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RHINOCEROS KS12-9 Operation Manual

Hydraulic crawler excavator
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Operation Manual
Hydraulic Crawler Excavator
Original Instruction
Shandong Ken Stone Heavy Machinery Co., Ltd.
South of National Highway 309#, Dingyuanzhai Town, Guanxian County,
Liaocheng City, Shandong Province, China
KS12
-9
Please read this manual and fully
understand its content before proceeding
with the operation, inspection and
maintenance of this machine

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  • Page 1 Operation Manual KS12 Hydraulic Crawler Excavator Original Instruction Shandong Ken Stone Heavy Machinery Co., Ltd. South of National Highway 309#, Dingyuanzhai Town, Guanxian County, Liaocheng City, Shandong Province, China Please read this manual and fully understand its content before proceeding with the operation, inspection and maintenance of this machine...
  • Page 2 Safety Warning Signs The improper methods during operations, This sign denotes a safety warning. The checking, and maintenance of machine will information behind the sign includes result in injuries or deaths. Before any operation, checking, or maintenance important safety information. Please read and understand this information to of machine, please read and understand this prevent personal injuries or deaths.

  • Page 3: Signal Words

    Signal Words The safety information on this manual and It’s impossible for us to predict all possibly machine identifications is indicated by words existed dangers. Therefore, the warnings in this “Danger”, “Warning”, and “Notice”. The manual or on this machine can’t cover all meanings of these signal words are as below: possible accidents.

  • Page 4: Introduction

    Introduction Foreword Serial number This manual describes the operations, checking, Important: Do not disassemble the machine and maintenance of this machine and the safety nameplate with serial number. Observe the descriptions to be observed during operations. serial numbers of machine and engine and Should you have any doubt, please contact a record them in the blank area below.
  • Page 5 Introduction Front, Rear, Left, and Right Product Features Front ● Small size, flexible operation ● Can be equipped with a variety of attachments ● Track width "flexible machine width structure" Run-in period For the first 100 hours of the new machine (as Left Right indicated by the timer), please follow the...
  • Page 6 Introduction Notes about Reading of This Noise and vibration Manual Please be noted that the descriptions and A-Weighted emission sound pressure level at graphics contained in this manual probably are the operator's position measured according to not applicable for your machine in use. The work cycle procedures specified in “ISO numbers in graphics are marked by circles.

  • Page 7: Table Of Contents

    Contents Transportation........4-1 Signal words........0-1 Loading and Unloading........4-2 Introduction........0-2 Lifting of Machine...........4-4 Safety..........1-1 Fixing of Machine..........4-6 General Precautions........1-2 Maintenance........5-1 Precautions during Preparations....1-8 Overview............5-2 Safety Measures at Start......1-10 Service Data.............5-4 Operation Precautions.........1-12 Critical Safety Parts........5-11 Precautions for Parking.......1-22 Maintenance List...........5-13 Precautions during Transport......1-23 Walk-Around Checking.........5-15 Precautions for Maintenance ......1-25 Daily routine checking (Every 10h)....5-17...
  • Page 8 Contents Parameters........7-1 Basic Parameters..........7-2 Overall Dimensions of Machine......7- Operating Range..........7-4 Machine lifting power........7-5 Accessories........8-1 General Safety Measures ......8-2 Precautions.............8-5 Hydraulic Hammer ........8-6 Optional accessories........8.11 Parts number position........8-13...

  • Page 9: Safety

    Safety...

  • Page 10: General Precautions

    Safety General Precautions General Precautions under sleepy status. You are liable to abiding by the safety laws Upon detection of machine abnormality During the operations, checking, or and regulations of relevant departments and maintenance of machine, upon detection of any fulfilling the operations, checking, and machine abnormality (Such as noise, vibration, maintenance of machine.
  • Page 11 Safety General Precautions cause serious harms. condition beyond above-mentioned outside ● Please use the hearing protection devices temperature range, please consult with during the operations of machine. your sales or service dealer. Exposure to a high noise environment for a long time will result in harm or even Wearing Appropriate Clothing and complete loss of hearing.
  • Page 12 Safety General Precautions No Disassembling of Safety Devices responsible for making gestures. ● All personnel must completely understand all gestures. ● The operator must respond to the gestures of designated person only. However, the operator must abide by the stop gesture made by anyone in all cases.
  • Page 13 Safety General Precautions ● Please be noted that, even if the safety flame or fire source. lock handle is placed at locking position, ● Do not smoke or use open fire while the bulldozing blade, boom, and auxiliary handling fuel or performing the operations hydraulic controls can’t be locked.
  • Page 14 Safety General Precautions (Foam fire extinguisher) as per the Toxic Exhaust Gas from Engine manufacturer’s procedures indicated on the containers. Operate in a well-ventilated place. ● Never use fuel for cleaning purpose. Always use non-inflammable solvent. ● Please open doors and windows for thorough ventilation during the handling of fuel and the cleaning of oil stain or ●...
  • Page 15 Safety General Precautions ● During operations, the non-authorized Use of Accessories personnel are prohibited to access the ● Please consult with Ken stone company working zone. before installing accessories. Based on the ● Please strictly abide by the rules and attachment types and their combinations, environmental standards applicable for this the attachments will probably come into...

  • Page 16: Precautions During Preparations

    Safety Precautions during Preparations Precautions during Preparations consideration. Understanding of working zone  Use a signaler and/or signals. Before starting operations, understand the  Isolate the working zone against the access situation of working zone to ensure safety. of non-authorized personnel. ●...
  • Page 17 Safety Precautions during Preparations Always Keeping Clean Machine ● Before operations, fulfill the designated checking and when necessary repair immediately. ● In event of operation failure due to malfunction or engine malfunction, immediately stop the engine as per stop procedure and park the machine securely, till the malfunction is repaired.

  • Page 18: Safety Measures At Start

    Safety Safety Measures at Start around the machine. Start the engine only Safety measures when starting after it’s confirmed that there is no person Support your body weight by three-point safety around the machine. posture while getting on/off the machine. ●...
  • Page 19 Safety Safety Measures at Start actuated and all joysticks and pedals are in procedure and report malfunction. neutral. Warm up the engine and hydraulic oil. ● Check whether the safety lock handle is at Check all instruments and warning devices for locking position.

  • Page 20: Operation Precautions

    Safety Operation Precautions weathers (Such as fog, snow, rain, and haze), Operation Precautions stop the operations of machine till the visibility Operating Machine with Maximum turns good. Track Width Clean the windows, mirrors, lamps, and camera to keep good visibility. Adjust the mirrors and camera to optimal positions to ensure that the driver sitting in the driver seat can see the rear view (Blind spot).
  • Page 21 Safety Operation Precautions Checking for Safe and Reliable Before operating the traveling joystick/pedal, Working Zone before Operations ensure that the bulldozing blade is in front of the driver seat. Please bear in mind that the operation direction of the traveling joystick/pedal with bulldozing blade behind the driver seat is reverse to that with bulldozing blade in front of driver seat.
  • Page 22 Safety Operation Precautions Bulldozing blade  Avoid driving over obstacles whenever  Keep the driver seat facing towards the possible. If it’s necessary to drive over up slope direction while climbing up a obstacles, keep the bucket operating device slope. Keep the driver seat facing near the ground and travel at low speed.
  • Page 23 Safety Operation Precautions Special Cautions for Operations of Machine on Ice/Snow  While traveling on snowy or icy roads, drive at low speed and avoid the sudden startup, stop, and direction change.  In snowy regions, the road curbs and the ...
  • Page 24 Safety Operation Precautions Keeping a Safe Distance from Overhead No Movement of Bucket over Personnel High-Voltage Cables Moving the bucket over the personnel has a Never close any part or loaded material of danger of splashing of loaded material or the machine to high-voltage cables, unless all sudden falling of bucket.
  • Page 25 Safety Operation Precautions cables, set up a signaler to sound warnings.  Keep all personnel within operation zone away from machine and loaded material.  Pay special attention to the underground high-voltage cables.  Keep a safe spacing between machine and edge of digging site.
  • Page 26 Safety Operation Precautions  Before the operations on the top of any building or other structure, check the strength and structure. It will cause serious harms or destruction if the building or structure collapses.  Keep away from unstable ground (Cliffs, road curbs, and deep ditches).
  • Page 27 Safety Operation Precautions Danger during Operations on Slopes No Lateral Slewing (Swing) with Bucket Heavily Loaded During operations on slopes, slewing or operating the working device can probably result in instability or rollover of machine. Avoid operations on slopes whenever possible. Landfill The machine is more vulnerable to rollover in lateral direction than longitudinal direction.
  • Page 28 Safety Operation Precautions Please pay attention to the objects serious injuries or deaths.  All rated lifting capacities are based on the above your head condition of using this machine on a firm and level ground. The user’s is recommended to reserve an appropriate allowance for specific working conditions, in order to ensure the safe lifting operations.
  • Page 29 Safety Operation Precautions machine in any dangerous place in which the Please refer to the section “Towing” to operator is probably subject to the impact of understand more description information. flying objects. Precautions for Towing 20°or less During towing, the improper operations, the incorrect use of rope, or the improper checking will cause serious injuries or deaths.

  • Page 30: Precautions For Parking

    Safety Precautions for Parking Precautions for Parking Safe parking ● Complete the following operations before leaving the machine: ● Stop the machine on a level, solid, and safe Lower the bucket and bulldozing blade onto the ground. ground. Set the parking device. Lift up the safety lock handle to the locking position.

  • Page 31: Precautions During Transport

    Safety Precautions during Transport to prevent movement. While loading or Precautions during Transport unloading the machine, drive the machine Safe loading/unlocking of machine slowly in 1st gear (low speed) as per the signals of the signaler. Fix to suspension Do not change direction on ramps. parts Do not slew/swing on ramps.
  • Page 32 Safety Precautions during Transport Safe Lifting of Machine Safe Transport of Machine Master and utilize the correct lifting gestures. During the transport of machine, understand Daily check the lifting device for damaged and and abide by all applicable safety rules, vehicle missing parts and when necessary replace.

  • Page 33: Precautions For Maintenance

    Safety Precautions for Maintenance Do not use any damaged or deteriorated tool or Precautions for Maintenance any tool designed for other application. Use Warning Information of “No tools suitable for related operations. Operation” Sign Periodically Replaced Critical Safety During the checking or maintenance of machine, the start of engine or the touch of any Parts joystick by non-authorized personnel will...
  • Page 34 Safety Precautions for Maintenance Please clean the machine before maintenance. No Access of Non-Authorized Personnel Stop the engine before cleaning the machine. Cover the electric parts against water ingress. The water ingress into the electric parts will probably result in short-circuit or malfunction. Do not clean the battery, electronic control units, sensors, connector, or cab by water or steam.
  • Page 35 Safety Precautions for Maintenance tracks. Keeping Away from Motion Parts If it’s necessary to operate beneath the lifted machine or device, always fix by cushion woods, jack, or other firm and stable supports. Do not access the area beneath the machine or working device before it’s firmly supported.
  • Page 36 Safety Precautions for Maintenance weights or attachments onto the ground during pressure in the fuel tank. disassembling or installation, please ensure to Do not use fuel for any cleaning purpose. place them in a steady place. Keep the non- Use correct fuel grade based on the season. authorized personnel away from the place for Handling of Hoses storage of such objects.
  • Page 37 Safety Precautions for Maintenance fluids are also under high temperature and high pressure status. Take cautions not to touch the hydraulic oil while loosening engine hood or connector. Operating the machine under such condition will cause out-spray of hot oil to result in scalding or injuries.
  • Page 38 Safety Precautions for Maintenance ● While disassembling connector or plug or In the track pensioner, the grease is injected disconnecting hose, stand on one side, under high pressure. If the tension is not loosen slowly to gradually relieve internal adjusted by the following designated procedure, pressure, and then take out.
  • Page 39 Safety Precautions for Maintenance Operations of Additional Devices Disconnection of Battery Cables Take special cautions while handling the high Please disconnect the battery cables before pressure nitrogen stored in the tank. The operations or electric welding of electronic improper handling will probably result in system.
  • Page 40 Safety Precautions for Maintenance ● The battery can generate inflammable electrolyte will leak out. The contact with hydrogen to probably cause explosion. such electrolyte can harm your skin or Keep away from fire sources including corrode the machine parts. open fire, spark, and ignited cigarette. ●...
  • Page 41 Safety Precautions for Maintenance ● Upon detection of any visible damage on cable, always wear goggles and gloves. the appearance, please replace the ● Use the battery charging cable and clamps “periodically replaced critical safety parts”, of dimensions suitable to the battery even if the designated replacement period capacity.
  • Page 42 Safety Precautions for Maintenance the any place near the working device pin machine into a container. The improper or hydraulic cylinder. treatment of waste oil will pollute the ● Before the welding of machine body, environment. disconnect the connector of electronic ●...

  • Page 43: Safety Signs

    Safety Safety Signs Safety Signs To guarantee the safety of operator and operation personnel in the working zone, please set up the following safety signs (markings) at some portions of machine. Walk around the machine with this manual and observe the contents and placement locations of these safety signs. Please review these signs and operation instructions contained in this manual jointly with the machine driver.
  • Page 44 Safety Safety Signs 1-36...
  • Page 45 Safety Safety Signs 1. Warning 4. Risk from rotating parts. Please turn Carefully read and understand the manual off before checking and maintenances. before operations, checking, and repairs of machine. 5. Safe distance and danger from 2. Safe distance. collision with working device. Please Never approach to or stand in the keep away from machine during working zone of machine.
  • Page 46 Safety Safety Signs 6. This sign denotes not to touch any hot part during operations or just after operations. Do not touch before these parts, Warning including engine, pump, and exhaust pipe, The operations or maintenance of this are cooled down. machine by incorrect method will cause bodily injury accident.
  • Page 47 Safety Safety Signs 11 、 No people are allowed to stand 13. Diesel in the working area 14. It’s prohibited to touch any joystick or traveling joystick while getting on or off the 12 、 Pay attention when relieving machine, otherwise the parts will be damaged. pressure Warning 15.
  • Page 48 Safety Safety Signs 16. Hydraulic oil 20. Keep the boom and bulldozing blade separated. While lowering the boom, take cautions not to touch the boom with bulldozing blade. 17. Fixed point 18. Lifting direction 19. When the machine is lifted, fix it by cushion blocks or supports.

  • Page 49: Controls

    Controls...

  • Page 50: Component Name

    Control Component Name Component Name Up frame Chassis Working device 1 、 seat 6 、 Track 12 、 Bucket 2 、 Rear cover 7 、 Drive wheel 13 、 Bucket cylinder 3 、 Maintenance cover 8 、 Track roller 14 、 Arm 4 、...
  • Page 51 Control Component Name Left traveling lever Safety lock handle Right traveling lever Start switch Bulldozer blade lever 10. Throttle lever Lever for telescopic track 11. Water temperature meter Boom swing lever 12. Warning sign Right joystick 13. Hour meter Lighting switch Left joystick Auxiliary circuit button The specific configuration depends on the machine specification or selected product.

  • Page 52: Start Key, Maintenance Cover, Rear Cover

    Control Start key, Maintenance cover, Rear cover Start Key Closing 1. After unlocking the limit of the maintenance cover, close the cover. 2. Turn the bolt clockwise to lock the maintenance cover. Rear cover The start key is used to start the engine. Maintenance cover Warning Before opening the repair cover, ensure that...

  • Page 53: Fuse Case, Fuel Filling Port

    Control Fuse case, Fuel filling port Fuse Case ● Do not top up the fuel tank. Leave an This case is functioned to protect the electric expansion space for the fuel. system against over-current. ● Tighten the fuel tank cap securely. Open Open 1.

  • Page 54: Seat

    Control Seat Seat Warning Adjustment and Fixing of Seats (For high-end seats only) A. Adjust the backrest angle 1. Stand up straight and sit back on the seat. 2. Adjust the backrest to the angle you want by rotating the handle (1). B.
  • Page 55 Records...

  • Page 56: Electrical Control Panel

    Control Electrical control panel Panel Name and Description name note Display working hours, the range is 0-9999.9h. hour meter When the engine is running, if there is a problem with the charging Charging warning system, the light flashes and an alarm sounds. light When the engine is running, if the oil pressure is abnormally low, the Oil pressure...
  • Page 57 Control Electrical control panel Precautions After-Service Information Provided that the operations are performed This instrument is a water-proof instrument, normally as per the instructions of the manual, featuring stable performance and high the malfunctions occurred within the warranty conciseness and elegance, and is an period will be repaired free of charge.

  • Page 58: Switches (Start Switch / Horn Button)

    Control Switches Horn button Start Switch Important: Do not rotate the starter key from OFF to ON and then from ON to OFF repeatedly within a short time, otherwise it will probably result in engine malfunction. OFF …… This position is used to stop the engine and insert and withdraw the starter key.

  • Page 59: Joysticks

    Control Joysticks Joysticks Safety lock handle Warning ● Before standing up from the driver seat to adjust the operator’s seat, lower the working device to the ground, lift up the safety lock handle to lock it, and stop the engine. When the safety lock handle This device is functioned to lock the operations is lowered down (Unlocked), the of bucket working device and machine slewing.
  • Page 60 Control Joysticks ● The descriptions in this manual use the (A) … Lower the bulldozing blade. ISO mode of machine. (B)… .Lift the bulldozingblade. Traveling Joystick Warning ● Before operating the traveling joystick, ensure that the bulldozing blade is in front of the driver seat. Please bear in mind that the operation direction of the traveling joystick with bulldozing blade behind the driver seat...
  • Page 61 Control Joysticks Auxiliary hydraulic circuit control Boom swing lever button This lever controls the hydraulic oil flow and This button is used for the operation of direction in the auxiliary hydraulic circuit. attachments that require hydraulic power such as (A) ..Boom swing right breakers.

  • Page 62: Accessory

    Control Accessory Auxiliary hydraulic pipeline (If installed) Warning These pipelines transport the hydraulic oil Disconnecting the pipelines before the needed to operate hydraulic breakers or pressure relief of hydraulic system will other working devices. (1)... Auxiliary hydraulic pipeline probably result in out-spray of hydraulic oil. ●...
  • Page 63 Control Accessory Connection of Hydraulic Circuits Important: If applicable, follow the attachment To connect the attachment hydraulic pipeline, manufacturer’s procedure to bleed the air. please operate as per following procedure: 6. Check for presence of oil leakage. Relieve the residual pressure from system and then close the shutoff valve.

  • Page 64: Operations

    Operations...

  • Page 65: Before Operations

    Operations Before Operations Before Operations Walk-Around Checking Getting on/off Machine Before the first start of engine each day, fulfill one walk-around checking. Warning ● Do not jump on or off the machine. Do not Refer to page 5-14 and 5-15 “Maintenance, attempt to get on or off a moving machine.

  • Page 66: Start And Stop Of Engine

    Operations Start and Stop of Engine Start and Stop of Engine Before Start of Engine Adjust the seat to comfortable operating position. ● All warning lamps turn on for 1s and the warning tone is issued for 2s. The instruments start working. ●...
  • Page 67 Operations Start and Stop of Engine Start of Engine Warning ● Keep all personnel away from working zone. ● Sound the horn to alert the personnel around machine. Important: Do not run the starter motor Rotate the starter key to START position continuously for >15s.
  • Page 68 Operations Start and Stop of Engine Rotate the start key counter-clockwise to Return the accelerator joystick and then HEAT position for approximately 10s. The run the engine at low idling speed under preheated indicator lamp turns on to no-load condition for 5min. indicate the running of preheated.
  • Page 69 Operations Start and Stop of Engine Stop of Engine Important: Do not stop the engine suddenly under heavy load or during high-speed running. Otherwise it will result probably in overheating or blockage of engine. Do not stop the engine hastily, unless in event of emergency Return to the throttle lever.

  • Page 70: Operate Machine

    Operations Operate Machine Operate Machine Joystick Mode (ISO Mode) Warning ● Before starting operations, please carefully check and confirm the joystick mode to be used. ● The descriptions in this manual use the ISO mode of machine. （ ISO ） Drive leftward Drive rightward Safety lock locked...
  • Page 71 Operations Operate Machine speed under no-load condition for Warm up the engine (hydraulic oil) approximately 5min. Warning 2. Completely lower down the safety lock It’s really dangerous to operate the working handle to unlock and lift the bucket from device without warm-up (Hydraulic oil), as the ground.
  • Page 72 Operations Operate Machine Check the warning lamps and instruments Drive forward and backward slowly for as below: several times. ● Whether all warning lamps turn off. ● Whether the water temperature meter is Warm-up in Cold Weathers ≤105℃. Fulfill the normal warm-up procedure. 2.
  • Page 73 Operations Operate Machine Change of Chassis Width Warning Operating Machine with Maximum Width ● Always operate the machine with extended chassis width of 950mm, in order to improve the machine stability to the maximum extent. Operating the machine with narrow chassis width 1.
  • Page 74 Operations Operate Machine Change of bulldozer blade width 1. loosen the bolts(1) and take out the pins(2) 3. Push the lever forward to increase the width of the chassis to 950 mm. 4. Pull the lever backward to reduce the Rotate the extension plate around the pins width of the chassis to 800 mm.
  • Page 75 Operations Operate Machine Operations of Traveling Joystick Move the machine back and forth Warning ● Do not allow any person to access the turning radius or path of machine. ● There are blind zones behind the machine. To reverse the machine, if necessary, slew the cab to check the safety and ensure there is no person Pull the accelerator joystick to increase the...
  • Page 76 Operations Operate Machine Retract the bucket and lower to 30~40cm When the bulldozing blade is behind of seat: off the ground. To drive forward: Pull backward the joystick. Lift the bulldozing blade. Operate the traveling joystick as per To drive backward: Pull forward the following procedure.
  • Page 77 Operations Operate Machine Parking Warning ● Park the machine on a level, solid, and safe ground. Set the parking device. If it's necessary to park the machine on a slope, block the track by wedges to prevent movement of machine. Turn left during traveling: ●...
  • Page 78 Operations Operate Machine Slewing Warning Before slewing, check the surrounding area for safety. Slowly place the left and right traveling levers to neutral position. Stop the machine. Operations of Working Device Warning ● Before starting operations, please carefully check and confirm the joystick mode to be used.
  • Page 79 Operations Operate Machine Operations of Arm Swing of Boom Swing the boom left: push this lever Retract bucket arm: Push the left joystick backward. forward. Extend bucket arm: Push the left joystick Swing the boom right: pull this lever forward. backward.

  • Page 80: Operating Procedures

    Operations Operating Procedures Operating Procedures No Digging during Traveling Prohibited Operations Warning ● Do not operate on a bed rock (hard or soft). ● Do not slew during the traveling. If it’s necessary to operate the bucket working device during traveling, operate at Do not insert the bucket into the ground or use sufficiently low speed to ensure the the traveling force for digging.
  • Page 81 Operations Operating Procedures When the machine body is lowered and the Do not operate by the down force of bucket arm cylinder is completely extended, do machine not support the machine body by bucket working device. Otherwise, the load will be concentrated on the bucket arm cylinder to probably damage the bucket arm cylinder.
  • Page 82 Operations Operating Procedures rock into small pieces by breaking hammer Prohibited Use of Bulldozing Blade as before digging. It can prevent the damages of Support machine and thus can be more economic. Guard Bulldozing Blade against Impact Caution of Bulldozing Blade during Digging Impacting the bulldozing blade with rock will damage the bulldozing blade and bulldozing...
  • Page 83 Operations Operating Procedures whenever possible. If it’s necessary to drive Caution of Downward Digging with over obstacles, close the bucket working device Bulldozing Blade to the ground, drive the machine at low speed, and drive the machine in such manner that the obstacles are in the middle of tracks.
  • Page 84 Operations Operating Procedures Precautions for Traveling on Slopes ● Permissible water depth Warning Operate this machine in the water only when the water level is not above the ● Do not drive the machine on a slope middle of track shoe (1). steep enough to cause instability of ●...
  • Page 85 Operations Operating Procedures Traveling Posture on Slopes Up slope Traveling ● Do not change direction on a slope or lateral slope. Firstly return the machine to a level ground and then select another To climb up a 15° or higher slope, maintain the path.
  • Page 86 Operations Operating Procedures Braking during Downs lope Traveling In Event of Engine Flame out While driving down a slope, the brake applies If the engine stops while driving down a slope, braking automatically after the traveling joystick shift the traveling joystick to neutral position, returns to neutral position.
  • Page 87 Operations Operating Procedures Out of the mud 1. Operate above-mentioned steps 1~4 for If the machine is entrapped in the mud, drive both tracks. out as per following procedure. Insert the bucket into the ground in the front of machine. If a track gets stuck in the mud Pull the bucket joystick during forward traveling to slowly drive out the machine.
  • Page 88 Operations Operating Procedures Ditching Loading While loading soil into the cargo body of a Install a bucket suitable for digging of ditches, truck, loading from the rear end of truck can adjust the tracks to be parallel with the ditch to load more soil easier than loading from the be dug, in order to improve the working front end.

  • Page 89: Parking Of This Machine

    Operations Parking of This Machine Parking of This Machine vehicles. ● Before leaving the seat, lift up the safety Parking lock handle to the locking position and stop the engine. Meanwhile, ensure to Warning withdraw the key, close the doors and hoods, and carry the key with you and then preserve it in a designated place.
  • Page 90 Operations Parking of This Machine Locking Ensure to lock the following parts. 3-27...

  • Page 91: Treatment In Cold Weather

    Operations Treatment in Cold Weathers Treatment in Cold Weathers ● Fully drain the water from fuel tank to prevent freezing. Preparations for Cold Weathers Refer to page 5-27 “Water drainage from It’s difficult to start the engine in cold weathers. fuel tank ”.

  • Page 92: Handling Of Rubber Tracks

    Operations Handling of Rubber Tracks ● Driving the machine on a riverbed or place Handling of Rubber Tracks with numerous pebbles can probably result This machine is equipped with rubber tracks in inclusion of pebbles in the tracks and and the rubber tracks have their intrinsic the damage or falloff of tracks.
  • Page 93 Operations Handling of Rubber Tracks Precautions Please abide by the following precautions during the operations of this machine: ● Driving the machine on irregular surfaces, such as new asphalt pavement and hot steel plates exposed to campfire or burning sun will result in irregular wear or damage ●...
  • Page 94 Operations Handling of Rubber Tracks potassium sulfate, and lime triple super Guard against Falloff of Rubber phosphate. Such substances adhered onto Tracks the tracks shall be immediately removed Abide by the following precautions to prevent thoroughly by water. the falloff of tracks: ●...
  • Page 95 Operations Handling of Rubber Tracks ● Do not change the direction when the tracks are loose as shown in the diagram. ● Please avoid driving the machine with one track on a slope or protrusion and the other ● In such case, the rubber tracks will fall off track on level surface (In such case, this if the machine drives backward.

  • Page 96: Transportation

    Transportation...

  • Page 97: Loading And Unloading

    Transportation Loading and Unloading Loading and Unloading ● Do not slew/swing on ramps. Otherwise the machine will probably roll over. Warning ● Slewing/swinging the machine on the The machine will probably roll over or fall cargo body of truck will probably result off during unloading.
  • Page 98 Transportation Loading and Unloading Align the center of truck cargo body with the center of machine and align the center of ramps with center of tracks. Ensure that the bulldozing blade will not touch the ramps. Lower the bucket working device as low as possible and take cautions not to impact it with the transport truck.

  • Page 99: Lifting Of Machine

    Transportation Lifting of Machine Lifting of Machine Lifting Slew the superstructure to place the Warning bulldozing blade behind the machine ● Master and use the correct lifting (Adjust the superstructure to be parallel signals. with track frame). ● Daily check the lifting device for Lift the bulldozing blade to highest damaged and missing parts and when position.
  • Page 100 Transportation Lifting of Machine unit: mm...

  • Page 101: Fixing Of Machine

    Transportation Fixing of Machine Fixing of Machine After loading the machine to designated position, fix as per following requirements. Transport Status Lower the bulldozing blade. Safety Measures Taken during Sufficiently extend the bucket cylinder and Transport bucket arm cylinder and then lower the boom. Warning Lift up the safety lock handle to the ●...

  • Page 102: Maintenance

    Maintenance...

  • Page 103: Overview

    Maintenance Overview Overview maintenance. Keep the machine clean. ● Stop the engine before cleaning the Maintenance Overview machine. Cover the electric parts against To maintain the good status and long-term water ingress. The water ingress into the serviceability of the machine, please fulfill the electric parts will probably result in short- checking and maintenance correctly and safely circuit or malfunction.
  • Page 104 Maintenance Overview non-inflammable detergent. ● Wrap the threads with seal ring and notice to leave 1~2 end threads of screw plug not Guard against Ingress of Dusts wrapped with seal ring. The installation and disassembling of parts shall Waste Disposal be operated in a dust-free place.

  • Page 105: Service Data

    Maintenance Service Data Service Data Fuel and Lubricant Table Please refer to following table to select appropriate fuel, lubricating oil, and grease based on the temperature. ● Regardless of the specified periods, replace the oil when the oil is too dirty or already deteriorated.
  • Page 106 Maintenance Service Data To maintain the performance and life of engine, please always use clean and high-quality fuel. ● To prevent freezing in cold weathers, please choose diesel still suitable when the actual temperature is less by at least 12℃ than the expected minimum outside temperature.
  • Page 107 Maintenance Service Data Lubricant Type depending on Replacement temperature Position Type period -20 -10 0 10 20 30 40℃ Diesel engine fuel First 50h * Oil sump SAE 10W-30 API: grade CD Afterwards every ACEA:E-3,E-4 or E-5 250h SAE 15W-40 Anti-wear hydraulic Hydraulic oil tank...
  • Page 108 Maintenance Service Data Periodical Replacement of Hydraulic With installed hydraulic breaking hammer, the Hydraulic device replacement period hydraulic oil deteriorates faster than the common digging operations. Ensure to replace the hydraulic oil and oil return filter element. Filter replacement ● The failure to replace timely will result in period damage of machine and breaking hammer...
  • Page 109 Maintenance Service Data List of Wearing Parts Periodically replace the wearing parts, including filters and filter elements, as per the table below. System Item Part name Replacement period Hydraulic system Return oil filter First 50 hours for new machine or every 500 hours Hydraulic system Ventilator...
  • Page 110 Maintenance Service Data List of Tools (If installed) List of tools Name and specification Unit Quantity Remark Tool box Socket hex. wrench (4mm) Piece Socket hex. wrench (5mm) Piece Socket hex. wrench (6mm) Piece Socket hex. wrench (8mm) Piece Socket hex. wrench (10mm) Piece Socket hex.
  • Page 111 Maintenance Service Data Table of Tightening Torques Nuts and Bolts (Grade ISO10.9) Unless otherwise specified, tighten the nuts and bolts to the torques listed in table below. ● The tightening torques for installation of plastic caps are not listed in the table below. To understand more details, please consult with your sales or service dealer.

  • Page 112: Critical Safety Parts

    Maintenance Critical Safety Parts Critical Safety Parts To operate the machine safely, please fulfill the periodical checking and maintenance. The following critical safety parts shall be replaced periodically to improve safety. These parts can cause serious injuries or fire accident if they are damaged. List of Critical Safety Parts Vehicle body Periodically replaced critical safety part...
  • Page 113 Maintenance Critical Safety Parts The materials of the above-mentioned critical safety parts will deteriorate along with time to cause wear or deteriorated performance. It’s difficult to determine the deterioration extent during periodical checking. Therefore, such parts shall be replaced with new ones to guarantee stable performance, even if such parts are still working well.

  • Page 114: Maintenance List

    Maintenance Maintenance List Maintenance List Checking and maintenance item Page Walk-Around Checking Opening of engine hood and machine hood for checking 5-16 Walk-around checking of machine 5-16 Checking in driver seat 5-16 Daily routine checking (Every 10h) Checking and adding of coolant 5-17 Checking and adding of engine oil 5-18...
  • Page 115 Maintenance Maintenance List Maintenance List Checking and maintenance item Page As necessary Replace the teeth 5-42 Replace the bucket 5-43 Lubricate Joysticks 5-44 Check the rubber track 5-45 Replace the rubber track 5-46 5-14...

  • Page 116: Walk-Around Checking

    Maintenance Walk-around Checking Walk-Around Checking Fulfill the following checking before the first start of engine each day. Warning ● Before operations, fulfill the walk-around checking and when necessary repair immediately. ● Before operations within the machine, please securely fix the engine hood or machine hood. Keep the engine hood and machine hood closed under windy weather or while parking the machine on a slope.

  • Page 117: Opening Of Engine Hood And Machine Hood For Checking

    Maintenance Walk-around Checking Opening of engine hood and machine Check traveling motor for oil leakage. hood for checking Check shelter and guard plates for damage Check for presence of branches, leaves, oil, and check for loose nuts and bolts. and other inflammable around the engine Check exterior and interior rear view and battery.

  • Page 118: Daily Routine Checking (Every 10H)

    Maintenance Daily routine checking (Every 10h) Daily routine checking (Every 10h) Fulfill the following checking before the first start of engine each day. Warning ● Before operations, fulfill the daily routine checking and when necessary repair immediately. ● Before operations within the machine, please securely fix the engine hood or Open the rear cover.

  • Page 119: Checking And Adding Of Engine Oil

    Maintenance Daily routine checking (Every 10h) compensate the lost coolant due to leakage. Tighten the oil filler cap (2). Start the engine, run at low idling speed Checking and adding of engine oil for 5min, and then stop the engine. Warning Check the oil level after approximately Please stop the engine and wait for the...

  • Page 120: Checking Of Hydraulic Oil Tank Oil Level And Adding Of Oil

    Maintenance Daily routine checking (Every 10h) Add fuel Start the engine and run at low speed. Fully extend the track width. Fully retract the cylinders (Bucket arm and Check the fuel level by fuel gauge . bucket cylinders) and lower the bucket If the fuel level is low, open the fuel tank onto the ground.
  • Page 121 Maintenance Daily routine checking (Every 10h) Add hydraulic oil Note: For machines equipped with a ventilator, there is no need to pressurize. Pressurization of Hydraulic Oil Tank Start the engine and run at low speed. Disassemble the bleeding plug (2) and set the safety lock handle to unlocking position.

  • Page 122: Lubrication Of Working Device

    Maintenance Daily routine checking (Every 10h) Lubrication of Working Device Maintain the machine under the status shown in above diagram, lower the working device to the ground, and then stop the engine. Lubricate the grease fitting by a grease gun. Wipe away excessive grease.
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  • Page 124: After First 50H(For New Machine Only)

    Maintenance After first 50h(for new machine only) After first 50h (For new machine only) Checking and adjustment of fan belt Warning Please stop the engine and wait for the machine to cool down before maintenance. . ● The engine, exhaust pipe, radiator, hydraulic pipes, sliding parts, and many other machine parts are really hot when 2.
  • Page 125 Maintenance After first 50h(for new machine only) alternator (7) and adjust the tension of fan belt (1). Increase tension: Clockwise Reduce tension: Counter-clockwise Tighten bolt (5) and lock nut (4). Note: After the replacement with new belt, run the engine at low idling speed for approximately 3~5min to run in new belt and then adjust the tension.

  • Page 126: Every 50H

    Maintenance Every 50h Every 50h Checking Check and adjust track tension Warning ● If it’s necessary to operate beneath the lifted machine or working device, always use cushion woods, jack, or other firm and stable supports. Do not access the area beneath the machine or working device before it’s firmly 1.

  • Page 127: Lubricate Slewing Support And Slewing Motor Gears

    Maintenance Every 50h 3. Check the clearance (A or B) between the Reduce tension frame bottom face and track top face in the middle of track frame. The clearance (A or B) shall be within following range: (A)Rubber tracks 59~64mm (B)Steel tracks 95 to 110mm Adjustment...

  • Page 128: Water Drainage From Fuel Tank

    Maintenance Every 50h Water drainage from fuel tank Warning ● Do not smoke or use open fire while handling fuel or performing the operations of fuel system. ● Do not disassemble the fuel tank cap or refuel while the engine is running or is not cooled down.

  • Page 129: Checking Of Battery Electrolyte Level And Adding Of Electrolyte

    Maintenance Every 50h Checking of battery electrolyte level and adding of electrolyte Danger ● Do not use the battery when the electrolyte level is below the lower limit. Otherwise it will speed up the internal aging and shorten the life of battery. In Start the machine only after draining.
  • Page 130 Maintenance Every 50h skin. Checking • In event of accidental contact with eyes, immediately flush by clean water and quickly seek for medical treatment. • In event of accidental swallowing, drink a lot of water or milk and immediately seek for medical treatment. •...

  • Page 131: Every 250H

    Maintenance Every 250h Every 250 hour Checking and adjustment of fan belt Refer to page 5-23 “Checking and adjustment of fan belt ”. Replacement of engine oil and filter Warning Please stop the engine and wait for the 1. Open the rear cover and remove the oil machine to cool down before maintenance.

  • Page 132: Cleaning Of Air Filter

    Maintenance Every 250h Important: During the operations under dusty oil filter wrench: 19.6 to 23.5N·m). environment, please daily fulfill the checking 10. Add lubricating oil between the upper and maintenance for the machine. limit (H) and lower limit (L) of the oil Important: Ensure to steadily install the filter dipstick (1).

  • Page 133: Checking Of Accelerator Control System

    Maintenance Every 250h Checking of accelerator control body (4) by cloth or tape to guard against system ingress of dusts. <If the secondary filter element is  The accelerator joystick and the speed installed> regulator on the engine side are connected To prevent the ingress of dusts into engine, by wiring.

  • Page 134: Replacement Of Fuel Filter

    Maintenance Every 250h Important: While cleaning by water, please cover the electric system against water ingress. Important: During the operations under dusty environment, please daily fulfill the checking and maintenance for the machine. Open the maintenance cover. Rotate the filter (1) counter-clockwise by a filter wrench to take it out.
  • Page 135 Records 5-34...

  • Page 136: Every 1000H

    Maintenance Every 1000h Every 1000h Replace the air filter Warning Please stop the engine and wait for the machine to cool down before maintenance. . ● The engine, exhaust pipe, radiator, and many other machine parts are really hot when the engine is just stopped. Take out the primary filter element (3).
  • Page 137 Maintenance Every 1000h • The engine coolant is also under high loosen and take out the radiator cap and temperature and high pressure when drainage plug. the engine is just stopped. Take special During cleaning, if the coolant temperature is cautions while loosening the cap or plug.
  • Page 138 Maintenance Every 1000h the detergent. 10. Repeat steps 4~8 to clean the cooling system. 11. Tighten the water drainage plug (4). 12. Add new coolant (Mixture of antifreeze and running water) through filler port to the radiator, till the radiator is full. Add the Place a tray beneath the water drainage coolant slowly and easily.
  • Page 139 Records 5-38...

  • Page 140: Every 1500H

    Maintenance Every 1500h Every 1500-hour Checking and Cleaning of Engine Fuel Injector Nozzles These operations require experiences. Please ask your sales or service dealer for operations. Checking of Crankcase Ventilation Hole System These operations require experiences. Please ask your sales or service dealer for operations. 5-39...

  • Page 141: Every 2000H

    Maintenance Every 2000h Every 2000h • While disassembling connector or plug or disconnecting hose, stand on one side, Connection of Engine Valve Seats loosen slowly to gradually relieve These operations require experiences.Please ask internal pressure, and then take out. your sales or service dealer for operations. Adjust the machine to the hydraulic oil Replacement of Hydraulic Oil and level checking status.
  • Page 142 Maintenance Every 2000h 19. Install the rubber plug (6), and then install the bleed plug (7). 20. Exhaust the air from the hydraulic oil circuit as described in the "Exhaust" section below. 21. Adjust the machine to the hydraulic oil level check posture, and check the oil level after the oil temperature drops.

  • Page 143: As Necessary

    Maintenance As Necessary As necessary Replace bucket teeth Replace the bucket teeth when the tooth sleeves are worn. Do not wait for the bucket to be damaged before replacement. Warning ● Before the maintenance or repairs beneath the machine, lower all movable working devices onto the ground or lowest position.
  • Page 144 Maintenance As Necessary tooth. If there is any soil or mud in this other. area, the bucket tooth and tooth sleeve • One operator must sit in the driver seat probably can’t be inserted completely. to get ready to stop the engine immediately when necessary.
  • Page 145 Maintenance As Necessary Installation Disassembling ② Ⓑ 1. Lower the bucket steadily onto the ground as shown in above diagram. Align the pin hole (A) on the bucket with Note: While disassembling the tooth pin, adjust the pin hole on the stick ① , install the the bucket position in such manner that the tooth pin and the fastening nut.
  • Page 146 Maintenance As Necessary Checking of Rubber Tracks Joysticks If the status of rubber tracks is as shown in the diagram below, please repair or replace. For detailed repair or replacement, please consult with your sales or service dealer. Rubber Tracks If any track is stretched and non-adjustable, please replace the track.
  • Page 147 Maintenance As Necessary Replacement of Rubber Tracks If two or more segments of the wire rope are exposed, please replace. Warning If more than half of the side face of wire rope is  If it’s necessary to operate beneath the cut, please replace.
  • Page 148 Maintenance As Necessary Installation Lift the machine body by working device. Lift the machine body by working device. Place rubber track on the sprocket. Place a steel tube (1) in the rubber track and rotate the sprocket slowly towards opposite direction. Rotate the sprocket till the steel tube (1) closes to the pensioner and the rubber track Place a steel tube (1) in the rubber track...

  • Page 149: Maintenance During Long-Time Parking

    Maintenance Maintenance during Long-Time Parking Maintenance during Long- During Parking Time Parking Warning ● Do not operate the machine in an Parking Procedure enclosed place with poor ventilation. If it’s necessary to park the machine for ≥30 ● If the natural ventilation is not possible, days, please park the machine indoors.
  • Page 150 Maintenance Maintenance during Long-Time Parking Stop for 30s. Repeat this procedure, till the engine is already cranked for 1min in total. This can enable the sufficient oil circulation throughout the lubrication system of engine. Get ready the fuel system. Start the engine. Idle the engine for approximately 15min and then: •...

  • Page 151: Troubleshooting

    Troubleshooting...

  • Page 152: Symptoms That Are Not Malfunctions

    Troubleshooting Symptoms that are not malfunctions Symptoms that are not ● A noise of traveling motor can be heard malfunctions when the machine stops suddenly during The following symptoms are not malfunctions. high speed traveling. ● A noise of control valve can be heard when the working device is subject to excessive external force or moves to the end of travel.

  • Page 153: Engine Overheating

    Troubleshooting Engine Overheating Engine Overheating Remedy procedure 1.Park the machine on a safe place. Warning ● If the steam overflows from the engine, 2.Check whether the steam overflows from do not open the engine hood or machine the closed engine hood or machine hood. hood.

  • Page 154: No Battery Power

    Troubleshooting No Battery Power No Battery Power cable to start engine. The following symptoms indicate no battery Important: The jumper cable and clamps in use shall be suitable to the battery capacity. Do not power. ● No rotation of starter motor or start failure use any damaged or corroded jumper cable or of engine.
  • Page 155 Troubleshooting No Battery Power (B) to the engine support of the from the charger (-). malfunctioned machine. Connect the Disconnect the jumper cable (R) clamp clamp to a point as far as possible from the from the charger (+). battery. Disconnect the jumper cable clamp (R) from the uncharged machine (+).

  • Page 156: Burnout Of Fuse

    Troubleshooting Burnout of Fuse Burnout of Fuse If a lamp fails to turn on or the electronic Burnout Normal system fails to work, the fuse is probably burnt. Check the fuse. Checking and Replacement of Fuses Warning If a fuse is burnt again shortly after replacement, the electronic system is If a fuse is burnt, please replace with spare probably malfunctioned.
  • Page 157 Troubleshooting Burnout of Fuse Checking of Fuses Precautions for external maintenance power supply If the machine does not start after turning the start switch to the ON position, it may be that Note: The external power supply is the starting power fuse has blown. Open the limited to 12V15A.

  • Page 158: Restart After Refueling

    Troubleshooting Restart after Refueling Restart after Refueling Turn the starter key to the ON position and hold it for about 60 seconds.. Air exhausting from Fuel System Important: Do not rotate the engine by starter Note: The air content in the fuel system will motor to get ready the fuel system.

  • Page 159: Flashing Of Warning Lamps

    Troubleshooting Flashing of Warning Lamps Flashing of Warning Lamps If a warning tone is heard or a warning lamp starts to flash during operations, park the machine in a safe place and take the following remedy measures. Warning lamp Lamp name Cause and solution There is a problem with charging.

  • Page 160: Other Symptoms

    Troubleshooting Other Symptoms Other Symptoms For the symptoms not listed in table below or the further existed problems after appropriate solutions, please consult with your sales or service dealer. Problem Cause Solutions The left and right joysticks  Lack of grease on left cannot move flexibly and right joysticks ...
  • Page 161 Troubleshooting Other Symptoms Problem Cause Solutions  Insufficient grease for  Lubricate the bearings Can't turn or turn inflexibly slewing support Please refer to page 5-23  Hydraulic oil level is too  Add to the The hydraulic oil specified liquid temperature is too high level.

  • Page 162: Towing

    Troubleshooting Towing Towing of following steps will probably damage the traction hole or other framework part. Warning During towing, the improper operations, the Towing of Machine incorrect use of rope, or the improper Use the following procedure to drag a heavy checking will cause serious injuries or object or a machine entrapped in mud.

  • Page 163: Parameters

    Parameter...

  • Page 164: Basic Parameters

    Parameter Basic Parameter Applicable models: KS12-9 Technical parameters Unit Overall weight 1130 Bucket capacity 0.02 Type of working device Backhoe Model Kubota D902 Displacement 0.898 Engine Rated output power/speed kw/r/min 11.8/2300 Maximum torque/rotating speed N.m/r/min 51.3/1800 Maximum traveling speed km/h...

  • Page 165: Overall Dimensions Of Machine

    Parameter Overall Dimensions of Machine Applicable models: KS12-9 Overall dimensions Unit: mm Wheel track Overall length of crawler 1235 Ground clearance of platform Tail slewing radius of platform Chassis width 800-950 Track width Track height Transport length 2170/2850 Ground clearance of seat...

  • Page 166: Operating Range

    Parameter Operating Range Applicable models: KS12-9 Working range Unit: mm Ground maximum digging radius 3040 Maximum digging radius 3135 Maximum digging depth 1580 Maximum digging height 2620 Maximum Dump height 2000 Maximum vertical digging depth 1580 Minimum slewing radius 1510...

  • Page 167: Machine Lifting Power

    Parameter Machine lifting power...
  • Page 168 Records...

  • Page 169: Accessories

    Accessories...

  • Page 170: General Safety Measures

    Accessories General Safety Measures General Safety Measures ● If it’s necessary to place temporarily heavy weights or accessories onto the Safety Measures ground during disassembling or Warning installation, please ensure to place them Please take the following safety measures in a steady place. while disassembling or installing ●...
  • Page 171 Accessories General Safety Measures installation/disassembling procedures of attachments, please consult with your sales or service dealer. Precautions for Operations of Attachment Warning The extended attachment will deteriorate the Driving laterally on a steep slope machine stability. While the machine is traveling or slewing on a steep slope, the imbalance will probably result in rollover.
  • Page 172 Accessories General Safety Measures attachment is stopped in the air) will speed The machine is more vulnerable to rollover in lateral direction than longitudinal direction. (1) Do not slew laterally when the bucket working device is heavily loaded. Especially, do not slow laterally on a slope.

  • Page 173: Precautions

    Accessories Precautions Precautions for Operations of Attachment Warning ● Please consult with Ken stone Heavy Machinery before installing optional products. ● Do not use any attachment not approved by Ken stone Heavy Machinery. Otherwise it will probably cause safety issues or cause adverse influence on operations or life of machine. ●...

  • Page 174: Hydraulic Hammer

    Accessories Hydraulic Hammer While operating the optional products such as Hydraulic Breaking Hammer breaking hammer, tipping bucket, and grab For the operations of breaking hammer, please bucket, ensure that the track width is extended refer to the separately provided manual of to 950mm.
  • Page 175 Accessories Hydraulic Hammer Precautions for Operations  Do not pry by hammer head or pry during  Start the engine and run at 75% of breaking. maximum speed.  Do not move the hammer head during crushing.  Do not impact one same surface continuously for >30s.
  • Page 176 Accessories Hydraulic Hammer Periodical Replacement of Hydraulic With installed hydraulic breaking hammer, the hydraulic oil deteriorates faster than the normal operations. Ensure to replace the hydraulic oil and oil return filter element. ● The failure to replace timely will result in damage of machine and breaking hammer ...
  • Page 177 Accessories Hydraulic Hammer Hydraulic oil replacement period Filter element replacement period Breaking hammer operating ratio (%) ( ): For the use of common anti-wear hydraulic oil.
  • Page 178 Records 8-10...

  • Page 179: Optional Accessories

    Optional accessories Auger Ripper Quick Thumb hitch part Rake Grab 200mm 600mm 300mm 500mm 600mm 700mm 800mm 800mm 900mm 8-11...
  • Page 180 Optional accessories Canopy 8-12...

  • Page 181: Parts Number Position

    Parts number position Upper-frame number ☆20060001☆ 8-13...

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