terrain and soil, and decide the best way to do the work.

•

When working on the street, provide a signal person or fence for the safety of vehicles and pedestrians.

•

If there are underground utilities at the work site, such as water pipes, gas pipes, high-voltage conduits or others, contact the responsible companies to locate them exactly, so as not to damage them.

20

6 Operating precautions

Inspect around the operator's seat •

Dirt, oil and snow on the floor, levers, handrails or steps are slippery and hazardous. Remove them all completely.

•

Keep parts and tools away from the operator's seat as they may damage the control levers or switches or create any other hazards.

Signal before starting the engine •

Check the machine carefully before initial start up for the day.

•

Make sure there are no persons near the machine before getting on it.

•

Never start the engine when the "SERVICING IN PROGRESS" tag is attached to the control system.

•

Sound the horn to alert people nearby before starting the engine.

•

Be sure to start the engine and operate the machine from the operator's seat only.

•

Do not allow any other persons to get on the machine.

Keep the headlight and the cabin windows clean (for cabin) •

Keep the surface of the cabin windows (according to the model) and the headlights clean for clear view.

•

Make sure that your machine is equipped with headlights and all required working lamps, and that they work properly.

CAUTION The headlight gets hot when it is turned on. Do not touch it carelessly with your bare hand to prevent burns.

ROPS / FOPS (depending on model) •

Never modify the structural member of ROPS/FOPS.

•

If ROPS/FOPS is damaged, replace it immediately to prevent bodily injury. Never repair or modify it.

6.3

Precautions when traveling

Make sure there are no persons nearby when turning or reversing the machine.

•

A signal person should be provided for safety when the work site is hazardous or when visibility is poor.

•

Keep all other persons away from the work site or the traveling path of the machine.

21

6 Operating precautions

•

Alert persons nearby with a horn or other signal before starting the machine.

•

The machine permits a limited range of vision toward the rear. Make sure there are no persons behind the machine before reversing.

Precautions when traveling •

When traveling with the machine, keep the wagon lowered. If the machine travels with the wagon in the dump position, the machine will be unstable.

•

If you need to operate the dump lever while traveling, never move it abruptly.

•

Run the machine at low speed and slow down it when turning on rough terrain.

•

Avoid running over obstacles if possible. If unavoidable, run the machine at low speed. Never run over obstacles that may cause the machine to tilt more than 10 degrees.

<10°

Running the machine on a slope •

Run the machine carefully on a slope to avoid overturning or skidding sidewards.

•

Run the machine at low speed on a slope of 9 to 10 degrees or more, with the automatic speed change switch turned off (for traveling at low speed, depending on model) and the engine throttled down to medium speed or lower.

•

If the machine goes down a slope at high speed, the engine speed will be increased excessively and overrun may be caused, which may cause the machine to go out of control.

•

Do not brake the machine suddenly, as that could cause the machine to lose its balance, resulting in an overturn of the machine.

•

Never turn the machine on a slope or run it across the slope. Move down to flat ground and then make a turn.

•

On grasses, dead leaves or a wet metal plate, even with a slight gradient, the machine will easily skid. Under those circumstances, run the machine carefully at low speed to prevent it from skidding.

Note: For the maximum accepted gradient, refer to the specification table.

Braking when going down a slope •

When going down a slope, you can automatically brake the machine by setting the travel levers to the neutral position.

22

6 Operating precautions

When the engine stops •

If the engine stops while climbing a slope, set the travel levers to the neutral position, stop the machine, and restart the engine.

6.4

Precautions when working

DANGER Keep away from electric power lines •

Working in the vicinity of overhead electric power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual you are considered to be working in the vicinity of overhead power lines when the wagon or load of your carrier, in any position, can reach to within the minimum safe distances shown in the table.

•

The following procedures are effective in preventing accidents or injuries.

1) Wear shoes with rubber soles.

2) Use a signal person to warn the operator when the machine is getting too close to a power line.

•

If the machine should contact a wire, the operator must not leave the seat.

•

When working near power lines, caution all ground personnel to stand clear of the machine.

•

To determine the transmission voltage at the working site, contact the electric utility concerned.

Power distribution Transmission line

Transmission voltage (V)

Minimum safe distance (m)

100/200 or less

2 or more

6600 or less

2 or more

22000 or less

3 or more

66000 or less

4 or more

154000 or less

5 or more

275000 or less

7 or more

Prevent bumping the wagon •

When traveling through tunnels or under bridges, or working at a site near other overhead obstacles, operate the machine carefully so as not to bump the wagon against those overhead obstacles.

23

6 Operating precautions

Work only where visibility is good •

When working in a dark place, light up the area with the work lights and head lights, and prepare extra lighting equipment as necessary.

•

Stop working when fog, snow or rain impedes your view.

Work carefully in a snow-covered areas •

A snow-covered ground and icy roads are dangerous as they may cause the machine to skid even on a slight slope.

Run the machine at low speed, and never start, stop or turn abruptly on such ground or under such road conditions.

•

Be careful removing snow as road shoulders or other hazards may be buried under snow.

Unstable ground creates a high possibility of overturn •

Keep away from cliffs, road shoulders or trenches if possible as the ground near them is unstable. The ground may crumble due to the weight or vibrations of the machine, resulting in an overturn or fall of the machine. Be particularly careful when working immediately after rainstorm or after blasting as the ground may be unstable.

•

Ground-fills or ground near a ditch may be unstable and may crumble due to the weight or vibrations of the machine, causing the machine to tilt. Much caution must be taken in working in these areas.

•

When working in an area where there is a high possibility of falling rocks, wear a hard-hat and stay under the canopy.

Travail sur une pente •

Be aware that the machine body may be raised suddenly and tip over due to its momentum when dumping the wagon on a slope.

•

Do not dump the wagon while swinging it. This will make the machine unstable. (For the swing wagon type.)

•

For work on a slope or a road shoulder, level off the work area to maintain the machine in a horizontal position before starting the work.

Note: For the maximum accepted gradient, refer to the specification table.

24

6 Operating precautions

6.5

Precautions for parking

Parking the machine •

Park on level ground. If parking on a slope is unavoidable, place the lock levers in the lock position and block the tracks with solid pieces of wood (1). (See the illustration.)

•

If necessary to park the machine on the side of a road, set up a warning flag, fence, or lamp that can be easily recognized by passing cars and pedestrians but does not impede them.

(1)

CAUTION When leaving the operator’s seat, be sure to place the lock levers in the lock position and to take the starter switch key out of the starter switch, to prevent accidental machine movement which could result in bodily injury.

•

(1)

(3) (6)(7) (2) (4) (5)

When leaving the operator's seat, do the following:

(1) Place the travel levers in the neutral position.

(2) Run the engine at low idling speed.

(3) Set the lock levers in the lock position.

(4) Lower the wagon completely.

(5) Lock the dump lever.

(6) Stop the engine.

(7) Be sure to take the starter switch key out of the starter switch.

Use handrails and steps when getting on and off •

Do not jump on or off the machine. Never get on or off a machine in motion as it may result in bodily injury.

•

When getting on and off the machine, face the machine and use the handrails and steps.

•

Do not use control levers as handrails.

•

Make sure that you maintain three point contact with the handrails or the steps.

•

If the handrails and the steps are soiled with oil or dirt, clean them off immediately. Repair any damaged parts and retighten any loose bolts.

6.6

Precautions for loading and unloading the machine

(1)

(1) Ramp plate (2) Block (3) Stoppers

<15°

(2)

Precautions for transportation

(3)

(3)

25

6 Operating precautions

•

Be careful in loading and unloading the machine, because it is a job of high hazard potential.

•

Load or unload the machine at a low engine speed, and low travel speed.

•

Load or unload the machine on the level, solid ground away from the shoulder of the road.

•

Use ramp plates of adequate strength with hooks on their ends.

•

Check to see that the ramp plates are wide, long, and thick enough to sustain the load so that you can load or unload the machine safely. Support the ramp plates with blocks, to provide additional strength.

•

Securely hook the ramp plates to the deck of the truck so that they will not come off.

•

Remove grease, oil, and other slippery deposits from the ramp plates, and remove mud from the tracks to prevent the machine from skidding on the ramp plates.

•

Do not load or unload the machine if the ramp plates are slippery because of rain, snow or ice.

•

Never change travel direction while on the ramp plates. If you need to change travel direction, go down the ramp plates, and change direction on the ground.

•

Do not dump the wagon or swing it (for the swing wagon type) on the ramp plates, as the machine may turn over.

•

After loading the machine, be sure to set the lock levers in the lock position before stopping the engine.

•

After loading the machine, block it with lumber and secure the machine with a chain or a wire rope so that the machine will not move during transit.

Precautions for transporting •

Transport the machine safely in accordance with the laws associated with applicable law.

•

After loading the machine in an appropriate position on the trailer, block the tracks with stoppers and secure the machine with a chain or a wire rope so that the machine will not move during transit.

•

Select a travel route consistent with the width, height and weight of the machine loaded on the truck.

CAUTION Load or unload the machine on level, solid ground far away from the shoulder of the road.

26

6 Operating precautions

6.7

Precautions for the battery

DANGER Be careful in handling the battery •

The battery electrolyte contains dilute sulfuric acid, which can severely burn the eyes or skin. Always wear safety goggles and protective clothing when servicing the battery.

If contact with the eyes or skin should occur, flush with a large amount of water and obtain prompt medical treatment.

•

Because flammable hydrogen gas is produced by the battery, ignition and explosion may occur. Keep flames and sparks away from the battery.

•

If you swallow battery electrolyte by mistake, drink a large amount of water, milk, or fresh eggs, and obtain medical treatment immediately.

•

Before checking or handling the battery, be sure to stop the engine and turn the starter switch to the "OFF" position.

•

Be careful not to cause a short circuit by placing a tool across the terminals of the battery.

•

If a terminal connection is loose, sparks may be generated due to contact failure, causing possible ignition and explosion. Be sure to connect the terminals securely.

CAUTION Observe the procedures for starting the engine using booster cables.

•

When you start the engine using booster cables, wear safety goggles.

•

If you start the engine by taking electric power from another machine, do not allow your machine to contact the other machine.

•

To connect the booster cables, begin with the positive terminal, and to disconnect them, begin with the negative terminal (ground side).

•

If a tool simultaneously touches the positive terminal and the machine, potentially hazardous sparks may be generated.

•

Do not connect the booster cables to the terminals in reverse polarity. In other words, never connect the negative terminal on one machine to the positive terminal on the other machine.

•

As the last step, connect the negative booster cable terminal to the upper structure frame. At that time, sparks will be generated. Consequently, connect the terminal to a point as far away from the battery as possible.

27

7 Precautions for servicing

7

Precautions for servicing 7.1

Precautions before servicing

•

Attach the "SERVICING IN PROGRESS" tag to an implement control lever.

•

If another person should start the engine or operate the control levers while service is in progress, the service personnel can sustain serious bodily injury.

•

Attach the "SERVICING IN PROGRESS" tag indicating "Servicing in Progress" to one of the implement control levers.

Use appropriate tools •

Using damaged or worn tools or using tools inappropriate for the required application is very dangerous, and may also cause damage to the machine. Make sure to use the tools that are appropriate for the specific job.

7.2

Replacing essential parts periodically

•

For safe operation, the machine must be serviced periodically. To increase safety, be sure to periodically replace the parts listed in the table of safety parts on the next page. A fire could result if they deteriorate or are damaged.

•

These parts are vulnerable to age and wear or deterioration and it is difficult to determine the degree to which they have deteriorated on the occasion of periodic service. To maintain their proper function at all times, therefore, replace them with new ones after using them for a specific period of time even if no abnormality is found with the parts.

•

If you find abnormalities in these parts before their scheduled replacement time is reached, repair or replace them immediately.

•

If a hose clamp is deformed or cracked, replace it immediately.

•

Check the hydraulic hoses (which are not periodic replacement parts). If any abnormality is found in them, retighten them or replace them immediately.

•

When replacing the hydraulic hoses, replace the O-rings and seals at the same time.

•

For further information about replacing the safety parts, ask your dealer.

28

7 Precautions for servicing

•

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Check categories

Check points

Start-up check

Oil leak from the connections or bodies of the fuel and hydraulic hoses

Voluntary monthly check

Oil leak from the connectionsor bodies of the fuel and hydraulic hoses Damage (crack, wear, or peeling) of the fuel and hydraulic hoses

Prescribed annual check

Oil leak from the connections or bodies of the fuel and hydraulic hoses Interference, crushing, aging, torsion, or damage (crack, wear, or peeling) of the fuel and hydraulic hoses

List of safety parts C12R-A

(5) (6) (8)

(A)

(C)

(B) (3)

(4)

(1)

(E) (2)

(D)

29

A = Fuel tank B = Fuel filter C = Fuel injection pump* D = Water separator E = Feed pump

7 Precautions for servicing

C30R-2A

(6)

(5)

(A)

(4)

(C)

(B)

(3) (2)

(E) (1)

(D)

A = Fuel tank B = Fuel filter C = Fuel injection pump* D = Water separator E = Feed pump

(A)

C50R-3A

(D)

(D)

(2)

(1)

(6) (3)

(E) A = Fuel tank B = Fuel filter C = Fuel injection pump* D = Water separator E = Feed pump

(C)

(B) (4)

30

(5)

(7)

7 Precautions for servicing

No.

Safety parts to be replaced periodically

Qté

1

Fuel hose (fuel tank to water separator)

1

2

Fuel hose (water separator to feed pump)

1

3

Fuel hose (pump to fuel filter)

1

4

Fuel hose (fuel filter to injection pump)

1

5

Fuel hose (injection pump to fuel filter)

1

6

Fuel hose (fuel filter to fuel tank)

1

7*

Fuel hose (fuel filter to fuel injection valve)

1

8*

Fuel hose (injection pump to fuel injection valve)

1

Replacement time intervals

Earlier of either every 2 years or every 4000 service hours

* = depending on model

Stop the engine before beginning the inspection and servicing •

3 2 1

4

Be sure to stop the engine before performing inspection and servicing.

1) Pre-heat 2) Off 3) On 4) Start •

If necessary to perform service while running the engine, as when cleaning the inside of the radiator, be sure to place the parking brake lever in the lock position, place the F-R lever in the neutral position, lock the dump lever and do the job together with a partner.

•

(One should take the operator's seat so that he or she can stop the engine at any time.)

•

That person must be careful not to touch any levers in the cabin.

•

Be extremely careful not to contact the moving fan or fan or fan belt, or any hot surfaces.

7.3

Precautions during servicing

Keep unauthorized persons away •

Never admit any persons into the work area who are not taking part in the work. Be conscious of the safety of other persons.

•

Be especially careful when grinding, welding, or using a large hammer.

Removed attachments •

When an attachment is placed on the ground or against a wall after removing it or prior to reinstalling it, be sure that it is stable to prevent it from falling down.

31

7 Precautions for servicing

Working under the machine •

Never perform service underneath the machine if it is not completely stable.

•

Before performing service or repairs underneath the machine, be sure to apply blocks to the tracks to lock the tracks securely.

•

To perform service or repairs with the wagon in the dump position, lock the dump lever and lock the wagon with the wagon stopper.

Keep the machine clean •

Spilled oil or grease, or scattered parts are dangerous and can cause falls. Keep the machine clean.

•

Getting water into the electrical system may cause it to malfunction, resulting in faulty operation of the machine.

Also it may permit electrical leaks that could cause a fire or electric shocks.

•

Never clean the sensors, connectors or the operator's seat with water or steam.

Radiator cooling water level •

Before checking the radiator cooling water level, stop the engine and wait until the engine and the radiator have cooled down.

•

Slowly loosen the cap to release the inner pressure before removing the cap.

Use an explosion-proof lighting source •

Use an explosion-proof lighting source when checking the fuel, the oil, the cooling water, or the battery electrolyte.

Failure to use an explosion-proof lighting source may cause ignition to occur, inducing an explosion.

Precautions for handling battery •

When welding or repairing the electrical system, disconnect the negative terminal of the battery to interrupt the electric circuit.

Handling high-pressure hoses •

Leaks of fuel and oil could cause a fire.

•

Do not bend a high-pressure hose forcibly, or strike it with a hard object. Because abnormally bent or damaged piping, tubes, and hoses easily burst under high pressure, never use them.

32

7 Precautions for servicing

Be careful of hot oil under high-pressure •

The hydraulic system for the implement operates under high pressure. When replenishing or draining hydraulic oil, be sure to first relieve the high pressure.

•

The emission of hot oil under high-pressure from a small leak could result in serious bodily injury. Wear safety goggles and thick gloves when checking for leaks. Use a piece of cardboard or a plywood block to detect emissions of hot oil.

•

If the hot oil should contact your body, obtain prompt medical treatment.

Hazards from the high-pressure grease when adjusting the track crawler tension High-pressure grease is enclosed in the track crawler adjuster.

Failure to use the specified procedures for adjusting the track crawler tension, could cause grease plugs or nipples to eject, which could result in bodily injury.

•

Do not loosen the grease draining plug more than one turn.

•

Never position your face, hands, legs, or body in line with the grease draining plug and valve.

Rotating radiator fan and fan belt •

Never contact the rotating radiator fan or fan belt with any object.

•

Contacting the rotating radiator fan or fan belt with any object can result in serious bodily injury.

Recycling and environment •

For the recycling of your machine, contact your AMMANNYANMAR dealer.

•

By entrusting the maintenance of your machine to your AMMANN-YANMAR dealer, you limit any risk of pollution and you contribute to the environmental protection.

Processing wastes •

Do not dispose of waste oil in the sanitary sewer system.

•

Always drain the oil from the machine into a secure container, and never directly to the ground.

•

When disposing of toxic wastes such as fuel, oil, cooling water, solvent, filters, and spent batteries, comply with all applicable disposal regulations.

33

8 Safety messages (warning labels)

8

Safety messages (warning labels) There are a number of Warning Labels on the machine. Full descriptions of all Warning Labels and their locations are reviewed in this section. Periodically confirm whether all Warning Labels are still mounted in their correct locations and can be easily read.

If a warning label is missing, damaged or cannot be read, it must be promptly replaced. Also, if a warning label was mounted on a part which is replaced, a new warning label must be installed on the replaced part.

Contact your dealer to obtain new labels. The part code number is shown on each warning label.

34

8 Safety messages (warning labels)

8.1

Location of warning labels C12R-A

(12) (10) (8) (3) Inside of engine hood

(14) (13) (9) Viewed from A

Frame part

(1)

(17) 2 (L, R)

A B (4) (5) (2) (11)

(6) (7) Viewed from B

1)

35

C

(16) (15) (18) Viewed from C

8 Safety messages (warning labels)

2)

3)

4)

5)

6)

36

8 Safety messages (warning labels)

7)

8)

9)

37

8 Safety messages (warning labels)

10)

11)

38

8 Safety messages (warning labels)

8.2

Location of warning labels C30R-2A

(7) (13) (6)

(2)

(5)

(4) (10)

(1) (12) (11) (9)

(3) (14) (8) 003628-00X

39

8 Safety messages (warning labels)

7

1

2

8 3

9 4

5

6

40

8 Safety messages (warning labels)

14

10

11

12

13

41

8 Safety messages (warning labels)

8.3

Location of warning labels C50R-3B

Pour cabine

(11) (14)

(4)

(4)

(15) (2) (16) (10) (7) (13)

(8)

(1)

(5)(3)(6)

Couvercle

Extérieur de la cabine

Pour canopy

(9)

(7)(8)(2)

(1)

(5)(3)(6) (16) Vue de A (10)

Intérieur de la cabine

Benne standard et pivotante

A (9)

(17)

(1)

1)

2)

42

(12)

Réservoir d'huile hydraulique

8 Safety messages (warning labels)

3)

4)

5)

6)

7)

8)

43

8 Safety messages (warning labels)

9)

10)

11)

12)

44

8 Safety messages (warning labels)

13)

14)

15)

16)

45

8 Safety messages (warning labels)

17)

18)

46

OPERATION

47

48

9 Identification of important parts

9

Identification of important parts 9.1

3

A = Right B = Left C = Front D = Rear 1) Operator’s seat 2) Dump lever

Overview of the machine C12R-A

4

2

5

7 8

6

9 1

3) Steering lever (G) 4) Steering lever (D) 5) Front / rear lever 6) Starter switch

C

B

7) Rearview mirror 8) Open / close lever 9) Wagon 10) Travel speed select lever

D

A

11) Travel pedal

13

12) Battery

10

11

12 17

13) Bumper

18

16

14) Brake pedal

15

15) Handrail 16) Dump lever 17) Accelerator lever

14

18) Fuel tank 19) Bumper 20) Transmission 21) Rubber crawler 22) Sprocket 23) Carrier roller 24) Track roller 25) Idler

19

25 23

49

20

22

24

21

9 Identification of important parts

9.2

Controls and switches C12R-A

6

7

5

8

4

9 10

3

11

12 2 1

1) Brake lock lever 2) Brake pedal 3) Dump lever stopper 4) Dump lever 5) Accelerator lever 6) Steering lever (G) 7) Steering lever (D) 8) Horn switch 9) Front / rear lever 10) Starter switch 11) Travel speed select lever 12) Travel pedal

50

9 Identification of important parts

9.3

Overview of the machine C30R-2A 5

6

7 2

3 8 4

1

9 A

18

D

C 17

11

16

12 15 14

13

8) Safety guard

A = Right B = Left C = Front D = Rear

9) Wagon 10) Idler 11) Frame

1) Direction light

12) Carrier roller

2) Rearview mirror

13) Track roller

3) Engine hood

14) Sprocket

4) Turn signal lamp

15) Rubber crawler

5) Rearview mirror

16) Head lamp

6) Seat

17) Front frame

7) ROPS

18) Bumper

51

10

B

9 Identification of important parts

9.4 2

3

4

Controls and switches C30R-2A 5

6

7

8

1 9 10

16

15

13

14

12

1) Seat

9) Light switch

2) Brake pedal

10) Fuel cap

3) Accelerator pedal

11) Hourmeter

4) Parking lever

12) Pilot box

5) Horn switch

13) Dump lever

6) Travel lever

14) Starter switch

7) Steering clutch lever

15) Brake pedal

8) Turn signal switch

16) Accelerator pedal

52

11

9 Identification of important parts

9.5

Overview of the machine C50R-3B 1) Lower windshield

4

2) Wiper 3) Upper windshield

5 3

4) Antenna

2

5) Side glass 6) Door stopper

6 7

1

7) Side door 8) Door handle

9

9) Cylinder key

8

A = Right B = Left C = Front D = Rear

13

14 15

12

10) Side cover

16

11

11) Fuel tank

10

12) Working lamp (option) 13) Right rearview mirror

D

14) Engine hood

B

15) Canopy

17

16) Battery cover 17) Bumper

19 18 19

A

18) Headlights 19) Turn signal lamps

22 20

20) Hydraulic oil tank

21

21) Dump cylinder 22) Wagon 23) Idler 24) Rubber crawler 25) Carrier roller 26) Track roller

23 28

27

26

25

24

27) Sprocket 28) Travel motor

53

C

9 Identification of important parts

9.6

Controls and switches C50R-3B

4 5 6 7 8

9

10 3

11 12 13

14

15

16 17

2 18

19 20 21 23 22 1

24

1) Heater (for cabin)

12) Starter switch

2) Lock levers (Operator’s seat reverse levers)

13) Fuel meter

3) Operator’s seat

15) Accelerator lever

4) Travel levers

16) Dump lever

14) Water temp. meter

5) Defroster (for cabin)

17) Dump lock lever

6) Ash tray (for cabin)

18) Heater switch (cabin)

7) Turn signal switches

19) Light switch

8) Travel speed change switch

20) Cigarette lighter (24V) (for cabin)

9) Horn switch

21) Wiper switch (cabin)

10) Wagon center indicating lamp (for the swing wagon type)

22) Hourmeter

11) Lock levers (Operator’s seat reverse levers)

24) Fuse box

23) Monitor

54

10 Description of operator’s area for C12R-A

10

Description of operator’s area for C12R-A This section describes several of the control devices necessary to operate the machine. In order to ensure safety and comfort in working with the machine, it is imperative for you to fully understand how to operate and interact with these devices.

10.1 Monitor (4)

(1) (3) (2)

CAUTION When an indicator lamp lights and a buzzer sounds during operation, immediately stop operation and check and service the abnormality.

When the starter switch key is in the “ON” position, the monitor lamps light and buzzer sounds.

(Only the water temp alarm lamp goes off in a few seconds.)

Normally, all monitor lamps go off after the engine starts.

When there is any failure during operation, a lamp lights and buzzer sounds. (If the starter switch key is in the “ON” position and a monitor lamp does not light, its bulb must be burnt out.)

(1) Engine oil pressure alarm lamp If the engine oil pressure falls below the normal level, the alarm lamp will light and the buzzer will sound. In this event, stop the engine and inspect it.

55

10 Description of operator’s area for C12R-A

(2) Battery charge alarm lamp If the battery is not charged properly, the alarm lamp will light and the buzzer will sound. In this event, inspect the battery charging circuit. If you find something abnormal with it, take corrective action.

(3) Water temp. alarm lamp When the cooling water temperature rises abnormally during operation, the alarm lamp lights and the buzzer sounds, indicating engine overheating.

Idle the engine for a while, and stop the engine. After the engine has cooled, take corrective actions.

(4) Hourmeter The hourmeter indicates the accumulated service hours for the machine.

The reading of the hourmeter helps you set time intervals for periodic servicing of the machine. While the engine is running, the hourmeter will continue registering even if the machine is not being operated.

While the engine is running, the indicator wheel will run indicating the hourmeter is counting.

The hourmeter reading increases by "1" per hour regardless of engine rotational speed.

2 1

3

1 = Hour 2 = Minute (indicated value x 6 minutes) 3 = Indicator wheel

56

10 Description of operator’s area for C12R-A

10.2 Switches (2)

(1)

(1) Starter switch Use this switch to start and stop the engine.

OFF

ON

START

•

OFF position Turn the starter switch key to "OFF" to stop the engine and disconnect electrical circuit or remove the starter switch key.

GLOW

•

ON position Turn the starter switch key to "ON" to connect the electrical fuel solenoid circuit and the electrical charging circuit.

(Keep the starter switch key in this position while running the engine.)

When the engine is not running and the starter switch key is in the "ON" position, a buzzer will sound. Turn the key to the "OFF" position to stop the buzzer.

•

START position Turn the starter switch key to "START" to start the engine.

Release the starter switch key after the engine is started and it will return to the "ON" position.

•

GLOW position Turn the starter switch key to "HEATER" to activate the preheating circuit and warm up intake air to make engine starting easier in cold weather. (Turn the starter switch key to this position when the outside temperature is low.)

57

10 Description of operator’s area for C12R-A

(2) Horn switch

(A)

Press the switch (A) on the instrument panel to sound the horn.

(3) Reverse travel alarm switch (1) (R)

When the F/R lever (1) is moved to reverse position, the reverse travel alarm is turned on and alarm sounds.

2 = Stopper bolt 3 = Travel alarm switch

(1) (R)

3 2

10.3 Control levers and pedals (8) (7)

(3)

(4)

(9) (6)

(5) (2) (1)

1) Brake lock lever 2) Brake pedal 3) Steering levers

4) F/R (Forward-Reverse) lever 5) Travel pedal 6) Travel speed select lever

58

7) Accelerator lever 8) Dump lever 9) Dump lever stopper

10 Description of operator’s area for C12R-A

(1) Brake lock lever

1 2 3 4

1 = Levier de verrouillage du frein 2 = Pédale de frein 3 = Presser vers le bas 4 = Verrouiller

WARNING •

When leaving the operator’s seat, always lower the wagon fully, lock the dump lever with the dump lever stopper, and place the brake lock lever in the lock position to apply the parking brake securely.

•

Keep in mind that if the brake lock lever should not be placed in the lock position, the machine may move abruptly and a serious accident could occur.

•

If the brake pedal is not fully depressed, the brake may not work properly.

IMPORTANT •

Do not run the machine with the brake lock lever in the lock position. If the machine travels with the brake applied, a brake system failure may occur.

•

Before running the machine, always place the brake lock lever in the unlock position.

•

If the brake pedal is locked with the brake lock lever for many hours during parking in a cold place, the brake pedal and the brake lock lever may freeze and the machine may not be able to travel.

•

The brake lock lever is used to lock the brake pedal so that it serves as a parking brake.

(2) Brake pedal 1

1 = Brake pedal 2 = Press down

2

IMPORTANT •

Always release and return the travel pedal to the neutral position before depressing the brake pedal.

•

Keeping the brake pedal depressed long will degrade the brake performance and get the brake heated.

•

Use the engine brake on a long downward slope to avoid applying the mechanical brake continuously.

The brake pedal is used to bring the machine to a temporary stop or to stop running the machine.

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10 Description of operator’s area for C12R-A

(3) Steering levers

WARNING •

Never turn the machine on a slope. If you change the direction of travel of the machine on a slope, the machine may travel in an unexpected direction. Move down to flat ground and then make a turn.

•

Run the machine longitudinally on a slope. Never run the machine diagonally on a slope or across a slope to prevent it from overturning or skidding.

•

Always turn the machine at low speed on flat ground when the wagon is loaded. Making a quick turn may cause the load to shift, come apart or fall.

IMPORTANT Keep in mind that the center of turning of the machine varies depending on whether the wagon is loaded or unloaded.

2

1 5

4 3

6

8

7

(F) N (R)

1 = Steering brake 2 = Steering clutch 3 = Stop 4 = Start 5 = Off 6 = On 7 = Pivot turn 8 = Gentle turn The steering levers control the turning of the machine.

The machine turns in response to the movement of each steering lever.

Operate the steering lever (R) to turn the machine to the right.

Operate the steering lever (L) to turn the machine to the left.

(4) F/R (Forward-Reverse) lever The F/R lever is used to change the traveling of the machine between forward travel (F) and reverse travel (R).

Always release and return the travel pedal to the neutral position before operating the F/R lever. If the travel pedal is not in the neutral position, the F/R lever cannot be operated.

On a slope, always stop the machine, apply the brake, and then operate the F/R lever.

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10 Description of operator’s area for C12R-A

(5) Travel pedal The travel pedal employs H.S.T., which allows travel speed control through pedal operation.

After moving the F/R lever to the forward travel position or to the reverse travel position, depress the travel pedal, and the machine will travel in that direction.

Note : As you depress the travel pedal, the travel speed increases but the power decreases. When more power is required, return the depressed pedal to an appropriate extent to reduce the travel speed.

(6) Travel speed select lever (B) (A)

Placing the travel speed select lever in the low speed position allows the machine to operate without an engine stall even with the travel pedal depressed. When more power is required with the lever in the low speed position, return the depressed pedal to an appropriate extent to reduce the travel speed. On a slope of 10 degrees or more, place the lever in the low speed position.

Traveling Condition Traveling on a slope Traveling on rough or muddy ground Traveling on flat ground

Lever Position (B) (Low speed) (A) (High speed)

(7) Accelerator lever The accelerator lever controls the engine speed (output).

(A) Idling : Push the lever forward fully.

(B) Run : Pull the lever backward fully.

(A) (B)

(8) Dump lever

WARNING •

Be aware that the machine body may be raised suddenly and tip over due to its momentum when dumping the wagon on a slope.

•

It is dangerous to run the machine with the wagon in the dump position, because the machine will be unstable.

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10 Description of operator’s area for C12R-A

•

1

(A)

Make sure that there are no persons near the machine before dumping the wagon.

The dump lever is used to dump and lower the wagon.

1 = Dump lever (A) Dump : Push the lever forward.

(B) Lower : Pull the lever backward.

(B)

(9) Dump lever stopper

2

WARNING

1

Always lock the dump lever with the dump lever stopper before inspecting, servicing or storing the machine.

The dump lever stopper is used to lock the dump lever.

1 = Lock 2 = Dump lever stopper

10.4 Engine hood

WARNING Do not open the engine hood while the engine is running.

Check and service the engine after it has been stopped and temperatures have cooled.

2

1 3 4 5

(1) Opening the engine hood 1 = Lock 2 = Key 3 = Open 4 = Unlock 5 = Lever •

Insert the starter switch key into the key hole in the engine hood and turn it counterclockwise to unlock the engine hood.

•

Turn the engine hood lever counterclockwise to release the engine hood, and it will open.

•

Open the engine hood fully, and it will be locked with the stopper rod.

62

10 Description of operator’s area for C12R-A

1

2

(2) Closing the engine hood 1 = Engine hood 2 = Stopper rod •

Raise the engine hood slightly and pull the stopper rod to disengage it.

•

Close the engine hood and press it until it clicks shut.

•

Check that the lever is in the lock position.

•

Turn the starter switch key clockwise to lock the engine hood.

10.5 Storage compartment for the operation & maintenance manual 1

2

The storage compartment for the Operation & Maintenance Manual is provided inside the engine hood.

Be sure to keep the Operation & Maintenance Manual in the provided vinyl bag and store it in the storage compartment, so that you can take out the manual from there and refer to it whenever you need.

Open the engine hood and take out the Operation & Maintenance Manual.

1 = Engine hood 2 = Storage compartment for operation and maintenance manual

10.6 Fuses

CAUTION •

When replacing a fuse, be sure to turn off the power by turning the starter switch key to the OFF position.

•

Using the wrong fuse or shorting out a fuse holder could damage the gauges, the electrical equipment and the wiring due to overheating.

•

If a new fuse blows out immediately after replacement, there may be a problem with the electrical system. Ask your dealer for assistance.

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10 Description of operator’s area for C12R-A

The following two types of fuses are used in the electrical wiring circuit: Blade fuse •

Protect the electrical equipment from overcurrent which exceeds the allowable limit of the electrical equipment.

•

Protect the wiring from overcurrent which exceeds the allowable limit of the wiring due to a problem with the electrical equipment.

Slow-blow fuse •

2

1 3

Protect the electrical equipment and the wiring from a burnout caused by overcurrent which flows in the circuit for large-capacity current when a problem occurs (such as short-circuit due to breaking of wire).

Position of the fuse Open the engine hood.

The fuse is installed at the rear on the right side of the machine.

4 5 (a)

1 = Lock 2 = Key 3 = Open 4 = Unlock 5 = Lever (a) : Blade fuse (b) : Slow-blow fuse

(b)

Replacing the fuses If the electrical equipment does not operate when the starter switch is turned to "ON" or "START", the fuse may have been blown out. Follow the procedure below: • Turn the starter switch key to the "OFF" position.

4

3

2

1

•

Open the fuse holder to take the fuses out.

•

If a fuse is blown out, replace it with a spare fuse of rated capacity.

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10 Description of operator’s area for C12R-A

Blade fuse Symbol

Fuse capacity

Circuit name

1

10A

Engine stop solenoid Timer

2

10A

Headlight (option) Horn Buzzer Alarm lamps Hourmeter Current limiter Back buzzer

3

Empty

4

10A

Spare fuse

Slow-blow fuse •

Open the slow-blow fuse cover to check it and replace it if necessary.

10.7 Fuel cap The fuel cap is provided with a key locking system. Use the starter switch key to open and close the fuel cap.

3

4

Locking and unlocking the fuel cap 1 = Starter switch key 2 = Lock 3 = Unlock 4 = Fuel cap cover 5 = Fuel cap

2 1

5

Unlocking the fuel cap •

Open the fuel cap cover and insert the starter switch key into the key hole in the fuel cap. Then, turn the key clockwise to unlock the fuel cap.

•

Turn the fuel cap counterclockwise and remove it.

Locking the fuel cap •

Install the fuel cap and turn it clockwise.

•

Turn the starter switch key counterclockwise to lock the fuel cap.

•

Remove the key.

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10 Description of operator’s area for C12R-A

10.8 Wagon support

WARNING Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

The wagon support serves to prevent the wagon from lowering. To install and remove the wagon support, follow the procedure below.

Installing the wagon support

1 2 3

4 5

A

1 = Dump lever 2 = Dump 3 = Lock 4 = Lower 5 = Dump lever stopper A = Wagon support •

Start the engine and idle it.

•

Move the dump lever to the dump position to dump the wagon fully.

•

Install the wagon support as illustrated.

•

Slowly move the dump lever to the lower side to lower the wagon slightly and securely engage the wagon support.

•

Stop the engine. Move the dump lever back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever with the dump lever stopper.

Removing the wagon support •

Unlock the dump lever, slowly move the dump lever to the dump side and remove the wagon support.

•

Return the wagon support to its storage position.

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11 Description of operator’s area for C30R-2A

11

Description of operator’s area for C30R-2A This section describes several of the control devices necessary to operate the machine. In order to ensure safety and comfort in working with the machine, it is imperative for you to fully understand how to operate and interact with these devices.

11.1 Monitor (6)

(3)

(2)

(5)

(4)

(1)

003681-00E

WARNING When an indicator lamp lights and a buzzer sounds during operation, immediately stop operation and check and service the abnormality.

When the starter switch key is turned to the “ON” position, the monitor lamps light and a buzzer sounds.

(Only the water temp. alarm lamp goes off in a few seconds.)

Normally, all monitor lamps go off after the engine starts.

When there is any failure during operation, a lamp lights and a buzzer sounds. (If the starter switch key is turned to the “ON” position and a monitor lamp does not light, its bulb must be burned out.)

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11 Description of operator’s area for C30R-2A

(1) Fuel oil gauge The fuel gauge works while the key is in the "ON" position and indicates the fuel amount in the fuel tank. When the gauge pointer indicates close to E (empty), refill fuel oil soon.

• It is not abnormal that the fuel oil gauge may not indicate properly immediately after the key is turned to "ON".

•

The reading on the fuel meter scale is affected by how much the machine is slanted.

(2) Engine oil pressure warning lamp If engine oil pressure falls below the normal level, the warning lamp will turn on and the buzzer will sound. In this event, stop the engine and inspect it.

003683-00X

(3) Battery charge warning lamp If the battery is not charged properly, the warning lamp will flash and the buzzer will sound. In this event, inspect the battery charging circuit.

003684-00X

(4) Water temp alarm lamp

003685-00X

When the key is in the "ON" position, the water temp alarm lamp lights and goes off in a few seconds. When the cooling water temperature rises abnormally during operation, the alarm lamp and buzzer go on, indicating engine overheating.

Idle the engine for a while, and stop the engine. After the engine has cooled, check the cooling water level, fan belt tension or radiator fins. Then take corrective actions.

(5) Parking lamp Only when you throw the parking brake lever to the "ON" (PARK) position while the engine is running, the parking lamp will turn on.

003686-00X

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11 Description of operator’s area for C30R-2A

(6) Hourmeter

a

The hourmeter indicates the accumulated service hours for the machine.

The reading of the hourmeter helps you set time intervals for periodic servicing of the machine. While the engine is running, the hourmeter will continue registering even if the machine is not being operated.

• While the engine is running, the green pilot lamp will flash indicating the hourmeter is counting.

b

•

The hourmeter registers "1" per hour regardless of engine rotational speed.

a = Pilot lamp b = Hourmeter

11.2 Switches (2)

(4)

(3)

(1) 003688-00X

(1) Starter switch Use this switch to start and stop the engine.

•

OFF Turn the key to "OFF" to stop the engine and disconnect electrical circuit or remove the key.

•

ON Turn the key to "ON" to connect electrical fuel solenoid circuit and electrical charging circuit. (Key position while running.)

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11 Description of operator’s area for C30R-2A

•

START Turn the key to "START" to start the engine. Release the key after the engine is started and it will return to the "ON" position.

AIR HEATER a

•

AIR HEATER Turn the key to activate the preheat circuit and warm up intake air to start engine easier in cold weather.

When the engine is not running and the switch is in "ON" position, the buzzer keeps sounding.

Turn the switch to the "OFF" position to stop sounding.

b

(2) Horn switch

c

Push the switch down to sound the horn. Release to stop. b = Push c = Horn switch

(3) Light switch

d

Turn the light switch (d) while the starter switch is in the "ON" position to turn on the head lamps and gauge backlights.

(2)

(1)

Position (1) : The gauge backlights are on, and the head lights illuminate downward.

Position (2) : The gauge backlights are on, and the head lamps illuminate upward.

Position OFF : All lamps are off.

Do not turn on the lamps for a long time while the engine is not running. The battery runs down and the engine cannot be started.

e R

L

(4) Turn signal switch While setting the starter switch to the "ON" position, turn this switch clockwise (counterclockwise), and the right (left) turn signal indicator lamp will flash.

Turn signal switch e = Turn signal switch R = Turn signal right L = Turn signal left

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11 Description of operator’s area for C30R-2A

11.3 Control levers and pedals (5) (1)

(3)

(2)

(4) (6) (7)

(5)

(2)

003693-00X

(1) Parking brake lever

WARNING •

When you are going to leave the driver's seat, set the parking brake lever securely to the "ON" (PARKING) position to apply the brake. If the parking brake lever should not be placed at the "ON" (PARKING), the machine can move suddenly, causing a serious accident.

•

If the parking brake lever is not be placed securely at the "ON" (PARKING) position, it may not work.

IMPORTANT If the machine travels with the lever of the parking brake set to the "ON" position, a problem may occur in the travel system. Be sure to set the lever to the "OFF" position before you start traveling. To release the parking brake, position the lever to "OFF".

a

b

The lever actuates the parking brake.

Position ON : actuates the parking brake.

Position OFF : releases the parking brake only when the engine is running. a = Parking b = Run

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11 Description of operator’s area for C30R-2A

(2) Brake pedal

IMPORTANT Pressing on the brake pedal for long time will degrade brake performance and overheat the brakes. Use a engine brake on long slopes to avoid having to pump the brakes repeatedly.

a

Use the brake pedal to make a temporary stop or to stop the machine when driving.

b

a = Brake pedal b = Step on

(3) Steering lever

WARNING

1

•

If you change the course on a slope, the machine may travel in an unexpected direction.

•

On a slope, directly travel up or down the slope.

•

Diagonally traveling a slope or traveling across the slope may cause turn-over or side skid.

•

You have to turn the machine slowly if needed. If you turn the machine quickly, it may cause the material pile on the wagon to crumble and drop out of the deck.

IMPORTANT Keep in mind that the center of turning will vary depending on whether the wagon is full or empty.

The steering lever controls machine travel.

The machine will turn in response to the direction you turn the lever.

003696-00E

1 = Travel lever

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11 Description of operator’s area for C30R-2A

(4) Steering clutch lever

WARNING The machine will turn in the direction indicated by the arrows, regardless of whether the seat faces forward or backward.

This lever can be used to change direction, and to change high or low speed.

A = Steering clutch lever When the seat is facing forward

A (1)

1 = Forward : The position in which the lever is pushed forward.

(2)

2 = Backward : The position in which the lever is pulled backward.

When the seat is facing backward 1 = Backward : The position in which the lever is pulled backward.

2 = Forward : The position in which the lever is pushed forward.

1

B

(5) Accelerator pedal The accelerator pedal controls the engine rotation speed (output).

B = Accelerator pedal 1 = Step on

(6) Dump lever

WARNING

B (2)

(1)

•

If you dump the materials out of the wagon on a slope, the machine may float above the ground and tip over by reaction.

•

If you travel with the wagon raised up, the machine will get unstable dangerously.

•

Before dumping, make sure that there is nobody around the machine.

The dump lever is used to raise and lower the wagon.

(1) Up position : The wagon goes up.

(2) Down position : The wagon goes down.

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11 Description of operator’s area for C30R-2A

(7) Lock lever

WARNING D 1 2 E

Before you check, service, or store the machine, support the lifted body using the stopper, and then be sure to lock the dump lever using the dump lever lock.

The lever lock is used to lock the dump lever.

D = Dump lever 1 = Unlock 2 = Lock E = Lock lever

11.4 Engine hood

WARNING Do not open the engine hood while the engine is running.

Check and service the engine after it has been stopped and temperatures have cooled.

CAUTION Before checking or performing maintenance under the engine bonnet, always lift the bonnet and lock ²it securely with the lock stay.

1. Opening the engine hood

1

2

1) Insert the starter key and turn counterclockwise to unlock.

2) Pull the engine hood lever forward to disengage the lock, pull up the hood slightly, and then the hood automatically opens.

3) Open the engine hood fully, and it will be locked with the stopper rod.

1 = Unlock 2 = Lock 3 = Engine hood 4 = Pull 5 = Engine hood lever

3

4 5

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11 Description of operator’s area for C30R-2A

2. Closing the engine hood

6

1) Lift the engine bonnet to release the lock stay (pull the stay toward you). Then, lower the bonnet and push down on it gently until it engages the lever catch 2) Turn the starter switch key clockwise to lock the engine hood.

7

6 = Engine hood lock stay 7 = Unlock

1

2

11.5 Storage for tools and the operation & maintenance manual Place the tools in the tool box, which is located in the front right area of the seat pedestal. Store the operation & maintenance manual in the tool box cover.

1 = Tools 2 = Operation & maintenance manual 3 = Cover

3

11.6 Fuse box and fusible link Fuse box

CAUTION 1

2 (A) (B)(C) (D) (E)

1

•

When replacing the fuse, be sure to turn off the electric power by turning the starter switch key to the "OFF" position.

•

Using a fuse of more than 15 A capacity, or shorting out a fuse holder could damage the gauges, electrical equipment and wiring.

•

If a new fuse blows out immediately after replacement, some electrical problem may exist. Contact the nearest dealer.

1 = Fuse box 2 = Cover The fuse protects the electrical equipment and wiring from becoming overheated. If the fuse is corroded with white deposits or if the fuse is loose in the holder, the fuse must be replaced with a new one.

Position of the fuse box and the fuse holder

(F)

(G)

The fuse box is located in the tool box, which is at the front right of the seat pedestal.

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11 Description of operator’s area for C30R-2A

Replacing the fuses When a device does not activate, check the fuse for blowout.

To check and replace the fuse with a new one : 1) Turn the starter switch to the "OFF" position.

2) Loosen the bolt and remove the cover.

3) When the fuse is damaged as illustrated on the left, replace it with a new one.

000370-00X

Fuse capacity and circuit name

Symbol A B C D E F G

Fuse capacity 15A 30A 15A 15A 15A 15A 5A

Circuit name Lamp checker, indicator box, buzzer Turn signal lamp, horn, head lamps, tail lamp Work lamp (option) Forward and backward solenoid Engine stop solenoid, feed pump, current limiter Spare fuse Spare fuse Fusible link

1

If there is no power to the machine (the lights won’t come on) when the key switch is turned on, a blown fuse may be the cause. Open the step to check or replace the fuse.

1 = Fusible link 0.85 Note : The fusible link is a special high-capacity fuse which is used In circuits that provide large currents.

Just as normal fuses do, the fusible link keeps electrical equipment and wires from being damaged by abnormal amounts of current.

11.7 Operator’s seat

IMPORTANT When traveling on a road, make sure the seat is facing forward.

The seat can be rotated on the platform. Because of this, it is not necessary to get the machine to change direction in a small area.

• Rotate the seat while lifting the lock lever up.

•

1

Then, make sure the seat is secured in its new position by the

1 = Lock lever

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11 Description of operator’s area for C30R-2A

CAUTION Rotate the seat until it is locked completely in its new position. Do not turn the seat around when traveling. It is very dangerous.

11.8 Dump deck support stopper

WARNING To service the machine while lifting the wagon, be sure to support the wagon using the frame support and lock the dump lever.

The frame support serves to lock the wagon to prevent it from lowering down. To install and remove it, follow the steps: Installing the frame support 1) Start the engine, then idle.

1

2) To dump the wagon, move the dump lever to the "UP" position.

3) Attach the frame support as illustrated.

4) Slowly move the dump lever toward the "DOWN" position to allow the stopper to be set in position.

5) Stop the engine and lock the dump lever.

Removing the dump deck support stopper

D

1) Slowly move the dump lever to the "UP" position to remove the frame support.

2) Store the frame support in place.

1 2 E

D = Dump lever 1 = Unlock 2 = Lock E = Lever lock

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12 Description of operator’s area for C50R-3B

12

Description of operator’s area for C50R-3B This section describes several of the control devices necessary to operate the machine. In order to ensure safety and comfort in working with the machine, it is imperative for you to fully understand how to operate and interact with these devices.

12.1 Monitor (C)

(B)

(C)

(A)

(A) Emergency stop items Attention must be paid to these items while the engine is running. The item requiring treatment would be displayed immediately. When there is any failure, the alarm lamps light and a buzzer sounds.

(B) Meters These indicate the cooling water temperature for the engine, the fuel amount in the fuel tank, and the service hours for the machine.

(C) Indicator lamps These indicate the state of the engine preheating and the swing state of the wagon.

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12 Description of operator’s area for C50R-3B

(C) (2)

(B) (2) (3) (1)

(C) (A) (1) (4) (1) (2) (3)

(A) Emergency stop items

WARNING When an indicator lamp lights and a buzzer sounds during operation, immediately stop operation and check and service the abnormality.

When the starter switch key is in the .ON. position, the monitor lamps (1), (2), (3) and (4) light and a buzzer sounds.

(The water temperature alarm lamp (1) and air cleaner alarm lamp (4) go off in a few seconds.)

Normally, all monitor lamps go off after the engine starts.

When there is any failure during operation, a lamp lights and a buzzer sounds. (If the starter switch key is in the ON. position and a monitor lamp does not light, its bulb must be burnt out.)

(1) Water temp. alarm lamp When the cooling water temperature rises abnormally during operation, the alarm lamp will light and the buzzer will sound.

Idle the engine at low speed for a while, and stop it. After the engine has cooled, take corrective actions.

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12 Description of operator’s area for C50R-3B

(2) Engine oil pressure alarm lamp If engine oil pressure falls below the normal level, the alarm lamp will light and the buzzer will sound. In this event, stop the engine and inspect it.

(3) Battery charge alarm lamp If the battery is not charged properly while the engine is running, the alarm lamp will light and the buzzer will sound. In this event, stop the engine and inspect the V-belt for slack and the battery charging circuit. If you find something abnormal with it, take corrective action.

(4) Air cleaner alarm lamp If the air cleaner filter is clogged while the engine is running, the alarm lamp will light and the buzzer will sound. Stop the engine and clean the filter of the air cleaner.

(B) Meters (1) Hourmeter The hourmeter starts operating after the engine starts. It indicates the accumulated service hours for the machine.

The reading of the hourmeter helps you set time intervals for periodic servicing of the machine. While the engine is running, the hourmeter will continue registering even if the machine is not being operated.

(2) Fuel meter This indicates the fuel amount in the fuel tank. When the meter pointer indicates close to E (empty) during operation, refill fuel tank soon.

The reading on the fuel meter scale is affected by how much the machine is slanted.

The fuel meter indicates the fuel amount regardless of whether the starter switch key is in the «ON.» or «OFF» position.

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12 Description of operator’s area for C50R-3B

1

(3) Water temp. meter

2

This indicates the cooling water temperature for the engine.

During the normal operation, the water temperature is within the green portion of the scale. When the cooling water temperature rises to the red portion of the scale, idle the engine at low speed until the water temperature cools down. Stop the engine and inspect it after the engine has cooled.

1= Green 2 = Red

(C) Indicator lamps (1) Glow lamp This indicates the required time for the engine preheating when starting the engine in the cold weather. The indicator lamp lights when the preheating starts and goes off in 15 seconds to indicate the end of the preheating.

(2) Wagon center indicating lamp (for the swing wagon type)

2

1 3

The indicator lamp lights when the wagon is in parallel to the crawlers and goes off when it swings to the right or the left.

1 = Lamp off 2 = Lamp off 3 = Lamp on

12.2 Switches (8) (2) (3)

(1)

(4) (6) (7) (5)

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12 Description of operator’s area for C50R-3B

(1) Starter switch

OFF

START

ON

Use this switch to start and stop the engine.

Cover the starter switch with a waterproof cover when the starter switch key is removed.

•

GLOW

OFF position Turn the starter switch key to "OFF" to stop the engine and disconnect electrical circuit or remove the starter switch key.

•

ON position Turn the starter switch key to "ON" to connect the electrical fuel solenoid circuit, the electrical charging circuit and the lamp circuit. (Keep the starter switch key in this position while running the engine.)

•

START position Turn the starter switch key to "START" to start the engine.

Release the starter switch key after the engine is started and it will return to the "ON" position.

•

T.S. (preheating) position Turn the starter switch key to .T.S.. when starting the engine in cold weather. Keep the starter switch key in this position, and the glow lamp will light and engine preheating will be activated. The glow lamp will go off in 15 seconds.

Then, immediately turn the starter switch key to «START» to start the engine.

(2) Travel speed change switch

WARNING When the load exceeds the specified level while the machine is traveling at high-speed, the travel speed of the machine is automatically switched to the low-speed.

When the load becomes lighter, the travel speed is automatically returned to the high-speed. Be careful in traveling with the machine as the travel speed changes depending on the load condition.

Press the switch button down to switch between the automatic speed change and the fixed low speed.

1 a 2 b

•

2 (Lamp ON) : Automatic speed change between high and low speed

•

1 (Lamp OFF) : Fixed low speed

a = Low-speed b = Travel-speed change

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12 Description of operator’s area for C50R-3B

(3) Horn switch A horn sounds by pressing the horn switch regardless of the position of the starter switch key.

(4) Light switch It operates when the starter switch is in the «ON» position.

The headlights and the indicator box light go on.

• •

position : The headlights and the indicator box light go on.

OFF : The lights go off.

IMPORTANT Do not keep the lamps on for a long time while the engine is not running. The battery will run down and the engine may not start.

(5) Wiper and windshield washer switch (for cabin) It operates when the starter switch is in the «ON» position.

•

position : Wiper works.

•

OFF : Wiper stops.

•

PUSH : The windshield will be sprayed with washer fluid.

IMPORTANT •

Do not push the wiper switch when the washer fluid tank is empty, as it could cause pump failure.

•

Wiping a dry windshield could damage the glass.

Use the wiper only when the windshield is wet.

•

The wiper blade may freeze in cold weather. Do not attempt to move it; otherwise the wiper motor will sustain damage.

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12 Description of operator’s area for C50R-3B

(6) Heater switch (for cabin) Use this switch to warm up the air in the cabin or canopy.

Move the switch to set the fan speed at either of the two levels.

• position : Low fan speed.

• •

position : High fan speed.

OFF : Fan stops.

Operate the heater switch after the cooling water has warmed up.

Open and close the circulation valve for the cooling water at the beginning and the end of the season when the heater is used, respectively.

1

1 =Circulation valve for the cooling water

1

2

(7) Cigarette lighter (for cabin)

WARNING

3

Do not keep the lighter knob pressed down. The wire may burn out, and it could cause a fire.

It operates when the starter switch is in the .ON. position. Use it to light a cigarette. Press down the lighter and release it. After a while the lighter will automatically pop up. Pull it out of the socket when using it. Clear cigarette from the lighter before putting it back in the socket.

1 = Press 2 = Remove 3 = Pop up

IMPORTANT If the lighter does not pop up within 30 seconds after pressing it down, there is something wrong with it.

Pull it out of the socket.

R L

(8) Turn signal switch It operates when the starter switch is in the «ON» position.

When the turn signal switch is set to the «L» (left) or «R» (right) position, the left or right turn signal lamp will flash.

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12 Description of operator’s area for C50R-3B

12.3 Control levers (5)

(1) (4) (3) (2)

(1) Lock levers (for the travel operation) The lock levers locks the travel operation. When the lock levers are pulled back, the parking brake is applied to lock the travel operation.

WARNING •

When leaving the operator's seat, be sure to lower the wagon fully and move all lock levers to the lock positions. Keep in mind that if you should touch an unlocked lever inadvertently, a serious accident could occur.

•

Do not operate the lock levers while the machine is traveling. If the lock levers are pulled back during the machine travel, the parking brake will be applied, and the machine could make a hazardous sudden stop.

•

Be sure to place the lock levers securely in the lock position. If not, they could slip out of the lock position.

Thus always make sure that the lock levers are in the lock position as illustrated in the figure at the right.

•

When operating the lock levers, be careful not to touch the travel levers. Remember that if the lock lever is not pulled back fully, the implement will not be locked.

•

Note that even if the lock levers are in the lock position, the dump operation of the wagon is not locked.

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12 Description of operator’s area for C50R-3B

IMPORTANT The machine uses the hydraulic lock system. If the lock lever is in the lock position, the travel motors will not operate although the travel levers are free to move. To reverse the operator’s seat, also use the lock levers.

(2) Dump lock lever

WARNING Be sure to set the dump lock lever to the lock position before inspecting, servicing or storing the machine.

Use this lever to lock the dump lever. When dump lock lever is pushed down, the dump lever is locked.

(3) Dump lever

WARNING

(B)

(N)

(C)

(D) (A)

•

Be aware that the machine body may be raised suddenly and tip over due to its momentum when dumping the wagon on a slope.

•

It is dangerous to run the machine with the wagon in the dump position, because the machine will be unstable.

•

When traveling with the machine, keep the wagon parallel to the crawlers. If the machine travels with the wagon swung to the right or the left, the machine will be unstable. (For the swing wagon type.)

•

Make sure there are no persons near the machine before dumping the wagon.

Use this lever to dump and lower the wagon. For the swing wagon type, the dump lever is also used for the swing operation of the wagon.

(A) Dump : The wagon is raised.

(B) Lower : The wagon is lowered.

For the swing wagon type (C) Right swing : The wagon rear is turned to the left.

(D) Left swing : The wagon rear is turned to the right.

Neutral position : The wagon is stopped and kept in the position.

(4) Accelerator lever (A)

(B)

The accelerator lever controls the engine speed (output).

(A) LOW IDLING : Push the lever fully forward.

(B) RUN : Pull the lever fully backward.

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12 Description of operator’s area for C50R-3B

(5) Travel levers

WARNING •

Never turn the machine on a slope or run it across the slope. Move down to flat ground and then make a turn to travel safely.

•

Run the machine longitudinally on a slope. Never run the machine diagonally on a slope or across a slope to prevent it from overturning or skidding.

•

Be sure to turn at low speed. Making a turn at high speed or a spin-turn may cause a load shift or falling load.

•

Do not return the travel levers to neutral position quickly while the machine is traveling at high speed. Return the travel levers to neutral position slowly.

IMPORTANT (A)

(A)

N

N

(B)

(B)

Note that the center of turn of the machine varies depending on whether the wagon is in loaded or unloaded state.

The travel levers control the traveling of the machine.

(A) Forward : Push the travel levers forward together.

(B) Reverse : Pull the travel levers backward together.

N = Neutral position : The machine stops.

12.4 Engine hood

WARNING •

Do not open the engine hood while the engine is running. Check and service the engine after it has been stopped and temperatures have cooled.

•

Be extremely careful in windy weather as the engine hood may be closed by a strong wind.

(1) Opening the engine hood (B) (A)

•

Insert the starter switch key into the cylinder key (A) and turn it counterclockwise to unlock the engine hood (B).

•

Turn the handle (B) to the right and lift the engine hood.

•

Set the stay (C) up and insert it into the stay hole in the engine hood to hold it.

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12 Description of operator’s area for C50R-3B

(2) Closing the engine hood (C)

•

Remove the stay (C) while supporting the engine hood by hand and put it back in the holder.

•

Close the engine hood softly and press it down holding the handle (B) in your hand.

•

Insert the starter switch key into the cylinder key (A) and turn it clockwise to lock the engine hood.

12.5 Side cover The air cleaner and the water separator are stored in the cover.

(1) Opening of the side cover •

Insert the starter switch key and turn it counterclockwise to unlock the side cover.

•

Fully open the cover, and the cover is locked.

(2) Closing of the side cover •

Hold the side cover by hand and disengage the stay to release the lock.

•

Close the side cover softly.

•

Insert the starter switch key and turn it clockwise to lock the side cover.

12.6 Battery cover The battery is stored in the battery cover.

(1) Opening of the battery cover •

Insert the starter switch key and turn it counterclockwise to unlock the battery cover.

•

Fully open the cover, and the cover is locked.

(2) Closing of the battery cover •

Hold the battery cover by hand and disengage the stay to release the lock.

•

Close the battery cover softly.

•

Insert the starter switch key and turn it clockwise to lock the battery cover.

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12 Description of operator’s area for C50R-3B

12.7 Cabin Handling the cabin

1

9 2 3 8 7

4

5

6

1) Antenna

6) Door handle

2) Upper windshield

7) Side door

3) Wiper

8) Door stopper

4) Lower winshield

9) Side glass

5) Cylinder key

WARNING •

To avoid bodily injury while operating the machine, make sure the side door and upper windshield are securely locked in either the open or shut position.

•

If they are not securely locked, they may open or close unexpectedly.

•

Never stick your hands or your head out of an open side door or windshield.

WARNING Both the upper and lower windshields can be opened and closed.

Securely lock the upper and lower windshield with the locks when storing or closing them.

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12 Description of operator’s area for C50R-3B

Opening and closing the cabin side door (B)

(1) From outside

(A)

•

Insert the starter switch key into the cylinder key (A).

•

Turn the key clockwise to unlock the side door.

•

Pull the door handle (B) to the side to open the side door.

•

Fully open the side door and press it on the cabin until the latch clicks, and the side door can be latched with it open.

•

When closing the side door latched with it open, push forward the release lever (C) or push down the release lever (D) inside the cabin.

•

Close the unlatched side door and turn the starter switch key counterclockwise to lock the side door.

(D) (C)

(2) From inside

(E)

•

Turn the inner handle (E) forward, and the side door opens.

•

When closing the side door latched with it open, push forward the release lever (C) or push down the release lever (D) inside the cabin to unlatch the side door.

•

Close the side door grasping the door handle.

1

Opening and closing the upper windshield

WARNING •

To avoid bodily injury, securely grasp the handles with both hands when opening and closing the windshield.

•

To avoid bodily injury while operating the machine, make sure the upper windshield is securely locked when it is in the open position. If it is not securely locked, it may close unexpectedly.

•

Never stick your hands or your head out of an open windshield.

The upper windshield can be opened and closed from inside and housed under the ceiling. When opening and closing the upper windshield, follow the steps below.

1

2

(1) Opening the upper windshield 1 = Unlock 2 = Lock

(A)

(A)

90

12 Description of operator’s area for C50R-3B

(A) (B)

(A)

(C)

•

Set the lock lever of the right and left stoppers (A) to the unlock position to unlock the upper windshield.

•

Grasp the lower handle (C) and the upper handle (B) with your left and right hands, respectively.

•

Raise the upper windshield and then slide it backwards.

•

Set the right and left stoppers (A) in position to lock the upper windshield securely while it is housed under the ceiling.

(2) Closing the upper windshield •

To close the upper windshield, set the lock lever of the right and left stoppers (A) to the unlock position.

•

Grasp the handles (B) and (C) to lower the upper windshield slowly.

•

Set the right and left stoppers (A) in position to lock the upper windshield securely.

(C) (A) (B) (A)

(D)

Opening and closing the lower windshield

(D)

CAUTION Open and close the lower windshield only after the upper windshield is housed under the ceiling.

(D)

(D)

(E)

(E)

(F)

•

Open and house the upper windshield under the ceiling.

•

Hold the lower windshield by the right and left projected parts (D) with your fingers to pull it out slowly.

•

Hold the lower windshield securely and put it on the supports (F) through the guides (E) at the rear of the cabin so that it is fixed.

(F)

(G)

Opening and closing the right window glass The windows on the right can be slid to the right and left directions.

• Unlock the window by taking the stopper (G) with your fingers.

•

Slide the window to the rear side of the machine.

Ash tray

CAUTION •

Be sure to completely put your matches and cigarettes out before placing them in the ash tray.

•

Do not place any combustible matter in the ash tray.

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12 Description of operator’s area for C50R-3B

•

Be sure to close the ash tray when it is not in use, or it may cause a fire.

•

Do not pile too much cigarette butts in the ash tray.

Pull the ash tray toward you when using it. To empty and clean the ash tray, lift it up while pressing the metal part for knocking ash.

12.8 Storage for tools and the operation & maintenance manual 1

The storage pocket have been provided at the positions shown in the figure at the left. Keep the operation & maintenance manual in a nylon bag and store it in either of the storage pocket so that you can refer to it whenever you need.

1 = Canopy

2 2 = Cabin

12.9 Fuse box

CAUTION •

When replacing a fuse, be sure to turn off the power by turning the starter switch key to the OFF position.

•

Using the wrong fuse or shorting out a fuse holder could damage the gauges, the electrical equipment and the wiring due to overheating.

•

If a new fuse blows out immediately after replacement, there may be a problem with the electrical system. Ask your dealer for assistance.

The fuses protect the electrical equipment and the wiring from a burnout.

If a fuse is corroded with white deposits or if a fuse is loose in the holder, it must be replaced with a new one.

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12 Description of operator’s area for C50R-3B

Replacing the fuses

(a) (1)

•

Turn the starter switch key to the "OFF" position.

•

Turn the knob to the left to remove the cover (1).

•

Replace fuse with a spare fuse of rated capacity.

•

A spare fuse for each capacity of 10A, 20A, and 30A is attached beside the fuses.

Fuse capacity and circuit name The fuses are arranged in the order shown in the list below.

Fuse capacity

Circuit name

10A

Horn

10A

Instrument panel, high-speed travel, lock lever, parking brake

30A

Engine stop solenoid

20A

Headlight, turn signal light, backlight (option)

20A

Back buzzer, cigarette lighter (for cabin), heater (for cabin), wiper & window washer (for cabin), radio (for cabin), room lamp (for cabin)

30A

Standby power source, cooler

12.10 Fuel cap The fuel cap is provided with a key locking system. Use the starter switch key to open and close the fuel cap.

(a)

(b) (c)

(d)

(a) Open (b) Close (c) Unlock (d) Lock

Locking and unlocking the fuel cap 1) Unlocking the fuel cap •

Open the fuel cap cover and insert the starter switch key.

•

Turn the starter switch key clockwise to unlock the fuel cap.

•

Turn the fuel cap counterclockwise to remove it.

2) Locking the fuel cap •

Install the fuel cap and turn it clockwise.

•

Turn the starter switch key counterclockwise to lock the fuel cap.

•

Pull out the starter switch key, and close the fuel cap cover.

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12 Description of operator’s area for C50R-3B

12.11 Operator’s seat

WARNING •

Be sure to adjust the seat slide to obtain the best operating position whenever a new operator begins work.

•

Do not place any objects within the moving area of the operator’s seat.

•

Do not adjust the operator.s seat while operating the machine.

Adjust the seat so that the operator can easily operate the control levers in good posture.

Seat position control 1) Fore/aft adjustment •

Pull lever (A) upward to slide the seat forward and backward.

(Adjustable amount : 3.93 in. (100 mm))

(A)

2) Reversing operator’s seat

WARNING (B)

Be sure to stop the engine when reversing the operator's seat, to avoid bodily injury.

•

180 °

Pull the lock levers (B) back from their lock position to unlock the operator.s seat, and turn the seat 180 degrees. After reversing the seat, check that the seat is locked. When the seat is locked, the lock levers (B) automatically return to their lock position.

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12 Description of operator’s area for C50R-3B

3) Backrest angle adjustment •

Pull lever (C) upward to latch into the desired position.

(Adjustable amount : 90 degrees)

(C)

Suspension part control 1) Height adjustment •

Raise the operator.s seat to the required height until it audibly latches into place.

•

When the operator.s seat is raised above the highest setting, it drops back down to the lowest position.

(Adjustable amount : 3 positions) (Suspension stroke : 3.94 in. (100 mm))

2) Weight adjustment •

The seat can be adjusted for the operator.s weight by turning the weight adjuster lever (D) with the seat empty.

•

The setting weight can be read at the indicator (E).

•

Turn the weight adjuster lever (D) clockwise, the setting weight is increased.

•

Turn the weight adjuster lever (D) counterclockwise, the setting weight is decreased.

(Adjustable weight : 110 to 287 lbs. (50 to 130 kg))

(D)

(E)

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12 Description of operator’s area for C50R-3B

12.12 Wagon stopper

WARNING Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

The wagon stopper is the lock device to prevent a fall of the wagon. To install and remove the wagon stopper, follow the procedures below.

1) Installation of the wagon stopper •

Start the engine and idle it.

•

Set the dump lever to the dump position, and dump the wagon fully.

•

Lock the dump lever and stop the engine.

•

Install the wagon stopper to the wagon.

2)I Removal of the wagon stopper •

Unlock the dump lever and slightly move it to the dump side to remove the wagon stopper.

•

Remove the wagon stopper.

•

Lower the wagon fully.

•

Store the wagon stopper in the specified position.

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13 Operating Instructions for C12R-A

13

Operating Instructions for C12R-A 13.1 Checking before starting the engine Visual inspection around the machine

WARNING •

If there are any combustibles in any heat build-up areas, or if there are any fuel and/or oil leaks, a fire can result.

•

Check for possible fire causes carefully. If there is anything abnormal, be sure to take corrective action or contact your dealer.

Before starting the engine, visually check the outside and underside of the machine as follows: Check bolts and nuts for loose connections; check the fuel, oil, and water for leaks; and also check the wagon and the hydraulic system to see that they are in good condition. In addition, check the electrical wiring for loose connections and for dust deposits in the heat build-up areas.

(1)

(6)

(7)

(8)

(2)(3)

(4) (5)

(2)

(6)

Check the following points before initial start-up for the day: 1) Checking the wagon, hydraulic cylinder, pins, and hoses for damage, wear and loose connections.

2) Removing dust deposits from around the engine, battery, and radiator.

3) Checking the engine and its accessories for oil or water leakage.

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13 Operating Instructions for C12R-A

4) Checking the transmission for oil leakage.

5) Checking the undercarriage (crawlers, sprockets, rollers and idlers) for breakage, wear, loose bolts, and oil leakage around the rollers.

6) Checking the handrails and safety guards for breakage and loose bolts.

7) Checking the gauges, monitor, switches, and rearview mirror for breakage and loose bolts.

8) Checking the water separator to see whether the red ring has sunk down to the cup bottom.

Checking and replenishing the cooling water

WARNING Do not remove the fill cap from the radiator unless supplying the cooling water.

Check the cooling water level in the sub-tank when the engine is cool.

(1)

A B

1) Open the engine hood.

2) Check that the cooling water lever in the sub-tank (1) (illustrated in the figure at the right) is between the FULL and LOW marks. If the water level is below the LOW mark, refill the sub-tank up to the FULL mark through the water supply port of the sub-tank (1).

A = Full B = Low

2

3) After replenishing, securely tighten the water supply port cap.

4) If the sub-tank is empty, check it for water leakage, and then, check the water level in the radiator. If the water level is low, refill the radiator first, then refill the sub-tank.

5) If the cooling water level is appropriate, close the engine hood.

Checking and replenishing the engine oil

WARNING •

At operating temperature, the oil and dipstick areas are hot. Do not allow hot oil or hot components to contact the skin, to prevent bodily injury.

•

Check the oil level and replenish oil after the engine has cooled down sufficiently.

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13 Operating Instructions for C12R-A

1) Open the engine hood and open the cover (1) of the step.

2

1

1 = Lock 2 = Key 3 = Open 4 = Unlock 5 = Lever

3 4

2) Pick up the dipstick (G) and wipe it with a rag to remove oil deposits.

5

3) Fully insert the dipstick (G) into the dipstick tube, then draw it out.

(G) (1)

4) If the dipstick (G) is wet above the midpoint between the H and L marks, the engine oil level is appropriate. If the oil level is below the midpoint between the H and L marks, add engine oil through the oil supply port (F).

5) If the engine oil level is above the H mark, open the cover (2), then remove the excessive amount of oil through the drain plug (P), then recheck the engine oil level.

(F)

H L

6) After verifying that the amount of engine oil is appropriate, securely retighten the oil supply port cap. Close the cover of the step and close the engine hood.

Note : When checking the engine oil level after running the engine, stop the engine and allow more than 15 minutes for the engine to cool down.

If the machine is slanted, reposition the machine to ensure it is level before checking the engine oil level.

Keep in mind that the excess engine oil must not be disposed of on the ground or the road.

Checking and replenishing the fuel in the fuel tank

WARNING Be careful not to overfill the fuel tank because it could cause a fire. If the tank is overfilled, completely wipe off the spilled fuel.

CAUTION •

Do not remove the strainer from the fuel supply port of the fuel tank when supplying fuel.

•

Be careful not to allow any water that may be in the fuel container or dirt on the refueling equipment to enter the fuel tank.

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13 Operating Instructions for C12R-A

1) Check the fuel level with the fuel level gauge (b) on the fuel tank. If the fuel level is low, open the fuel cap and add fuel through the fuel supply port.

a

2) After refueling, securely close the fuel cap (a).

b Checking and replenishing the hydraulic oil in the hydraulic oil tank

WARNING

a b

•

Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

•

When removing the plug of the oil supply port, slowly loosen it to gradually relieve the internal pressure in the tank, or oil may spurt from the tank.

1) Park the machine on level ground. Dump the wagon, install the wagon support to hold the wagon securely and stop the engine. Then, move the dump lever back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever with the dump lever stopper.

2) Check the hydraulic oil level with the oil level gauge. If the oil level is between the upper limit and lower limit marks on the gauge, it is proper.

c d

3) If the hydraulic oil level is low, remove the oil supply port cap and add hydraulic oil until the oil level reaches the middle on the oil level gauge. a = Oil level gauge b = Oil supply port c = Upper limit d = Lower limit

IMPORTANT Do not replenish hydraulic oil above the midpoint between the upper limit and the lower limit marks on the oil level gauge with the wagon in the dump position. An excessive amount of hydraulic oil may damage the hydraulic system by placing stress on its components, causing a dangerous high-pressure leak.

Note : Note that the oil level varies with the oil temperature.

When reading the oil level, follow these guidelines: • Before start-up, the oil level gauge should read at or near the midpoint of the gauge scale. [oil temperature : 10 to 30°C].

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13 Operating Instructions for C12R-A

•

During normal operation, the oil level gauge should read at or near the upper limit mark of the gauge scale. [oil temperature : 50 to 80°C].

Checking the fan belt tension

WARNING a

•

Stop the engine, take out the starter switch key, and attach the “Do NOT operate” tag to the starter switch.

•

The drive belt is hot immediately after the engine is stopped. Do not adjust the drive belt tension immediately after stopping the engine.

•

Adjust the drive belt tension after all of the parts of the engine have cooled sufficiently.

1) Open the engine hood.

2

1 3 4

1 = Lock 2 = Key 3 = Open 4 = Unlock 5 = Lever 2) Check the fan belt for cracks and peeling.

5

3) Press down on the fan belt between the fan pulley and the generator with a finger, to check the fan belt tension.

Pressing force : Approximately 10 kg Correct slack : 10 to 15 mm

a

b c

a = Fan pulley b = Generator c = Fan belt 4) Adjust the tension if necessary.

5) When the tension is proper, close the engine hood.

IMPORTANT Improper fan belt tension will shorten the life of the belt.

Checking the drive belt tension

WARNING •

Stop the engine, take out the starter switch key, and attach the “Do NOT operate” tag to the starter switch.

•

The drive belt is hot immediately after the engine is stopped. Do not adjust the drive belt tension immediately after stopping the engine.

•

Adjust the drive belt tension after all of the parts of the engine have cooled sufficiently.

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13 Operating Instructions for C12R-A

1) Open the engine hood and remove the step.

2) Press down on the drive belt between the engine pulley and the H.S.T. pulley with a finger and check the drive belt tension. Check the drive belt for damage.

Pressing force : 2.5 to 3.5 kg Correct slack : 10 mm 3) Adjust the tension if necessary.

4) If the tension is proper, install the step and close the engine hood. a = Engine pulley b = HST pulley c = Lock nut

a b

IMPORTANT

c

Improper drive belt tension will shorten the life of the belt.

Checking and adjusting the rubber crawler tension

WARNING •

When raising the machine, support it with safety blocks of sufficient strength.

•

When the machine is being checked or adjusted by two persons, one must operate the machine in response to signs from the other.

How a rubber crawler wears out depends on the working conditions and the nature of the ground. Be sure to check the rubber crawlers for wear and tension from time to time.

Checking the rubber crawler tension

1

(20 - 30 mm)

•

After moving the machine forward and backward two or three times on level ground, reverse the machine and gather slack on the upper side of the rubber crawler.

•

Place a weight of about 60 kg on the rubber crawler between the idler and the carrier roller and measure the slack. If it is between 20 mm and 30 mm, the rubber crawler tension is proper.

2 3

1 = Carrier roller 2 = Idler 3 = Bottom surface of middle track roller 4 = Rubber crawler •

(30 mm)

4

Alternatively, jack up one rubber crawler from the ground and measure the clearance between the bottom surface of the middle track roller and the inside surface of the rubber

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13 Operating Instructions for C12R-A

crawler. If the clearance is about 30 mm, the rubber crawler tension is proper.

•

If the rubber crawler tension is improper, adjust it as follows.

Adjusting the rubber crawler tension

5

•

Loosen the lock nut and turn the adjusting bolt to adjust the rubber crawler tension so that the slack is within the specified range.

•

To increase the rubber crawler tension, turn the adjusting bolt clockwise.

6 7

5 = Lock nut 6 = Tighten 7 = Loosen •

To reduce the rubber crawler tension, turn the adjusting bolt counterclockwise.

•

After adjustment, be sure to tighten the lock nut securely.

Greasing

WARNING Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

a b

c

a = Dump lever stopper b = Lock c = Wagon support •

Grease the fittings thoroughly after washing the machine or after operation in rain, on soft ground, or in muddy water.

•

Park the machine on level ground. Dump the wagon, install the wagon support to hold the wagon securely and stop the engine. Then, move the dump lever back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever with the dump lever stopper.

•

Clean the grease fittings indicated by arrows in the figures at the right and grease them with a grease gun.

•

After greasing, wipe off any excess that remains.

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13 Operating Instructions for C12R-A

1

2

3

4.

1 = Dump fulcrum 2 = Cylinder 3 = Steering lever link 4 = Travel pedal fulcrum link

Checking the electrical equipment

CAUTION If a fuse blows out frequently, contact your dealer for assistance.

Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action.

Check the following items after the starter switch is turned to the "ON" position.

1) Check the monitor functions.

•

Check the hourmeter function.

•

Check the engine oil pressure alarm lamp, battery charge alarm lamp and water temp. alarm lamp for lighting.

2) Check that the headlight (option) lights correctly.

3) Check that the horn functions correctly.

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13 Operating Instructions for C12R-A

Checking the steering clutches and brakes •

Check each steering lever for play. If the play is between 5 mm and 10 mm, it is proper.

Check that both the right and left steering levers have the same stroke length.

B

A 2 (5-10 mm)

3

1

Checking the steering levers

4

A = Steering clutch B = Steering brake 1 = On 2 = Start 3 = Off 4 = Stop •

Adjust the steering clutches and the steering brakes if necessary.

Checking the brake pedal

(a)

Depress (b) the brake pedal (a) with your hand and check that the play of the pedal is no more than (90 mm).

If the play exceeds 90 mm, ask your dealer to check the brake pedal and replace the brake friction plates and steel plates if necessary.

(b)

Checking the travel pedal and the F/R lever

CAUTION (3)

(2)

(4)

•

The F/R lever cannot be operated unless the travel pedal is in the neutral position.

•

Always release and return the travel pedal fully to the neutral position before operating the F/R lever.

Move the F/R lever (2) from the neutral position to the forward or reverse travel position, press down on the brake pedal (3) fully and then start the engine, before checking the following items: • Take your foot off the brake pedal (3) and check that the machine does not move.

•

Press down on the travel pedal (4) slightly to move the machine at very low speed. Then, release the travel pedal (4).

Check that the machine stops completely.

•

Adjust the travel pedal and the F/R lever if necessary.

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13 Operating Instructions for C12R-A

13.2 Operating and checking instructions before starting up the engine

WARNING (1)

(3)

(4) (5) (2)

(6)

•

When leaving the operator’s seat, always lower the wagon fully, lock the dump lever with the dump lever stopper, and place the brake lock lever in the lock position to apply the parking brake securely.

•

Keep in mind that if the brake lock lever should not be placed in the lock position, the machine may move abruptly and a serious accident could occur.

•

Never operate the machine unless the ROPS bar is in its full upright and locked position to prevent bodily injury.

(1)

1) Check that the brake lock lever (1) is in the lock position (a).

(a)

2) Check that the travel pedal (6) is in the neutral position.

3) ICheck that the F/R lever (5) is in the neutral position.

N

(5)

4) Check that all other levers are in their appropriate positions.

5) Fasten the seatbelt snugly.

6) Insert the starter switch key (2) into the starter switch and turn it to the "ON" position.

•

Then check the following points:

The buzzer will sound, and the following alarm lamps will light.

• Engine oil pressure alarm lamp (3) •

Battery charge alarm lamp (4)

•

The buzzer will stop when the engine starts.

If any of the alarm lamps does not light or the buzzer does not sound, it may mean that an alarm lamp has blown out or is broken. In this event, ask the dealer for repair.

ON

START

(2)

OFF GLOW

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13 Operating Instructions for C12R-A

(1)

(2)

13.3 Starting up the engine Normal start-up

WARNING

(B)

•

First check that there are no people or obstacles around the machine.

•

Then sound the horn and start the engine.

•

Be sure that you are seated on the operator's seat when starting the engine.

•

When starting the engine in an enclosed place, be sure that there is adequate ventilation so that the exhaust gases can escape.

(1)

1) Pull the accelerator lever (1) back to the run position (B).

2) Turn the starter switch key (2) in the starter switch to the "START" position. The engine will start.

ON

START

OFF GLOW

3) After the engine has started, let go of the starter switch key. The starter switch key will return to the "ON" position by itself.

Note : When the engine is warm, the engine can start up even if the accelerator lever is left in the idling position.

ON

IMPORTANT

START

To protect the starter motor and the battery:

OFF GLOW

•

Do not keep the starter switch key in the "START" position for more than 10 seconds.

•

If the engine fails to start, do not attempt to start the engine immediately again, but set the starter switch to the "OFF" position and wait for approximately 30 seconds, then start the engine again.

Starting the engine in cold weather

WARNING (1)

•

First check that there are no people or obstacles around the machine.

•

Then sound the horn and start the engine.

•

Be sure that you are seated on the operator's seat when starting the engine.

•

When starting the engine in an enclosed place, be sure that there is adequate ventilation so that the exhaust gases can escape.

(2)

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13 Operating Instructions for C12R-A

To start the engine when the outside air temperature is low, follow the steps below : 1) Pull the accelerator lever (1) back to the run position (B).

(B) (1)

START ON OFF

2) Turn the starter switch key (2) in the starter switch to the "GLOW" position and keep it there for approximately 10 to 15 seconds to preheat the intake air of the engine.

3) Turn the starter switch key in the starter switch (2) to the "START" position to start the engine.

4) After the engine has started, let go of the starter switch key (2). The starter switch key will return to the "ON" position by itself.

5) When the engine speed has increased, push the accelerator lever (1) forward to the idling position immediately.

GLOW

IMPORTANT To protect the starter motor and the battery:

ON

Do not keep the starter switch key in the "START" position for more than 10 seconds.

•

If the engine fails to start, do not start the engine immediately again, but set the starter switch to the "OFF" position and wait for approximately 30 seconds, then start the engine again.

•

Traveling or operating the machine without adequate warming in cold weather may adversely affect the machine performance.

START

OFF GLOW

ON

•

START

OFF GLOW

13.4 Operating and checking instructions after starting the engine

WARNING •

Emergency stop.

If abnormal operation occurs, turn the starter switch key to the "OFF" position, to shut off the electrical system and the engine. Then ask your dealer to check the machine.

•

Be sure to warm up the engine. If you operate the wagon without full warm-up, the wagon may not respond or operate properly, especially in cold weather.

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13 Operating Instructions for C12R-A

IMPORTANT •

The proper hydraulic oil temperature is between 50°C and 80°C.

•

If you have to operate the machine at a low hydraulic oil temperature, increase the hydraulic oil temperature to about 20°C before operating the wagon.

•

In the event that you have to operate any control lever at a temperature lower than 20°C, operate it gently.

•

Do not accelerate the engine rapidly until the engine warms up.

After starting the engine, do not start operating the machine immediately but follow this procedure:

(1) (2) (3) (4) (5)

1) Pull the accelerator lever (1) to the midpoint between the idling and run positions, and run the engine with no load at medium speed for approximately five minutes.

2) After warming up the engine, check that the alarm lamps are in the following status. If there is anything abnormal, take corrective action.

Hourmeter (2): Normal Engine oil pressure alarm lamp (3): Off Water temperature alarm lamp (4): Off Battery charge alarm lamp (5): Off 3) Check the exhaust gas color, the machine noise, and the vibration level for abnormality. If something is abnormal, take corrective action.

4) Make a test run with the machine to check that the brakes normally work, that the steering levers and the wagon normally operate and that the machine normally travels.

13.5 Traveling Folding the ROPS bar (option)

WARNING •

Never operate the machine unless the ROPS bar is in its full upright and locked position to prevent bodily injury.

•

Never disengage the ROPS bar except:

•

When moving the machine on a truck bed or similar means of transport.

•

When moving the machine under its own power from one location to another where height access is restricted.

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13 Operating Instructions for C12R-A

•

Keep clear of pinch-point when folding ROPS bar to prevent bodily injury.

•

Be careful with the ROPS bar since it is very heavy in weight.

The ROPS bar can be folded down when the machine travels through a place of a limited height.

a

a = Wire b = Bolt c = Lock nut

L

Folding the ROPS bar

M

1) Remove the linchpin M and pull the linchpin L out.

2) Do this for the right and left sides.

3) Slowly fold back the ROPS bar.

Unfolding the ROPS bar 1) Slowly unfold the ROPS bar.

b

2) Insert the linchpin L and lock it with the linchpin M for each side.

c

Note : Be careful not to get your finger or other part of your body caught in the moving part of the ROPS bar when handling it.

Traveling forward and in reverse

WARNING (2) (1)

(4) (3)

(5)

•

A signal person should be in attendance to give signals at sites which are dangerous or not clearly in view of the operator.

•

Clear all people from the working area.

•

Sound the horn before beginning travel, to alert the people near the machine.

•

Clear obstacles from the path of the machine.

•

Do not operate the travel pedal rapidly while the engine is running at high speed. Otherwise, the machine may move unexpectedly, causing a serious accident.

•

There is a blind spot behind the machine. Make sure that no people are in the blind spot before traveling in reverse.

•

Do not step on the bumper.

1) Pull the accelerator lever (1) back to the run position (B) to increase the engine speed.

(B) (1)

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13 Operating Instructions for C12R-A

2) Press down on the brake pedal and place the brake lock lever (2) in the unlock position (a).

(2)

(a)

3) Place the travel speed select lever (3) in the low (c) or high (b) speed position depending on the conditions of the work site.

(c)

(b) (3)

N

(5)

(4)

4) Move the F/R lever (4) from the neutral position to the forward or reverse travel position in accord with the direction of travel of the machine.

5) Depress the travel pedal (5).

13.6 Steering (turning the machine)

WARNING (1)

•

Never turn the machine on a slope. If you change the direction of travel of the machine on a slope, the machine may travel in an unexpected direction. Move down to flat ground and then make a turn.

•

Never turn make a quick turn on concrete or asphalt roads to prevent machine hunting.

•

Never turn at high speed on rough terrain.

To steer the machine, operate the steering levers (1).

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13 Operating Instructions for C12R-A

IMPORTANT •

Be extremely careful that the turning radius of the machine varies depending on whether the wagon is loaded or unloaded, and on the road surface condition.

•

Do not turn the machine too sharply.

Operate the two steering levers (1) as follows: Pivot-turning the machine To pivot-turn left, pull the left steering lever to its stroke end.

Note : To turn right, operate the right steering lever in the same manner as above.

Turning the machine gently To gently turn left, pull the left steering lever to the OFF position of the steering clutch.

2

1 4

5

3

6

7

8

Note : To turn right, operate the right steering lever in the same manner as above.

1 = Steering brake 2 = Steering clutch 3 = Stop 4 = Start 5 = Off 6 = On 7 = Pivot turn 8 = Gentle turn

13.7 Stopping the machine

CAUTION Do not stop the machine suddenly but provide a safety margin.

WARNING •

Park on solid, level ground.

•

Do not park on a slope. If parking on a slope is unavoidable, place the brake lock lever in the lock position to apply the parking brake and place solid blocks of wood behind the crawlers.

WARNING •

When leaving the operator’s seat, always lower the wagon fully, lock the dump lever with the dump lever

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13 Operating Instructions for C12R-A

stopper, and place the brake lock lever in the lock position to apply the parking brake securely.

•

Keep in mind that if the brake lock lever should not be placed in the lock position, the machine may move abruptly and a serious accident could occur.

1) Return the travel pedal to the neutral position.

(1)

N

2) Return the F/R lever (1) to the neutral position.

3) Press down on the brake pedal (2) fully, and the machine will stop traveling.

(2)

(3)

4) Press down on the brake pedal (2) and place the brake lock lever (3) in the lock position.

13.8 Dumping the wagon

WARNING •

Check the area around the machine for safety before beginning to dump the wagon.

•

Do not operate the dump lever while traveling.

CAUTION (A)

(2) (B)

(1)

When traveling with the machine, keep the wagon completely lowered. If the machine travels with the wagon dumped halfway, the machine could be damaged.

1) Place the dump lever stopper (1) in the unlock position before dump operation.

2) Operate the dump lever (2) to dump the wagon. To control the dump speed, operate the accelerator lever.

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13 Operating Instructions for C12R-A

3) After completing the dump operation, place the dump lever in the lower position to lower the wagon completely.

(A) : Dump (B) : Lower

IMPORTANT When lowered in a loaded state, the wagon may suddenly fall down due to the weight of the load. Operate the dump lever slowly.

13.9 Precautions for working Precautions for traveling Driving over a stone or a stump subjects the machine (especially undercarriage) to a shock, which may cause damage to the machine.

Avoid such obstacles by driving around them, or removing them. If driving over them is unavoidable, reduce speed, and drive over the obstacles with the center of the track shoes.

Allowable water depth

IMPORTANT <10°

When driving out of water, if the machine goes up a slope at an angle of more than 10 degrees, the frame may submerge too deeply in the water, which may damage the radiator fan. Avoid this if possible when driving out of water.

The maximum water depth in which the machine can be used is up to the top of the track frame.

Apply a generous amount of grease to the moving parts that have been submerged in the water for a long time until the used grease is extruded out of the bearings.

(Apply grease especially to the following parts.)

•

Dump fulcrums

•

Dump cylinder fulcrums

•

Steering lever fulcrum

•

Travel pedal fulcrum

•

Brake pedal fulcrum

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13 Operating Instructions for C12R-A

13.10 Precautions for going up and down a slope

WARNING •

Run the machine at low speed on a slope of 9 to 10 degrees or more, with the travel speed select lever in the low speed position.

•

When going down a slope, run the machine at low speed and adequately apply the engine brake by operating the travel pedal and the accelerator lever.

•

When driving over obstacles such as foot paths, drive the machine slowly.

•

Never turn on or traverse a slope.

•

Descend to flat ground to make a course change.

•

Recognize that the machine may roll over when dumping the wagon on a slope.

•

Do not dump the wagon toward the downward side of the slope.

•

If dumping is unavoidable, first lay earth on the slope to maintain the machine as horizontal as possible, then dump the wagon.

•

Do not travel on a slope of 20 degrees or more, as the machine may upset.

Going up and down a slope •

To go down a steep slope, place the accelerator lever in the idling position and depress the travel pedal in a smaller degree to run the machine at low speed.

•

To go down a slope of 10 degrees or more, place the travel speed select lever in the low speed position to run the machine at low engine speed.

•

When the wagon is loaded, run the machine in the posture as shown in the figure at the right.

Braking when going down a slope •

To brake the machine when going down a slope, return the travel pedal to the neutral position and depress the brake pedal.

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13 Operating Instructions for C12R-A

When the crawler is slipping •

If the crawler is slipping while the machine is going up a slope, stop traveling, descend the slope and take the other route.

Going up a slope •

When going up a steep slope, place the travel speed select lever in the low speed position and depress the travel pedal in a smaller degree and to run the machine at low speed.

•

When the wagon is loaded, run the machine in the posture as shown in the figure at the left.

When the engine stops •

If the engine stops when the machine is going up a slope, return the travel pedal to the neutral position, press down on the brake pedal fully and place the brake lock lever in the lock position to prevent the machine from moving. Return the F/R lever to the neutral position, place the accelerator lever in the run position, and then restart the engine.

13.11 Removal of wagon flaps

WARNING Special care must be taken in handling a wagon flap, as it is heavy in weight.

Place the machine on a solid, level ground when removing a flap. Any work performed by a team should be conducted surely in accordance with signals, taking much care about safety.

The wagon has the right, left and front flaps, which can be removed.

Removing the side flaps Mass of wagon flaps Front flap: approx. 13 kg Right and left flaps: approx. 21 kg each

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13 Operating Instructions for C12R-A

1) Start the engine.

a

a

2) Raise the wagon slightly by moving the dump lever to just disengage the hook(s) on the bottom of the flap to be removed.

a

a = Open b = Open/close lever

b

3) While holding the flap with one hand, open the open/close lever on one side of the flap and then the lever on the other side, and slowly remove the flap.

Removing the front flap 1) Start the engine.

c

2) Operate the dump lever to slightly dump the wagon and unhook the front flap.

3) Remove the front flap by pushing it forward while lifting it up.

d

c = Push d = Front flap

13.12 Parking the machine

CAUTION Do not stop the machine suddenly but provide a safety margin.

WARNING •

Park on solid, level ground.

•

Do not park on a slope. If parking on a slope is unavoidable, place the brake lock lever in the lock position to apply the parking brake and place solid blocks of wood behind the crawlers.

WARNING

N

(1)

•

When leaving the operator’s seat, always lower the wagon fully, lock the dump lever with the dump lever stopper, and place the brake lock lever in the lock position to apply the parking brake securely.

•

Keep in mind that if the brake lock lever should not be placed in the lock position, the machine may move abruptly and a serious accident could occur.

1) Return the travel pedal (6) to the neutral position.

2) Return the F/R lever (1) to the neutral position (N).

3) Lower the wagon completely.

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13 Operating Instructions for C12R-A

4) Press down on the brake pedal (2) fully and move the brake lock lever (3) to the lock position to lock the brake pedal (2).

(2)

5) Lock the dump lever with the dump lever stopper.

6) Place the accelerator lever in the idling position and turn the starter switch key to the “OFF” position to stop the engine.

(3)

13.13 Inspection requirements after completing operation

(1) (3) (2)

Check the monitor for the engine oil pressure (1), the battery charge (2), and the water temperature (3), and also check the residual quantity of fuel with the fuel level gauge. Take any actions necessary. a = Fuel cap b = Fuel gauge

a

b

13.14 Stopping the engine

IMPORTANT (1)

•

Stopping the engine after rotation at high speed may shorten the engine life. Do not stop the engine suddenly except in case of emergency.

•

If the engine is overheated, do not stop the engine immediately. Gradually lower the engine temperature by rotating the engine at medium rotational speed before stopping the engine.

1) Idle the engine for approximately five minutes with no load.

(The engine temperature gradually lowers.)

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13 Operating Instructions for C12R-A

2) To stop the engine, turn the starter switch key (1) to the "OFF" position.

3) Take the starter switch key out of the starter switch (1).

13.15 Inspection requirements after stopping the engine 1) Check oil and water for leaks, and visually inspect the wagon, the machine, and the undercarriage by walking around them.

If there are any leaks of oil or water, or any observed abnormality, take corrective action.

2) Completely fill the fuel tank.

3) Confirm that the engine compartment is free of any foreign matter.

4) Combustibles or dust in the engine compartment may cause a fire. Remove them, if any.

5) Remove mud adhering to the undercarriage of the machine.

13.16 Locking Make sure that you lock the following : 1. Fuel cap (a) 2. Engine hood Note : The starter switch key is used to lock all of the items mentioned above.

a

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13 Operating Instructions for C12R-A

13.17 Handling the rubber crawlers Using the rubber crawlers properly Rubber crawlers have some advantages over steel crawlers.

However, you cannot take full advantage of them if you use them in the same manner as steel ones. Use care in operating with rubber crawlers in accord with the conditions of the work site and the type of work.

Comparison Table of Rubber and Steel Crawlers

Rubber

Steel

Low vibration Smooth travel (with no creak) Silent travel Less damage to paved roads Simple handling Susceptibility to damage (strength) Tractive force : Excellent

: Good

: Ordinary

Rubber crawlers have many advantages inherent in the unique properties of the material. On the other hand, however, they are low in strength. It is essential that you fully understand the properties of rubber crawlers, and observe the precautions for operating and handling them to prolong their life and get the most out of them.

Precautions for using the rubber crawlers Prohibitions Observe the following prohibitions: • Do not operate or turn on surfaces or terrains that have sharp stones, a hard, uneven rock base, or that expose the crawlers to steel rods, scrap iron, or edges of iron plates.

Failure to observe these prohibitions may damage the rubber crawlers.

•

Do not operate the machine on a stony surface like a riverbed. Doing this may damage the rubber crawlers by catching gravel in the crawlers or may cause the crawlers to come off. Forcibly running or turning the machine will also shorten the life of the rubber crawlers.

•

Prevent the rubber crawlers from getting exposed to oil, fuel, or chemical solvents. If they are exposed, immediately wipe them. Also, do not travel on roads which have oily surfaces.

•

When storing the rubber crawlers for a long time period (more than three months), avoid placing them in a place subject to direct exposure to sunlight or rain.

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13 Operating Instructions for C12R-A

•

Do not operate the machine where the crawlers will be exposed to heat, (i.e., near an open-air fire, on a steel plate that has been exposed to the blazing sun, or on a hot asphalt road.)

Other precautions for using the rubber crawlers Observe the following precautions when operating the machine: • Do not change course suddenly. Doing this will cause the rubber crawler to wear early or be damaged.

•

Do not turn the machine across a large level gap while traveling. Remember that running over a level gap at a right angle will prevent the crawler from coming off.

•

It is not recommended that the machine be used to handle any materials that become oily after being crushed (e.g., soybeans, corn, rapeseed oil seeds, etc.). After unavoidably using the machine to handle such materials, clean the crawlers with water.

•

It is not recommended that the machine be used to handle materials such as salt, ammonium sulfate, potassium chloride, potassium sulfate, or double superphosphate of lime.

Handling these materials may affect the core metal adversely. After using the machine to handle such materials, clean the crawlers with water.

•

Do not operate the machine at the seashore. Doing this may affect the core metal adversely due to the salt content.

•

If a rubber crawler is cracked, it could be easily damaged when exposed to salt, sugar, wheat, or soybeans. Be sure to repair any cracks in the rubber crawler to prevent rubber chips from getting into the materials being handled.

•

Do not allow the rubber crawler to rub against a concrete boundary, wall or the like.

•

The rubber crawlers are prone to skid on snow or on a frozen road. Be careful of skidding when traveling or operating on a slope in cold weather.

•

Operating the machine in extremely cold weather will deteriorate the rubber crawlers, shortening their life.

•

Use the rubber crawlers between -25°C to +55°C because of the physical characteristics of rubber.

•

Keep the crawlers in appropriate tension to prevent them from coming off.

•

If the tension is too low, the rubber crawlers may come off under the following conditions.

•

(Even if the tension is adequate, take care when operating the crawlers under these conditions.)

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13 Operating Instructions for C12R-A

1) Do not steer the machine at an angle other than 90 degrees across a large level gap created by a curbstone or a rock [approximately more than 20 cm. Run over a level gap at a right angle only to prevent the crawlers from coming off.

2) Do not steer the machine across a boundary between flat ground and a slope, while traveling in reverse. If such travel is not avoidable, slow down the speed.

3) Do not travel with the crawler on one side on a slope or on convex ground (causing a machine angle of more than 10 degrees), and with the crawler on the other side on flat ground, to prevent the rubber crawler from being damaged. Be sure to travel with the crawlers on both sides on the same level surface.

4) The three cases illustrated above are those which could cause the rubber crawlers to loosen. In addition, do not subject the machine to such ground conditions as are illustrated in the figure at the right.

[How the rubber crawlers come off]

1 2

•

When running over a level gap, a clearance is created between the crawlers and the track rollers. At this point, the crawlers tend to come off.

1 = Rubber crawler 2 = Track roller •

If the machine is traveling in reverse, clearance may also be created between the track rollers and the rubber crawlers, and between the idlers and the rubber crawlers, causing the rubber crawlers to come off.

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13 Operating Instructions for C12R-A

Other situations to be avoided:

a

•

When the machine changes the travel direction while the rubber crawlers are blocked sideways by an obstacle or the like.

•

When the idler and the track rollers are misaligned from the core metal, due to rubber crawler misalignment.

b

a = Rubber crawler side b = Frame side c = Details of P

c •

Traveling in reverse under the condition illustrated will cause the rubber crawlers to come off.

•

Changing the travel direction of the machine under the condition illustrated will cause the rubber crawlers to come off.

123

14 Operating Instructions for C30R-2A

14

Operating Instructions for C30R-2A 14.1 Checking before starting the engine Visual inspection around the machine

WARNING •

If there are any combustibles in any heat build-up areas, or if there are any fuel and/or oil leaks, a fire can result.

•

Check for possible fire causes carefully. If there is anything abnormal, be sure to take corrective action or contact your dealer.

Before starting the engine, visually check the outside and underside of the machine as follows: Check bolts and nuts for loose connections; check the fuel, oil, and water for leaks; and also check the wagon and the hydraulic system to see that they are in good condition. In addition, check the electrical wiring for loose connections and for dust deposits in the heat build-up areas.

(8)

(2)

(2)(3) (6) (5) (9) (4)

(6)

(4)

(7)

(1)

(8)

(6) (8)

(7) (6)

Check the following points before initial start-up for the day:

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14 Operating Instructions for C30R-2A

•

Checking the wagon, hydraulic cylinder, pins, and hoses for damage, wear and loose connections.

•

Removing dust deposits from around the engine, battery, and radiator.

•

Checking the engine and its accessories for oil or water leakage.

•

Checking hydraulic devices, hydraulic oil tank and hoses for oil leakage.

•

Checking the transfer case and final case for oil leakage.

•

Checking the undercarriage (crawlers, sprockets, rollers and idlers) for breakage, wear, loose bolts, and oil leakage around the rollers.

•

Checking ROPS/FOPS for breakage and loose bolts.

•

Checking the gauges, monitor, switches, turn signal lamp and head light for breakage and loose bolts.

•

Checking the water separator to see whether the red ring has sunk down to the cup bottom.

Checking and replenishing the cooling water

WARNING Do not remove the fill cap from the radiator unless refilling the coolant.

A

Check the coolant water level in the sub-tank when the engine is cool.

1) Open the engine hood (A). Then check to see that the cooling water level in the sub-tank (1) (illustrated) is between the FULL (3) and LOW (4) marks. If the water level is down below the LOW (4) mark, refill the sub-tank up to the FULL (3) mark through the water port of the subtank (1).

2) After replenishing, securely tighten the radiator cap (2).

2 1

3) If the sub-tank (1) is empty, check for leaks and water level in the radiator. If the water is low, refill the radiator first, then the sub-tank (1).

4) If the cooling water level is appropriate, close the engine hood.

3 4

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14 Operating Instructions for C30R-2A

Checking and replenishing the engine oil (F)

(G)

WARNING •

At operating temperature, oil and dipstick areas are hot. Do not allow hot oil or components to contact skin to prevent bodily injury.

•

Check oil level and refill oil after engine has cooled down.

1) Open the engine hood.

2) Pick up the dipstick (G) and wipe it with a rag to remove oil deposits.

H

3) Insert the dipstick (G) all the way into the dipstick tube, then draw it out.

L

(F)

4) If the dipstick (G) is wet above the midpoint between the H (high) and L (low) marks, the engine oil level is appropriate. If the oil level is below the midpoint between the H and L marks, refill through the oil port (F).

5) If the engine oil level is above the H mark, remove an excessive amount of oil through the drain plug (P), then recheck the engine oil level.

003714-00X

(P) 003715-00X

6) After verifying that the amount of engine oil is appropriate, securely retighten the oil port cap and close the engine hood.

Note: When checking the engine oil level after starting up the engine, stop the engine and allow more than 15 minutes for the engine to cool down.

If the vehicle Is slanted, reposition the vehicle to ensure it is level before checking the engine oil level.

Keep in mind that excess engine oil must not be disposed of on the ground or the road.

Checking the fuel level in the fuel tank and refueling

WARNING Be careful not to overfill the fuel tank because it could cause a fire. If overfilled, completely wipe off the spilled fuel.

CAUTION •

Do not remove the strainer from the fill port of the fuel tank before refilling fuel oil.

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14 Operating Instructions for C30R-2A

•

Be careful not to allow water settled at the bottom of the fuel oil container or dirt on refueling equipments to enter into the fuel tank.

1) Turn the starter switch to the "ON" position, and check the fuel level. If the fuel level is low, open the fuel cap and add fuel through the fuel supply port (F).

When the fuel meter pointer indicates "E", approximately 6 L of fuel is left in the tank.

2) After refueling, securely close the fuel cap (F).

(F)

003717-00X

Checking and replenishing the hydraulic oil system

WARNING When removing the plug of the fill port, slowly loosen it to release pressure in the tank.

1) Park the machine as illustrated. When the machine is not in the posture at right, start the engine, engine speed low, lower the dump deck down, and stop the engine.

2) Check the oil level by the oil gauge (1) on the side of the tank. Check that the oil level is between the upper (2) and lower (3) limit marks.

1

IMPORTANT

(F)

2 limit Upper 3

Do not replenish hydraulic oil above the upper limit mark on the oil level gauge. An excessive amount of hydraulic oil may damage the hydraulic system by placing stress on its components, causing a dangerous high-pressure leak.

3) Open the plug of the oil port (F) and replenish oil if the oil level is at the lower limit or less.

Note: Note that the oil level varies with oil temperature. When reading the oil level, follow these guidelines: Before start-up, the oil level should read around the midpoint of the gauge scale (oil temperature : 10 to 30°C).

At normal operation, the oil level should read around the upper limit mark of the oil gauge scale (oil temperature : 50 to 80°C).

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14 Operating Instructions for C30R-2A

Checking the fan belt tension Press down on the fan belt between the fan pulley and the generator with a finger, to check the fan belt tension.

Pressing force : Approximately 10 kg Correct slack : 10 to 15 mm

Crawler tension

1

W

2

Check the crawler tension only when on level ground, Otherwise, the slack can all be transferred to the top of the crawler.

Put a weight (approx. 60 kg) on top of the crawler, between the idler and the carrier roller, to check its deflection.

Deflection : 20 to 30 mm 1 = Carrier roller 2 = Idler

Greasing

IMPORTANT Grease fittings thoroughly after washing the machine or after operation in rain, on soft ground, or in muddy water.

1) Upper the dump deck and stop the engine.

2) Clean the grease fittings indicated by arrows and grease using a grease gun.

003722-00X

3) After greasing, wipe off the excessive grease.

003723-00X

Checking the electric equipment

CAUTION When a fuse blows out frequently, contact your dealer.

Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action.

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14 Operating Instructions for C30R-2A

Check the following items after the starter switch is turned to the "ON" position.

1) Check the monitor functions •

Check the fuel gauge and hourmeter function.

•

Check charge alarm lamp, water temp alarm lamp, and engine oil alarm lamp for lighting.

2) Check that all switches function correctly and lamps light correctly.

•

Operating of the headlights, and turn signal lamp

14.2 Operating and checking instructions before starting up the engine

CAUTION

(8)

•

When the parking brake lever is released, the machine can move suddenly.

•

When leaving the driver’s seat, be sure to place the parking brake lever securely at the "ON" (PARK) position.

1) Make sure that parking brake lever (1) is set securely at the "PARK" (a) position and that the F-R lever is set at the "NEUTRAL" position.

(7) (6) (4) (3)

a = Park-position b = Run-position

(5) (2)

(1)

003724-00X

2) Check to see that other levers are in their appropriate positions.

3) Fasten the seatbelt snugly.

(1)

a

4) Insert the key into the starter switch (2) and set it to the "ON" position. Then check the following points:

b

(2)

003727-00X

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14 Operating Instructions for C30R-2A

•

(4) (3)

The following indicator lamps will turn on or flash.

Engine oil pressure alarm lamp (3) Battery charge alarm lamp (4) Parking brake lamp (5)

(5)

003728-00X

•

If some indicator does not turn on, it may mean that the indicator lamp has blown out or broken. In this event, ask the dealer to repair.

•

Turn the light switch (6) to check to see that the head lights will turn on.

If they does not turn on, the lamp(s) might have blown or broken. In this event, ask the dealer to repair.

•

Turn the turn signal switch (7) to check to see that the turn signal will turn on.

If they does not turn on, the lamp(s) might have blown or broken. In this event, ask the dealer to repair.

(6)

003729-00X

R = Right L = Left

(7) R

L 003730-00X

(8)

•

Press the horn switch (8) to check to hear that the horn will sound.

If the horn does not sound, the horn supposes to be faulty or electrically disconnected. In this event, ask the dealer to repair.

14.3 Starting up the engine Normal start-up

WARNING First check to see that there are no people or obstacles around the machine. Then sound the horn and start the engine.

(1)

1) Put the steering clutch lever in the "NEUTRAL" position.

Note: For safety, the starter will not work unless you put the steering clutch lever in the "NEUTRAL" position.

(2)

003732-00X

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14 Operating Instructions for C30R-2A

2) Press the accelerator pedal (1) lightly.

3) Set the key on the starter switch (2) to the "START" position. The engine will start.

4) After start-up, let go of the key. The key will return to the "ON" position by itself.

IMPORTANT

003733-00X

•

To protect the starter motor and the battery: Do not keep the key in the "START" position for more than 10 seconds.

•

When you fail to start the engine, do not start the engine immediately again, but set the switch to the "OFF" position and wait for approximately 30 seconds, than start the engine again.

Starting the engine in cold weather

WARNING

(1)

(2)

A

•

First check to see that there are no people or obstacles around the machine. Then sound the horn and start the engine.

•

Be sure that you are seated in the operator’s seat when starting the engine.

•

When starting the engine in an enclosed place, be sure that there is adequate ventilation so that the exhaust gases can escape.

1) Put the steering clutch lever in the "NEUTRAL" position, and press the accelerator pedal (1) to its midpoint.

003732-00X

2) Turn the key (2) to "AIR HEATER" position (A) for 10 seconds to preheat the intake air of the engine.

(2)

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14 Operating Instructions for C30R-2A

3) Turn the key (2) to START position (B) to start the engine.

C

4) After start-up, let go of the key. The key will return to the "ON" position (C) by itself.

5) As soon as the engine speed increases, immediately move your foot off the accelerator pedal (1) to allow the engine to idle. 10 seconds 15 seconds 30 seconds 15 seconds

B (2)

IMPORTANT To protect the starter motor and the battery: •

Do not keep the key In the "START" position for more than 10 seconds.

•

When you fail to start the engine, do not start the engine immediately again, but set the switch to the "OFF" position and wait for approximately 30 seconds, than start the engine again.

•

Traveling or operating without adequate warm-up in cold weather may adversely affect machine performance.

14.4 Operating and checking instructions after starting the engine After starting the engine, do not start working immediately but follow this procedure:

IMPORTANT •

Do not accelerate the engine rapidly until the engine warms up.

•

The engine must not be at low or high idle for more than 20 minutes.

•

The engine must be switched to medium speed if the engine needs to idled for longer periods of time.

1) Press the accelerator pedal (1) to the midpoint, to run the engine at a mid-range speed. Idle the engine for about 5 minutes.

(1)

2) After warming up, make sure that the gauges and pilot lamp are in the following status. If there is something abnormal, take corrective action.

003736-00X

Engine water temp alarm lamp (2): OFF Engine oil pressure alarm lamp (3): OFF Battery charge alarm lamp (4): OFF Parking lamp (5): OFF

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14 Operating Instructions for C30R-2A

3) Check the exhaust gas color, machine noises, and vibrations for abnormality. If there is something abnormal, take corrective action.

(4) (3)

4) Test drive the machine to check performance of the brake and the steering clutch levers. Also check the pIatform.

(5) (2)

003737-00X

14.5 Traveling Traveling forward

(3) (2)

(1)

1 = Steering clutch lever 2 = Parkinglock lever 3 = Accelerator pedal

CAUTION 003738-00X

•

Decide on which direction the driver’s seat needs to face, then set it in position.

•

Sound the horn before beginning travel, to alert the people near the machine.

•

Clear all people from the working area.

•

Clear obstacles from the path of the machine.

1) Tilt the F-R lever (1) in the direction (forward) you want to go. Move the lever to the "LOW SPEED" position.

(1)

a

a = Forward

003739-00E

2) Unlock the parking lock lever (2).

(2)

b

b = Unlock

003740-00E

c

(3)

3) Press the accelerator pedal (3) lightly to start driving the machine. c = Step on

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14 Operating Instructions for C30R-2A

Traveling backward

(3) (2)

(1)

1 = Steering clutch lever 2 = Parkinglock lever 3 = Accelerator pedal

CAUTION 003738-00X

(1)

•

Decide on which direction the driver’s seat needs to face, then set it in position.

•

Sound the horn before beginning travel, to alert the people near the machine.

•

Clear all people from the working area.

•

Clear obstacles from the path of the machine.

1) Tilt the F-R lever (1) in the direction (backward) you want to go. Move the lever to the "LOW SPEED" position. a = Backward

a

003742-00E

2) Unlock the parking lock lever (2).

(2)

b

b = Unlock

003740-00E

c

(3)

3) Press the accelerator pedal (3) lightly to start driving the machine. c = Step on

14.6 Steering

WARNING •

Do not steer the machine on a slope. It may cause the machine to tip over or slip sideways dangerously.

•

If you steer the machine sharply on a concrete asphalt pavement, the machine may become hunting dangerously.

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14 Operating Instructions for C30R-2A

IMPORTANT

1 •

Keep in mind that a turning radius varies depending on whether the dump deck is full or empty and road surface conditions.

•

Do not steer the machine sharply.

To steer the machine, operate the steering lever.

The machine will turn in response to the direction you turn the lever.

003696-00E

14.7 Stopping the machine 1 = Accelerator pedal 2 = Brake pedal 3 = Parking lever 4 = Steering clutch lever

(1) (3)

(2)

(4)

CAUTION

003744-00X

Do not stop the machine suddenly but provide a safety margin.

WARNING

(2)

a

(1)

•

Park on solid, level ground.

•

Do not park on a slope. If it is unavoidable to park on a slope, block the tracks with solid pieces.

1) Release the accelerator pedal (1) and press the brake pedal (2) to stop the machine. a = Step on

(3)

b

2) While the brake pedal (2) is being pressed, pull the parking brake lever (3) all the way up. b = Parking c = Pull up

c

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14 Operating Instructions for C30R-2A

3) Put the F-R lever (4) in the "NEUTRAL" position.

d

(4)

d = Neutral

003747-00E

14.8 Dumping (2)

(1)

1 = Dump lever lock 2 = Dump lever

WARNING •

Before starting dumping, be sure to make sure that there is nobody around the machine.

•

Do not dump while the machine is traveling.

CAUTION Before traveling, lower the wagon all the way down. If the machine travels with the wagon not seated in position, the machine may be damaged.

1) Before starting dumping, disengage the dump lever lock (1). a = Unlock b = Lock

a

(1)

(2)

b 2) Dump the wagon by operating the dump lever (2). Adjust the dump speed with stroke of the accelerator lever.

d

c

3) When dumping is finished, lower the wagon all the way down by moving dump lever (2) to the "DOWN" position. c = Up (dump) d = Down

14.9 Precautions for working Precautions for traveling

003751-00X

Driving over a stone or a stump gives the machine (especially undercarriage) a shock, which may cause damage to the machine.

Avoid these obstacles by driving around them, or removing them.

If it is unavoidable to drive over them, reduce speed, and drive over the obstacles with the center of the track shoes.

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14 Operating Instructions for C30R-2A

Allowable water depth

IMPORTANT When driving out of water in reverse, if the machine climes a slope at an angle of more than 10 degrees, the front of the upperstructure may submerge in the water, which may damage the radiator fan by splashing water.

Keep this in mind when driving out of water. <10°

003753-00X

The limit of the water depth that the machine can be used in is up to the upper of the track frame.

Apply a generous amount of grease to the moving parts that have been submerged in the water for a long time until the used grease is extruded out of the bearings. (especially the parts listed below).

•

Track roller moving plates

•

Wagon pivot pin

•

Dump cylinder pivot pin

•

Final gear

14.10 Precautions for going up and down a slope Driving down on a slope

CAUTION •

When driving down on a slope, apply the engine brake sufficiently to control the travel speed by operating the travel lever and the accelerator lever.

•

When driving over obstacles, drive the machine slowly.

•

Never turn or traverse on a slope. Go down to the flat ground once and take a detour.

•

Be careful of the fact that the machine may lose its balance and upset when operating the dump on a slope.

•

Especially, dumping on the downward side of the slope is very dangerous. If this is not avoidable, you must raise the ground level to maintain the vehicle horizontal (1).

•

Do not travel on a slope of 20 degrees or more, the machine may upset.

003754-00X

1

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14 Operating Instructions for C30R-2A

1) When driving down on a steep slope, you have to steering clutch lever to the "LOW SPEED" position and return the accelerator pedal to slow down the vehicle.

When driving up or down on a slope of more than 15 degrees, if the dump deck is empty you have to orient the vehicle as illustrated and slow down the engine.

2) If the wagon is full, you have to orient the vehicle as illustrated and drive the vehicle slowly.

Braking while traveling down a slope Press the brake pedal to slow the machine. The braking effect can be adjusted by the pressure you apply to the brake pedal.

Climbing a slope 1) When climbing a steep slope, use a low speed (the steering clutch lever should be in the LOW SPEED position).

2) When the carrier is loaded, travel as shown in the figure.

If the crawler skids If the crawler slips while climbing a slope, stop climbing immediately. Choose another angle of approach.

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14 Operating Instructions for C30R-2A

14.11 Removal of wagon flaps

CAUTION The flaps are heavy. Carefully remove or reinstall the flaps.

To dismount the wagon, select a solid, flat ground and communicate well with your partners for safety.

You can remove the three (right, left, and rear) flaps from the wagon. If you remove all the flaps, the wagon becomes flat type.

Removing the side (right or left) board 1) Remove the bolts (M8 × 16 mm) from the side flap.

1 (A)

2) Release each open/close lever by turning it up (see the arrow (A) in the figure), and you can open the side gate.

2

3) Shift the gate in the arrow (B) direction, and you can remove the flap. To remove the opposite side flap, also shift it in the same direction.

Weight of side flap : 33 kg

(B)

3

1 = Open / close lever 2 = Open 3 = Bolt 8 x 16

Remove the rear boflapard 1) Start the engine.

4

5

6

2) Slightly lift the wagon using the dump lever, and release the flap open/close hook.

3) Release each open/close lever by turning it up and you can remove the flap. Then push the gate in the arrow direction (6).

Poids de la ridelle arrière : 34 kg 4 = Open 5 = Open / close lever

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14 Operating Instructions for C30R-2A

14.12 Parking the machine

CAUTION Do not stop the machine suddenly but provide a safety margin.

WARNING 1

•

Park on solid, level ground.

•

Do not park on a slope. If it is unavoidable to park on a slope, block the tracks with solid pieces (1).

WARNING If the parking brake lever is released accidentally, the machine can move suddenly and a serious accident may occur. Before leaving the driver’s seat, be sure to engage the parking brake lever securely.

(2)

1) Make sure the F-R lever (1) is in the "NEUTRAL" position.

(1)

2) While the brake pedal (2) is being pressed, pull the parking brake lever (3) all the way up.

(3)

a = Parking b = Unlock 003763-00X

IMPORTANT

(3)

a

When the engine is stopped, engaging the steering clutch lever will not brake the crawler.

If you need to park the machine on a slope, put blocks under the crawler.

b

14.13 Inspection requirements after completing operation Check the monitors for engine coolant temperature, the engine oil pressure, and the residual quantity of fuel, and take the necessary actions.

003765-00X

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14 Operating Instructions for C30R-2A

14.14 Stopping the engine

IMPORTANT

1

•

Stopping the engine after rotation at high speed may shorten the engine life. Do not stop the engine suddenly except in case of emergency.

•

If the engine is overheated, do not stop the engine immediately. Gradually lower the engine temperature by rotating the engine at medium rotational speed before stopping the engine.

1) Idle the engine for approximately five minutes with no load. (The engine temperature gradually lowers.)

2

2) To stop the engine, turn the starter switch key (1) to the "OFF" position (2).

3) Take the key out of the starter switch (1).

14.15 Inspection requirements after stopping the engine 1) Check oil pressure and water for leaks, and check the dump, the machine, and the undercarriage by walking around them.

If there are any leaks of oil or water, or any observed abnormalities, take corrective action.

2) Completely fill the fuel tank.

3) Confirm that the engine room compartment is free of any foreign matter.

Combustibles or dust in the engine compartment may cause a fire. Remove them, if any.

4) Remove mud adhering to the undercarriage of the machine.

14.16 Locking Make sure to lock UP the following parts: Engine hood (1) Note : The starter switch key is used to lock all of the parts mentioned above.

(1)

003768-00X

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14 Operating Instructions for C30R-2A

14.17 Handling the rubber crawlers (for machines equipped with rubber) Using the rubber crawlers properly Rubber crawlers have some advantages over steel crawlers.

However, you cannot take full advantage of them if you use them in the same manner as steel ones. Use care in operating with rubber crawlers in accord to the conditions of the work site and the type of work.

Comparison Table of Rubber and Steel Crawlers

Rubber

Steel

Low vibration Smooth travel (with no creak) Silent travel Less damage to paved roads Simple handling Susceptibility to damage (strength) Tractive force : Excellent

: Good

: Ordinary

Rubber crawlers have many advantages inherent in the unique properties of the material. On the other hand, however, they are low in strength. It is essential that you fully understand the properties of rubber crawlers, and observe the precautions for operating and handling them to prolong their life and get the most out of them.

Precautions for using the rubber crawlers Prohibitions •

Do not operate or turn on surfaces or terrains that have sharp stones, a hard, uneven rock base, or that expose the crawlers to steel rods, scrap iron, or edges of iron plates. Failure to observe these prohibitions may damage the rubber crawlers.

•

Do not operate the machine on a stony surface like a riverbed. Doing this may damage the rubber crawlers by catching gravel in the crawlers or may cause the crawlers to come off. Forcibly running or turning the machine will also shorten the life of the rubber crawlers.

•

Prevent the rubber crawlers from getting exposed to oil, fuel, or chemical solvents. If they are exposed, immediately wipe them. Also, do not travel on roads which have oily surfaces.

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14 Operating Instructions for C30R-2A

•

When storing the rubber crawlers for a long time period (more than three months), avoid placing them in a place subject to direct exposure to sunlight or rain.

•

Do not operate the machine where the crawlers will be exposed to heat, (i.e., near an open-air fire, on a steel plate that has been exposed to the blazing sun, or on a hot asphalt road.)

Other precautions for using the rubber crawlers •

Observe the following precautions when operating the machine:

•

Do not change course suddenly. Doing this will cause the rubber crawler to wear early or be damaged.

•

Do not turn the machine across a large level gap while traveling. Remember that running over a level gap at a right angle will prevent the crawler from coming off.

•

It is not recommended that the machine be used to handle any materials that become oily after being crushed (e.g., soybeans, corn, rapeseed oil seeds, etc.). After unavoidably using the machine to handle such materials, clean the crawlers with water.

•

It is not recommended that the machine be used to handle materials such as salt, ammonium sulfate, potassium chloride, potassium sulfate, or double superphosphate of lime.

Handling these materials may affect the core metal adversely. After using the machine to handle such materials, clean the crawlers with water.

•

Do not operate the machine at the seashore. Doing this may affect the core metal adversely due to the salt content.

•

If a rubber crawler is cracked, it could be easily damaged when exposed to salt, sugar, wheat, or soybeans. Be sure to repair any cracks in the rubber crawler to prevent rubber chips from getting into the materials being handled.

•

Do not allow the rubber crawler to rub against a concrete boundary, wall or the like.

•

The rubber crawlers are prone to skid on snow or on a frozen road. Be careful of skidding when traveling or operating on a slope in cold weather.

•

Operating the machine in extremely cold weather will deteriorate the rubber crawlers, shortening their life.

•

Use the rubber crawlers between -25°C to +55°C because of the physical characteristics of rubber.

•

Keep the crawlers in appropriate tension to prevent them from coming off.

•

If the tension is too low, the rubber crawlers may come off under the following conditions.

143

14 Operating Instructions for C30R-2A

•

(Even if the tension is adequate, take care when operating the crawlers under these conditions.)

1) Do not travel on a large level gap created by a curbstone or a rock (approximately more than 20 cm). Run over a level gap at a right angle to prevent the crawlers from coming off.

003769-00X

2) Do not travel to a boundary between the flat ground and a slope while moving forward.

If such travel is not avoidable, slow down the speed.

003770-00X

3) Do not travel with one crawler on a slope or on convex ground (raising the angle of the machine to more than 10 degrees), with the other crawler on flat ground, to prevent the rubber crawlers from being damaged. Be sure to travel with both crawlers on the same level surface.

003771-00X

4) The three cases illustrated above are those which could cause the rubber crawlers to loosen. In addition, do not operate under such ground conditions as illustrated.

003772-00X

[How the rubber crawlers come off]

1 2

•

When running over a level gap, a clearance is created between the crawler and the track rollers. At this point, the crawlers easily come off.

1 = Rubber crawlers 2 = Track roller

144

14 Operating Instructions for C30R-2A

•

3

If the machine is traveling in reverse, clearance may also be created between the track rollers and the rubber crawlers, and between the idlers and the rubber crawlers, causing the rubber crawlers to come off.

3 = Idler

Other Hazards to be Avoided:

A

B

P

F

•

When the machine is travelling while the rubber crawlers are blocked sideways by an obstacle.

•

When the idler and the track rollers are misaligned from the core metal due to rubber crawler misalignment.

A = Rubber crawler side B = Frame side C = Détail of P

C •

Travelling backwards under this condition will cause the rubber crawlers to come off.

•

Travelling under this condition will cause the rubber crawlers to come off.

003776-00X

003777-00X

145

15 Operating Instructions for C50R-3B

15

Operating Instructions for C50R-3B 15.1 Checking before starting the engine Visual inspection around the machine Before starting the engine, visually check the outside and underside of the machine as follows: Check bolts and nuts for loose connections; check the fuel, oil, and water for leaks; and also check the wagon and the hydraulic system to see that they are in good condition. In addition, check the electrical wiring for loose connections and for dust deposits in the heat build-up areas.

(7)

(5)

(5)

(2)(3)

(4)

(5)

(6)

(1) (2)

(7)

(7)

(5)

(6)

(6)

(5)

(5)

WARNING •

If there are any combustibles in any heat build-up areas, or if there are any fuel and/or oil leaks, a fire can result.

•

Check for possible fire causes carefully. If there is anything abnormal, be sure to take corrective action or contact your dealer.

Check the following points before initial start-up for the day:

146

15 Operating Instructions for C50R-3B

•

Checking the wagon, hydraulic cylinder, pins, and hoses for damage, wear and loose connections.

•

Removing dust deposits from around the engine, battery, and radiator.

•

Checking the engine and its accessories for oil or water leakage.

•

Check the engine for oil leakage and the cooling system for water leakage.

•

Checking the hydraulic system, hydraulic oil tank, hoses, and joints for oil leakage.

•

Checking the undercarriage (crawlers, sprockets, rollers, and idlers) for breakage, wear, loose bolts, and oil leakage around the rollers.

•

If oil leakage is found, take corrective action.

•

Checking the handrails and safety guards for breakage and loose bolts.

•

Checking the gauges, monitor, switches, flashers, headlights, and rearview mirror for breakage and loose bolts.

•

Checking whether the windows have been on their groove and have no breakage (for cabin).

Checking and replenishing the cooling water

WARNING Do not remove the fill cap from the radiator unless supplying the cooling water.

Check the cooling water level in the sub-tank when the engine is cool.

(2) (1) H L

(3)

1) Open the engine hood. Then check whether the cooling water level in the sub-tank (1) (illustrated in the figure) is between the H (FULL) and L (LOW) marks. If the water level is below the L mark, refill the sub-tank up to the H mark through the water supply port (2) of the sub-tank (1).

2) After replenishing, securely tighten the cap (2).

3) If the sub-tank is empty, check it for water leakage, and then, check the water level in the radiator (3). If the water level is low, refill the radiator (3) first, then refill the subtank (1).

4) If the cooling water level is proper, close the engine hood.

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15 Operating Instructions for C50R-3B

Checking and replenishing the engine oil

WARNING •

At operating temperature, the oil and dipstick areas are hot.

•

Do not allow hot oil or hot components to contact the skin, to prevent bodily injury.

•

Check the oil level and replenish oil after the engine has cooled down sufficiently.

1) Open the engine hood and securely hold it in that position with stay.

(2)

2) Pick up the dipstick (1) and wipe it with a rag to remove oil deposits.

(1)

3) Fully insert the dipstick (1) into the dipstick tube, then draw it out.

4) If the oil level is between the H (upper limit) and L (lower limit) marks, the engine oil level is appropriate. If the oil level is below the L mark, add engine oil through the oil supply port (2).

H L

5) If the engine oil level is above the H mark, remove the excessive amount of oil through the drain plug (P), then recheck the engine oil level.

(1)

(P)

6) After verifying that the amount of engine oil is appropriate, securely retighten the oil supply port cap and close the engine hood (3).

(3)

Note : When checking the engine oil level after starting up the engine, stop the engine and allow more than 15 minutes for the engine to cool down.

If the machine is slanted, reposition the machine to ensure it is level before checking the engine oil level.

Keep in mind that the excess engine oil must not be disposed of on the ground or the road.

Checking and fuel level in the fuel tank and refueling

WARNING Be careful not to overfill the fuel tank because it could cause a fire. If the tank is overfilled, completely wipe off the spilled fuel.

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15 Operating Instructions for C50R-3B

CAUTION (1)

•

Do not remove the strainer from the fuel supply port of the fuel tank when supplying fuel.

•

Be careful not to allow any water that may be in the fuel container or dirt on the refueling equipment to enter the fuel tank.

1) Check the fuel level with the fuel meter (1). If the fuel level is low, add necessary fuel.

2) Turn the starter switch key to the "ON" position.

(3)

3) Remove the fuel supply port cap (3), and supply fuel to the fuel supply port, checking the fuel level with the fuel level gauge (2).

4) After refueling, securely retighten the fuel supply port cap (3).

(2)

Checking and replenishing the hydraulic oil in the hydraulic oil tank

WARNING

(2)

(1)

•

Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

•

When removing the plug of the oil supply port, slowly loosen it to gradually relieve the internal pressure in the tank, or oil may spurt from the tank.

1) Park the machine on the level ground. Dump the wagon, set the dump lock lever to the lock position and stop the engine.

H

2) Hold the wagon with the wagon stopper.

M

3) Check the oil level gauge (1). If the oil level is between M and L mark on the level gauge, the hydraulic oil level is proper.

L

IMPORTANT Do not replenish hydraulic oil above the midpoint between M and L mark on the level gauge with the wagon in the dump position. It may cause the hydraulic oil to spout out. (When the wagon is lowered, the oil level reaches close to the M mark.)

4) If the hydraulic oil level is below the L mark, remove the air breather (2) and refill the hydraulic oil tank until the oil level reaches the midpoint between M and L mark (specified level) on the oil level gauge.

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15 Operating Instructions for C50R-3B

Note : When the hydraulic oil tank cannot be refilled directly as the wagon cannot be dumped, open the engine hood and remove the plug (3) to replenish hydraulic oil.

(3)

Checking the fan belt tension 1) Open the engine hood.

(A) (10 - 15 mm)

2) Press down on the fan belt between the fan pulley and the generator with a finger, to check the fan belt tension.

Check the fan belt for cracks and peeling.

Pressing force : Approximately 10 kg Correct slack for (A) : 10 to 15 mm 3) If the tension is proper, close the engine hood.

Checking the crawler tension (A)

Park the machine on the level ground and gather slack on the upper side of the rubber crawler. Place straight rods on the rubber crawler as illustrated in the figure at the right and check the slacks (A) and (B).

(B)

•

Correct slack for (A) and (B) : 5 to 15 mm

Greasing

WARNING A

a

1

Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

•

Prepare a grease gun.

1) Clean the grease nipples indicated by circles in the figures, and grese them with a grease gun.

2

2 3

B

b

2

2 3

A = Three-side flaps type a = Type of grease : Lithium soap base multipurpose grease n° 2 B = Scoop-end type b = Type of grease : Lithium soap base multipurpose grease n° 2 C = Swing type D = Wagon (Swing wagon type) 1 = Rear link 2 = For each side

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15 Operating Instructions for C50R-3B

3 = Cylinder pins

C

2) After greasing, wipe off any excess grease that remains.

Number of grease nipples :

D

Wagon : • Three-side flaps type : 7 • Scoop-end type : 4 • Swing type : 6 • Crawlers : 8

Greasing the swing bearing (for the swing wagon type)

WARNING Do not swing the wagon while greasing. Swing the wagon after each stage of greasing is completed to avoid serious bodily injury.

1) Grease the swing bearing through the grease nipple (1), using a grease gun.

(1)

2) Swing the wagon in small increments and grease after each stop, until the wagon has made a full revolution.x

Checking the electric equipment

CAUTION If a fuse blows out frequently or if the electrical wiring shows a sign of having been short-circuited, contact your dealer for assistance.

Check the fuses for damage, the wiring for poor connections or short-circuits, and the battery terminals for corrosion and loose connections. If any connections are loose, retighten the connectors.

Especially, check the wiring for the following items carefully: • • •

Battery Starter motor Generator

WARNING If there are any combustibles in the heat build-up area around the battery, a fire can result. Be sure to remove any combustibles.

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15 Operating Instructions for C50R-3B

Check the following items after the starter switch is turned to the "ON" position.

1) Check the monitor function.

•

Check the hourmeter, fuel meter and water temp. meter functions.

•

Check the water temp. alarm lamp, engine oil pressure alarm lamp, battery charge alarm lamp and air cleaner alarm lamp.

2) Check that all switches function correctly and all lamps light correctly.

•

Check the headlight.

•

Check the horn.

•

Check the flasher function.

•

Check the wiper function (for cabin).

•

Check the heater function (for cabin).

15.2 Operating and checking instructions before starting up the engine

CAUTION •

(9) (10) (1)

Accidentally setting the lock levers to the unlock position can cause the machine to move suddenly, possibly causing a serious accident.

•

When leaving the operator's seat, be sure to place the lock levers securely in the lock position.

(3) (2) (8)

1) Confirm that the “SERVICING IN PROGRESS” tag is not attached.

(4) (5) (6) (7) (1) (1)

2) Check that the travel levers are in neutral, that the lock levers (1) are in the lock position, and that the dump lever (2) is locked.

(2)

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15 Operating Instructions for C50R-3B

3) Fasten the seatbelt snugly.

4) Insert the starter switch key into the starter switch (3) and set it to the “ON” position.

5) Then check the following points : The alarm lamps (4) and (5) on the monitor will keep lighting until the engine starts.

•

Engine oil pressure alarm lamp (4)

•

Battery charge alarm lamp (5)

•

Air cleaner alarm lamp (6) (It will goes off in 1 second)

•

Water temperature alarm lamp (7) (It will goes off in 1 second) If any of the alarm lamps do not go on, it may mean that an alarm lamp has blown out or is broken. Take corrective action, or consult your dealer for assistance.

(6) (7)

(4) (5)

(A)

R L

Turn the light switch (8) to the "A" position to see whether the headlights will go on. If either or both of them do not go on, the lamp(s) might have blown out or might be broken.

Take corrective action, or consult your dealer for assistance.

Operate the turn signal light switch (9) to see whether the the turn signal will light. If either or both of them do not go on, the lamp(s) might have blown out or might be broken.

Take corrective action, or consult your dealer for assistance.

Press the horn switch (10) to see whether the horn will sound. If the horn does not sound, the horn might be defective or the wire might be broken. Take corrective action, or consult your dealer for assistance.

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15 Operating Instructions for C50R-3B

15.3 Starting up the engine Normal start-up

WARNING •

First check that there are no people or obstacles around the machine.

•

Then sound the horn and start the engine.

•

Be sure that you are seated on the operator's seat when starting the engine.

•

When starting the engine in an enclosed place, be sure that there is adequate ventilation so that the exhaust gases can escape.

(2) (1)

IMPORTANT To protect the starter motor and the battery:

(1)

•

Do not keep the starter switch key in the "START" position for more than 10 seconds.

•

If the engine fails to start, do not attempt to start the engine immediately again, but set the switch to the "OFF" position and wait for approximately 30 seconds, then start the engine again.

1) Slightly pull the accelerator lever (1) back to the "RUN" direction.

2) Set the starter switch key in the starter switch (2) to the "START" position. The engine will start.

(2)

3) After the engine has started, let go of the starter switch key. The starter switch key will return to the "ON" position by itself.

Starting the engine in cold weather

WARNING (2) (1)

•

First check that there are no people or obstacles around the machine.

•

Then sound the horn and start the engine.

•

Be sure that you are seated on the operator's seat when starting the engine.

•

When starting the engine in an enclosed place, be sure that there is adequate ventilation so that the exhaust gases can escape.

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15 Operating Instructions for C50R-3B

IMPORTANT To protect the starter motor and the battery: •

Do not keep the starter switch key in the "START" position for more than 10 seconds.

•

If the engine fails to start, do not start the engine immediately again, but set the switch to the "OFF" position and wait for approximately 30 seconds, then start the operation from step 2).

•

Traveling or operating the machine without adequate warming in cold weather may adversely affect the machine performance.

(1)

To start the engine when the outside air temperature is low, follow the steps below: 1) Pull the accelerator lever (1) back to the midpoint between "LOW IDLING" and "RUN".

(2)

2) Turn the starter switch key in the starter switch (2) to the "T.S. (preheating)" position and keep it there for approximately 15 seconds to preheat the intake air of the engine.

The glow lamp will go on.

3) Turn the starter switch key in the starter switch (2) to the "START" position to start the engine after the glow lamp goes off.

4) After the engine has started, let go of the starter switch key. The starter switch key will return to the "ON" position by itself.

Note : It is normal that the alarm lamps on the monitor will light when the starter switch key is set to the T.S. position.

15.4 Operating and checking instructions after starting the engine

WARNING •

Emergency stop.

If abnormal operation occurs, turn the starter switch key to the "OFF" position, to shut off the electrical system and the engine. Then ask your dealer to check the machine.

•

Be sure to warm up the engine. If you operate the wagon without full warm-up, the wagon may not respond or operate properly, especially in cold weather.

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15 Operating Instructions for C50R-3B

IMPORTANT •

The proper hydraulic oil temperature is between 50°C and 80°C. If you have to operate the machine at a low hydraulic oil temperature, increase the hydraulic oil temperature to about 20°C before operating the implement.

•

In the event that you have to operate any control lever at a temperature lower than 20°C, operate it gently.

•

Do not accelerate the engine rapidly until the engine warms up.

•

Do not keep idling at low or high speed for more than 20 minutes.

When idling the engine is necessary, sometimes apply load or idle the engine at medium speed.

After starting the engine, do not start operating the machine immediately but follow this procedure:

(1)

1) Idle the engine, to check that the engine oil pressure alarm lamp (4) is off.

2) Pull the accelerator lever to the midpoint between the "LOW IDLING" and "RUN" positions, and run the engine with no load at medium speed for approximately five minutes.

(6) (7)

3) After warming up the engine, check that the gauges and the monitor are in the following status. If there is anything abnormal, take corrective action.

(4) (5)

• • • •

Engine oil pressure alarm lamp (4): Off Battery charge alarm lamp (5): Off Air cleaner alarm lamp (6): Off Water temperature alarm lamp (7): Off

4) Check the exhaust gas color, the machine noise, and the vibration level for abnormality. If something is abnormal, take corrective action.

15.5 Traveling (3)

Traveling forward

WARNING •

A signal person should be in attendance to give signals at sites which are dangerous or not clearly in view of the operator.

•

Set the operator’s seat to the desired direction and securely lock it.

•

Sound the horn before beginning travel, to alert the people near the machine.

(2) (1)

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15 Operating Instructions for C50R-3B

•

Clear all people from the working area.

•

Clear obstacles from the path of the machine.

•

Do not operate the travel levers rapidly while the engine is running at high speed. Otherwise, the machine may move unexpectedly, causing a serious accident.

1) Pull the accelerator lever (1) to the “RUN” position to increase the engine speed.

(1)

2) Push the lock levers (2) down to unlock the travel operation.

(2) (2)

3) Slowly push the travel levers (3) forward to move the machine forward.

N

N

(3)

(3)

Traveling in reverse

WARNING (3)

•

A signal person should be in attendance to give signals at sites which are dangerous or not clearly in view of the operator.

•

Set the operator’s seat to the desired direction and securely lock it.

•

Sound the horn before beginning travel to alert the people near the machine.

•

Clear all people from the working area.

•

Clear obstacles from the path of the machine.

•

There is a blind spot behind the machine. Make sure that no people are in the blind spot before traveling backwards.

(2) (1)

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15 Operating Instructions for C50R-3B

•

Do not operate the travel levers rapidly while the engine is running at high speed. Otherwise, the machine may move unexpectedly, causing a serious accident.

1) Pull the accelerator lever (1) to the “RUN” position to increase the engine speed.

(1)

2) Push the lock levers (2) down to unlock the travel operation.

(2) (2)

N

N

(3)

3) Slowly pull the travel levers (3) back to move the machine backwards.

(3)

15.6 Steering Steering (turning the machine)

WARNING (1)

•

Never turn the machine on a slope to prevent it from overturning or skidding.

•

Never turn at high speed and spin-turn on concrete or asphalt roads to prevent machine hunting.

•

Never turn at high speed on rough terrain.

To steer the machine, operate the travel levers (1).

IMPORTANT •

Be extremely careful that the turning radius of the machine varies depending on whether the wagon is in loaded or unloaded state, and on the road surface condition.

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15 Operating Instructions for C50R-3B

•

Do not turn the machine too sharply.

Operate the two travel levers (1) as follows: Steering the machine when it is not traveling To turn left, push the right travel lever forward and start traveling forward to the left. Pull the right travel lever back and start traveling in reverse to the left.

(a) N

a = Turn left forward b = Turn left backward N = Neutral

(b)

Note : To turn right, operate the left travel lever in the same manner as above.

Steering the machine while traveling (the left and right travel levers are both tilted in the same direction)

(c)

To turn left, return the left travel lever to the neutral position.

N

c = Turn left forward d = Turn left backward N = Neutral

N

(d)

Note: To turn right, return the right travel lever to the neutral position.

Spin-turning the machine when it is not traveling To spin-turn left, push the right travel lever forward while pulling the left travel lever back.

N

N = Neutral Note : To spin-turn right, push the left travel lever forward while pulling the right travel lever back.

15.7 Stopping the machine

CAUTION Do not stop the machine suddenly but provide a safety margin.

(1)

•

Park on solid, level ground.

•

Do not park on a slope. If it is unavoidable to park on a slope, place solid blocks of wood (1) behind the crawlers.

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15 Operating Instructions for C50R-3B

WARNING •

Do not touch the control levers accidentally. Otherwise, the implement or the machine may move unexpectedly, causing serious bodily injury.

•

Whenever leaving the operator's seat, be sure to place the lock levers securely in the lock position and remove the starter switch key.

1) Set the right and left travel levers (1) to the neutral position (N) to stop the machine.

N

N

(1)

(1)

2) Return the accelerator lever to the “LOW IDLING” position (3).

(3)

3) Set the lock levers to the lock position.

15.8 Dumping the wagon

WARNING •

Check the area around the machine for safety before beginning to dump the wagon.

•

Do not operate the dump lever while traveling.

CAUTION (2) (1)

When traveling with the machine, keep the wagon completely lowered. If the machine travels with the wagon dumped halfway, the machine could be damaged.

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15 Operating Instructions for C50R-3B

1) Pull up the dump lock lever (1) to set it to the unlock position before dump operation.

(1)

(B)

2) Operate the dump lever (2) to dump the wagon. To control the dump speed, operate the accelerator lever.

(2)

3) After completing the dump operation, set the dump lever to the lower position to lower the wagon completely.

(A)

(A) : Dump (B) : Lower

15.9 Swinging the wagon (for the swing wagon type)

WARNING

(2) (1)

•

Before swinging, make sure that there are no people or obstacles within the swing range of the wagon.

•

Do not operate the dump lever while traveling.

CAUTION When traveling with the machine, keep the wagon parallel to the crawlers. If the machine travels with the wagon swung to the right or the left, the machine will be unstable.

1) Pull up the dump lock lever (1) to the unlock position before swing operation.

(1)

(B) (A)

(2)

2) Operate the dump lever (2) to swing the wagon. To control the swing speed, operate the accelerator lever.

(A) : Right swing (B) : Left swing

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15 Operating Instructions for C50R-3B

15.10 Precautions for working Precautions for traveling

>10°

Driving over a stone or a stump subjects the machine (especially undercarriage) to a shock, which may cause damage to the machine.

Avoid such obstacles by driving around them, or removing them.

If driving over them is unavoidable, reduce speed, and drive over the obstacles with the center of the track shoes.

Allowable water depth

IMPORTANT

<10°

When driving out of water, if the machine goes up a slope at an angle of more than 10 degrees, the front frame may submerge too deeply in the water, which may damage the radiator fan. Avoid this if possible when driving out of water.

The maximum water depth in which the machine can be used is up to the top of the track frame.

Apply a generous amount of grease to the moving parts that have been submerged in the water for a long time until the used grease is extruded out of the bearings.

(Apply grease especially to the following parts.)

• • •

Track roller rocking plate Wagon fulcrum pin Dump cylinder fulcrum pin

15.11 Precautions for going up and down a slope Going up and down a slope

WARNING •

Run the machine at low speed on a slope of 9 to 10 degrees or more, with the automatic speed change switch turned off (for traveling at low speed) and the engine throttled down to medium speed or lower.

•

When driving over obstacles such as foot paths, drive the machine slowly.

•

Never turn on or traverse a slope.

•

Descend to flat ground to make a course change.

•

Recognize that the machine may roll over when dumping the wagon on a slope.

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15 Operating Instructions for C50R-3B

•

Do not dump the wagon toward the downward side of the slope.

•

If dumping is unavoidable, first lay earth on the slope to maintain the machine as horizontal as possible, then dump the wagon.

•

Do not travel on a slope of 20 degrees or more, as the machine may upset.

1) To go down a steep slope, run the machine at low speed with the automatic speed change switch turned off, the travel levers placed slightly forwards and the engine throttled down to medium speed or lower with the accelerator lever.

To go up or down a slope of 15 degrees or more, run the machine at low engine speed if the wagon is unloaded.

2) When the wagon is loaded, run the machine in the posture as shown in the figure.

Braking when going down a slope •

When going down a slope, you can automatically brake the machine by setting the travel levers to the neutral position.

When the crawler is slipping •

If the crawler is slipping while the machine is going up a slope, stop traveling, descend the slope and take another route.

15.12 Removal of wagon flaps

WARNING Special care must be taken in handling a wagon flap, as it is heavy in weight.

Place the machine on a solid, level ground when removing a flap. Any work performed by a team should be conducted surely in accordance with signals, taking much care about safety.

The three-side flaps wagon has the right, left and rear flaps, which can be removed.

Removal of the side flaps

(1)

(2) A

1) Remove the bolts (3) (8Õ20) from the side flap of the wagon.

2) Set the lever (1) to the open position [in the direction indicated by the arrow (A) in the figure] to open the side flap.

B

(3)

3) Move the side flap (2) in the direction indicated by the arrow (B) in the figure to remove it. (For both side flaps).

4) Side flap mass : 42 kg

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15 Operating Instructions for C50R-3B

Removal of the rear flap

(4)

1) Start the engine.

C (5)

2) Open the dump lever to slightly dump the wagon and get off the hooks for the rear flap (4).

3) Move up the lever (5) in the direction indicated by the arrow (C) in the figure. Remove the rear flap while lifting it up in the direction indicated by the arrow (D) in the figure.

D

4) Rear flap mass : 58 kg

15.13 Parking the machine

CAUTION Do not stop the machine suddenly but provide a safety margin.

WARNING •

Park on solid, level ground.

•

Do not park on a slope. If it is unavoidable to park on a slope, place solid blocks of wood (1).

(1)

WARNING •

Be careful not to set the lock levers to the unlock position accidentally. Otherwise, the machine may move unexpectedly, causing a serious accident.

•

When leaving the operator's seat, be sure to place the lock lever securely in the lock position and remove the starter switch key.

1) Set the travel levers (1) to the neutral position (N).

N

N

(1)

(1)

2) Return the accelerator lever (3) to the “LOW IDLING” position to idle the engine at low speed.

(3)

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15 Operating Instructions for C50R-3B

3) Set the lock levers to the lock position.

4) Lower the wagon and lock the dump lever.

(2)

(5) (1) (3) (4)

15.14 Inspection requirements after completing operation Check the water temperature alarm lamp (1), the engine oil pressure alarm lamp (3), the battery charge alarm lamp (4), the air cleaner alarm lamp (5), and the residual quantity of fuel with the fuel meter (2). Take any actions necessary.

15.15 Stopping the engine

IMPORTANT •

Stopping the engine after rotation at high speed may shorten the engine life. Do not stop the engine suddenly except in case of emergency.

•

If the engine is overheated, do not stop the engine immediately. Gradually lower the engine temperature by rotating the engine at medium rotational speed before stopping the engine.

1) Idle the engine for approximately 5 minutes with no load.

(The engine temperature gradually lowers.)

2) To stop the engine, turn the starter switch key to the "OFF" position.

3) Take the starter switch key out of the starter switch.

15.16 Inspection requirements after stopping the engine 1) Check oil and water for leaks, and visually inspect the wagon, the machine, and the undercarriage by walking around them.

If there are any leaks of oil or water, or any observed abnormality, take corrective action.

2) Completely fill the fuel tank.

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15 Operating Instructions for C50R-3B

3) Confirm that the engine compartment is free of any foreign matter.

Combustibles or dust in the engine compartment may cause a fire. Remove them, if any.

4) Remove mud adhering to the undercarriage of the machine.

15.17 Locking Make sure that you lock the following parts :

b a

a = Lock b = Unlock

a b

(1) Fuel supply port cap (2) Side door (for cabin)

(3) Engine hood (4) Side cover (5) Battery cover Note : The starter switch key is used to lock all of the items mentioned above.

15.18 Handling the rubber crawlers Using the rubber crawlers properly Rubber crawlers have some advantages over steel crawlers.

However, you cannot take full advantage of them if you use them in the same manner as steel ones. Use care in operating with rubber crawlers in accord with the conditions of the work site and the type of work.

Comparison Table of Rubber and Steel Crawlers

Rubber

Steel

Low vibration Smooth travel Silent travel Less damage to paved roads Simple handling Susceptibility to damage (strength) Tractive force : Excellent

: Good

: Ordinary

Rubber crawlers have many advantages inherent in the unique properties of the material. On the other hand, however,

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15 Operating Instructions for C50R-3B

they are low in strength. It is essential that you fully understand the properties of rubber crawlers, and observe the precautions for operating and handling them to prolong their life and get the most out of them.

Precautions for using the rubber crawlers Prohibitions Observe the following prohibitions: •

Do not operate or turn on surfaces or terrains that have sharp stones, a hard, uneven rock base, or that expose the crawlers to steel rods, scrap iron, or edges of iron plates.

Failure to observe these prohibitions may damage the rubber crawlers.

•

Do not operate the machine on a stony surface like a riverbed. Doing this may damage the rubber crawlers by catching gravel in the crawlers or may cause the crawlers to come off. Forcibly traveling or turning will also shorten the life of the rubber crawlers.

•

Prevent the rubber from getting exposed to oil, fuel, or chemical solvents. If they are exposed, immediately wipe them. Also, do not travel on roads which have oily surfaces.

•

When storing the rubber crawlers for a long time period (more than three months), avoid placing them in a place subject to direct exposure to sunlight or rain.

•

Do not operate the machine when the crawlers will be exposed to heat, (i.e., near an open-air fire, on a steel plate that has been exposed to the blazing sun, or on a hot asphalt road.)

Other precautions for using the rubber crawlers Observe the following precautions when operating the machine: • Never spin-turn on concrete or asphalt roads.

•

Do not change course suddenly. Doing this will cause the rubber crawler to wear early or be damaged.

•

Do not turn the machine across a large level gap while traveling. Remember that running over a level gap at a right angle will prevent the crawler from coming off.

•

It is not recommended that the machine be used to handle any materials that become oily after being crushed (e.g., soybeans, corn, rapeseed oil seeds, etc.). After unavoidably using the machine to handle such materials, clean the crawlers with water.

•

It is not recommended that the machine be used to handle materials such as salt, ammonium sulfate, potassium chloride, potassium sulfate, or double superphosphate of lime.

Handling these materials may affect the core metal adver-

167

15 Operating Instructions for C50R-3B

sely. After using the machine to handle such materials, clean the crawlers with water.

•

Do not operate the machine at the seashore. Doing this may affect the core metal adversely due to the salt content.

•

If a rubber crawler is cracked, it could be easily damaged when exposed to salt, sugar, wheat, or soybeans. Be sure to repair any cracks in the rubber crawler to prevent the materials being handled from getting into the cracks in the rubber crawler.

•

Do not allow the rubber crawler to rub against a concrete boundary, wall or the like.

•

The rubber crawlers are prone to slipping on snow or on a frozen road. Be careful of skidding when traveling or operating on a slope in cold weather.

•

Operating the machine in extremely cold weather will deteriorate the rubber crawlers, shortening their life.

•

Use the rubber crawlers between -25°C to +55°C because of the physical characteristics of rubber.

•

Keep the crawlers in appropriate tension to prevent them from coming off. If the tension is too low, the rubber crawlers may come off under the following conditions.

(Even if the tension is adequate, take care when operating the crawlers under these conditions.)

1) Do not steer the machine at an angle other than 90 degrees across a large level gap created by a curbstone or a rock (approximately more than 20 cm). Run over a level gap at a right angle only to prevent the crawlers from coming off.

2) Do not steer the machine across a boundary between flat ground and a slope, while moving forwards.

If such travel is not avoidable, slow down the speed.

3) Do not travel with the crawler on one side on a slope or on convex ground (causing a machine angle of more than 10 degrees), and with the crawler on the other side on flat ground, to prevent the rubber crawler from being damaged. Be sure to travel with the crawlers on both sides on the same level surface.

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15 Operating Instructions for C50R-3B

4) The three cases illustrated above are those which could cause the rubber crawlers to loosen. In addition, do not subject the machine to such ground conditions as are illustrated in the figure at the left.

[How the rubber crawlers come off]

1 2

1) When running over a level gap, a clearance is created between the crawlers and the track rollers. At this point, the crawlers tend to come off.

1 = Rubber crawler 2 = Track roller

2) If the machine is traveling forward, clearance may also be created between the track rollers and the rubber crawlers, and between the idlers and the rubber crawlers, causing the rubber crawlers to come off.

a

b

3) Other situations to be avoided: When the machine changes the travel direction while the rubber crawlers are blocked sideways by an obstacle or the like.

•

When the idler and the track rollers are misaligned from the core metal, due to rubber crawler misalignment.

a = Rubber crawler side b = Frame side c = Detail of P •

Traveling in reverse under the condition illustrated below at the left will cause the rubber crawlers to come off.

•

Changing the travel direction of the machine under the condition illustrated below at the right will cause the rubber crawlers to come off.

c

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16 Transportation

16

Transportation 16.1 Loading and unloading the machine

WARNING

b a

f

e

d

c

•

Be careful when loading and unloading the machine, because it is a job of high hazard potential.

•

Use ramp plates of adequate strength having hooks.

Check to see that the ramp plates are wide, long, and thick enough to safely sustain the machine so that you can load or unload safely. To prevent the ramp plates from bending too much, support them with blocks.

a = Ramp plate b = Hook c = Wheel stopper d = Block e = Less than 15 degrees f = Span between the ramp plates •

Load or unload the machine on level, solid ground far away from the shoulder of the road.

•

Securely hook the ramp plates to the deck of the trailer so that they will not come off.

•

Remove mud, grease, and other slippery deposits from the track shoes, and grease, oil, and ice deposits from the ramp plates to prevent the machine from skidding.

•

Never change the travel direction on the ramp plates.

If you need to change the travel direction, go back down the ramp plates, then do this.

•

Load or unload the machine at a low engine speed.

•

Turn slowly when on the trailer bed, if it becomes necessary to do so, since the machine’s position will be unstable.

•

Make sure that the side door of the cabin is locked, whether in the open or closed position. Never open or close the side door on the ramp plates, to prevent it from swinging violently.

170

16 Transportation

To load or unload the machine, be sure to use the ramp plates and follow the procedures outlined below.

•

Firmly brake the trailer and apply wheel stoppers to the tires. Securely install the ramp plates on the bed of the trailer in a position where the center of the truck aligns with the center of the machine. Make sure that the left and right ramp plates are at the same level.

•

The ramp plates should be set at an angle of less than 15 degrees.

•

Determine the span between the ramp plates on the basis of the centers of the track shoes.

•

Return the accelerator lever to reduce engine speed.

•

Turn off the automatic speed change switch.

(For C50R-3B)

•

Travel toward the ramp plates at a low speed, and load or unload the machine according to the leader’s signals.

•

Load the machine front first.

•

Do not operate any levers other than the travel levers while driving on the ramp plates.

•

Load the machine in a safe position on the trailer.

16.2 Precautions for loading the machine Shipping weight: Refer to the specification table.

CAUTION •

Select a route for transporting the machine based on the road width and clearance, and the height and weight of the machine.

Provide wood blocks in front and back of the crawlers and secure the machine with chain or wire rope so that the machine will not move during shipping. In particular, be sure to secure it to prevent sideward motion.

Note: For safer transportation, comply with all local regulations and laws.

171

16 Transportation

16.3 Suspending the machine (only for C12R-A and C30-2A)

CAUTION •

Never suspend the machine if any person is on the machine or the implement.

•

Use wire ropes strong enough for the weight of the machine.

•

Do not suspend the machine in any way other than that explained here below.

•

Failure to suspend the machine as prescribed will throw the machine off balance.

•

Do not swing the machine being suspended.

•

Do not tie ropes to the bumper and the wagon. They are not strong enough to support the weight of the machine for suspending or towing.

•

When suspending the machine, keep the machine in balance taking care on the center of gravity of the machine.

•

Never stand near or under the suspended machine.

For safety in suspending the machine, comply with all applicable regulations.

C12R-A (A) (A)

1) Start the engine, and dump the platform. After attaching the platform position stopper under the platform, lock the dump lever.

2) Pull the parking brake lever and stop the engine. Then, make sure nothing is left around the driver’s seat and get off the machine.

3) Thread the wire cables (A) through the three support hooks (1), which are in the middle of the machine, and then lift the machine carefully.

4) After lifting the machine, make sure it is balanced.

C30R-2A

IMPORTANT

(A)

Use cables that are strong enough to support the machine.

(1)

C12R-A

C30R-2A

Cable length

1,75 m x 3

3mx3

Min. cable diameter

12 mm

12 mm

172

17 Care in cold weather and long-term storage

17

Care in cold weather and long-term storage 17.1 Preparing for cold weather In cold weather, you may have difficulty in starting the engine or the cooling water may freeze. So take measures as follows:

Fuel and lube oil Use low viscosity fuel and lube oil.

Cooling water

WARNING Anti-freeze is flammable. When handling anti-freeze, keep away from any sources of ignition and do not smoke.

IMPORTANT Never use an anti-freeze containing methanol, ethanol, or propanol.

Note : Because a YANMAR genuine long-life coolant (LLC) is added to the cooling water, you need not change it until the temperature falls below -35°C.

Battery

WARNING •

The battery generates flammable gas and it can cause a fire and an explosion. Keep sparks or flames away from the battery.

•

Battery electrolyte contains dilute sulfuric acid which is a strong acid. To avoid serious injury, do not allow the electrolyte to contact skin or splash into eyes.

•

If the electrolyte contacts your skin or gets in your eyes, flush immediately with large amounts of water, and obtain medical treatment at once.

Battery performance deteriorates as the temperature goes down. When the battery voltage is low, battery electrolyte will easily freeze. Keep the charging rate close to 100% (full charging) and keep the battery warm for easy start the next day.

173

17 Care in cold weather and long-term storage

Note : Measure the specific gravity of the electrolyte to determine the charge ratio using the conversion table given below.

20°C

0°C

-10°C

-20°C

100 %

1,28

1,29

1,30

1,31

90 %

1,26

1,27

1,28

1,29

80 %

1,24

1,25

1,26

1,27

75 %

1,23

1,24

1,25

1,26

Electrolyte temperature Charging rate

The specific gravity of the electrolyte varies with its temperature and recharged condition.

Precautions after a day's work To prevent the machine from getting stuck in the morning due to frozen mud or water deposits on the undercarriage, be sure to observe the following precautions: •

Remove any mud or water adhering to the machine. If mud or water droplets adhering to the hydraulic cylinder rod should get into the seals, the seals could be damaged.

•

Park the machine on solid, dry ground. If no solid, dry ground is available, lay plates on the ground and park the machine on the plates to prevent the frozen tracks from sticking to the ground.

•

Drain the water accumulated in the fuel system by opening the drain cock, to prevent freezing.

•

As battery performance deteriorates in low temperatures, cover the battery or move it to a warm place, and reinstall it in the machine on the next morning. If the level of the battery electrolyte is low, add distilled water before starting operation on the next morning. To prevent the battery from freezing at night, do not add distilled water after completing operation.

After cold weather ends When the temperature rises, do the following: •

Replace the lube oil and fuel with the specified viscosities.

•

If you have added an AF-PT anti-freeze (for one winter season only), fully drain the cooling system, flush the inside of the cooling system well, and fill the sub-tank with tap water.

174

17 Care in cold weather and long-term storage

17.2 Long-term storage Before storing

IMPORTANT When storing the machine, lower the wagon as illustrated in the figure, to protect the hydraulic cylinder rod from becoming corroded.

•

Apply lube oil and grease to the machine and replace the engine oil.

•

Apply a small amount of antirust and grease to exposed parts of the hydraulic cylinder rod.

•

Add an anti-freeze to the cooling water if the air temperature can fall below 0°C.

•

To prevent condensation inside the fuel tank, either drain the fuel tank or fill the tank completely.

Storing Move the machine at least once a month to form new oil films on all the moving parts during long-term storage, and recharge the battery at the same time.

Note: Store the machine in accordance with the ISO 6749/1984 Standard.

Using the machine again

IMPORTANT When reusing a machine that has been stored for a long time without receiving antirust treatment once a month, consult your dealer.

To use the machine again after a long period of storage, follow the procedure below: •

Wipe antirust off the hydraulic cylinder rod.

•

Apply generous amounts of grease or oil to the moving parts.

•

Drain water from the fuel tank, the engine oil pan and the hydraulic oil tank by removing the drain plugs.

•

After starting the engine, warm-up the machine before use.

175

18 Troubleshooting

18

Troubleshooting 18.1 Phenomena that are not breakdowns The following phenomena are not breakdowns: •

Any of the wagon flaps does sometimes not close completely. Earth, grit or other objects may be jammed between the wagon and the flap. Remove them.

•

When the machine makes a sharp turn on a concrete road or an asphalt road, hunting occurs. Turn the machine gently to prevent hunting.

•

An abnormal sound sometimes comes from the H.S.T. when the machine starts or stops traveling.

•

In some cases, the steering lever does not return to its original position. This is caused by the steering clutch being engaged. If the machine goes on traveling, the lever will return to its original position.

18.2 Precautions for operation in water •

After operating the machine in water, always grease all the fulcrum parts which were submerged in water.

•

After greasing, dump and lower the wagon and move the machine back and forth several times. Then, grease the fulcrum parts again.

18.3 If the battery is overdischarged

WARNING •

Stop the engine and turn the starter switch key to the "OFF" position before checking or servicing the battery.

•

Flammable hydrogen gas is produced by the battery, which may cause ignition. Keep flames, sparks and lit cigarettes away from the battery.

•

The battery electrolyte contains dilute sulfuric acid, which is a strong acid.

•

If the battery electrolyte contacts your clothes, they may be damaged.

•

If the battery electrolyte gets into your eyes or contacts your skin, flush immediately with large amounts of water, and obtain medical treatment at once.

•

Be sure to wear safety goggles when handling a battery.

176

18 Troubleshooting

•

To disconnect the terminals, begin with the negative terminal (ground side); to connect the terminals, begin with the positive terminal. If a tool touches both the positive terminal and the machine, hazardous sparks may be generated.

•

If a terminal is loose, hazardous sparks may be generated due to poor contact, which could cause ignition and explosion. Be sure to securely connect the terminals.

18.4 Troubleshooting (depending on model) Electrical equipment

Problem Electrical equipment

•

Contact your dealer about the measures shown in parentheses in the list below.

•

If there is any abnormality or trouble whose cause is unknown other than those shown below, ask your dealer for repair.

Cause

Measure • Check and repair wiring system.

• Replace starter switch.

• Recharge battery.

• (Check and repair.)

Turning starter switch to "START" dose not start starter motor.

• Defective wiring system

Maximum engine speed does not provide enough brightness of lamps.

• Defective wiring system

During engine operation, lamp is extremely bright, and frequently burns out.

• Defective regulator

• (Replace regulator).

Electrolyte leaks from battery.

• Defective diode

• (Repair).

Speed of starter motor is too low.

• Defective wiring system

• Check and repair wiring system.

• Recharge battery.

• (Check and repair.)

• Defective starter switch • Insufficiently charged battery • Defective starter motor

• Defective generator or regulator

• Insufficiently charged battery • Defective starter motor

177

• Check terminals for looseness and disconnection. Repair terminal, if necessary.

• (Check and repair.)

18 Troubleshooting

Engine

Problem Engine

Steam comes out of top of radiator.

Water temp alarm lamp lights.

Turning on starter motor does not start engine.

•

Contact your dealer about the measures shown in parentheses in the list below.

•

If there is any abnormality or trouble whose cause is unknown other than those shown below, ask your dealer for repair.

Cause • Shortage of cooling water

• Loose fan belt • Buildup of dust and water scale on cooling system • Defective thermostat • Clogged radiator fin or inclined fin • Defective electrical system • Shortage of fuel • Air mixed in fuel system • Defective fuel injection pump or deteriorated nozzle performance • Improper compression • Blown out fusible link • Damaged key stop solenoid.

Link disengagement

Dark fumes come out of machine.

Exhaust color is white or bluish white.

Measure • Check cooling water level.

Refill, if necessary. (Check cooling water for leak from water port.)

• Adjust belt tension.

• Replace cooling water. Clean inside of cooling water system.

• Replace thermostat.

• Clean or repair fin.

• Check or replace electrical system.

• Refill fuel tank.

• Repair air leak.

Release air from fuel system.

• (Replace pump or nozzle.)

• (Check and repair.)

• Replace fusible link.

• (Check and repair.)

• Clogged air cleaner element

• Clean or repair element.

• Deteriorated nozzle performance • Improper compression

• (Check and repair.)

• Too much oil in oil pan

• Drain oil from oil pan to specified level.

• Replace fuel with recommended one.

• (Repair.)

• Improper fuel • Worn cylinder or piston ring

178

• (Check and repair.)

18 Troubleshooting

Machine body

Problem Under carriage Crawler type

Hydraulic system / Wagon

One side of each sprocket tooth is worn or rubber crawler comes off.

Oil leaks from idler, track roller or carrier roller Wagon does not dump or dumps too slowly when operating dump lever to the dump position.

(For the swing wagon type) Wagon does not swing when operating dump lever.

Abnormal sound from pump

Rear flap does not close.

(For the swing wagon type) Wagon does not swing or does not swing smoothly.

•

Contact your dealer about the measures shown in parentheses in the list below.

•

If there is any abnormality or trouble whose cause is unknown other than those shown below, ask your dealer for repair.

Cause • Abnormality of hydraulic cylinder for tension adjustment • Distorted track frame • Worn idler or track roller • Damaged seal • Damaged bearing • Overload • Insufficient amount of hydraulic oil • Insufficient discharge volume of hydraulic pump • Dust caught in valve • Air mixed from pump suction side • Too high viscosity of hydraulic oil (in extremely cold weather) • Clogged filter • Clogged filter • Air mixed from pump suction side • Worn or damaged internal part of pump • Distorted fulcrum pin • Earth and sand, ready-mixed concrete, etc. attached to fulcrum pin part • Distorted hook or rod • Large play of wagon stay • Insufficient grease applied to swing bearing

179

Measure • (Check and repair) • (Repair and reinforcement or replace) • (Replace) • (Replace parts) • (Replace parts) • Lower load • Replenish hydraulic oil up to specified leve (Check for oil leakage) • Contact dealer for measuring oil quantity and oil pressure) • Clean • Check and retighten piping and joint part • Replace with oil of proper viscosity • Check and clean or replace • Check and clean or replace • Check and retighten piping and joint part • Repair or replace) • Correct • Clean

• Correct or replace • Adjust • Apply grease

18 Troubleshooting

Equipment and adjustments (only for C30R-2A)

Problem

•

Contact your dealer about the measures shown in parentheses in the list below.

•

If there is any abnormality or trouble whose cause is unknown other than those shown below, ask your dealer for repair.

Cause

Measure

• The steering lever pressure is incorrectly adjusted • The clutch friction plate is burned or worn out • The brakes need to be adjusted • The brake friction plate is burned or worn out

• Adjust it.

• The brake is incorrectly adjusted • The brake rod does not work.

• Adjust it.

The engine smokes when the steering clutch is disengaged.

• The brake is being engaged before the steering clutch is disengaged.

• Check and adjust it.

Strange noise comes from the transfer case

• Insufficient oil • Worn or damaged gear teeth

• Check and add oil • (Replace it.)

Strange noise from the final case

• Seized or worn bearings • Worn spline between the gear and the shaft

• (Replace it.)

• (Replace it.)

Oil leaks from the transfer case or the final case

• Oil is overfilled • Bolts are loose • Defective O-ring, oil seal, or packing

• Check and drain oil • Retighten • (Replace bad parts.)

The machine cannot be steered with the steering lever.

The brake does not work.

180

• (Replace it.)

• Adjust them.

• (Replace it.)

• (Replace it.)

MAINTENANCE

181

182

19 Precautions for servicing

19

Precautions for servicing Do not use any inspection or servicing procedures that are not described and recommended in this manual.

Park the machine on solid, level ground to inspect and service it.

Attach the warning tag When the oil or the cooling water is drained, attach the "SERVICING IN PROGRESS" tag to the operator's seat so that other persons will not start the engine.

Observe the precautions for welding •

Make sure to disconnect the battery cables (positive and negative terminals).

•

Do not apply more than 200 V continuously.

•

Ground the machine within 1 m from the welded part.

•

Make sure that there is no seal or bearing between the welded part and the grounded part.

•

Do not ground around the pins on the implement or the hydraulic cylinder.

Observe the precautions for cleaning the machine •

Do not spray steam directly at the connectors.

•

Do not splash water on the monitors in the cabin.

•

Do not spray high-pressure water directly at the radiator and the oil cooler.

Do not mix oils Never mix oils of different makes or types. If you have to replenish an oil with a different make or type than the one already in the tank, remove the remaining oil completely.

183

20 Basic servicing practices

20

Basic servicing practices 20.1 Filter The filters are very important parts which prevent impurities from getting into critical devices through the lube oil, fuel and air systems. Replace the filter elements periodically according to the instructions of the Operation Manual. Under difficult conditions, you need to replace the filter elements earlier than suggested in the Operation Manual depending on the type of oil and fuel (sulfur content).

•

Never reuse the filter elements (cartridge type) by cleaning them.

•

When replacing an oil filter element, check that no metallic dust or foreign solids are present on the old filter.

•

If they are found to be present, contact the nearest dealer.

•

Do not unpack the filter element before use.

•

Use YANMAR genuine filter elements.

184

21 Fueling, oiling and greasing based on temperature range

21

Fueling, oiling and greasing based on temperature range 21.1 Fuel and oil Select fuel and oil based on the temperature range.

If you start the engine at air temperatures lower than 32°F (0°C), use SAE10W, SAE10W-30, or SAE15W-40 even if the temperature in the daytime rises to 50°F (10°C) or so.

Use only the recommended fuel: • ISO 8217 DMX •

EN 590:96

Fuel cetane number minimum 45

21.2 Cooling water Because a YANMAR genuine long-life coolant (LLC) is added to the cooling water, you need not change it unless the temperature falls bellow -35°C. Recommendations with regard to temperature ranges Components

Prescribed amount (litre)

Fluid (°F) -4 14 (°C)(-20) (-10)

32 (0)

50 68 (10) (20)

86 (30)

C12R-A

C30R-2A

C50R-3B

1,8

3,8

14

+ 0,4

+ 0,4

+0,4

with filter

*for each reduction gear

SAE 10WCD

Engine

Engine oil

SAE 10W-30CD SAE 15W-40CD

4,3

Final reduction gear

Gear oil

SAE 90 (GL-4)

single reduction gear

1,5*

2,6*

Transfer reduction gear

Gear oil

TF500 / Terrac Tractran 9

-

9,5

-

Hydraulic oil system

Hydraulic oil

14,0

13,0

35

in the tank

2,5

6,0

22

the rest

14,5

40,0

78

1,6

4,2

10,8

radiator

0,4

0,3

0,4

subtank

ISO VG46

No.2-D Fuel tank

Light oil

No.3-D No.3-D (S)

Cooling system

Water

YANMAR genuine long-life coolant (LLC) added

185

22 Standard tightening torque for bolts and nuts

22

Standard tightening torque for bolts and nuts 22.1 Torque table Bolts or nuts in the metric system should be tightened at the torque described below unless specified otherwise.

Item Screw (7T) Nut

Coarse threads

Fine threads

PT plug

Pipe joint bolt

Thread size pitch

Tightening torque N•m

M6 1

9,8 - 11,8

M8 1,25

22,6 - 28,4

M10 1,5

44,1 - 58,8

M12 1,75

78,5 - 98,1

M14 2

117,7 - 147,1

M16 2

166,7 - 206,0

M18 2,5

235,4 - 284,4

M20 2,5

323,6 - 402,1

M8 1

23,3 - 25,7

M10 1,25

47,5 - 52,5

M12 1,5

83 - 91,6

M14 1,5

127,5 - 147,1

M16 1,5

210,9 - 240,3

M20 1,5

429,5 - 474,7

1/8

9,8

1/4

19,6

3/8

29,4

1/2

58,8

M8

12,7 - 16,7

M12

24,5 - 34,3

M14

39,2 - 49,0

M16

49,0 - 58,8

Remarks 1) Apply 80 % tightening torque if screws or nuts are in aluminium.

2) Apply 60 % tightening torque for 4T bolt and lock nut.

3) Use fine thread screws for engine only.

IMPORTANT If a part to be tightened is made of resin like a panel board, excessive tightening torque may damage the tightened part. Be careful when tightening.

186

23 Maintenance table

23

Maintenance table Daily and periodic inspection are important to keep the machine in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection intervals vary depending on the use, loads, fuels and lube oils used and handling conditions. The following should be treated only as a general standard.

When the time for an inspection approaches, study the relevant pages in the Operation & Maintenance Manual. Keep a record of daily operation and the results of maintenance work.

23.1 List of periodic inspection and servicing : Check

: Supply

: Replace first time

: Replace

Check & service items Machine General

Daily

Falling off or breakage of parts Retighten bolts and nuts Engine condition Clean

Lube oil

*Swing gear case oil Travel reduction gear oil *Transmission oil *Differential gear oil

Hydraulic system

Hydraulic oil Suction filter Return filter *HST Filter Hydraulic pump

Grease

Greasing points *Swing gears and Swing bearings

Undercarriage

Crawler tension

187

: Adjust (clean) Every 50h

Every 250h

: Oil and grease Every 500h

Every 1000h **

23 Maintenance table

Pilot

Steering lever Travel lever *Speed change Accelerator lever Pilot forward / backward Brake pedal Parking brake

Electric equipment

Lights, horn Hourmeter Warning lights Function of electric wiring and battery Electrical circuit Monitor

: Check

: Supply

: Replace first time

: Replace

Check & service items Engine

Daily

: Adjust (clean) Every 50h

Every 250h

: Oil and grease Toutes les 500h

Every 1000h **

Fuel tank Tank / Oil/water separator Fuel filter Engine oil Oil filter Cooling water Radiator fins Fan-belt tension Rubber hose (fuel and cooling water) *Turbocharger Air filter Valves Nozzle valves and injection pressure Fuel pump * Applicable to models with the relevant equipment ** Every 1000 hours or once a year

188

23 Maintenance table

Note : • When machine is used at dusty worksites clean and replace filter element twice or more frequently than specified in the table.

• Execution of periodic inspection and servicing is indispensable to conform to the EPA emission control regulations.

Keep a record of the results.

189

24 Procedures of maintenance for C12R-A

24

Procedures of maintenance for C12R-A IMPORTANT The checking and the repair of the articles below require experience. Consult your Ammann-Yanmar Dealer.

24.1 Checking the rubber crawlers Rubber crawlers in the following condition require repair or replacement. Ask your dealer to repair or replace them.

1

Height of lugs

2

•

a

As the lug height "a" is reduced by wear, the tractive force decreases.

If "a" becomes 5 mm or less, replace the crawler with a new one.

1 = Track roller 2 = Rubber crawler •

If two or more links of the steel cord inside the crawler are exposed due to wear of the lugs, replace the crawler with a new one.

3 = Exposed steel cord

3 Rubber crawler steel cord breakage •

If half or more of either of the steel cords is broken, replace the rubber crawler with a new one.

4 = Half or more breakage 1/2 1/2

5

4 Separation of the core metal of the rubber crawler •

If the core metal of the rubber crawler separates even at one place, replace the rubber crawler with a new one.

5 = Separation of the core metal

190

24 Procedures of maintenance for C12R-A

Crack in the rubber crawler

6

•

If a crack occurs between any lugs of the rubber crawler, repair it if the crack length reaches approximately 60 mm.

If the inside steel cord is exposed even though the crack is small, repair the rubber crawler immediately.

•

If the crack length is less than 30 mm or the crack depth is less than 10 mm, you do not need to repair the rubber crawler.

For a decision on whether the rubber crawler should be replaced, repaired or should continue to be used, ask your dealer.

7

8

6 = Exposed steel cord 7 = To be repaired if 60 mm long or more 8 = (Not yet to be repaired)

24.2 Replacing the rubber crawler

WARNING •

Be sure to do the replacement work on level ground.

•

To replace the rubber crawler with a new one, work with a partner. You must operate the machine in response to signs from your partner.

•

Because the rubber crawler is replaced with the machine in a raised position, there is a danger that the machine may accidentally fall. Do not move any parts other than the rubber crawler to be replaced in doing the job.

•

When jacking up the machine, support it with safety blocks of sufficient strength to keep the balance of the machine body.

•

The oil temperature is very high immediately after the machine stops operating. Be sure to do the work after the oil temperature lowers sufficiently.

•

When removing the hydraulic hose, oil may spout out due to the high internal pressure. Loosen the hydraulic hose slowly to prevent high pressure oil from contacting your eyes or skin.

•

If the tension of the rubber crawler cannot be loosened by the procedure described here, ask your dealer to repair the rubber crawler.

191

24 Procedures of maintenance for C12R-A

Removing the rubber crawler

WARNING •

It is very dangerous to loosen the rubber crawler by any procedure other than that described below.

•

If the tension of the rubber crawler cannot be loosened, ask your dealer to repair or replace the rubber crawler.

CAUTION

(5 - 10 mm)

(1)

(3)

a b (4)

(2)

•

Take great care in handling rubber crawlers, because they are very heavy.

•

Be careful not to get injured, because the clearance between the rubber crawler and the wagon is small.

•

Prepare a jack and some wooden blocks.

1) Loosen the lock nut (1) and then the adjusting bolt (2), and press the idler (3) in.

2) With the idler (3) pressed in, if the distance shown in the figure at the right exceeds the specified range, mud may be caught in the idler fork. Remove the cover (4) and clean the idler fork to remove the mud.

3) Jack up the machine so that a clearance can be created between the core metal protrusion of the rubber crawler and the track rollers, and put wooden blocks between the frame and the ground.

4) Remove the rubber crawler from the idler first, and then from the sprocket.

Installing the rubber crawler •

Prepare two crowbars.

1) Engage the rubber crawler with the sprocket.

2) Place the rubber crawler on the idler, and at the same time, install the core metal protrusion of the rubber crawler beyond the carrier roller.

3) Press the lower side of the rubber crawler toward the center of the machine, and place the core metal of the rubber crawler so that it is adjacent to the idler.

4) Insert a crowbar into the sprocket hole and touch the end of the crowbar to the side face of the idler (on the inner side of the machine). While pressing the crowbar toward the inside of the machine, insert another crowbar between the core metal of the rubber crawler and the idler. Then, pry and move the crowbar toward the idler gradually until the core metal protrusion covers the idler.

192

24 Procedures of maintenance for C12R-A

24.3 Adjusting the fan belt tension 1) Prepare a wooden bar (e.g., the handle of a hammer).

1

2) Loosen the generator mounting bolts and.

2 3 a

3) Insert a wooden bar between the generator and the cylinder block, and move the generator to adjust the fan belt tension so that the belt will be depressed approximately 10 to 15 mm with a pressing force of 10 kgf.

4) Retighten the mounting bolts and to secure the generator.

5) Check the pulleys, the V-groove, and the fan belt for damage, and check that the fan belt does not touch the bottom of the V-groove.

4 (10 - 15 mm)

5

3

6) If the fan belt cannot be properly adjusted because it has lost its elasticity or if it is damaged or cracked, replace the fan belt with a new one. a = Wooden bar or similar object 1 = Adjustor 2 = mounting bolt 3 = Generator 4 = Cooling water pump 5 = Fan pulley

24.4 Adjusting the drive belt tension 1) Loosen the lock nut.

2) Turn the adjusting nut for the tension rod clockwise to adjust the drive belt tension so that the drive belt will be depressed 10 mm with a pressing force of 2.5 to 3.5 kg.

3) Be sure to tighten the lock nut securely. a = Engine pulley b = HST pulley c = Lock nut

IMPORTANT a b c

If the drive belt cannot be adjusted properly because of lost elasticity or any other damage, it needs to be replaced. Ask your dealer to replace the drive belt with a new one.

193

24 Procedures of maintenance for C12R-A

24.5 Checking, cleaning and replacing the air cleaner element

WARNING •

Never attempt to clean and replace the air cleaner while the engine is running.

Always stop the engine and allow it to cool first.

•

Compressed air is used to clean the element. Always wear safety goggles to prevent injury to your eyes.

•

The maximum compressed air pressure should be less than 0.7 MPa for cleaning purposes.

Cleaning procedure for air cleaner element 1) Open the engine hood.

1

2) Remove the clips (2) and remove the dust cup (1).

3) Remove the element (3).

Cover the connector side at the back of the air cleaner body using a clean cloth and tape to prevent dirt from entering.

2 3

4) Clean the dust cup (1) and the inside of the body.

5) Blow the dry, compressed air (0.7 MPa or less) from inside the element along the pleats to initially remove the dirt.

Then blow compressed air from outside the element along the pleats to remove dirt. Blow compressed air again from inside the element, to complete the dirt removal.

6) After cleaning, illuminate the element from inside with a light bulb and check it. If there are any small holes or thin areas, replace the element with a new one.

IMPORTANT

3

•

When cleaning the element, do not tap it or strike it against other objects. Otherwise the element may be damaged.

•

Do not reuse the element if the pleat, gasket or seal is damaged.

•

Replacement elements should be wrapped in clean paper and stored in a dry place.

7) Remove the protective cloth and tape used to cover the air cleaner body.

8) Insert the newly-cleaned element.

9) Install the dust cup with the arrow mark on it turned 22.5 degrees counterclockwise, as shown in the figure at the right.

194

24 Procedures of maintenance for C12R-A

10) Close the engine hood.

22.5°

a = Top

a

Replacing procedure for air cleaner element

WARNING Never attempt to replace the air cleaner element while the engine is running.

Replace the air cleaner element after the engine has been stopped and has cooled sufficiently.

1) Open the engine hood.

1

2) Remove the clips (2) and remove the dust cup (1).

3) Remove the element (3).

Cover the connector side at the back of the air cleaner body using a clean cloth and tape to prevent dirt from entering.

2 3

4) Clean the dust cup and the inside of the body.

Remove the protective cloth and the tape used to cover the air cleaner body.

5) Install a new element.

6) Install the dust cup (1) with the arrow mark on it turned 22.5 degrees counterclockwise, as shown in the figure.

7) Close the engine hood.

22.5°

a

195

24 Procedures of maintenance for C12R-A

24.6 Draining the water and deposits from the fuel tank

WARNING •

Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

•

Keep sparks, flames and lit cigarettes away.

•

If any fuel is spilled when draining the fuel, it may cause a fire. Wipe up the spilled fuel completely.

Thing to prepare •

1) Park the machine on level ground. Dump the wagon, install the wagon support to hold the wagon securely and stop the engine. Then, move the dump lever back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever with the dump lever stopper.

1

1

Container for fuel waste

2

1 = Open 2 = Close 2) Draw out the drain cock (P) hose on the bottom of the fuel tank and place the container for fuel waste under the hose.

3) Open the drain cock (P) to discharge the water and dirt deposits in the fuel tank.

Take care that the fuel does not contact your body.

(P)

4) When clean fuel starts coming out, close the drain cock (P).

24.7 Cleaning the fuel filter element (with water separator)

WARNING •

Keep sparks, flames and lit cigarettes away.

•

At operating temperature, the engine components are hot.

•

Disconnect the battery and clean the element after the engine has cooled sufficiently.

•

Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire.

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24 Procedures of maintenance for C12R-A

Things to prepare •

Cloth

•

Filter wrench

1) Open the engine hood.

2) Place a cloth under the fuel filter.

a a

6) Install the element (5) and the cup (3) and turn the cock (1) to the open position.

e d (2) (1)

(3)

(4)

4) Remove the element (5) and clean it and the inside of the cup (3) using light oil or a washing agent.

5) Check the O-ring and if it is damaged or deformed, replace it with a new one.

b c

3) After setting the fuel filter cock (1) to the closed position, loosen the retainer ring (2) to remove the cup (3) and drain the water from the cup.

Do not lose the red ring (4) in the cup.

(5)

7) Remove the cloth, then release air.

8) After releasing air, start the engine and check for fuel leak.

If there is nothing wrong, stop the engine and close the engine hood. a = Fuel filter b = Close c = Open d = Loosen e = Tighten

24.8 Replacing the fuel filter element

WARNING •

Keep sparks, flames and lit cigarettes away.

•

At operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the battery and replace the element after the engine has cooled sufficiently.

•

Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire.

•

Drain the fuel from the fuel filter into a container before removing the fuel filter.

Things to prepare •

Cloth

•

Filter wrench

1) Open the engine hood.

197

24 Procedures of maintenance for C12R-A

2) Place a cloth under the fuel filter (a).

3) After setting the fuel filter cock (1) to the closed position, loosen the retainer ring (2) to remove the cup (3), and remove the element (5).

Be sure not to lose the red ring (4) inside the cup.

a a

5) After replacing the fuel filter element, remove the cloth, then release air.

e

a = Fuel filter b = Close c = Open d = Loosen e = Tighten

b c

d (2) (1)

(3)

(4)

4) Clean the cup (3) using light oil or washing agent and install a new element.

Replace the O-ring when replacing the element.

(5)

6) After releasing air, start the engine and check for fuel leak.

If there is nothing wrong, stop the engine and close the engine hood.

How to release air: 1) Fill up the fuel tank.

2) Place the accelerator lever in the "RUN" position.

3) Turn the starter switch to the "START" position to crank the engine for approximately 10 seconds.

Air will be automatically released and the engine should starts.

IMPORTANT If the engine does not start within 10 seconds, wait at least a minute before again attempting to restart the engine.

Whenever you refuel, release air in the same way. After the engine starts, sometimes it will revolve irregularly. In that case, turn the starter switch to the "OFF" position, wait for one minute or more and turn the starter switch to the "START" position again.

24.9 Replacing the pre-filter

WARNING •

Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

•

Never attempt to replace the pre-filter immediately after the engine stops. At the operating temperature, the

198

24 Procedures of maintenance for C12R-A

engine components are hot and can cause a burn. Replace the pre-filter after the engine components have cooled sufficiently.

•

After replacing the pre-filter, install the fuel hoses securely to prevent oil leak.

•

Keep sparks, flames and lit cigarettes away.

(1)

Things to prepare •

(2)

a c

b

Container for fuel

1) Park the machine on level ground. Dump the wagon, install the wagon support (1) to hold the wagon securely and stop the engine. Then, move the dump lever (2) back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever with the dump lever stopper (c). a = Lock b = Unlock c = Lever lock 1 = Wagon support 2 = Dump lever 2) Remove the pre-filter (3) from the clamp (4).

3) Place the container for fuel under the pre-filter (3).

(3)

4) Loosen the clamp (5) to remove the fuel hose (6) from the pre-filter (3).

(8)

5) Loosen the clamp (7) to remove the fuel hose (8) from the pre-filter (3).

(7)

6) Install the fuel hoses (6) and (8) to a new pre-filter (3), then fasten them with the clamps (5) and (7).

(5) (4) (6)

(3)

7) Install the new pre-filter (3) to the clamp (4).

8) Release air.

24.10 Replacing the engine oil and the engine oil filter

WARNING •

Do not replace the oil immediately after the engine stops to prevent bodily injury, because all the components are hot.

•

Do not allow hot oil or components to contact your skin.

•

Replace the oil and the oil filter after the oil and the components have cooled sufficiently.

199

24 Procedures of maintenance for C12R-A

Things to prepare

a

•

Replacement new oil : 1,8 L

•

Container for waste oil : Capacité de 1,8 L or more

•

Filter wrench for engine oil filter cartridge

1) Open the engine hood.

2) Remove the step (a).

3) Put the container for waste oil under the drain plug on the bottom of the machine body.

4) Open the cover (1) and slowly remove the drain plug (P) so that the oil should not splash on you and drain the waste oil.

(1)

(P)

5) Check the waste oil, and contact your dealer if any metallic particles or foreign objects are mixed in it.

6) Reinstall the drain plug (P).

7) Turn the oil filter cartridge (2) counterclockwise with the filter wrench to remove it.

After removing the oil filter, wait 10 to 15 minutes before replacing it.

a

a = Loosen b = Tighten

(2)

b

8) Wipe the dirt and oil from the filter mount and apply engine oil (or apply grease lightly) to the seal surface of a new oil filter cartridge.

9) When mounting the new filter (cartridge), turn it 2/3 of a turn after the seal surface has contacted the filter mount.

10) Reinstall the step.

(G) (3)

11) Open the cover (3) of the step, and add engine oil up to the upper limit (H) mark on the oil dipstick through the oil supply port (F).

12) Idle the engine for several minutes and then stop the engine. Then check that the oil level exceeds the midpoint between the upper and lower limit marks on the oil dipstick.

13) Install and tighten the oil supply port cap (G) securely.

(F)

14) Close the cover (3) of the step, and close the engine hood.

Replace the engine oil and the oil filter 6 months after the previous replacement, even if the service hours have not reached 250 hours.

Also replace them at 250 service hours, even if 6 months have not elapsed since the previous replacement.

200

24 Procedures of maintenance for C12R-A

24.11 Replacing the hydraulic oil and cleaning the suction filter

WARNING •

Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

•

The hydraulic oil and the tank are hot and under pressure at operating temperature. Never replace the oil immediately after operation is stopped. Wait until the tank has cooled enough to permit you to touch its surface with your bare hand.

•

When removing the oil supply port cap, slowly loosen it to relieve the internal pressure, then remove the cap carefully.

Things to prepare (1)

(2)

a c

b

•

Container for waste oil : : Capacity of 16,5 L or more

•

New hydraulic oil : 14.5 L

•

O-rings

1) Park the machine on level ground. Dump the wagon, install the wagon support (1) to hold the wagon securely and stop the engine. Then, move the dump lever back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever (2) with the dump lever stopper (c). a = Lock b = Unlock c = Lever lock 2) Place the container for waste oil under the drain plug (P) on the bottom of the hydraulic oil tank.

A

A = Viewed from under 3) Slowly loosen and remove the drain plug (P), and drain the hydraulic oil into the container.

Take care that the hydraulic oil does not contact your body.

(P)

d e

4) Remove the oil supply port cap. d = Oil supply port cap e = Hydraulic oil tank f = Hose bands g = Suction filter 5) Degrease and clean the threads of the drain plug (P), and replace the O-ring mounted on the plug with a new one.

f

g

(P)

6) After draining the waste oil, install and tighten the drain plug.

Tightening torque : 59 N•m

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24 Procedures of maintenance for C12R-A

7) Loosen the hose bands to remove the hose from the suction filter.

8) Remove the suction filter. Remove the dirt from the filter and wash it with a washing agent or light oil.

9) Check the filter. If the filter is damaged or cracked, replace with a new one.

10) Degrease and clean the threads of the filter and replace the O-ring mounted on it with a new one. Then, install the filter in the hydraulic oil tank.

Tightening torque : 98.1 to 117.7 N•m

IMPORTANT Do not allow any dirt to enter the tank when installing the filter.

a b

11) Install the hose to the filter, and tighten the hose bands.

Tightening torque : 2.5 to 3.4 N•m 12) Add oil to the specified level in the hydraulic oil tank..

Check the oil level with the oil level gauge (a) on the side of the machine and do not add oil beyond the midpoint between the upper (c) and lower (d) limit marks on the oil level gauge (a).

c d

13) Reinstall the oil supply port cap (b).

14) After replacing the oil, place all control levers in the neutral position and idle the engine for approximately 2 to 3 minutes. Then, test the dump lever for proper operation.

24.12 Replacing the hydraulic oil return filter

WARNING •

Always install the wagon support to hold the wagon securely when inspecting or servicing the machine with the wagon in the dump position.

•

The hydraulic oil and the tank are hot and under pressure at the operating temperature. Never replace the filter immediately after ceasing machine operation.

Wait until the hydraulic oil tank has cooled enough to permit you to touch its surface with your bare hand.

Things to prepare

(1)

•

Container for oil

•

Filter wrench

1) Park the machine on level ground. Dump the wagon, install the wagon support (1) to hold the wagon securely and

202

24 Procedures of maintenance for C12R-A

(2)

a

stop the engine. Then, move the dump lever (2) back and forth to relieve the pressure in the hydraulic cylinder circuit and lock the dump lever (2) with the dump lever stopper (c). a = Lock b = Unlock

c

b

2) Place the container for oil under the return filter (d).

3) Remove the filter cartridge using the filter wrench.

4) Wipe off the dirt and oil from the filer mount with a cloth moistened with light oil, and install a new filter cartridge after applying hydraulic oil to the sealing surface of the cartridge.

5) Gently turn the new filter cartridge by hand until its sealing surface touches the filter mount, and then give it another 2/3 of a turn with the filter wrench.

d

6) After installing the new filter cartridge, run the engine and check that there is no oil leak from between the mating faces.

24.13 Adjusting the steering clutches 1) Remove the step (a).

a

2) Adjust the steering lever (1) with the steering rod (2) so that the play of the lever will be between 5 mm and 10 mm.

3) Check that both the right and left steering clutches disengage at the same time when both steering levers are operated together.

4) Be sure to tighten the lock nuts (3) securely.

24.14 Adjusting the steering brakes 1) If the stroke length of one steering lever (1) is not the same as that of the other one, adjust the steering lever having the shorter stroke with the steering rod (2) so that the steering lever will have the same stroke length as the other steering lever.

1

3 2

(2)

(1)

2) If the stroke length of the steering lever exceeds 300 mm, ask your dealer to check the lever and replace the brake friction plates and steel plates if necessary.

24.15 Adjusting the travel pedal 1) Remove the step (a).

2) Move the F/R lever (1) from the neutral position to the forward or reverse travel position, press down on the brake pedal (2) fully and then start the engine. Run the engine at medium speed.

203

24 Procedures of maintenance for C12R-A

3) Release the brake pedal (2). Loosen the lock nut and slowly turn the return spring (3) to the F side to find the point at which the machine starts moving.

Next, slowly turn the return spring (3) to the R side to find the point at which the machine starts moving.

When doing this, count the number of turns you give the return spring (3) from the F side to the R side. Then, give it half of the turns back to the F side.

(3)

R

(3)

[Example] If you give the return spring (3) three full turns from the F side to the R side, give it a turn and a half from the R side to the F side.

(4)

F

24.16 Adjusting the F/R lever (3)

(1) (4) (2)

(5) (6) (5)

(B)

(A)

1) Remove the knob (3) from the F/R lever (1) and remove the instrument panel (4).

2) Place the F/R lever (1) in the neutral position.

Loosen the lock nuts (5) and adjust the F/R lever by the turnbuckle (6) so that the machine does not move even if the travel pedal is pressed down.

•

If the machine moves to forward : Turn the turnbuckle to the (A) side.

•

If the machine moves to reverse : Turn the turnbuckle to the (B) side.

3) Tighten the lock nuts (5).

Tightening torque : M8 : 22.6 to 28.4 N•m 4) Install the instrument panel (4).

5) Install the knob (3).

204

25 Procedures of maintenance for C30R-2A

25

Procedures of maintenance for C30R-2A IMPORTANT The checking and the repair of the articles below require experience. Consult your Ammann-Yanmar Dealer.

25.1 Checking the rubber crawlers Rubber crawlers in the following condition require repair or replacement. Ask your dealer to repair or replace it.

1

Height of lugs

2

•

a

As the lug height "a" is reduced by wear, the tractive power decreases.

If "a" becomes 5 mm or less, replace the crawlers with new ones.

1 = Track roller 2 = Rubber crawler •

If two or more of the steel cords in the crawler are exposed two due to wear of the lugs, replace the crawlers with new ones.

3 = Exposed steel cord

3 Rubber crawler steel cord breakage •

If half or more of the steel cords are broken, replace the rubber crawler with a new one.

4 = Half or more breakage 1/2 1/2

5

4 Detachment of the core metal of the rubber crawler •

If the core metal of the rubber crawler detaches even at one place, replace the rubber crawler with a new one.

5 = Come off of the core metal

205

25 Procedures of maintenance for C30R-2A

Crack in the rubber crawler

6

•

If a crack occurs between any lugs of the rubber crawler, repair if the crack length reaches approximately 60 mm. If the inside steel cord is exposed even though the crack is small, repair the rubber crawler immediately.

•

If the crack length is less than 30 mm or the crack depth is less than 10 mm, you do not need to repair the rubber crawler.

For a decision on whether the rubber crawler should be replaced, repaired or should continue to used, ask your dealer.

7

8

6 = Exposed steel cord 7 = To be repaired if 60 mm long or more 8 = Not yet to be repaired

25.2 Replacing the rubber crawler

WARNING •

Park the machine on the flat ground for work.

•

To replace the rubber crawler with a new one, work with a partner. You must operate the machine according to the sign from the partner.

•

Because the rubber crawler is replaced with the machine in lifted position, it is danger of the machine from falling down accidentally.

•

When lifting the machine, support it with safety block of sufficient strength.

WARNING •

The inner high-pressure grease can eject the nipple valve.

•

When you loosen the nipple valve (1), do not loosen the nipple valve more than one turn.

•

At this point, do not loosen any parts other than the nipple valve (1). Also, do not turn your face toward the nipple valve (1).

•

If the rubber crawler cannot be loosened by using the procedure described here, ask the your dealer to repair the rubber crawler.

•

Prepare a grease gun and steel pipes.

(1)

206

25 Procedures of maintenance for C30R-2A

Removing the rubber crawler

WARNING •

It is very dangerous to discharge the grease by using any other procedure than described below.

If the rubber crawler cannot be loosened, ask your dealer to repair the rubber crawler.

•

Before detach the rubber crawler, make sure that the grease has been completely discharge from the adjuster, then turn the sprocket.

CAUTION The rubber crawler are heavy. Carefully remove or reinstall the rubber crawler.

(3)

1) Raise the dump deck and lock it with the dump deck support stopper. Then lock the dump lever.

Stop the engine after finishing this procedure.

(1)

2) Loosen nipple valve (1) and press idler (2) in.

3) Dismount sprocket (3) to loosen the rubber crawler.

(2) 003800-00X

4) Jack up the track until a gap is made between the metallic boss of the rubber crawler and the track roller and then place a wood block under the frame.

5) Detach the crawler. To do this, begin with the idler side.

Installing the rubber crawler

CAUTION The rubber tracks are heavy. Carefully remove or reinstall the rubber tracks.

(4)

1) Install the sprocket on the drive axle.

2) Fit the rubber crawler to the sprocket.

3) Place the rubber crawler over the idler and at the same time let the core metal of the track install over the track carrier roller. Note that the crawler can be easily mounted by placing a wooden rest under the crawler to bring the sag of the crawler to its upper deflections.

4) Press the bottom of the crawler toward the center of the machine, and place the core metal of the rubber crawler against the idler.

5) Insert a crowbar (4) into the hole of the sprocket and touch the tip of the crowbar to the side of the idler (the inner side of the machine body). Then while pressing the crowbar toward the inside of the machine, insert another crowbar

207

25 Procedures of maintenance for C30R-2A

into between the core metal of the rubber crawler and the idler.

Finally force the rubber crawler to move toward the idler with the crowbar step by step until the core metal boss covers the idler completely.

25.3 Adjusting the fan belt tension •

To adjust the fan belt, loosen the generator mounting bolt and change the generator position.

1 = Fan belt 2 = Generator •

2

1

a = Fan pulley b = Generator c = Press •

If the belt is already stretched too much to be tightened or if it is damaged, replace it with a new one.

•

When replacing the V-belt with a new one, it may become loose after a short period of use. After 50 hours of use, check and adjust a new V-belt.

(b)

(a)

Push on the fan belt at a point between the fan pulley and the generator with your finger. Use a pressure of about 10 kgf. A deflection of 10 to 15 mm is normal.

(c)

25.4 Checking, cleaning and replacing the air cleaner element

WARNING

(1) (2)

•

Never attempt servicing while engine is running or immediately after stopping operation.

•

Compressed air can cause personal injury.

•

Whenever using compressed air for cleaning, wear protective goggles, clothing and safety shoes.

Cleaning procedure for element 1) Open the engine hood.

2) Remove the clip (1) and remove the dust cup (2).

3) Remove the element (3).

Cover the connector side at the back of the air cleaner body using a clean cloth and tape to prevent dirt from entering.

4) Clean the inside of the air cleaner body.

(3) 003785-00X

5) Blow the dry, compressed air (7 kg or less) from inside the element along the pleats to initially remove the dirt. Then blow compressed air from outside the element along the

208

25 Procedures of maintenance for C30R-2A

pleats to remove dirt. Blow compressed air again from inside the element.

The element (3) should be cleaned 5 times a year and replaced after 1 year.

6) After cleaning, illuminate the element (3) from inside using a light bulb and check it. If there are any small holes or a thin parts, replace the element.

IMPORTANT

003787-00X

•

When cleaning the element, do not knock it or strike it against other objects. Otherwise the element may be damaged.

•

Do not use the element if the pleat, gasket or seal is damaged.

•

Unwrap and install the new element if it is clean and dry.

7) Remove the clean cloth and the tape covering the connector in the back.

8) Mount the cleaned element (3).

9) When installing the dust cup (2), align it using the arrow mark on it and tighten the clip (1).

(3) 003785-00X

(1) (2)

Replacing procedure for the air cleaner element 1) Open the engine hood.

2) Disengage the clip (1) and remove the dust cup (2).

(1) (2)

3) Remove the element (3).

Remove the clean cloth and the tape covering the connector in the inside of the body.

4) Clean the inside of the body.

Remove the clean cloth and the tape covering the connector in the inside of the body.

5) Install a new element (3) and tighten the wing nut.

6) When mounting, align it with the arrow mark on the dust cup (2).

(3) 003785-00X

209

25 Procedures of maintenance for C30R-2A

25.5 Draining the water and deposit in the fuel tank 1) Remove the water and debris from the fuel tank before starting the vehicle.

2) Prepare a container to hold the waste fuel.

3) Loosen the drain plug (1) to remove the water and debris together with the fuel out of the fuel tank. At this point, be careful not to splash yourself with the fuel.

4) Tighten the drain plug (1) when the clean fuel begin to come out.

25.6 Checking the water separator

AVERTISSEMENT •

Keep sparks, flames and lit cigarettes away. At the operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the ground of the battery and clean the element after the engine has cooled sufficiently.

•

Fuel oil leaked or spilled onto hot surfaces or electrical components could cause a fire.

Drain the fuel from the water separator into a container before removing the water separator retainer ring.

Things to prepare : •

Container for fuel waste

a = Water separator If the red ring (1) has sunk down on the cup bottom, water has not mixed into the oil; if the red ring (1) floats in the cup, water is mixed into the oil under the red ring (1). In this case, take out the cup and remove the water.

1) Open the engine hood and move handle (3) to the «CLOSED» position.

a

2) Loosen retainer ring (4), remove case (2), and then discard the water out of the case.

1 (b) (c)

(d) 3

3) Place case (2) back in position and secure it by tightening the ring.

2 (e) 4

4) Place handle (3) at the «OPEN» position.

5

5) Remove water and debris from the fuel tank. b = Open c = Close d = Loosen e = Tighten

210

25 Procedures of maintenance for C30R-2A

25.7 Cleaning the water separator element

WARNING •

Keep sparks, flames and lit cigarettes away. At the operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the ground of the battery and clean the element after the engine has cooled sufficiently.

•

Fuel oil leaked or spilled onto hot surfaces or electrical components could cause a fire.

Drain the fuel from the water separator into a container before removing the water separator retainer ring.

Things to prepare : •

Container for fuel waste

a = Water separator 1) Open the engine hood, move handle (1) to the «CLOSED» position and place an oil container underneath case.

2) Loosen retainer ring (2), remove case, and then discard the water out of the case. Be careful not to lose red ring (4) in the case.

a

3) Remove the element and clean the element (5) and inside the cup using light oil.

1 (b) (c)

(d) 3

4) Place case (3) in postion, and retighten retainer ring (2) to install the case.

2 (e) 4

5) Place handle (1) at the «OPEN» position.

5

b = Open c = Close d = Loosen e = Tighten

25.8 Cleaning / replacing the fuel filter element

WARNING •

Keep sparks, flames and lit cigarettes away. At the operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the ground of the battery and clean the element after the engine has cooled sufficiently.

211

25 Procedures of maintenance for C30R-2A

•

Fuel oil leaked or spilled onto hot surfaces or electrical components could cause a fire.

Drain the fuel from the fuel oil filter into a container before removing the fuel oil filter retainer ring.

Things to prepare: •

Container for fuel

Close the fuel retainer cock and remove the retainer ring so you can take out the element. Wash the element with cleaning oil.

a

After cleaning or replacing the element and when the fuel runs out, bleed the element as follows : 1) Fill the fuel tank.

2) Turn the key switch to the "ON" position.

a

3) The air will be bled automatically.

(b)

1

(c) (d)

(e)

2

1 = Retainer ring 2 = Filter a = Fuel filter b = Close c = Open d = Loosen e = Tighten

25.9 Replacing the engine oil and the engine oil filter

WARNING •

Hot oil and components can cause personal injury.

•

Do not allow hot oil or components to contact skin.

•

Replace oil and filter element after oil and components have cooled sufficiently.

Things to prepare :

(P) 003715-00X

•

Filter wrench (for cartridge)

•

Container for waste oil ... Capacity of 4 L or more

•

Replacement new oil ... 3.1 L

1) Open the engine hood, and place a waste oil container underneath the drain plug (P) on the underside of the vehicle.

2) Take the cap off the oil port.

3) Slowly remove the drain plug so that you will not be splashed with oil and discharge the waste oil.

212

25 Procedures of maintenance for C30R-2A

4) Check the waste oil, and contact your dealer if any metallic particles or any foreign objects are mixed in it.

5) Reinstall the drain plug (P).

6) Turn the oil filter (cartridge) (1) counterclockwise using the filter wrench to remove it.

(1)

(a)

a = Loosen b = Tighten

(b)

(F)

7) Remove the oil filter and do not replace it for 10 to 15 minutes.

8) Wipe off dirt or oil from the filter mount using a cloth moistened with light oil.

9) Apply engine oil to the seal surface of a new oil filter and mount it.

003714-00X

10) Mount the filter and turn it 2/3 of a turn after the seal surface has contacted the filter mount.

11) After replacing the oil filter (cartridge) fill the engine oil to the upper limit mark of the oil gauge through the oil port (F).

12) Idle the engine for several minutes and then stop the engine. Then check that the oil level exceeds the midpoint between the upper and lower limit marks.

13) Properly tighten the oil port cap.

Replace the engine oil and the oil filter element 6 months after the previous replacement, even if the service hours have not reached 250 hours.

Also replace them at 250 service hours, even if 6 months has not elapsed since the previous replacement.

25.10 Replacing the oil in the hydraulic oil tank and cleaning the suction filter

WARNING •

The hydraulic oil and the tank are hot and under pressure at operating temperature and can cause burns.

•

Remove the lid and replace the filter only when the engine is stopped and the tank is cool enough to touch with your bare hand.

Things to prepare:

(P)

•

Container for the waste oil...Capacity of 13 L or more.

•

New hydraulic oil...13 L (When you drain all oil from all hydraulic equipment, pipes and hoses, the new oil amounts to 19 L).

003815-00X

213

25 Procedures of maintenance for C30R-2A

a

b

1) Lower the platform on level ground and stop the engine.

Put a container below the drain plug (P) to catch the drained oil.

2) Remove the drain plug (P) to drain the oil. Check the Oring on the plug. If there is any flaw on the O-ring, replace it with a new one.

3) Remove the filter cover (b) under the hydraulic tank, and take out the suction filter (a).

1

4) Clean the pickup filter and wash it in light oil or cleaning oil. Then, reattach it. Check the filter and replace it if it is damaged.

(F)

2 limit Upper 3

5) Attach the pickup filter and pour oil through the supply port (F) to the specified level. Make sure the oil level is between the upper and lower limits on the oil level gauge.

1 = Level gauge 2 = Upper limit 3 = Lower limit

25.11 Replacing the return oil filter

WARNING Oil are hot immediately after ceasing machine operation and can cause bodily injury.

1

•

A container is necessary to catch the drained oil.

1) Secure the platform with the platform position stopper (1).

Lock the dump lever and stop the engine.

2) Put the container below the line filter (2).

3) Loosen the filter using a filter wrench or other suitable tools, and remove it.

IMPORTANT (2)

•

3 kgfñm of torque may be needed to loosen the filter if the gasket is stuck.

•

After removing the filter, check the surface of the seal on the head and the threads of the screws for damage.

Make sure nothing is stuck on them.

4) Apply a coating of oil to the filter fitting screw and the Oring. Tighten the filter until the edge of the element comes into contact with the flat area on the head. Then tighten it about one-tenth of a turn more by hand (aprox. 1,5 to 2 kgm).

214

25 Procedures of maintenance for C30R-2A

IMPORTANT •

Be careful not to over tighten the filter with a tool. The filter will be damaged.

•

The friction ring prevents the filter from coming loose.

If the friction ring is damaged or comes off, replace the filter immediately. When replacing the filter, check the inside of the filter for foreign objects or corrosion.

5) After driving the machine for a short while, check for oil leaks.

25.12 Checking and replenishing the transfer case oil

WARNING The oil temperature will be very high just after stopping the machine. Before checking it, wait until the oil has cooled down.

(G)

1) Remove the step.

(F) 003806-00X

(G)

2) Insert the oil dipstick (G) fully and pull it out.

3) Check to see that the oil level is above the middle of the upper (b) and lower (a) limit marks.

Open the cap of the oil port (F) and replenish oil if the oil level is lower.

4) Even when you operate the machine for a short time, replenish oil if the oil level is lower than the middle.

(a)

5) If the engine oil level is higher than the high (b) mark, drain the excessive engine oil through the drain plug (P), and check the engine oil level again.

(b)

(P) 003810-00X

25.13 Replacing the transfer case oil

WARNING •

Oil are hot immediately after ceasing machine operation and can cause bodily injury.

215

25 Procedures of maintenance for C30R-2A

•

Do not allow hot oil or gearbox to contact skin.

•

Replace oil after oil and gearbox are cool have cooled sufficiently.

•

At operating temperature, the reduction gearbox is hot and under pressure. It may violently eject the oil or plugs causing bodily injury. Remove the plug slowly to relieve pressure.

Things to prepare •

Container for the waste oil...Capacity of 10 L or more

•

New oil...9,5 L right and left each

1) Put a container below the drain plug (P) in the transmission case to catch the drained oil.

(P) 003810-00X

3) Check to see that the oil level is above the middle of the upper (b) and lower (a) limit marks.

Open the cap of the oil port (F) and replenish oil if the oil level is lower.

(G)

(F) 003806-00X

(G)

(a)

2) Remove the drain plug (P) and discharge the waste oil.

Install the drain plug (P).

4) Even when you operate the machine for a short time, replenish oil if the oil level is lower than the middle.

5) If the oil level is higher than the high (b) mark, drain the excessive oil through the drain plug (P), and check the oil level again.

G = Oil dipstick a = Lower limit b = Upper limit

(b)

1

25.14 Checking and cleaning the oil filter in the transfer case 1) Remove the filter cover (1) from the bottom right of the transfer case. Remove the filter (2).

2) Wash the filter in light oil or cleansing oil.

Note : Clean the filter whenever you replace the transfer case oil.

1

2

3) Check the filter. If the filter is damaged or ripped, replace it with a new one.

IMPORTANT The filter removes impurities such as dust or steel filings from oil. It has an important role in supplying clean oil to hydraulic devices, preventing them from failing, and

216

25 Procedures of maintenance for C30R-2A

increasing the useful life of the machine. Handle the filter carefully. Wash and replace it regularly.

25.15 Replacing the final case oil

WARNING •

Oil are hot immediately after ceasing machine operation and can cause bodily injury.

•

Do not allow hot oil or gearbox to contact skin.

•

Replace oil after oil and gearbox are cool have cooled sufficiently.

•

At operating temperature, the reduction gearbox is hot and under pressure. It may violently eject the oil or plugs causing bodily injury. Remove the plug slowly to relieve pressure.

Things to prepare (1)

•

Container for the waste oii...Capacity of 2 L or more.

•

New oil...1.5 L right and left each.

1) Put a container below the drain plug (2) to catch the drained oil.

(2) 003813-00X

2) Gently remove the fill port plug (1) and the drain plug (2) with a wrench. After draining the oil, reinstall the drain plug (2).

3) Add oil through the fill port plug (1) until oil spills over the lip.

IMPORTANT If there are any oil leaks, remove the filter and clean the sealing surface on the head and gasket. Then, reattach them.

25.16 Greasing the final drive Grease the final drive

217

26 Procedures of maintenance for C50R-3B

26

Procedures of maintenance for C50R-3B IMPORTANT The checking and the repair of the articles below require experience. Consult your Ammann-Yanmar Dealer.

26.1 Checking the rubber crawlers Rubber crawlers in the following condition require repair or replacement. Ask your dealer to repair or replace them.

1

Height of lugs

2

•

a

As the lug height "a" is reduced by wear, the tractive force decreases.

If "a" becomes 5 mm or less, replace the crawler with a new one.

1 = Track roller 2 = Rubber crawler •

Si les câbles aciers des chenilles sont à découvert sur 2 articulations ou plus, il est nécessaire de remplacer ces chenilles.

3 = Exposed steel cords

3 Rubber crawler steel cord breakage •

If half or more of either of the steel cords is broken, replace the rubber crawler with a new one.

4 = Half or more breakage 1/2 1/2

5

4 Separation of the core metal of the rubber crawler •

If the core metal of the rubber crawler separates even at one place, replace the rubber crawler with a new one.

5 = Come off of the core metal

218

26 Procedures of maintenance for C50R-3B

Rubber crawler tension •

The rubber crawler tension is controlled by the hydraulic cylinder. It is not necessary to adjust the rubber crawler tension periodically.

•

If a rubber crawler is so loose that it comes off, the hydraulic cylinder is assumed to be malfunctioning. Contact your dealer for assistance.

Crack in the rubber crawler

6

•

If a crack occurs between any lugs of the rubber crawler, repair it if the crack length reaches approximately 60 mm.

If the inside steel cord is exposed even though the crack is small, repair the rubber crawler immediately.

•

If the crack length is less than 30 mm or the crack depth is less than 10 mm, you do not need to repair the rubber crawler. For a decision on whether the rubber crawler should be replaced, repaired or should continue to be used, ask your dealer.

7

8

6 = Exposed steel cord 7 = To be repaired if 60 mm or more 8 = Not yet to be repaired

26.2 Checking the rubber crawler tension

WARNING When two persons check the rubber crawler tension, one must operate the machine in response to signs from the other. Never operate the machine while actually checking the rubber crawler tension.

How a rubber crawler wears out depends on the working conditions and the nature of the ground. Be sure to check the rubber crawlers for wear and tension from time to time.

When a new rubber crawler is mounted, perform the first check after 30 hours operation.

(A)

(B)

Checking the rubber crawler tension 1) After moving the machine forward and backward two or three times on level ground, reverse the machine and gather slack on the upper side of the rubber crawler.

2) Place a straight rod on the rubber crawler between the carrier roller and the sprocket, and another straight rod between the carrier roller and the idler. If the slacks (A) and (B) are 5 to 15 mm, the rubber crawler tension is proper.

219

26 Procedures of maintenance for C50R-3B

Adjustment of the rubber crawler tension If the amount of slack is large, contact your dealer for assistance.

26.3 Replacing the rubber crawler

WARNING •

Be sure to do the replacement work on level ground.

•

To replace the rubber crawler with a new one, work with a partner. You must operate the machine in response to signs from your partner.

•

Because the rubber crawler is replaced with the machine in a raised position, there is a danger that the machine may accidentally fall. Do not move any parts other than the rubber crawler to be replaced in doing the job.

•

When jacking up the machine, support it with safety blocks of sufficient strength to keep the balance of the machine body.

•

The oil temperature is very high immediately after the machine stops operating. Be sure to do the work after the oil temperature lowers sufficiently.

•

When removing the hydraulic hose, oil may spout out due to the high internal pressure. Loosen the hydraulic hose slowly to prevent high pressure oil from contacting your eyes or skin.

•

If the tension of the rubber crawler cannot be loosened by the procedure described here, ask your dealer to repair the rubber crawler.

•

Prepare a bar.

Removing the rubber crawler

WARNING •

It is very dangerous to loosen the rubber crawler by any procedure other than that described below.

•

If the tension of the rubber crawler cannot be loosened, ask your dealer to repair or replace the rubber crawler.

CAUTION Take great care in handling rubber crawlers, because they are very heavy.

220

26 Procedures of maintenance for C50R-3B

IMPORTANT

A

Prepare two wrenches for removal and installation of hydraulic hoses. Use one of the wrenches for holding the hydraulic hose to prevent it from twisting.

A = Three-side flaps wagon type 1) Dump the wagon and set the dump lock lever to the lock position. Then stop the engine.

2) Hold the wagon with the wagon stopper.

3) Change the connecting locations of the hydraulic hoses connected to the auto-tension valve (1). Changing the connecting locations of the hydraulic hoses allows the tension cylinder to be retracted and extended.

Right rubber crawler: Change the connecting locations of the hydraulic hoses (2) and (3) for each other.

Left rubber crawler: Change the connecting locations of the hydraulic hoses (4) and (5) for each other.

(1)

4) Start the engine and retract the tension cylinder fully. Then stop the engine.

5) Jack up the machine so that a clearance can be created between the core metal protrusion of the rubber crawler and the track rollers, and put wood bases or the like between the crawler frame on its lower side and ground.

(2)

(3)

6) Remove the rubber crawler from the idler first, and then from the sprocket.

B = Machine front C = Swing wagon type

B (5)

(4)

Installing the rubber crawler 1) Engage the rubber crawler with the sprocket, and place the rubber crawler on the idler.

C (5)

(3)

2) Start the engine and turn the rubber crawler slowly to install the rubber crawler onto the idler securely, using a lever.

3) Stop the engine and confirm that the rubber crawler is fully engaged with the sprocket, the rollers and idler.

(4)

(2)

4) Change the connecting locations of the hydraulic hoses connected the auto-tension valve (1) as described above, to return those to the original state before the removal of the rubber crawler.

5) Start the engine and check that the rubber crawler tension is sufficient. Then lower the machine to the ground.

6) Check the hydraulic hoses for oil leakage.

221

26 Procedures of maintenance for C50R-3B

26.4 Adjusting the fan belt tension (A) (10 - 15 mm)

•

Prepare a wooden bar (e.g., the handle of a hammer).

1) Remove the cover (1).

2) Loosen the generator mounting bolts (2) and (3).

3) Insert a wooden bar between the generator (4) and the cylinder block, and move the generator (4) to adjust the fan belt tension so that the belt will be depressed approximately 10 to 15 mm with a pressing force of 10 kgf.

4) Retighten the mounting bolts (2) and (3) to secure the generator (4).

(1)

5) Check the pulleys, the V-groove, and the fan belt for damage, and check that the fan belt does not touch the bottom of the V-groove.

6) If the fan belt cannot be properly adjusted because it has lost its elasticity or if it is damaged or cracked, replace the fan belt with a new one.

(2)

(4)

(3)

26.5 Checking, cleaning and replacing the air cleaner

WARNING •

Never attempt to clean and replace the air cleaner while the engine is running.

Always stop the engine and allow it to cool first.

•

Compressed air is used to clean the element. Always wear safety goggles to prevent injury to your eyes.

•

The maximum compressed air pressure should be less than 0.7 MPa for cleaning purposes.

If the air cleaner alarm lamp on the monitor flashes and the alarm buzzer sounds, immediately stop the engine, and check and clean the air cleaner.

222

26 Procedures of maintenance for C50R-3B

Cleaning procedure for element 1) Open the side cover and loosen the clamps (1) to remove the dust cup (2). Remove the dirt from the dust cup and clean it.

2) Remove the element (3).

IMPORTANT This air cleaner is of a double element type. Normally do not remove the inner element (5).

(4) (5)

3) Clean the inside of the air cleaner body (4).

(2)

(3) (1) (3)

4) Blow the dry, compressed air (0.7 MPa or less) from inside the element along the pleats to initially remove the dirt.

Then blow compressed air from outside the element along the pleats to remove the dirt. Blow compressed air again from inside the element, to complete the dirt removal.

•

Replace the outer element (3) after it has been cleaned 5 times or used for one year, whichever first occurs.

•

Replace the inner element (5), together with the outer element (3).

5) After cleaning, illuminate the element from inside with a light bulb and check it. If there are any small holes or thin areas, replace the element with a new one.

IMPORTANT •

When cleaning the element, do not tap it or strike it against other objects. Otherwise the element may be damaged.

•

Do not reuse the element if the pleat, gasket or seal is damaged.

•

Replacement elements should be wrapped in clean paper and stored in a dry place.

6) Insert the newly-cleaned element (3).

7) Install the dust cup, using the arrow mark on it to confirm proper alignment.

8) Close the side cover.

223

26 Procedures of maintenance for C50R-3B

Replacement procedure for elements 1) Open the side cover and loosen the clamps (1) to remove the dust cup (2).

2) Remove the outer element (3).

3) Clean the inside of the air cleaner body (4).

4) Remove the inner element (5).

5) Install new elements.

6) Install the dust cup, using the arrow mark on it to confirm proper alignment.

(4) (5)

7) Close the side cover.

(2)

(3) (1)

26.6 Draining the water and deposits from the fuel tank

WARNING Keep sparks, flames and lit cigarettes away.

Things to prepare (2)

•

Container for fuel waste

1) Put the container under the drain cock (4) on the bottom of the fuel tank.

(4)

(1)

(3)

2) Open the drain cock (4) to discharge the water and dirt deposits in the fuel tank.

3) Take care that the fuel does not contact your body.

4) When clean fuel starts coming out, close the drain cock (4).

26.7 Checking the water separator (a) (2)

(b) (6)

(1)

(3)

If the red ring (6) lies down at the bottom of the cup (4) of the water separator, no water is mixed into the oil.

If the red ring (6) is floating in the cup, water is mixes into the oil under the red ring. In this case, remove the water following the procedure below.

(5)

WARNING

(4) •

Keep sparks, flames and lit cigarettes away.

•

At operating temperature, the engine components are hot and can cause a burn.

224

26 Procedures of maintenance for C50R-3B

•

Disconnect the battery and replace the element after the engine has cooled sufficiently.

•

Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire.

•

Drain the fuel from the fuel oil filter into a container before removing the fuel oil filter.

•

Prepare a container for fuel waste.

1) Open the side cover and place the container for fuel waste under the water separator (1).

2) Close the cock (2).

(1)

(a) (2)

(b) (6)

a = Close b = Open

(1)

(3)

3) Loosen the retainer ring (3) to remove the cup (4), the element (5) and the red ring (6), and clean them, using light oil or a washing agent.

4) Check the O-ring, and if it is damaged or deformed, replace it with a new one.

(5)

5) Install the red ring (6), the element (5) and the cup (4), and tighten the retainer ring (3).

(4)

6) Open the cock (2), and release air from the fuel system.

7) Drain the water and deposits from the fuel tank.

IMPORTANT After servicing the fuel system, be sure to check again that there is no fuel leakage.

26.8 Draining and cleaning the water separator

WARNING •

Keep sparks, flames and lit cigarettes away.

•

At operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the battery and replace the element after the engine has cooled sufficiently.

•

Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire.

•

Drain the fuel from the fuel oil filter into a container before removing the fuel oil filter.

225

26 Procedures of maintenance for C50R-3B

Things to prepare •

Container for fuel waste

1) Open the side cover and place the container for fuel waste under the water separator (1).

2) Close the cock (2).

(1)

3) Loosen the retainer ring (3) to remove the cup (4), the element (5) and the red ring (6), and clean them, using light oil or a washing agent.

(a) (2)

(b) (6)

(1)

4) Check the O-ring, and if it is damaged or deformed, replace it with a new one.

(3)

5) Install the red ring (6), the element (5) and the cup (4), and tighten the retainer ring (3).

(5)

6) Open the cock (2), and release air from the fuel system.

(4)

a = Close b = Open

IMPORTANT After servicing the fuel system, be sure to check again that there is no fuel leakage.

26.9 Cleaning / replacing the fuel filter element

WARNING •

Keep sparks, flames and lit cigarettes away.

•

At operating temperature, the engine components are hot and can cause a burn.

•

Disconnect the battery and replace the element after the engine has cooled sufficiently.

•

Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire.

•

Drain the fuel from the fuel filter into a container before removing the fuel filter.

Things to prepare (1)

•

Container for fuel waste

•

Filter wrench for fuel filter cartridge

1) Open the engine hood and place the container for oil under the fuel filter cartridge (1).

2) Clean the area around the filter cartridge (1).

226

26 Procedures of maintenance for C50R-3B

(2)

(1)

(a)

(b)

3) After loosening the air release plug (2), turn the fuel filter cartridge counterclockwise with the filter wrench to remove it. a = Loosen b = Tighten 4) Wipe off the dirt and oil from the filter mount.

5) Apply fuel thinly to the seal surface of the new filter, then mount the filter. When installing the filter cartridge, turn it slowly until the seal surface contacts the filter mount, and then give the filter cartridge 3/4 of a turn to one turn to tighten it.

6) After installing the filter cartridge, release air from the fuel system.

7) After air release, start the engine and check for fuel leak.

If the there is nothing wrong, stop the engine and close the engine hood.

How to release air : Air mixed into the fuel system could cause difficulty in starting the engine or engine trouble. Be sure to release air from the fuel system whenever the fuel tank is drained, the water in the fuel tank is discharged or the filter element is replaced.

WARNING •

Keep sparks, flames, and lit cigarettes away.

•

At operating temperature, the engine components are hot and can cause a burn. Do not release air immediately after the engine is stopped. Be sure to release air after the engine components have cooled sufficiently.

IMPORTANT If the engine does not start within 15 seconds after turning the starter switch to the “START” position, wait about a minute before again attempting to restart the engine.

Release air from the fuel system according to the following procedure.

Things to prepare •

Container for fuel

1) Fill up the fuel tank.

2) Open the engine hood and the side cover.

3) Open the cock (2) of the water separator (1).

227

26 Procedures of maintenance for C50R-3B

a

(3)

(3)

(2)

b

(4)

(1)

(5)

a = Close b = Open 4) Place the containers for fuel under the fuel filter cartridge and the water separator (1), and give the air release bolts (3) two or three turns to loosen them.

5) Move the priming pump (5) up and down to feed fuel to the fuel filter cartridge. Repeat this pumping operation until all the air in the filter cartridge is released.

6) When fuel with no air bubble included begins coming out from the air release bolt holes, install and tighten the air release bolts (3).

7) Turn the starter switch to the “START” position and hold it there for about 15 seconds.

8) Wait about a minute after the above step 7), and then repeat the step 7) two or three times until the engine starts.

When the engine starts, the air release procedure is completed.

9) Close the engine hood and the side cover.

26.10 Replacing the engine oil and the engine oil filter element

WARNING •

Do not replace the oil immediately after the engine stops to prevent bodily injury, because all the components are hot.

•

Do not allow hot oil and components to contact your skin.

•

Replace the oil and the filter element after the oil and the components have cooled sufficiently.

Things to prepare •

Replacement new oil : 14 L

•

Container for waste oil : Capacity of 14 L or more

•

Filter wrench for engine oil filter cartridge

1) Open the engine hood and put the container for waste oil under the drain plug (3) on the underside of the machine body.

(2) (1)

2) Remove the oil supply port cap (2).

3) Slowly remove the drain plug (3) so that the oil should not splash on you, and drain the waste oil.

4) Check the waste oil, and contact your dealer if any metallic particles or foreign objects are mixed in it.

5) Reinstall the drain plug (3).

228

26 Procedures of maintenance for C50R-3B

6) Remove the under cover (5).

(4) (3) (5)

7) Turn the oil filter cartridge (4) counterclockwise with the filter wrench to remove it.

8) Wipe off the dirt and oil from the filter mount and apply engine oil (or apply grease thinly) to the seal surface of a new oil filter cartridge, then install the filter cartridge.

9) When mounting the filter cartridge, give it 3/4 of a turn to one turn to tighten it after the seal surface has contacted the filter mount.

10) After replacing the oil filter cartridge, add engine oil through the oil supply port (2) so that the engine oil level will be between the H and L marks on the oil dipstick (1).

11) Install and tighten the oil supply port cap (2). Idle the engine for several minutes and then stop the engine. Then check that the engine oil level is between the H and L marks on the oil dipstick (1).

12) Install the under cover (5).

13) Close the engine hood.

Replace the engine oil and the oil filter element 6 months after the previous replacement, even if the service hours have not reached 250 hours.

Also, replace them at 250 service hours, even if 6 months have not elapsed since the previous replacement.

26.11 Replacing the hydraulic oil and cleaning the suction filter element

WARNING •

The hydraulic oil and the tank are hot and under pressure at operating temperature. Never replace the oil immediately after operation is stopped.

Wait until the tank has cooled enough to permit you to touch its surface with your bare hand.

•

When removing the oil supply port cap, slowly loosen it to relieve the internal pressure, then remove the cap carefully.

•

If the cover of the tank is removed too quickly, the cover may pop out due to the spring force applied to the filter. Also, the hydraulic oil may spout out if the pressure inside the tank has not been gradually relieved.

Slowly loosen the four bolts diagonally to remove the cover.

•

Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

229

26 Procedures of maintenance for C50R-3B

Things to prepare •

Container for waste oil : Capacity of 35 L or more

•

New hydraulic oil : 35 L

•

O-ring

1) Park the machine on the level ground. Dump the wagon, set the dump lock lever to the lock position and stop the engine.

2) Hold the wagon with the wagon stopper.

3) Put the container for waste oil under the drain plug (1) on the underside of the hydraulic oil tank.

4) Remove the drain plug (1) to drain the hydraulic oil. Check the O-ring mounted on the drain plug (1), and if it is damaged or cracked, replace it with a new one.

IMPORTANT Take care not to splash the waste oil on the rubber crawlers, because the waste oil will reduce the service life of the rubber crawlers.

(1)

5) Remove the cover (2) of the hydraulic oil tank and take out the suction filter (3) from the tank.

6) Remove the dirt from the suction filter (3) and wash it with a washing agent. Check the suction filter, and if it is damaged or cracked, replace it with a new one.

(2)

7) Install the suction filter into the hydraulic oil tank.

(3)

IMPORTANT Do not allow any dirt to enter the tank when installing the filter.

H

8) Replenish new hydraulic oil up to the L mark on the oil level gauge.

M

9) Install the cover (2) on the hydraulic oil tank.

L

10) Remove the air release plug (4) from the hydraulic pump to release air.

11) When hydraulic oil begins overflowing from the hole for the air release plug (4), install and tighten the plug (4).

(4)

230

26 Procedures of maintenance for C50R-3B

26.12 Replacing the return filter

WARNING •

The hydraulic oil and the tank are hot and under pressure immediately after the engine stops, and can cause bodily injury.

Be sure to replace the filter only after the hydraulic oil tank has cooled enough to permit touching the tank surface with your bare hand.

•

Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

Things to prepare

A

•

Container for oil

•

Filter wrench

A = Three-side flaps wagon type 1) Park the machine on the level ground. Dump the wagon, set the dump lock lever to the lock position and stop the engine.

2) Hold the wagon with the wagon stopper.

3) Place the container for oil under the return filter (1).

4) Turn the filter cartridge (1) counterclockwise with the filter wrench to remove it.

5) Wipe off the dirt and oil from the filter mount and apply hydraulic oil (or apply grease thinly) to the seal surface of a new filter cartridge.

6) Install the filter cartridge by hand. Give the filter cartridge 3/4 of a turn to tighten it after the seal surface has contacted the filter mount.

(1)

7) After installing the filter cartridge, check the oil level with the oil level gauge. If the oil level is low, replenish the hydraulic oil tank with hydraulic oil.

B = Swing wagon type

B

(1)

231

26 Procedures of maintenance for C50R-3B

26.13 Replacing the line filter element

WARNING

A

•

The hydraulic oil and the tank are hot and under pressure at operating temperature, and can cause bodily injury. Never replace the filter element immediately after operation is stopped. Wait until the hydraulic oil tank has cooled enough to permit you to touch the tank surface with your bare hand.

•

Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in the dump position.

Things to prepare •

Container for waste oil

•

Hexagon wrench

A = Three-side flaps wagon type 1) Park the machine on the level ground. Dump the wagon, set the dump lock lever to the lock position and stop the engine.

2) Hold the wagon with the wagon stopper.

3) Place the container for waste oil under the line filter.

4) Using the hexagon wrench, remove the case (1).

5) Take out the element (2) from the case (1) and clean the case (1).

6) Insert a new element into the case (1), and then install it in the original position.

Tightening torque : 39 to 49 N•m

(3) (2)

7) After installing the line filter, check the oil level with the oil level gauge. If the oil level is low, replenish the hydraulic oil tank with hydraulic oil.

(1)

26.14 Replacing the travel reduction gear oil

WARNING •

The gear oil and casing of the reduction gearbox are hot immediately after ceasing machine operation and can cause bodily injury such as a burn. Do not allow hot oil or the gearbox to contact your skin.

232

26 Procedures of maintenance for C50R-3B

•

Replace the oil after the oil and the gearbox have cooled enough to permit touching the surface of the gearbox casing with your bare hand.

•

At operating temperature, the reduction gearbox is hot and its contents are under pressure. In such condition, the oil or a plug may be ejected violently, causing bodily injury. Loosen a plug slowly to gradually relieve the residual pressure.

Things to prepare •

Container for waste oil : Capacity of 2.6 L or more

•

New gear oil : 2.6 L for each side

•

Oil jig

(3)

1) Park the machine on the level ground and position it so that the plugs (1), (2) and (3) will be in the positions, as illustrated in the figure at the left.

(2)

2) Place the container for waste oil under the drain plug (1).

FILL LEVEL DRAIN

(1)

3) Remove the plugs (1), (2) and (3) and drain the gear oil.

4) Install the drain plug (1).

5) Replenish gear oil to the specified level through the oil supply port (the hole for the plug (3)).

6) When gear oil begins overflowing from the level port (the hole for the plug (2)), install the plugs (2) and (3).

Tightening torque : 149 to 165 N•m

26.15 Checking and replenishing the windshield washer fluid (for cabin) Check the level of the washer fluid in the washer fluid tank. If the level is low, replenish windshield washer fluid for cars.

•

Take care not to allow any dirt to enter the washer fluid tank when replenishing washer fluid.

•

Use washer fluid of proper density according to the air temperature. The density of the washer fluid and the handling instructions for it are indicated on the container of the washer fluid.

233

26 Procedures of maintenance for C50R-3B

234

SPECIFICATIONS

235

236

27 Specifications

27

Specifications 27.1 Specifications

Item

Unit

C12R-A

C30R-2A

C50R-3B

-

2TE67L-FW

3TNV88-FFW

4TNV106-NTB

Rated output

kW

7,7

24,6

67,7

Rated speed

rpm

2800

3000

2500

Operating mass

kg

1100

2365

5575

Loading capacity

kg

1150

2500

3500

Drive system

-

HST

HST

HST

Travel speed

km/h

0~5,5

0~11

0~10

°

30°

30°

30°

Overall length

mm

2650

3200

4540

Overall width

mm

950

1655

2000

Overall height

mm

2250

2255

3470

Track gauge

mm

230

320

450

Minimum ground clearance

mm

150

265

450

Inside dimensions

Length

mm

1470

1685

2500

Width

mm

860

1410

1850

Height

mm

315

370

300

Struck

m3

0,40

0,88

2,3

Heaped

m3

0,52

1,24

1,4

°

56

58

65

Loaded

kg/cm²

0,41

0,57

0,31

Unloaded

kg/cm²

0,20

0,27

0,17

Engine

Type

Maximum gradient Dimensions

Wagon

Capacity

Maximum dump angle Ground pressure

Subject to technical modifications

237

27 Specifications

27.2 Model view and working range for C12R-A

150

860

1470

230 720 950

2250

325

°

58

58 °

635

710

1180 2650

238

760

(1470)

(1355)

315

°

56

2025

960

27 Specifications

27.3 Model view and working range for C30R-2A

265

1410

880

1685

320 855 1200

415

775

1865

370

2255

2360

58

°

1655

760

1915 3200

239

525

27 Specifications

27.4 Model view and working range for C50R-3B

1760

2620

5

980

430

1800

R198

450 1550 2000

1040

3190 4610

240

1610

1325

2680

3600

63

°

2640

27 Specifications

27.5 Noise emitted by the machines Results of inspections: C12R-A

C30R-2A

C50R-3B

LwA (dBA)

100

100

102

LpA/LAeq (dBA)

83

86

82

LpPeak (dBC)

103

109

104 Rounded values

LwA: Weighted sound power level A. LpA/LAeq: Weighted sound pressure level A on the operator's ears.

LpPeak: Maximum value of the instantaneous sound pressure measured with frequency weighting C.

Measurements made: •

Machine in static position

•

Motor running at rated power

LwA: Determined and guaranteed in accordance with the directive 2000/14/CE amended by the directive 2005/88/ CE. LpA/LAeq: Measured and guaranteed in accordance with the NF-ISO 6396: 1997 standard.

Note: These values are declared in accordance with the directive 98/37/CE and do not correspond to exposure values for 8 hours of work.

241

27 Specifications

27.6 Vibrations emitted by the machines Results of inspections:

Machine

Entire body in m/s² (Threshold value < 0.5)

Hand-arm in m/s² (Threshold value < 2.5)

Travel on grass

Static - Hydraulic

Travel on grass

Static - Hydraulic

C12R-A

1,19

0,46

3,47

3,52

C30R-2A

1,39

0,32

3,88

1,38

C50R-3B

0,84

0,24

2,78

0,99

These are mean acceleration values established according to the cycles below.

Rounded values

The vibrations were mesured with the operator's seat in good condition. In order to maintain the values within the authorized limits, it must be replaced in case of damage.

Measured in accordance with the ISO EN 1032 (2003) standard for the entire body and with the NF EN ISO 53491 (2002) and NF EN ISO 5349-2 (2001) standards for the arm system.

Note: These values are declared in accordance with the directive 98/37/CE and do not correspond to exposure values for 8 hours of work.

To transmit minimum vibrations over the entire body during operation of the machine and avoid harming the operator's health, it is recommended that the following measures be taken: •

Adjust the seat according to the operator's height.

•

Maintain the ground in a good condition.

•

Use the machine under suitable conditions, by considering the actual ground conditions and the specific effects of vibrations caused by the actual operating mode of the machine.

It is recommended that the operator acquaint himself with and retain the instructions relating to the setting up and use of attachments.

242

28 Options

28

Options 28.1 Options Installing options not authorised by Ammann-Yanmar can cause accidents and reduce the machine's service life.

The installation and use of the unauthorised options or parts can result in the cancellation of the guarantee.

243

29 Hydraulic and wiring diagrams

29

Hydraulic and wiring diagrams 29.1 Hydraulic diagrams C12R-A Dump speed (sec.)

Relief pressure (PSI (MPa))

Up

3.9

Down

2.8

Control valve

2233 to 2318 (15.4 to 16.0)

HST (High)

3959 to 4002 (27.4 to 27.7)

HST (Low)

58 to 87 (0.4 to 6.0)

Dump cylinder 2.4 1.2 10.5 30 266.5) ( 60

A1

B1

T Control valve Line filter 10 35.6PSI (0.25MPa) P Engine 2TE67L-FW 7.7kW/2800rpm (10.5PS/2800rpm)

B1

B2

Pga

Gear pump 0.25cu.in./rev (4.1cm3/rev)

Motor 1.12cu.in./rev (18.3cm3/rev) Pump 0 to 1.12cu.in./rev (0 to 18.3cm3/rev)

S

HST (18Z+GP

Pgb

T

Suction filter 150 mesh

244

2

245

#

6

Oil cooler

㨕㧩

4)

㨪 EE TGX

&5* 6 ,)

Ǿ

Brake release cylinder

6

㨄

7 6 㨄

)

㨄

# 8/ *#

㨄

㨄

Clutch R

/

㨄

SOCZ

SOKP

Brake R

㧝㧜㧡Ǵ

#

$

Brake L

4+8 %

6

2

Ԝ

:

㨄

D

:

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C

176

176

㧝㧜㧡Ǵ

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6

4

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4 6 㨄

ԝ

ԛ

.

Ԙ

2$

608 ((9

㨪 EE TGX

2%

Clutch L

㨄

+0

)

Flow-devider

Dump cylinder

(C

/#

Ǵ

㨄

/$ 㨄

#

MIH EO 㧕

/2C

Ԛ

# 8) &#

ԙ

2U

Ǿ Ǿ

$

2

#

5

#

6

$

5

#

Set pressure Ԙ 4640 PSI (32.0 MPa) ԙ 363 PSI (2.5 MPa) Ԛ 2490 PSI (17.2 MPa) ԛ 156 PSI (1.1 MPa) Ԝ 213 PSI (1.5 MPa) ԝ 21.3 PSI (0.15 MPa)

EE TGX

EE TGX

29 Hydraulic and wiring diagrams

C30R-2A

29 Hydraulic and wiring diagrams

C50R-3B

246

Or Orange Br Brown

Glow relay

Timer unit

Glow register

Safety relay

Current limiter

1.25 RW 1.25 B 1.25 YG 1.25 R

2

30BY

(+)

55B24L

Battery

(-)

3.0R

1

1.25 YG 15A 1.25 RW 16A 3.0 G 2 3.0 R 1A

16 9C 15 8B

1.25 B 1.25 Or 2.0 LW 2.0 GR 2.0 R 0.85 Br

40BR

3.0 R 2.0 R

2.0 WB 6A 2.0 W 5A

9I 7B 13 12 1C 11

14

Slow brow fuse

1

3 4 3 4

1 1 2 2

RW B YG R

0.85 Br 2.0 RB 2.0 RY 0.85 B

0.75 Y 1.25 B 0.75 Or 1.25 Sb 1.25 Sb 1.25 R 0.75 Br

Sb 11A So 4A S 10 E 9H

Y B Or Sb Sb R Br

0.5 Y

Green

S

10A

Starter motor

B

LgR Light green red

LG Blue green RG Red green BW Black white

WB White black Lg Light green G

2.0 RY

W White

YL Yellow blue LB Blue black RB Red black BR Black red 7A

Horn

20

1.25 GW

B Black

1.25 YR

RW Red white

20A

Horn switch

Dynamo

G1 G2

12A13A

1.25 GW

YR Yellow red LR Blue red

2.0 GR 2.0 LW

GW Green white Gr Gray

9G19A

9A

2.0 W

5B

Glow plug

Back buzzer

2.0 B 2.0 B 0.5 B 0.5 YB

Red

0.5 GW

Oil pressure switch

17

LG Y Or

RG B

Lamp switch

3B

Water temp. switch

18

1A 3 2B

5 3 1 4 2

0.5 R 0.5 L

R

Tael lamp

Option

2C

2A 9 8A

Engine stop solenoid

3C

2

Work lamp

0.85 B

Blue

2.0 B

0.5 RG 0.5 LG 0.5 Or 0.5 Y 0.5 B 0.85 YR 0.85 R 0.5 B

0.5 R 0.5 R

0.5 B 0.5 B

3A

0.5 RB 0.85 B 0.85 YR

0.85 R

L

3.0 G 2.0 B 1.25 YB 3.0 W 3.0 B 2.0 R

247 P G H

Y Yellow

2A 1

1.25 B 9B 0.5 YR 7E

Diode

8C9F

0.5 WB 0.5 B

YB Yellow black LW Blue white RY Red yellow GR Green red

3A 7 8

1 3 2

ÅD ÅD ÅD ÅD ÅD

0.5 B

START

ON

OFF

HEAT

19

30

17

AC

30

19

50

10A

10A

50

17

9E

7C

0.5Lg 0.5YB

0.5 YB 0.5 GW

0.5 G 0.5 B

2.0 WB 2.0 W 2.0 R 2.0 RB 2.0 RW

14A 9D

18A 7D

0.5 B 0.5 R

0.5 YR

7G

17B

7F 17A

1.25 RW 1.25 YB 1.25 YR

6 5 1B 4 3

0.5 Y 0.5 B

0.5L 0.5 YR

0.5 YR 0.5 GW

0.5 YR

2.0 BW 2.0 BW

Starter switch connection

1.25 RW 1.25 YR 1.25 YB

2.0 WB 2.0 W 2.0 R 2.0 RB 1.25 RW

19 7H

0.5 GW

0.5 YR

0.5 YB

Instrument panel

AC

Fuse

Starter switch

Hour meter

Charge indicator lamp

Water temp. indicator lamp

Oil pressure indicator lamp

Buzzer

Safety switch

29 Hydraulic and wiring diagrams

29.2 Wiring diagrams C12R-A

#

#

#

#

#

248

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g

29 Hydraulic and wiring diagrams

C30R-2A

$ $ $

4)

29 Hydraulic and wiring diagrams

C50R-3B

249

29 Hydraulic and wiring diagrams

250

NOTES

251

252

30 Maintenance

30

Maintenance Maintenance Log

Date

Machine hours

Service performed

253

30 Maintenance

Date

Machine hours

Service performed

254

30 Maintenance

Date

Machine hours

Service performed

255

30 Maintenance

Date

Machine hours

Service performed

256

31 Notes

31

Notes Notes

257

31 Notes

258

31 Notes

259

31 Notes

260

Inspection after 1 year or 1000 hours (first term reached) Customer's copy

INSPECTION AFTER 1 YEAR OR 1000 HOURS (first term reached) Machine:

Serial number:

Customer:

Delivery date:

Inspection's date:

Hours:

The inspection was carried out according to the Ammann Yanmar schedule Note:

Dealer's signature and stamp:

Customer's signature:

This copy to be retained by the dealer

INSPECTION AFTER 1 YEAR OR 1000 HOURS (first term reached) Machine:

Serial number:

Customer:

Delivery date:

Inspection's date:

Hours:

The inspection was carried out according to the Ammann Yanmar schedule Note:

Dealer's signature and stamp:

Customer's signature:

*The inspection date must be notified to AMMANN YANMAR

YANMAR CRAWLER CARRIERS

C12R-A C30R-2A C50R-3B AMMANN - YANMAR S.A.S. rue de la Tambourine 52100 Saint-Dizier / France