Yanmar ViO80-1A User Operation And Maintenance Manual
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Yanmar ViO80-1A User Operation And Maintenance Manual

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MUB11ENMA00202
12/01/2016
USER OPERATION AND
MAINTENANCE MANUAL
EXCAVATOR
ViO80
-1A
Original manual

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  • Page 1 USER OPERATION AND MAINTENANCE MANUAL EXCAVATOR ViO80 Original manual MUB11ENMA00202 12/01/2016...
  • Page 2 The right and left hand sides are determined by facing the forward movement direction. The warranty is a part of the YANMAR product support programme for customers who use and maintain their equipment as described in this manual. If the equipment has been used incorectly or modifications have been made to transform its perfomances beyond the original factory speci- fications, the warranty expires and the improvements on site under warranty are rejected.
  • Page 4 Name and address of the person established in the European community, authorized to compile the technical file and transmit it in whole or part to the public authorities in response to a reasonable request: Jean Marc REYNAUD, Directeur Général, YANMAR C.E. Europe SAS – 25, rue de la Tambourine 52115 SAINT DIZIER CEDEX –FRANCE...
  • Page 6 EFERENCE INFORMATION Note information about your YANMAR machine here. Always use these references for everything to do with your YANMAR machine. Model name : Machine serial number : Serial number of the engine : Your YANMAR dealer : Address :...
  • Page 8 • YANMAR provides its customers with products that conform to the regulations and indus- trial standards that apply in their respective countries. If you are using a YANMAR machine that you have bought from a foreign company, you should be aware that certain safety mecha- nisms may be missing from the machine.
  • Page 10 AFETY SIGNALS The following signals are used in this manual to indicate the severity of the risks that may be en- countered if the warnings concerning the product are not respected : DANGER Dangerous situation imminent that may cause death or serious injury.

  • Page 11: Table Of Contents

    ABLE OF CONTENT Description and illustration of the machine ............1 Applications and regulations ..............3 1.1 Applications................3 1.2 Warranty ................... 3 1.3 Driving permits ................3 1.4 Lifting..................3 Identification plates ................4 Machine serial number plate ............4 Engine serial number plate .............
  • Page 12 Location for the tools and user manual ..........33 5.6.1 Toolkit ................33 5.6.2 User manual ..............33 Fuses ..................34 5.7.1 Fusebox................35 Cabin ..................37 5.8.1 Cab side door ..............37 5.8.2 Upper windscreen .............. 38 5.8.3 Lower windscreen .............. 39 5.8.4 Right hand cab window ............
  • Page 13 Avoid crush injuries due to accessories ..........67 1.10 Have an extinguisher and a first aid kit ..........68 1.11 Avoid any unauthorised modifications ..........68 1.12 Precautions for optional parts and tools ..........68 1.13 Warning concerning the cab windows ..........69 1.14 Cabin's emergency exit ...............
  • Page 14 When cold weather is over ............99 9 Rubber tracks ................... 100 Correct use of rubber tracks ............100 Rubber track warranty ............... 100 Precautions for using rubber tracks ..........101 Track maintenance ..............102 Track replacement ..............102 Handling the bucket ................. 103 Machine stability when using with a bucket or an accessory ....
  • Page 15 2.1 Precautions before maintenance ............. 139 2.1.1 Removing the residual pressure..........139 2.1.2 Place a warning label ............139 2.1.3 Establish a safety perimeter ..........140 2.1.4 Keep the machine clean ............. 140 Precautions during maintenance ............ 140 2.2.1 Oil and grease ..............140 2.2.2 Tools ................
  • Page 16 Noise emitted by the machine ............... 177 Vibrations emitted by the machine ............178 F Lifting capacities ..................179 1 Lifting ViO80-1A ................181 2 Lifting ViO80–1A With rear counterweight ..........182 Appendices ....................183 List of error codes displayed on the operator display station ......184 Control sheets to be photocopied ............

  • Page 18: A Description And Illustration Of The Machine

    Description and illustration of the machine HAPTERS COVERED IN THIS PART PPLICATIONS AND REGULATIONS DENTIFICATION PLATES ARNING LABELS DENTIFICATION OF IMPORTANT PARTS ESCRIPTION OF THE DRIVING POSITION PERATION OF THE AIR CONDITIONING OVERS SING THE ELECTRIC FUEL FILLING PUMP PTIONS...

  • Page 20: Applications And Regulations

    • Consult your YANMAR dealer for more information about the lifting function. CAUTION It is forbidden to transport or lift people with the machine.

  • Page 21: Identification Plates

    DENTIFICATION PLATES 2.1 Machine serial number plate The machine's serial number plate is located on the rotating frame, as shown opposite. Never remove this plate for any reason. 1= Model name 2= Type (Machine Category ) 3= Date of manufacture of the machine 4= Transport weight (Machine weight without operator,...

  • Page 22: Epa Information Plate

    2 Identification plates 2.3 EPA information plate The EPA information plate is attached to the engine. Never remove this plate for any reason. 2.4 Spare parts order and intervention request When you order spare parts or call for an inerven- tion, tell your dealer the model name, the serial number of the machine and the serial number of the engine and the number of hours displayed on...
  • Page 23 • Contact your YANMAR dealer to obtain new adhesive labels. The part code number is clearly indicated on each label.

  • Page 24: Warning Labels

    3 Warning labels 3.1 Location of the warning adhesive labels...
  • Page 25 3 Warning labels...

  • Page 26: Explanation Of The Warning Adhesive Labels

    3 Warning labels 3.2 Explanation of the warning adhesive labels Machine's Danger Zone 2.2 Movement precautions , page 72 2.2.4 Dismantling the accessory , page 141 2.2.1 Machine's Danger Zone, page 72 Pressurised product. Read the user manual. 6.5 Rubber track maintenance , page 156 6.6 Steel track maintenance , page 160 Read the user manual.
  • Page 27 3 Warning labels 5.3.1 Locking lever , page 25 Measured sound pressure 3 Noise emitted by the machine , page 177 4.4 Checking and topping up the fuel level , page 88 Hydraulic oil 3 Recommended greases and fluids , page 144 4.5 Checking and topping up the hydraulic oil level , page 89 Transporting the machine 16 Transporting the machine , page 122...
  • Page 28 3 Warning labels The battery is located under the right cover. 2.7 Precautions for the battery , page 83 If the battery is discharged 18.1 Precautions for connecting and disconnecting the starter cables , page 131 Scheduled maintenance points of the machine (lubrication, filters...) 1 Periodic inspections and upkeeps, page 137 6.1.5 Greasing points , page 151 Tension check...
  • Page 29 3 Warning labels Description of the driving position 5.3 Joysticks and pedals, page 24 The maximum weight when in use in bucket mode or with accesso- ries ensure machine dynamic stability in use. It corresponds to the maximum weight allowed at the end of the empty arm. 10.1 Machine stability when using with a bucket or an accessory, page 103 Lifting capacities...

  • Page 30: Identification Of Important Parts

    DENTIFICATION OF IMPORTANT PARTS 4.1 General view of the machine A = Right B = Left C = Front D = Rear 1= Blade 2= Boom cylinder 3= Bucket 4= Bucket pin 5= Bucket link 6= Arm 7= Bucket cylinder 8= Arm cylinder 9= Boom headlamp 10= Boom...

  • Page 31: Commands And Switches

    4 Identification of important parts 4.2 Commands and switches 1= Driver's seat 12= Horn 2= Adjustable proportional PTO, P.T.O. 1 13= Operator display station 14= Right command lever 3= Slide movement levers 15= Start key 4= Left command lever 5= Adjustable proportional PTO, P.T.O. 2 16= Air conditioning / heating switch 6= Locking lever 17= Control panel...

  • Page 32: Description Of The Driving Position

    ESCRIPTION OF THE DRIVING POSITION This section describes the different command mechanisms necessary to operate the machine. In order to work in complete safety and comfort, it is vital that you understand how to operate and use these mechanisms. 5.1 Operator display station •...
  • Page 33 5 Description of the driving position a. Warning light If the warning light flashes and the alarm sounds continuously, immediately stop using the machine. After stopping the machine, check the error details and take corrective measures. b. Alert light If the alert light blinks and the alarm sounds intermittently, stop the machine as soon as possible.

  • Page 34: Diesel Gauge

    5 Description of the driving position 5.1.2 Diesel gauge • The diesel gauge operates when the starter key is in ON position. It indicates the level of diesel in the tank. • When the gauge reaches the two indicators near the symbol "Empty"...

  • Page 35: Time Counter

    5 Description of the driving position 5.1.4 Time counter • The time counter indicates the number of hours for which the machine has been working. • Reading this time counter will help you define the intervals between maintenance operations. • When the engine is running, the time counter per- manently records the time even if the machine is not 1 = Time counter being used.

  • Page 36: Information And Error Icons

    5 Description of the driving position 5.1.7 Information and error icons Date and time setting indicator The time and date must be set from the settings screen. Note If the battery in the machine is removed, the date and time settings will be reset.

  • Page 37: Switches

    5 Description of the driving position 5.2 Switches 1= Horn 2= Start key 3= Engine slow down switch 4= Eco mode switch 5= Side movement switch 6= Manual regeneration 7= Windscreen wiper switch and windscreen wiper 8= Headlight switch 9= Engine rate setting 10= Interior lighting switch 11= Engine stop switch...

  • Page 38: Start Key

    5 Description of the driving position 5.2.1 Start key IMPORTANT The machine is fitted with an electrical safety system. If the locking levers are not in safety position, the engine cannot start. • Use this command to start and stop the engine. 1= OFF 2= ON 3= START...

  • Page 39: Horn

    5 Description of the driving position 5.2.3 Horn Press the switch at the top of the right joystick to acti- vate the horn. 1= Horn 5.2.4 Windscreen wiper switch and windscreen wiper • This switch is used both for the windscreen wipers and the washer.

  • Page 40: Engine Slow Down Switch

    5 Description of the driving position 5.2.7 Engine slow down switch • Use this switch to automatically reduce engine speed. • When the auto-idle switch is ON and the machine controls are in neutral, the engine speed is automatically reduced after 4 seconds. •...

  • Page 41: Manual Regeneration

    5 Description of the driving position 5.2.11 Manual regeneration Repeated use of the machine with the engine at low speed or at no-load can cause insufficient regeneration of the DPF. In case of insufficient regeneration of the DPF, the mo- nitor displays the DPF regeneration icon.

  • Page 42: Locking Lever

    5 Description of the driving position 5.3.1 Locking lever • The locking levers condemn the joysticks as well as the travel. • When you raise the left hand locking lever, the left hand command lever is raised. 1 = Locking lever 2= Left hand side IMPORTANT The machine is fitted with a hydraulic safety system.

  • Page 43: 3Rd Hydraulic Circuit Control (P.t.o. 1)

    5 Description of the driving position 5.3.3 3rd hydraulic circuit control (P.T.O. 1) 1= Proportional roller 2= Knob 3= Position holding button P.T.O. switch • Use the proportional roller to adapt the dual effect P.T.O. rate. 14 Implementing the 3rd hydraulic circuit , page 116 •...

  • Page 44: Left Command Lever

    5 Description of the driving position Position holding button To use the position holding button: 1. Operate the accessory with the proportional roller.(1) 2. Press the position holding button. (3)Release the proportional roller. (1) The proportional roller control pressure is blocked and the LED on the corresponding joystick comes 3= Position holding button 3.

  • Page 45: 4Th Hydraulic Circuit Control (P.t.o. 2)

    5 Description of the driving position 5.3.5 4th hydraulic circuit control (P.T.O. 2) 1= Proportional roller 2= Knob P.T.O. switch • Use the proportional roller to adapt the dual effect P.T.O. rate. • Dual action accessory (tilt bucket, auger, etc.) : operate only the proportional roller. 1= Proportional roller Adjustable proportional PTOAdjustable proportional PTO •...

  • Page 46: Travel Levers And Pedals

    5 Description of the driving position 5.3.6 Travel levers and pedals DANGER It is strictly forbidden to handle the machine controls outside the cockpit. Incorrect use of the machine may cause serious injury or even death. Personnel involved in using and maintaining the machine must familiarise themselves with the content of this manual before carrying out a task.

  • Page 47: Blade Lever

    5 Description of the driving position • To move the machine forward, push the travel le- vers, or press the back of the pedals. To move the machine backwards, pull the travel le- vers, or press the back of the travel pedals. •...

  • Page 48: Protection Of Pedals

    5 Description of the driving position 5.3.8 Protection of pedals • Fold the protection to lock the pedal. It may then be used as a foot rest. WARNING To avoid the risk of any inappropriate or involuntary use, always place the pedals in locked position when they are not being used.

  • Page 49: Driver's Seat

    5 Description of the driving position 5.5 Driver's seat • Adjust the seat position so that the driver can operate the controls easily and comfortably. WARNING Do not adjust the seat position when you are working on the machine; adjust it before you start.

  • Page 50: Location For The Tools And User Manual

    5 Description of the driving position 5.6 Location for the tools and user manual 5.6.1 Toolkit • The location for the toolkit is between the cab and cover B. 5.6.2 User manual • The location for the user manual is under the dri- ver's seat.

  • Page 51: Fuses

    5 Description of the driving position 5.7 Fuses • The fuses protect the equipment and the electrical cabling against a surge. In case of a bad contact, or if the electrical system does not work when the key is on, replace the faulty fuse with a fuse in good condition.

  • Page 52: Fusebox

    5 Description of the driving position 5.7.1 Fusebox Fusebox Symbol Fuse capacity Circuit name Electrical start signal Starter Cabin power supply Cab lighting Electric fuel tank filling pump Engine Electronic Control Unit (ECU) 2 EGR valve Air conditioning Engine Electronic Control Unit (ECU) Engine Electronic Control Unit (ECU) Engine Operator display station Power socket...
  • Page 53 5 Description of the driving position General supply fuses Symbol Fuse capacity Circuit name 100A Fusebox Preheating relay Bougies de préchauffage Starter Power fuse options Symbol Fuse capacity Circuit name Rotating headTILTROTATOR Quick hydraulic hitch • Medium pressure hydraulic line •...

  • Page 54: Cabin

    5 Description of the driving position 5.8 Cabin CAUTION The upper and lower parts of the windscreen can be opened. The opening and closure of the windscreen must be secured with the safety levers in order to avoid any sudden, un- planned closure which may cause injuries: Do not pass your hand or head through the open door or windscreen.

  • Page 55: Upper Windscreen

    5 Description of the driving position Locking the door • The door lock is used to hold the door open during the machine operation. To lock the door: 1. Open the door. 2. Push the door against the outer side of the cabin for engaging the cylindrical lock.

  • Page 56: Lower Windscreen

    5 Description of the driving position 5.8.3 Lower windscreen Opening of the lower part of the windscreen IMPORTANT Only open and close the lower windscreen when the upper windscreen is closed. 1. Push the locking levers on the right and left of the lower windscreen towards the inside.

  • Page 57: Right Hand Cab Window

    5 Description of the driving position 5.8.4 Right hand cab window 1. Open the right hand cab window by sliding it in the direction indicated by the arrows. 2. Tighten the pressure lock to hold the window in the position you want. 3.

  • Page 58: Operation Of The Air Conditioning

    PERATION OF THE AIR CONDITIONING 1 = Operating switch 2 = Ventilator switch: sets the ventilator speed. 3 = Temperature joystick: allows setting the desired temperature. 4 = Air diffusers 5 = air recycling WARNING Ice may form on the air intake if the air conditioning is running. This is normal and comes from the condensation of water particles suspended in the air.
  • Page 59 6 Operation of the air conditioning • The exterior air is cooled down or heated and introduced into the cab. • The cab air is cooled down or heated up then re-expelled into the cab. 4. Adjust the air output by turning the air vents.

  • Page 60: Covers

    OVERS 1 = Bonnet 2 = Cover B 3 = Cover R 7.1 Bonnet • Under the bonnet you find: – expansion flask – Engine oil gauge – engine oil tank orifice WARNING Do not open the bonnet during machine operation. Verification and topping off of the va- rious levels should be done when the engine is stopped and the temperatures are brought back down.

  • Page 61: Cover B

    7 Covers 7.2 Cover B • The filling ports for hydraulic oil and fuel tanks are under bonnet B. Opening the cover 1. Insert the starter key into the lock. 2. Turn the key anti-clockwise. 3. Pull the lever to unlock the safety mechanism. The cover opens.

  • Page 62: Using The Electric Fuel Filling Pump

    SING THE ELECTRIC FUEL FILLING PUMP • Park the machine on flat, firm ground. • Stop the engine by turning the key from ON position to OFF position. 1. Open the bonnet. R The electric fuel filling pump is under the machine's right cover. (A) 2.

  • Page 63: Options

    PTIONS • Mounting options that are not authorised by YANMAR may cause accidents and reduce the machine's life span. • The installation and use of unauthorised parts may lead to the warranty being cancelled. 9.1 Long arm • The machine can be fitted when this option is requested.

  • Page 64: Safety Valves

    9 Options 9.3.2 Safety valves The safety valves must be installed with the ring. These flaps are installed on the machine's boom, rocker arm and blade cylinders to avoid the equipment falling to the ground if the hoses break. 9.3.3 Overload box •...

  • Page 65: Fops 2 Protection Grill For Demolition Work

    9 Options 9.4 FOPS 2 protection grill for demolition work. WARNING If one of the safety structures is damaged, replace it immediately to avoid any injury. Do not repair or modify it. • The machine must be fitted with this protection structure to ensure operator safety when performing the following operations: –...

  • Page 66: Plug-In Flashing Light

    9 Options 9.6 Plug-in flashing light DANGER Keep three points of support with the machine to complete the installation safely. If three points of stable support are not available, use suitable equipment to operate the machine safely. • The machine can be fitted when this option is requested.

  • Page 67: Immobilizer With Coded Key

    9 Options 9.8 Immobilizer with coded key • The machine can be fitted when this option is requested. • The immobilizer keypad consists of an immobilizer box and a key reader installed in the cockpit. • For more information, consult the instructions supplied with the device. 1.

  • Page 68: Fleet Management System

    9 Options 9.10 Fleet management system • The machine can be fitted when this option is requested. • The fleet management system is composed of a telemetry control box and an electric harness. • The fleet management system makes it possible to know the geographical position of the machines that are equipped.

  • Page 69: Radio

    9 Options 9.12 Radio The machine's cab is equipped with a radio. Refer to the user manual supplied with the radio. 2= Radio 9.13 Quick hitch CAUTION Before any connection or disconnection of the hydraulic hoses, remove the residual pres- sure from the hydraulic circuit.

  • Page 70: Centralized Greasing System

    9 Options 9.14 Centralized greasing system • The centralised lubrication automates the greasing of the swivel pins on your machine.It comes with a timer allowing adjusting the lubrication cycle and time. CAUTION The lube cycles are factory set to optimize the performance of your machine, it is not ad- visable to change them.

  • Page 71: Mechanical Quick Hitch

    9 Options 9.15 Mechanical quick hitch IMPORTANT Use YANMAR original parts as recommended in the parts catalogue. IMPORTANT Before using an accessory requiring hydraulic power, check the pressure compatibility from the machine specifications chart. 1 Specifications , page 175 WARNING Before mounting a bucket or an accessory on your machine, make sure that: •...

  • Page 72: Mechanical Quick Hitch Arden Equipment

    9 Options 9.15.1 Mechanical quick hitch ARDEN EQUIPMENT Quick hitch structure The quick hitch system is composed of: A= Fastening hooks B= Locking pins C= Locking screw Dismantling the accessory 1. Park the machine preferably on a stable, flat and level surface.
  • Page 73 9 Options Mounting the accessory 1. Place the accessory on a stable, flat surface. 2. Clean all the parts. 3. Be equipped with the wrench supplied with the accessory and insert it into the quick hitch hole. 4. Turn the key to unlock the quick hitch (1). 5.

  • Page 74: Mechanical Quick Hitch Retromatic Morin

    9 Options 9.15.2 Mechanical quick hitch RETROMATIC MORIN Quick hitch structure The quick hitch system is composed of: A= Fastening hooks B= Locking pins Dismantling the accessory 1. Park the machine preferably on a stable, flat and level surface. 2. Place the accessory at about 5 cm above the ground.

  • Page 75: Mechanical Quick Hitch Cseri

    9 Options 9.15.3 Mechanical quick hitch CSERI Quick hitch structure The quick hitch system is composed of: A= Locking pins B= Fastening hooks C= Locking screw Dismantling the accessory 1. Park the machine preferably on a stable, flat and level surface. 2.

  • Page 76: Quick Hydraulic Hitch Cseri

    9 Options 9.16 Quick hydraulic hitch CSERI WARNING Before mounting a bucket or an accessory on your machine, make sure that: • the bucket or accessory is compatible with the capabilities of your machine; • the bucket or accessory mounting operation is performed on a level and stable ground;...

  • Page 77: Dismantling The Accessory

    9 Options 9.16.1 Dismantling the accessory 1. Park the machine preferably on a stable, flat and level surface. 2. Place the accessory on the ground. 3. Turn the switch (1) to ON. The contactor switch indicator lights and the alarm sounds. WARNING If the warning light does not come on or if the alarm does not sound, stop the current operation and contact your dealer.

  • Page 78: Mounting The Accessory

    9 Options 9.16.2 Mounting the accessory 1. Turn the switch (1) to ON. The contactor switch indicator lights and the alarm sounds. WARNING If the warning light does not come on or if the alarm does not sound, stop the current operation and contact your dealer.

  • Page 80: B Operating Instructions

    Operating instructions HAPTERS COVERED IN THIS PART ASIC PRECAUTIONS SAGE PRECAUTIONS RECAUTIONS FOR THE ENGINE HECKS BEFORE STARTING THE MACHINE HECKS AFTER START HECKS AFTER USE OPERATOR DISPLAY STATION INTERFACES SING THE MACHINE IN COLD WEATHER UBBER TRACKS ANDLING THE BUCKET 11 H ANDLING OF ACCESSORIES 12 A...

  • Page 82: Basic Precautions

    ASIC PRECAUTIONS CAUTION The user must determine whether dangerous phenomena may occur in an application, for example, the release of toxic gases, or whether the ground conditions require specific precautions. The user establish the measures to be taken to eliminate or reduce the risks. 1.1 Comply with your workplace's safety rules •...

  • Page 83: Do Not Drive Under The Influence Of Alcohol, Drugs Or Medication

    1 Basic precautions 1.4 Do not drive under the influence of alcohol, drugs or medication. • Never use the machine if you are under the influence of alcohol, if you are ill or if you do not feel well as this may cause an accident. 1.5 Provide adequate ventilation when working in an enclosed space •...

  • Page 84: Keep Fuel And Oil Away From Sparks

    1 Basic precautions 1.7 Keep fuel and oil away from sparks • Leaving flames near fuel, oil, hydraulic oil or anti- freeze solutions, which are highly flammable and dan- gerous, may cause a fire. • Specific attention must be paid to the following points : –...

  • Page 85: Have An Extinguisher And A First Aid Kit

    • Any modifications that are not approved by YANMAR may cause safety risks. • If the equipment you want to add to your machine is not listed by YANMAR, you must contact your dealer. YANMAR cannot be held responsible for any physical injuries, accidents, failure or damage to the machine due to any unauthorised modifications.

  • Page 86: Warning Concerning The Cab Windows

    1 Basic precautions 1.13 Warning concerning the cab windows • If, by accident, a cab window is broken, the sharp edges may represent a danger to the oper- ator. Stop the machine immediately and replace the broken window with a new one. 1.14 Cabin's emergency exit •...

  • Page 87: Usage Precautions

    SAGE PRECAUTIONS 2.1 Precautions before starting the engine 2.1.1 Make sure that your workplace is safe • Before you start the engine, make sure that there is no danger in your working area. If there are any underground installations such as water or gas pipes, high voltage lines or other elements, con- tact the companies responsible to locate them exactly and to avoid damaging them.

  • Page 88: Check The Safety Structures

    2 Usage precautions • To change a light bulb: 6.4.2 Replacing a bulb , page 155 2.1.3 Check the safety structures WARNING If one of the safety structures is damaged, replace it immediately to avoid any injury. Do not repair or modify it. •...

  • Page 89: Accessing The Machine

    2 Usage precautions 2.1.5 Accessing the machine • Do not jump on or out of the machine. Do not climb into or out of the machine when it is operating as this may cause physical injuries. • When you enter and leave the machine, face the machine and use the handles and the top of the track.

  • Page 90: Movement Precautions

    2 Usage precautions 2.2 Movement precautions 2.2.1 Machine's Danger Zone DANGER The operator must manipulate the machine controls from the operator seat. Any use of the machine controls from the ground is strictly prohibited because it can lead to physi- cal injury.

  • Page 91: Driving The Machine On A Slope

    2 Usage precautions 2.2.3 Driving the machine on a slope • Drive the machine carefully on a slope to avoid any tipping over or slipping to the side. • When driving the machine on a slope, keep the bucket between 20 and 30 cm above the ground to be able to lower it to the ground and stop the machine in the event of an emergency.

  • Page 92: Working Precautions

    2 Usage precautions 2.3 Working precautions 2.3.1 Precautions for using the equipment WARNING Do not use the equipment's command levers during side movement. Stop the side move- ment then use the equipment. • Do not use the equipment's rotation force. Do not use the rotation force to level the ground or break a wall.
  • Page 93 2 Usage precautions • Do not use the machine's lowering force. Note Do not use the machine's lowering force to dig the ground. • When excavating a hard rock, keep the ma- chine's tracks flat on the ground. Note It is also recommended to break hard rock into several pieces using other means to prevent damage to the machine.

  • Page 94: Dangerous Tasks

    2 Usage precautions 2.3.2 Dangerous tasks • Digging from the top is dangerous as there is a risk of rock falls or landslides. • Digging from the bottom is dangerous as this may destabilise and tip over the machine. 2.3.3 Working near electricity lines DANGER Working close to overhead electricity lines is very dangerous and specific precautions must be taken.

  • Page 95: Working Near Obstacles

    2 Usage precautions 2.3.4 Working near obstacles • When moving in a tunnel, under a bridge or when you are working in an area near tall ob- stacels, drive the machine carefully to avoid knocking the boom, the arm or the accessory against these obstacles.

  • Page 96: Working On Unstable Ground

    2 Usage precautions 2.3.8 Working on unstable ground WARNING Unstable ground increase the risks of the machine tipping over. • Keep away from cliffs, verges and ditches as the ground there is unstable. There is a risk that it will give way because of the machine's vibrations or weight, which would cause the machine to tip over or fall.

  • Page 97: Working In A Muddy Area

    2 Usage precautions 2.3.10 Working in a muddy area • Operate the machine carefully so that it does not get stuck. If it does get stuck, release it us- ing the following procedures. If only one track is stuck 1. Place the bucket on the muddy side. 2.

  • Page 98: Parking Precautions

    2 Usage precautions 2.4 Parking precautions IMPORTANT Park the machine preferably on a stable, flat and level surface. 1. Release the right and left side movement levers in neutral position to stop the machine. 2. Turn the switch to the left to decrease the engine speed.

  • Page 99: Precautions For The Accessories

    2 Usage precautions 2.5 Precautions for the accessories CAUTION An accessory that is not adapted to the machine may imbalance it. • When you mount or remove an accessory, follow these precautions : 1. Place the machine on flat, firm ground. 2.

  • Page 100: Precautions For The Battery

    2 Usage precautions 2.7 Precautions for the battery • The battery is located under the right cover. DANGER Be careful when handling the battery. • The battery electrolyte can cause severe burns to the eyes or skin. Always wear safety glasses and clothes when handling the battery.

  • Page 101: Precautions For The Engine

    RECAUTIONS FOR THE ENGINE • It is vital that you respect a running in period for the machine during the first hundred hours of service (read the time counter). During this period, the machine must not be used with an excessive load, even though it has been correctly prepared and checked before despatch.

  • Page 102: Checks Before Starting The Machine

    HECKS BEFORE STARTING THE MACHINE 4.1 Overall visual inspection WARNING If there is any fuel on hot areas or if there are any fuel and/or oil leaks, this may cause a fire. Carefully check these possible causes of fire. If there are any faults, contact your dealer.

  • Page 103: Checking And Topping Up The Level Of Cooling Fluid

    Only remove the radiator cap to top up the radiator. Replacing the cooling fluid : The cooling fluid must be changed every 1000 hours. Contact your dealer. Note For any top off or replacement of the fluid, use the original YANMAR long life coolant.

  • Page 104: Checking And Topping Up The Engine Oil Level

    4 Checks before starting the machine 4.3 Checking and topping up the engine oil level 1. Wait until the engine has cooled down. 2. Lock it with the safety rod. 3. Read the engine oil gauge. (G) WARNING At operating temperature, the oil and the gauge area are hot.

  • Page 105: Checking And Topping Up The Fuel Level

    4 Checks before starting the machine 4.4 Checking and topping up the fuel level 1. Set the starter key to ON position. 2. Determine the fuel level by looking at the fuel gauge on the dashboard. 3. Set the starter key to OFF position. 4.

  • Page 106: Checking And Topping Up The Hydraulic Oil Level

    4 Checks before starting the machine 4.5 Checking and topping up the hydraulic oil level 1. Put the machine in the position shown opposite: blade back and lowered to the ground, equipment par- allel to the tracks, boom cylinder half out, arm cylin- der retracted to the end of its run, bucket teeth on the ground.
  • Page 107 4 Checks before starting the machine Temperatures °C Quantity prescribed (L) -20 -10 60,0 in the tank Hydraulic oil ISO VG46 52,0 the rest IMPORTANT Do not mix different types of oils.If you need to top up the oil with a different make or type from the oil left in the tank, remove the remaining oil completely.
  • Page 108 HECKS AFTER START WARNING Emergency stop : if an abnormal action occurs, turn the key in the ignition switch to the OFF position. The electrical system is interrupted and the engine stops. Ask your dealer to check the machine. IMPORTANT The hydraulic oil must be at a temperature from 50°C to 80°C.

  • Page 109: Checks After Start-Up

    5 Checks after start-up 6. Check the colour of the exhaust gas, the noise and the vibrations of the machine. 7. Raise the locking lever to ensure that no handling of the equipment and no rotation of the upper structure is possible with the joysticks. 8.

  • Page 110: Checks After Use

    HECKS AFTER USE If the machine is used in a rocky place : • Check for damage to the lower chassis. If the machine is used in a dusty place : • Check whether the air filter is clogged. • Check the air filter cartridge regularly. •...

  • Page 111: Operator Lcd Display Station Interfaces

    OPERATOR DISPLAY STATION INTERFACES 1= Menu change 1= User Interface 2= Maintenance interface 3= Machine usage management interface 4= Configuration interface 1. Press the "Menu Change" button to access the main menu. 2. Move the selection with the navigation keys F2 and F3 on the icon to select ( The colour of the selected icon is reversed (the icon background becomes black) and it is dis- played above the other icons.

  • Page 112: User Interface

    7 operator LCD display station interfaces 7.2 User Interface • The user interface displays the machine use infor- mation (hour meter, fuel gauge) and information af- ter a failure (error code and error icon). • In case of malfunction, the visual indicator LED lights up, the error code is displayed with the icon and the buzzer sounds.

  • Page 113: Machine Usage Management Interface

    7 operator LCD display station interfaces 4. Press F4 to complete the process. The display returns to the maintenance interface and a confirmation sound is emitted. Changing the maintenance interval To change the maintenance interval, follow this procedure: 1. Select the maintenance interface. 2.

  • Page 114: Configuration Interface

    7 operator LCD display station interfaces 7.5 Configuration interface This interface allows you to change the settings shown in the table below. Language: Changes the language used by the various interfaces. Date and time setting: If the battery in the machine is removed, the date and time settings will be reset.

  • Page 115: Using The Machine In Cold Weather

    SING THE MACHINE IN COLD WEATHER 8.1 Preparation for use in cold weather • In cold weather, you may have difficulty starting the engine because the coolant and fuel can be frozen. • Consequently, take the following measures : 1. Use oil and fuel suitable for the outside temperature. 3 Recommended greases and fluids , page 144 2.

  • Page 116: Precautions After Use

    8 Using the machine in cold weather 8.3 Precautions after use To avoid that the machine is jammed due to mud, water or frozen deposits on the rubber tracks : 1. Park the machine on firm, dry ground or place boards on the ground and park the machine on these boards to avoid the tracks freezing on the ground.

  • Page 117: Rubber Tracks

    UBBER TRACKS 9.1 Correct use of rubber tracks • Rubber tracks have certain advantages over steel tracks. However, you cannot get the full benefit out of rubber tracks if you use them in the same way as steel tracks. • Use the rubber tracks moderately according to the conditions at the work site and the type of work.

  • Page 118: Precautions For Using Rubber Tracks

    9 Rubber tracks 9.3 Precautions for using rubber tracks • Do not use them or pivot them on broken stones, a hard, rough rock base or around steel or iron rods or the edges of iron plates. • Do not use the machine on rocky ground such as a river bed as there is a risk that the tracks will be damaged by gravel entering the runners or the tracks becoming loose.

  • Page 119: Track Maintenance

    9 Rubber tracks • Do not drive with a track on a slope or convex sur- face (one that generates an angle of over 10°) and the other track on flat ground; this will damage the tracks. Drive with both tracks on the same flat surface. •...

  • Page 120: Handling The Bucket

    DANGER Any excess can lead to a loss of stability of the machine and tip it over. YANMAR CON- STRUCTION EQUIPMENT EUROPE S.A.S. accepts no responsibility in case of non compliance with the safety instructions described in this chapter.
  • Page 121 10 Handling the bucket To determine the weight that your machine will handle, make the following calculation: Weight handled = Weight of equipped quick hitch Weight of the accessory (hammer, empty bucket...) Bucket load capacity x material density) This operation is reminded by a sticker af- fixed in the cab interior and visible from the driver's compartment.Compare the result with the maximum weight under condition of use...

  • Page 122: Compatible Accessories

    10 Handling the bucket Weight of material handled: The bucket loading capacity (or SAE volume) allows calculating the weight of material handled in the bucket (in case of full buckets) and it takes into account the extra weight caused by the dome piling of certain materials.To determine the weight of materials handled, make the following calculation: Weight of materials (kg) = Load Capacity (L) x Density Materials...
  • Page 123 10 Handling the bucket Mounting with quick hitch Quick hitch Module GMO32R0800 GMO32R0900 Retro bucket Ditching bucket GMO32C1250 GMO32C1500 Bucket – – Swivel ditching bucket GMO32R0800 GMO32R0900 Loading bucket GMO32C1250 GMO32C1500 Quick hitch Module GMO40R0600 GMO40R0800 Retro bucket – – Ditching bucket Bucket Swivel ditching bucket...
  • Page 124 10 Handling the bucket Quick hitch Retro bucket GMO32R0800 GMO32R0900 Ditching bucket GMO32C1250 GMO32C1500 – – Bucket Swivel ditching bucket GMO32R0800 GMO32R0900 Loading bucket GMO32C1250 GMO32C1500 Hydraulic hammer DMS530 DMS530 Quick hitch Retro bucket GMO40R0600 GMO40R0700 Ditching bucket – – Bucket Swivel ditching bucket –...

  • Page 125: Operation Of The Retro Bucket

    10 Handling the bucket 10.3 Operation of the retro bucket • The retro bucket is adapted to dig the ground at a level below the machine. • The maximum digging force is obtained when the angle between the bucket cylinder and the bucket arm and the angle between the arm cylinder and the arm is 90°.

  • Page 126: Handling Of Accessories

    11 H ANDLING OF ACCESSORIES 11.1 Hydraulic hammer SOCOMEC Usage recommendations WARNING Before using the machine with a hydraulic hammer, close the front wind shield to work safely. WARNING During the work phase, keep everyone out of the 20m danger zone. IMPORTANT •...
  • Page 127 11 Handling of accessories Tool change 1. Park the machine preferably on a stable, flat and level surface. 2. Place the accessory at about 30 cm above the ground in horizontal position. 3. Stop the engine. 4. To remove the tool from the housing: a.

  • Page 128: Accessory Change By Direct Coupling

    12 A CCESSORY CHANGE BY DIRECT COUPLING 12.1 Dismantling the accessory A & B = Bucket or attachment bore 1. Place the machine on flat ground. 2. Place the accessory at about 5 cm above the ground. 3. Stop the engine. 4.

  • Page 129: Mounting The Accessory

    12 Accessory change by direct coupling 12.2 Mounting the accessory IMPORTANT Before using an accessory requiring hydraulic power, check the pressure compatibility from the machine specifications chart. 1 Specifications , page 175 WARNING Before mounting a bucket or an accessory on your machine, make sure that: •...
  • Page 130 12 Accessory change by direct coupling Note Make sure to install the swivel pin stops cor- rectly by positioning them with the flat plane against the stop. 8. Grease the hinged parts. Special features concerning the hammers 1. Connect the coupled hoses from the hammer to the machine connections. 14 Implementing the 3rd hydraulic circuit , page 116 2.

  • Page 131: Loading Bucket

    12 Accessory change by direct coupling 12.2.1 Loading bucket IMPORTANT Protect the various elements from dirt and dust. Take care not to damage seals on each bushing side. 1 = Arm 2 = Bucket link 1. Clean and lubricate the bores. 2.

  • Page 132: Load Lifting

    13 L OAD LIFTING Do not hang a load without the kit's lifting facilities. 9.3 Lifting Kit , page 46 WARNING It is forbidden to lift loads over people. IMPORTANT It is forbidden to handle the loads without turning on the overload box. To make lifting a load with the machine, use the following procedure: 1.

  • Page 133: Implementing The 3Rd Hydraulic Circuit

    14 I MPLEMENTING THE RD HYDRAULIC CIRCUIT 14.1 Description 1= 3rd circuit selector 2= 3rd hydraulic circuit control CAUTION Do not operate the controls of the 3rd circuit if there are no installed accessories.

  • Page 134: 3Rd Circuit Selector

    14 Implementing the 3rd hydraulic circuit 14.1.1 3rd circuit selector • Use this valve, located under the mat, to select the 3rd hydraulic circuit in single or dual effect. A = 3rd circuit - dual effect B = 3rd circuit - single effect with direct tank return •...

  • Page 135: Precautions For Using The Accessory

    14 Implementing the 3rd hydraulic circuit 14.3 Precautions for using the accessory • Follow the procedures described in the user manual provided by the accessory's manufacturer. Hydraulic hammer (single action accessory) • Set the return pipe selector valve to the position for a single action accessory. •...

  • Page 136: Using The Particle Filter

    DPF is necessary to prevent the substances recovered from clogging the filter, which could reduce engine performance. YANMAR engines are equipped with a continuous regeneration system which filters harmful substances using a DPF and to perform the regeneration without interrupting the operation of the machine.

  • Page 137: Launching The Regeneration

    15 Using the particle filter 15.3 Launching the regeneration The exhaust gas temperature increases to high levels. When launching the regeneration, an icon representing the temperature of the exhaust gas is displayed on the operator display station to warn of the emission of high temperature gas.
  • Page 138 15 Using the particle filter • The manual regeneration lasts about 30 minutes and then the engine speed gradually de- creases and the operator display station stops displaying the exhaust gas temperature icon. WARNING You can stop the regeneration of the DPF by performing one of the following –...

  • Page 139: Transporting The Machine

    RANSPORTING THE MACHINE WARNING Choose a road taking account of the width, height and weight of the machine loaded on the truck. Transport the machine safely according to the rules associated with applicable legislation. 16.1 Loading/unloading the machine 16.1.1 Precautions for loading/unloading the machine •...

  • Page 140: Procedure

    16 Transporting the machine 16.1.2 Procedure 1. Engage the truck's brake. 2. Position buttresses to immobilise the truck. 3. Position the ramp plates on the truck deck so that the centre of the truck and the centre of the machine are aligned. Check that the left and right ramp plates are at the same level. 4.

  • Page 141: Immobilising The Machine On The Truck

    16 Transporting the machine 16.2 Immobilising the machine on the truck Once the machine is in a suitable position on the truck, immobilise it as follows : 1. Lower the blade to the ground. 2. Fold the bucket and the arm to the maximum, then lower the boom to wedge the arm on a wooden block.

  • Page 142: Tying Down The Machine

    16 Transporting the machine 16.3 Tying down the machine WARNING Do not perform the tie-down if a person stands on the machine or on an accessory. WARNING Use a tie-down accessory (belt, chain, cable) compatible with the weight of the machine and compliant with European standards. Check the tie-down accessory labelling to know the WLL .

  • Page 143: Slinging The Machine

    16 Transporting the machine 16.4 Slinging the machine WARNING Never lift the machine with someone on it or on an accessory. Use a slinging method that is compatible with the weight of the machine and that complies with current standards. If you do not lift the machine as shown, it will be out of balance.

  • Page 144: Detecting Anomalies

    ETECTING ANOMALIES 17.1 Phenomena that do not constitute faults The following phenomena are not faults : • Bucket shaking When the boom is raised immediately after the arm is extended while the bucket is pulled back, the bucket may shake. This is not a fault. •...

  • Page 145: Engine

    17 Detecting anomalies 17.2.1 Engine Problem Cause Solution Check the cooling water level. If necessary, top up the water. (Check Lack of cooling water. any water leaks on and around the Vapour comes filling hole). out of the Adjust the belt tension. radiator.

  • Page 146: Electrical Equipment

    17 Detecting anomalies 17.2.2 Electrical equipment Problem Cause Solution Check and replace the electric Defective electric circuit. Positioning the circuit. starter switch to Replace the starter switch. Defective starter switch. START does not launch the starter Battery insufficiently charged. Recharge the battery. motor.

  • Page 147: Machine Structure

    17 Detecting anomalies 17.2.3 Machine structure Problem Cause Solution Lack of pressure due to wear on the (Replace the hydraulic pump). hydraulic pump. Pressure drop in the distributor be- (Check and repair the valves). The power or low the set value. speed of the Damaged hydraulic cylinder.

  • Page 148: If The Battery Is Discharged

    F THE BATTERY IS DISCHARGED 18.1 Precautions for connecting and disconnecting the starter cables WARNING • When you start the engine using connection cables, wear protective goggles. • If you start the engine by taking electrical power from another machine, check that your machine does not come into contact with the other machine.

  • Page 149: Starting The Engine

    18 If the battery is discharged 18.3 Starting the engine 1. Check that the cables are connected safely to the battery terminals. 2. Start the engine on the repair machine and increase the engine speed to maximum. 3. Turn the starter switch of the machine that has broken down to START to start the engine. If the engine does not start, wait at least two minutes before trying again.

  • Page 150: Charging The Battery

    18 If the battery is discharged 18.5 Charging the battery Disconnecting • To disconnect, start with the negative terminal. (-) Charging the battery WARNING Remove the cables from the positive and negative terminals of the battery before setting the battery to charge. Otherwise, abnormal voltage may be applied to the alternator and may damage it.

  • Page 151: Towing The Machine

    OWING THE MACHINE WARNING Always tow a machine that has broken down in complete safety by using the suitable tools. An unsuitable procedure may cause serious physical injuries. IMPORTANT Check that the metal cables, the slings and the towing mechanisms to be used are resistant enough and that they are not cracked or broken.

  • Page 152: C Periodic Maintenance Programme

    Periodic maintenance programme HAPTERS COVERED IN THIS PART ERIODIC INSPECTIONS AND UPKEEPS AINTENANCE PRECAUTIONS ECOMMENDED GREASES AND FLUIDS IRST MAINTENANCE IST OF PERIODIC INSPECTIONS AND MAINTENANCE OPERATIONS AINTENANCE BY THE OPERATOR AINTENANCE BY THE DEALER...

  • Page 154: Periodic Inspections And Upkeeps

    ERIODIC INSPECTIONS AND UPKEEPS ○: Verification and adjustment ●: Replacement □: Cleaning ■: Greasing Every Every 1000h / 2000h / Every Parts & Operations Daily Every 50h Every Every two 500h year years ○ Missing or broken parts ○ Tightening of nuts and bolts General ○...
  • Page 155 1 Periodic inspections and upkeeps Scheduled maintenance points of the machine (lubrication, filters...) = Hydraulic oil = Engine oil = Hydraulic oil return filter = Travel gears = Greasing points = Air filter = Fuel filter Dependent on technical modifications.

  • Page 156: Maintenance Precautions

    AINTENANCE PRECAUTIONS CAUTION No maintenance operations described in this guide are to be performed with the engine running; please refer to the Maintenance Manuel for any other operation. 2.1 Precautions before maintenance 2.1.1 Removing the residual pressure Before performing any maintenance operation, remove residual pressure in the hydraulic circuit. 1.

  • Page 157: Establish A Safety Perimeter

    • Do not point the pressure washers on the electrical connectors. 2.2 Precautions during maintenance 2.2.1 Oil and grease • Always use oils and greases recommended by YANMAR. 3 Recommended greases and fluids page 144 • Use clean oils and greases. Avoid any contamina- tion by dust.

  • Page 158: Tools

    2.2.3 Parts • Use YANMAR original parts as recommended in the parts catalogue. • Clean parts with a non-combustible and non-aggressive detergent. • If you need to remove a seal or a hydraulic component, refer to the maintenance manual.

  • Page 159: Lighting

    2 Maintenance precautions 2.2.6 Lighting Use flameproof lighting when checking the fuel, oil, cooling water or battery electrolyte. If you do not, there is a risk of fire and explosion. 2.2.7 Battery • Disconnect the negative terminal from the battery to disconnect the electric current when working on the electrical circuit (repair, welding).

  • Page 160: Soldering

    2 Maintenance precautions 2.2.10 Soldering If you need to solder, respect the following points : • Disconnect the battery cabling (negative terminal then positive terminal). • Disconnect the operator display station before performing a welding operation. • Ground the machine no more than 1 metre away from the part to be welded. •...

  • Page 161: Recommended Greases And Fluids

    • Select a fuel and an oil according to the machine's operating temperature. • The machines may run on type B bio diesel. • Always use a Yanmar long-life cooling fluid. IMPORTANT Do not mix different types of oils.If you need to top up the oil with a different make or type from the oil left in the tank, remove the remaining oil completely.

  • Page 162: First Maintenance

    IRST MAINTENANCE 4.1 After the first 50 hours of service • Have the engine oil and the engine oil filter element replaced. • Replace the side movement reducer oil. • Have oil in the rotation gears replaced. • Greasing the pin and rotation crown •...

  • Page 163: List Of Periodic Inspections And Maintenance Operations

    IST OF PERIODIC INSPECTIONS AND MAINTENANCE OPERATIONS • The table below indicates the maintenance intervals to be respected for optimum operation of the machine. Read the machine's time counter every day to check whether a procedure should be implemented. • The inspection sheets provided at the end of this manual enable you to keep a trace of the maintenance operations carried out.
  • Page 164 5 List of periodic inspections and maintenance operations Parts Operations Daily Machine 6.1.1 Checking the machine before use , page 150 Commands 6.1.3 Checking the commands , page 150 Seat 6.1.4 Checking the seat , page 150 Greasing points 6.1.5 Greasing points , page 151 Hydraulic oil 4.5 Checking and topping up the hydraulic oil level , page 89...
  • Page 165 5 List of periodic inspections and maintenance operations Parts Operations Every two weeks Air conditioning/heating system 6.3.1 Checking the air conditioning/heating system , page 154 Every 50h Rotation pin and crown 6.2.1 Greasing the pin and rotation crown , page 154 Every 500h Rotation reducer Replenish engine oil...
  • Page 166 5 List of periodic inspections and maintenance operations Non periodic Fuses 6.4.1 Fuse replacement, page 155 Windscreen washer ( for cab ) 6.4.3 Top up the windscreen washer fluid, page 156 Windscreen wiper 6.4.4 Replacing the windscreen wiper, page 156 Tracks 6.5 Rubber track maintenance, page 156...

  • Page 167: Maintenance By The Operator

    AINTENANCE BY THE OPERATOR 6.1 Daily maintenance 6.1.1 Checking the machine before use • Before each use of the machine, visually check the following : – no missing, broken or loose parts – ventilator belt correctly tightened – no oil, water or fuel leaks –...

  • Page 168: Greasing Points

    6 Maintenance by the operator 6.1.5 Greasing points • Grease the machine swivel pins daily using the nipples, and also before using the machine or after use in the rain, on soft ground or in muddy water. • Proceed as follows : 1.

  • Page 169: Using The Centralized Greasing System

    6 Maintenance by the operator 6.1.6 Using the centralized greasing system • The timer is triggered at machine startup and stops at the machine's complete shutdown. When the ignition switch is turned off, the elapsed time before the next lubrication is saved and the timer restarts with this value when the machine is restarted.

  • Page 170: Purging The Fuel Tank

    6 Maintenance by the operator 4. Loosen the bowl tightening ring. 1 = Tightening ring 2 = Element 3 = Ring 5. Remove the bowl. 6. Empty into the container. Make sure you do not lose the red floater. 7. Remove the element and the holding ring. 8.

  • Page 171: Visual Inspection Of The Fuel Hoses

    6 Maintenance by the operator 6.1.10 Visual inspection of the fuel hoses • Visually check that the fuel does not leak from the fuel hose connectors. • Also check that the hoses are not damaged. If there are any faults, contact your dealer. •...

  • Page 172: Non Periodic Maintenance

    6 Maintenance by the operator 6.4 Non periodic maintenance 6.4.1 Fuse replacement 1. Set the starter key to OFF position. 2. Remove the lid from the fusebox. 3. Identify the burnt out fuse. 4. Replace it with an equivalent fuse. Fuse strip General supply fuses IMPORTANT...

  • Page 173: Top Up The Windscreen Washer Fluid

    6 Maintenance by the operator 6.4.3 Top up the windscreen washer fluid. 1. Open the windscreen washer tank. (1) 2. Top up the windscreen washer fluid. Do not over fill the windscreen washer tank. IMPORTANT Do not let any impurities into the tank. 6.4.4 Replacing the windscreen wiper •...

  • Page 174: Track Replacement

    2 = Not yet to be repaired • To find out whether the track must be replaced, repaired or you can continue to use it, con- tact your YANMAR dealer. 6.5.2 Track replacement • If a track (or both tracks) needs to be replaced, contact your dealer.

  • Page 175: Tension Check

    6 Maintenance by the operator 6.5.3 Tension check 1. Move the machine so that the seal on the internal sur- face of the track is placed in the centre of the upper chassis. A = Mark inside the track 1 = Cover 2 = Idle wheel 2.

  • Page 176: Increasing The Tension

    6 Maintenance by the operator 6.5.4 Increasing the tension 1. Prepare a grease pump. 2. Loosen the two screws and rotate the bottom cover to access the lubrication nipple. a = Cover b = Track roller c = Track 3. Raise the machine with the equipment by activat- ing the command lever.

  • Page 177: Releasing The Tension

    It is very dangerous to remove the grease using procedures other than those described here. If the track cannot be relaxed, ask your YANMAR dealer to intervene. 1. Loosen the two screws and rotate the bottom cover to access the lubrication nipple.

  • Page 178: Steel Track Maintenance

    (for example, muddy conditions if the task is carried out on muddy ground). • To find out whether the track must be replaced, repaired or you can continue to use it, con- tact your YANMAR dealer. 6.6.2 Track replacement • If a track (or both tracks) needs to be replaced, contact your dealer.

  • Page 179: Increasing The Tension

    6 Maintenance by the operator 6.6.4 Increasing the tension 1. Prepare a grease pump. 2. Loosen the two screws and rotate the bottom cover to access the lubrication nipple. a = Cover 3. Raise the machine with the equipment by activating the command lever.

  • Page 180: Releasing The Tension

    It is very dangerous to remove the grease using procedures other than those described here. If the track cannot be relaxed, ask your YANMAR dealer to intervene. 5. Tighten the greaser. Tightening torque : 49,0 N•m.

  • Page 181: Maintenance By The Dealer

    AINTENANCE BY THE DEALER Frequency Parts Operations 1st time Every 500h Hydraulic oil return filter Replacement Replacement Engine oil Replacement Oil filter Replacement – Fuel filter Rotation reducer Replenish engine oil – Travel gears Replenish engine oil – Air filter Replacement –...

  • Page 182: Maintenance Of The Particle Filter

    7 Maintenance by the dealer 7.1 Maintenance of the particle filter To service the DPF, contact your YANMAR dealer. • Particle filter, cleaning every 3000h and replacement every 9000h. • Catalytic converter, replace every 9000h.

  • Page 184: D Conservation And Storage

    Conservation and storage HAPTERS COVERED IN THIS PART ONSERVATION TORAGE ECOMMISSIONING IMPORTANT The conservation and storage of the machine must comply with standard NF ISO 6749 " Earth moving equipment, conservation and storage " of October 1987. The following chapters take part of the standard mentioned above but are not exhaustive. Refer to the standard for any additional information.

  • Page 186: Conservation

    ONSERVATION • Placing in conservation is intended to ensure the protection of the machine against corro- sion from the environment and against minor damage that may occur during handling, trans- port and storage. • Return the machine to good condition before placing it in conservation. 1.
  • Page 187 TORAGE • You are recommended to store the machine in a closed and covered location. • If the machine is stored outdoors, park it on flat ground and cover it with a protective sheet. • The machine must be placed in the position illus- trated opposite to protect the hydraulic cylinder rods against corrosion.

  • Page 188: Recommissioning

    ECOMMISSIONING WARNING After storage of the machine at temperatures outside the machine's operating tempera- ture range, make sure the temperature is again in the operating temperature range be- fore restoring the machine to working order. Before using the machine again after a storage period of two months, do the following: 1.

  • Page 190: E Technical Data

    Technical data HAPTERS COVERED IN THIS PART PECIFICATIONS ORKING DIMENSIONS OISE EMITTED BY THE MACHINE IBRATIONS EMITTED BY THE MACHINE...

  • Page 192: Specifications

    PECIFICATIONS Tracks Rubber | Steel H(track tension) 20 ~ 25 | 150 ~ 160 Elements Cabin Weight (in conformity with CE standards) Weight of the machine (with operator +75 kg) 8065 / 8125 Working range and performance °C -15 ~ 40 Operating temperature range 0,28 Bucket capacity, standard...

  • Page 193: Working Dimensions

    ORKING DIMENSIONS Unit : mm 6820 7160 6960 7290 4440 4790 1940 1590 3800 4130 1135 1265 4150 4500 4680 4910 H / swing 2470/2130 2520 / 2170 6790 7020 2710 2890 1870 6410 6450 2270 10. With rear counterweight...

  • Page 194: Noise Emitted By The Machine

    OISE EMITTED BY THE MACHINE Examination results : LwA (dBA) LpA/LAeq (dBA) LpCrête (dBC) Rounded values LwA : weighted acoustic power level A. LpA/LAeq : weighted acoustic pressure level A on operator's ears. LpCrête : maximum value of the instant acoustic pressure measured with frequency weighting C. Measurements carried out : •...

  • Page 195: Vibrations Emitted By The Machine

    IBRATIONS EMITTED BY THE MACHINE Declared vibration value in accordance with EN 12096 Unit : m/s² Measured vibration emission Work cycle Vibrations Uncertainty, K value, a < 2,5 – Roadworks trench < 2,5 – Levelling Hand-arm in m/s² Displacement 2,56 0,47 Hydraulic hammer <...

  • Page 196: F Lifting Capacities

    The data marked with * show the hydraulic limits of the lifting force. YANMAR CONSTRUCTION EQUIPMENT EUROPE S.A.S. declines all responsibility for any use of the machine that does not respect the instructions in this regulation. IMPORTANT The position of the blade (raised or lowered) does not affect the machine's lifting capacity.

  • Page 198: Lifting Vio80-1A

    O80-1A IFTING Machine with cab and rubber tracks. A = Tilt from the rotation axis B = Attachment point height *= Hydraulic capacity limits of the lifting force = Maximum load raised by the machine = Housing overload alarm value setting...

  • Page 199: Lifting Vio80-1A With Rear Counterweight

    O80–1A W IFTING ITH REAR COUNTERWEIGHT Machine with cab and rubber tracks. A = Tilt from the rotation axis B = Attachment point height *= Hydraulic capacity limits of the lifting force = Maximum load raised by the machine = Housing overload alarm value setting...

  • Page 200: Appendices

    Appendices Additional informations: A List of error codes displayed on the operator display station Control sheets to be photocopied Notes D Lashing record...

  • Page 201: A List Of Error Codes Displayed On The Operator Display Station

    A List of error codes displayed on the operator display station Error Code Type Description Corrective actions 00 000091.00 CAUTION Failure of the acceleration sensor Maintenance required 00 000091.01 CAUTION Failure of the acceleration sensor Maintenance required 00 000091.02 CAUTION Failure of the acceleration sensor Maintenance required 00 000091.03...
  • Page 202 00 522241.02 CAUTION Rack actuator relay fault Maintenance required 00 522241.03 WARNING Rack actuator relay fault Maintenance required 00 522241.0 WARNING Rack actuator relay fault Maintenance required 00 522242.02 CAUTION Cold start assistance system fault Maintenance required 00 522242.03 CAUTION Cold start assistance system fault Maintenance required 00 522242.04...
  • Page 203 E1 033024.00 CAUTION Abnormal voltage of the management computer Maintenance required power supply (top) E1 033024.01 CAUTION Abnormal voltage of the management computer Check the battery, or power supply (bottom) perform the maintenance E1 033024.11 CAUTION Abnormal voltage of the management computer Check the battery, or power supply (bottom) perform the maintenance...

  • Page 204: B Control Sheets To Be Photocopied

    B Control sheets to be photocopied Photocopy the following sheets and carry out maintenance on your machine according to the number of hours of service. Control sheet: Maintenance every 50 hours Number of hours of service hours Operations Done by Parts 6.2.1 Greasing the pin and rotation Rotation pin and crown...
  • Page 205 Control sheet: Maintenance every 500 hours Number of hours of service hours Operations Done by Parts Rotation pin and crown Greasing Rotation reducer Replenish engine oil Travel gears Replenish engine oil Replacement Engine oil Replacement Dealer Oil filter Cleaning Radiator vents Verification and adjustment Side movement and acceleration levers Hydraulic oil return filter...
  • Page 206 Control sheet: Maintenance every 1000 hours / Every year Number of hours of service hours Operations Done by Parts Rotation pin and crown Greasing Rotation reducer Oil replacement Travel gears Oil replacement Hydraulic oil Replacement Bearing rollers and bearings, idler wheels Greasing Engine oil Replacement...
  • Page 207 Control sheet: Maintenance every 1000 hours / Every year Number of hours of service hours Operations Done by Parts Rotation pin and crown Greasing Rotation reducer Oil replacement Travel gears Oil replacement Hydraulic oil Replacement Bearing rollers and bearings, idler wheels Greasing Engine oil Replacement...
  • Page 208 Control sheet: Maintenance every 2000 hours / Every two years Number of hours of service hours Operations Done by Parts Rotation pin and crown Greasing Rotation reducer Oil replacement Travel gears Oil replacement Bearing rollers and bearings, idler wheels Greasing Hydraulic oil Replacement Engine oil...

  • Page 209: C Notes

    C Notes...

  • Page 210: D Lashing Record

    D Lashing record YANMAR CONSTRUCTION EQUIPMENT EUROPE S.A.S 25, rue de la Tambourine 52100 SAINT-DIZIER CEDEX FRANCE + 33 (0) 3 25 56 39 75 GENERAL PRINCIPLE OF APPLICATION Road transport Model : ViO80-1A Type of operation: Tie-down Activity: Earthmover...

  • Page 212: Index

    NDEX 3rd hydraulic circuit ........116 Engine oil ..........144 Accessing the machine ........72 Accessories.........105, 109 fuel Dismantling ........60, 111 type ............144 adhesive labels .........6, 48 Fuses ............33, 35 Applications ...........3 Greasing Basic precautions ........65 Greasing points ........151 Battery Battery charge warning alert ....16 discharged..........131 Battery charge warning alert Headlights ...........40...
  • Page 213 Options ............46 Maintenance ..........139 use of equipment Power socket ..........31 Precautions ..........75 Precautions User manual ..........33 Accessories..........82 Using the electric fuel filling pump ....45 Battery .............83 Before starting the engine ......70 Displacement..........72 Optional parts and tools ......68 Windscreen washer ........22 Use............70 Windscreen wiper switch and windscreen use of equipment ........75...
  • Page 214 http://www.yanmar.eu...

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