Professional Documents
Culture Documents
Leo18gt FL GB
Leo18gt FL GB
ating instructions
Manufacturer:
TEUPEN Maschinenbau GmbH
Marie-Curie-Straße 13
D-48599 Gronau
Telephone: +49 (0) 2562 8161-0
Fax: +49 (0) 2562 8161-888
email: info@teupen.com
Internet: www.teupen.com
Service:
Telephone: +49 (0) 2562 8161-313
email: service@teupen.com
Table of contents
1 General................................................................ 7
1.1 Information about these instructions............. 7
1.2 Explanation of symbols................................. 7
1.3 Limitation of liability....................................... 9
1.4 Copyright....................................................... 9
1.5 Warranty provisions.................................... 10
1.6 Note regarding warranty card...................... 10
1.7 Customer service........................................ 11
2 Safety................................................................. 13
2.1 Basic hazards.............................................. 13
2.1.1 General hazards in the workplace............ 13
2.1.2 Danger due to electric current.................. 15
2.1.3 Danger due to mechanism....................... 17
2.1.4 Danger due to hydraulic energies............ 18
2.1.5 Danger due to high temperatures............ 19
2.1.6 Danger due to chemicals......................... 19
2.1.7 Danger due to traffic and vehicles............ 20
2.2 Proper use................................................... 21
2.3 Responsibility of the owner......................... 21
2.4 Personnel requirements.............................. 23
2.4.1 Qualifications............................................ 23
2.4.2 Unauthorised persons.............................. 25
2.4.3 Training.................................................... 25
2.5 Personal protective equipment.................... 25
2.6 Safety equipment........................................ 26
2.6.1 Position of the safety equipment.............. 27
2.6.2 Description of the installed safety equip-
ment......................................................... 28
2.7 Symbols on the machine............................. 32
2.8 Behaviour in case of fire or accidents......... 34
2.9 Environmental protection............................ 35
3 Technical data................................................... 37
3.1 Dimension sheet......................................... 37
3.1.1 Main dimensions...................................... 37
3.1.2 Work diagram........................................... 38
3.2 Machine....................................................... 38
3.3 Bracing........................................................ 39
3.4 Platform system.......................................... 39
3.5 Chassis....................................................... 39
9 Disposal........................................................... 143
10 Index................................................................ 145
Appendix......................................................... 147
1 General
1.1 Information about these instructions
These instructions enable the safe and efficient han-
dling of the machine. These instructions are a compo-
nent of the machine and must be kept in the immediate
vicinity of the machine so that they are accessible to the
personnel at any time.
Before beginning any work, the trained personnel must
have read through these instructions carefully and
understood them. The basic requirement for safe
working is adherence to all the specified safety instruc-
tions and operating instructions in these instructions.
In addition, the local accident prevention regulations
and general safety provisions for the area of application
of the machine apply.
Figures in these instructions serve the purpose of basic
understanding and can deviate from the actual model.
DANGER!
This combination of symbol and signal word
indicates an immediately-dangerous situation
which could cause death or severe injuries if
not avoided.
WARNING!
This combination of symbol and signal word
indicates a possibly-dangerous situation
which could cause death or severe injuries if
it is not avoided.
CAUTION!
This combination of symbol and signal word
indicates a possibly-dangerous situation
which could cause slight injuries if it is not
avoided.
NOTICE!
This combination of symbol and signal word
indicates a possibly-dangerous situation
which could cause property and environ-
mental damage if it is not avoided.
Special safety instructions The following symbols are used in the safety instruc-
tions to draw attention to specific dangers:
DANGER!
This combination of symbol and signal word
indicates an immediately-dangerous situation
due to electric shock. If an instruction so
marked is not heeded, severe or even fatal
injuries can be the consequence.
Marking Explanation
Step-by-step instructions
ð Results of action steps
References to sections of these
instructions and to other relevant
documents
Marking Explanation
Listing without fixed sequence
[Buttons] Operating elements (e.g. buttons,
switches), display elements (e.g.
signal lamps)
„Display“ Screen elements (e.g. buttons, pro-
gramming of function keys)
1.4 Copyright
The contents of these instructions are copyrighted.
Their use is permitted in the context of using the
machine. Any use extending beyond this is not allowed
without written permission from the manufacturer.
2 Safety
This section provides an overview of all safety aspects
that are essential to the best possible protection of the
personnel and the safe and trouble-free operation of the
machine. Additional safety instructions for specific work
tasks are contained in the sections regarding the indi-
vidual life stages of the machine.
Exhaust gases
WARNING!
Danger to life through poisoning and suf-
focation by exhaust gases!
Exhaust gases can lead to suffocation if
inhaled, as also severe poisoning and
marked damage to the respiratory system.
– While operating the machine in diesel
mode, always ensure the supply of fresh
air.
– In case of inhalation of exhaust gases,
immediately take the affected person into
fresh air. Call a doctor in.
Batteries
WARNING!
Danger of injury due to incorrect handling
of batteries!
In case of batteries are improperly handled,
there is the danger that the batteries can
explode or that liquids that are hazardous to
health can egress from the batteries. The
liquid egressing can cause severe burns
upon skin contact, severe poisoning upon
swallowing and blindness in case it comes in
contact with eyes.
– Never short circuit the contacts (positive
and negative poles) of the batteries!
– Never use or store batteries in places
where the atmosphere is explosive or
where temperatures can rise excessively.
– Never attempt to solder batteries, to repair
them, to change their form, to remodel
them or to dismantle them.
– Always protect batteries from access by
unauthorised persons.
– In order to avoid fires, overheating, explo-
sions or escape of fluids, do not subject
batteries to heavy vibrations or shocks,
place heavy weights on them or subject
them to other damaging exposures. Liq-
uids which emanate from batteries can get
inflamed.
– Avoid contact with escaping liquids.
Chain drive
WARNING!
Danger to life due to pulling in and
pinching off body parts on the chain drive!
Running chains and rotating chain wheels
can pull in pieces of clothing as well as body
parts and thus cause severe to fatal injuries.
– During operation, do not reach into run-
ning chains or chain wheels.
– Keep chain drives inaccessible during
operation. Do not open any covers.
– While in the danger zone, wear closely-fit-
ting protective clothing with low tear
strength.
– Before all work on chains or chain wheels,
switch the machine off and secure against
switching on again. Wait until all compo-
nents have come to a standstill.
– During operation, maintain a sufficient
safety distance.
– Pay attention to the change of direction.
Engine oil
WARNING!
Danger of injury through engine oil!
Engine oil contains poisonous substances
which can cause inflammations and / or are
carcinogenic.
– Avoid all skin contact with engine oil.
– In case of accidental skin contact, wash
the hands or affected area immediately
with soap. Do not ever use petrol, gaso-
line, solvents or other chemical cleaning
agents.
Industrial trucks
WARNING!
Danger to life due to industrial trucks!
There is a danger that people can be over-
looked and run over by the vehicle driver.
– Only have industrial trucks operated by
trained personnel.
– Only walk past industrial trucks if the
vehicle driver has indicated that he has
seen the people.
WARNING!
Danger due to misuse!
Misuse of the aerial access platform can
create dangerous situations.
– Do not use the aerial access platform to
support loads.
– Do not use the aerial access platform as a
crane, lift or side pull.
– Do not use the aerial access platform in or
near unprotected active parts of electrical
systems.
– Do not operate the aerial access platform
in an atmosphere subject to explosion.
Duties of the owner The machine is used in the commercial realm. There-
fore, the owner of the machine is subject to the legal
obligations relating to occupational safety.
WARNING!
Danger of injury in case of insufficient
qualification of the personnel!
If unqualified personnel undertakes work on
the machine or is in the machine's danger
zone, dangers arise which can cause severe
injuries and significant property damage.
– Only have all activities performed by quali-
fied personnel.
– Keep unqualified personnel away from the
danger zones.
Hydraulics Specialist
The Hydraulics Specialist is trained for the special area
of responsibility he is involved with and knows the rele-
vant standards and regulations.
Based on his technical training and experience, the
Hydraulics Specialist can perform work on hydraulic
systems and can recognise and avoid potential hazards
himself.
Qualified Electrician
Based on his technical training, knowledge, experience
and knowledge of the applicable standards and regula-
tions, the Qualified Electrician is able to perform work
on electrical systems and recognise and avoid potential
hazards himself.
The Qualified Electrician is specially trained for the area
of responsibility he is involved with and knows the rele-
vant standards and regulations.
The Qualified Electrician must comply with the require-
ments of the applicable legal regulations for accident
prevention.
Qualified personnel
Qualified personnel is able to carry out assigned work
and to recognize and prevent possible dangers self-reli-
antly due to its professional training, knowledge and
experience as well as profound knowledge of applicable
regulations.
Trained people
The trained people have been trained in demonstrable
fashion in a training session by the owner about the
proper use without additional prior knowledge of the
method of functioning and possible hazards which can
arise from the aerial access platform.
WARNING!
Risk to life for unauthorised persons due
to hazards in the danger and working
zone!
Unauthorised persons who do not meet the
requirements described here will not be
familiar with the dangers in the working zone.
Therefore, unauthorised persons face the risk
of serious injury or death.
– Unauthorised persons must be kept away
from the danger and working zone.
– If in doubt, address the persons in ques-
tion and ask them to leave the danger and
working zone.
– Cease work while unauthorised persons
are in the danger and working zone.
2.4.3 Training
The customer has been trained by the owner. The per-
sonnel must be trained by the owner accordingly.
Description of the personal pro- The personal protective equipment is explained below:
tective equipment
Harness
The harness provides protection against falling in the
case of increased risk of falling. This is the case if
specified height differences are exceeded and the work
location is not protected by a railing.
Protective clothing
Protective clothing are tight fitting working clothes with
low tear resistance, with tight sleeves and without any
parts sticking out. These clothes primarily protect
against getting caught by moving machine parts. Do not
wear rings, chains, necklaces, and other jewellery.
Protective helmet
The protective helmet provides protection against falling
and flying parts and materials.
Safety boots
Safety boots are intended to protect against slipping
hazards or foot hazards like heavy gear.
WARNING!
Danger to life from nonfunctional safety
devices!
If safety devices are not functioning or are
disabled, there is a danger of grave injury or
death.
– Check that all safety devices are fully
functional and correctly installed before
starting work.
– Never disable or bypass safety devices.
– Ensure that all safety devices are always
accessible.
WARNING!
Danger to life due to uncontrolled
switching on again!
Uncontrolled switching on again of the
machine can cause severe injuries or even
death.
– Ensure before switching on again that the
cause of the emergency stop has been
eliminated and all safety equipment is
mounted and functioning properly.
– Only unlock the Emergency Stop button if
there is no more danger.
Limit switch
Limit switches find out the correct position of definite
components. Thus they can, for example prevent unin-
tended movement of the machine.
WARNING!
Danger of injury due to illegible symbols!
In the course of time, stickers and signs can
get soiled or become illegible in other ways,
so that hazards are not recognised and nec-
essary operating instructions cannot be fol-
lowed. This creates a danger of injury.
– Always keep all safety, warning and oper-
ating instructions in easily-legible condi-
tion.
– Replace damaged signs or stickers imme-
diately.
Steps in case of fire and acci- n Immediately trigger an Emergency Stop using
dents EMERGENCY-STOP devices.
n Provided your own health is not in danger, rescue all
personnel from the danger area.
n If necessary, initiate first aid measures.
n Alert the fire department and/or emergency medical
services.
n In case of fire: provided your own health is not in
danger, extinguish the fire using fire extinguishing
equipment and continue to do so until the fire
department arrives.
n Notify the person in charge at the machine's place of
installation.
n Clear access paths for rescue vehicles.
n Wave rescue vehicles into position.
NOTICE!
Danger to the environment due to incor-
rect handling of materials which can harm
the environment!
In case of incorrect handling of materials
which can harm the environment, especially
improper disposal, there can be significant
damage to the environment.
– Always heed the notes below about the
handling of materials which can harm the
environment and their disposal.
– If materials which can harm the environ-
ment accidentally escape into the environ-
ment, take suitable measures immedi-
ately. In case of doubt, inform the
responsible local authority about the
damage and ask what suitable measures
to take might be.
Hydraulic oil Hydraulic oil may not be allowed to escape into the
environment. Hydraulic oil can cause long-term damage
to bodies of water. Disposal must be handled by a pro-
fessional disposal company.
Cooling water with frost protec- Cooling water and frost guards contain toxic sub-
tion stances. They must not be allowed to escape into the
environment. Disposal must be carried out by a spe-
cialist disposal company.
3 Technical data
3.1 Dimension sheet
3.1.1 Main dimensions
3.2 Machine
Data Value Unit
Overall length with working 5,12 m
basket (min.)
Overall length without working 4,39 m
basket (min.)
Overall length without working 4,34 m
basket and rollers (min.)
Overall width (min) 0,78 m
Overall height (min) 1,99 m
Net weight approx. kg
2400
Carrying capacity while driving 5,19 kN/m2
Carrying capacity in work posi- 2,13 kN/m2
tion
3.3 Bracing
Data Value Unit
Bracing width max./min. 3,32/3,13 m
Bracing pads Æ 0.2 m
Bracing possible up to slope of 5,7/10 °/%
Max. chassis clearance 25 cm
3.5 Chassis
Data Value Unit
Height adjustable 8 cm
Width adjustable 16 cm
Climbing ability 19,7/36 °/%
Slope angle 16/28 °/%
Chain (LxW) 145x20 cm
Travel speed 1,5 km/h
3.9 Lubricants
Lubricant Type TEUPEN item number Fill quan- Unit
tity
Gearbox oil Gearbox oil 3917/0122 * max. 1 l
Hydraulic oil Plantohyd 32-S 3917/0066 * 75 l
Multi-purpose - 3917/0095 (cartridge) 0,5 kg
lubricant
Engine oil SAE 10W-30 - 1,1 l
(Otto engine)
Engine oil Titan 15W-40 - 2,5 l
(diesel)
Cooling water - - 2,8 l
(diesel engine)
Otto fuel type - - 5,1 l
Diesel fuel - - 12 l
* upon order, please specify order quantity in litres
Oil recommendations The hydraulic system of the aerial work platform is filled
with the abovementioned hydraulic oil at the factory. It
is recommended that you continue to use this hydraulic
oil or that you replace it with one of the following
hydraulic oils:
4.3.2 Outriggers
1 - toggle switch The various operating functions are selected with the
toggle switch. The operating functions Platform, Move
and Outriggers are available for selection.
2 - Left control lever Depending on the operating function selected and the
position of the pre-selection lever, the functions marked
in colour can be executed with the left control lever.
3 - Red light After switching on the power supply, the red light blinks
until the machine is ready for operation.
4 - Green light The green light blinks in the transport position and stays
lit when the machine is braced correctly.
5 - Right control lever Depending on the operating function selected and the
position of the pre-selection lever, the functions marked
in colour can be executed with the right control lever.
6 - Pre-selection lever Various function groups are selected with the pre-selec-
tion lever. There are three function groups from which
to select; these are active depending on the position of
the toggle switch.
Pre-heating switch (no fig.) Used for pre-heating the diesel engine (option).
4.4.4 Lighting
The machine has two floodlights (Fig. 28/1). These are
switched on and off using the light switch on the control
box.
4.5 Connections
The electric motor is connected by the customer to a
230V connection (Fig. 29/1).
4.7 Accessories
4.7.1 Keys
The included key ring contains keys for the following
components:
n Control box (double bit key)
n Base plates
n Filling necks on the hydraulic tank
n Combustion engine
n Control panel
5.3 Transport
Attachment points The following attachment points are provided:
Transport with a crane Transport pieces can be transported with a crane under
the following conditions:
n The crane and lifts must be designed for the weight
of the aerial access platform.
n The user must be authorised to operate the crane.
n The aerial access platform must be in the transport
position.
n Belts and chains must be the same length and suffi-
ciently long.
Attaching Protective equipment: n Protective helmet
n Safety boots
WARNING!
Property damage due to improper attach-
ment!
The use of unsuitable attachment points can
cause damage to the machine.
– Only use the attachment points specified
here.
Transport with a fork lift The aerial access platform can be transported with a
fork lift under the following conditions:
n The fork lift must be designed for the weight of the
aerial access platform.
n The aerial access platform must be in the transport
position.
Transport Protective equipment: n Protective helmet
n Safety boots
4. Insert the forks of the fork lift into the fork eyes pro-
vided (Fig. 37/1).
WARNING!
Property damage due to improper lashing!
The use of unsuitable attachment points can
cause damage to the machine.
– Only use the lashing eyes specified here.
WARNING!
Danger of injury due to improper moving
of the aerial access platform!
With improper moving, the machine can tip or
slide. This can cause severe injuries and sig-
nificant property damage.
– The incline of the ramps may not exceed
36 %.
– During loading, do not stand downhill
behind the aerial access platform.
– Go up the ramps forwards.
– Do not turn the aerial access platform on
the ramp or loading area.
5.4 Storage
Storage of the machine Store the machine under the following conditions:
n Do not store outdoors.
n Store dry and dust-free.
n Do not subject to any aggressive media.
n Protect against solar radiation.
n Avoid mechanical shocks.
n Storage temperature: 15 to 35 °C.
n Relative humidity: max. 60 %.
n In case of storage longer than 3 months, check the
condition of all parts regularly. If necessary, freshen
or replace the rust-proofing.
n Turn the main battery switch to position "0".
6 Operation
6.1 Safety instructions for operation
Improper operation
WARNING!
Danger of injury due to improper opera-
tion!
Improper operation can cause severe injuries
and significant property damage.
– Execute all operating steps according to
the details and instructions in these
instructions.
– Always perform all work with at least two
people.
– Before beginning work, heed the following:
– Make sure that all covers and safety
equipment are installed and functioning
properly.
– Make sure that there are no people in
the danger zone.
– Never take safety equipment out of
service or bypass it during operation.
DANGER!
Danger to life due to electric current!
Upon contact with voltage-conducting parts,
there is an immediate danger to life due to
electric shock. Damage to the insulation or
individual components can present a danger
to life.
– In case of damage to the insulation, switch
off the power supply immediately and
have the machine repaired.
– Before performing work on voltage-con-
ducting parts, pull the mains plug.
– Never bypass fuses or take them out of
operation. When changing fuses, adhere
to the correct amperage.
– Keep humidity away from voltage-con-
ducting parts. This can cause a short-cir-
cuit.
Switching on
Connect the plug (Fig. 41/1) to the extension cable
(230V). Here, heed the required cable lengths (Ä
„Cable lengths“ on page 41).
The machine is ready for operation when the green
light is blinking.
Switching off
Disconnect the plug (Fig. 42/1) from the extension
cable or press Emergency Stop.
NOTICE!
Voltage drop of the starter battery
Frequent starting of the Otto engine can
cause a voltage drop of the starter battery.
– Avoid frequent starting of the Otto motor.
NOTICE!
Long starting processes can cause
damage to the starter.
Fig. 43: Starting the Otto 2. Let the Otto engine warm up for approximately 15
engine
seconds before starting to operate the aerial
access platform.
Switching off
To switch off the Otto engine, turn the toggle
switch (Fig. 44/1) on the control panel to and
hold it until the Otto engine stops.
NOTICE!
Voltage drop of the starter battery
Frequent starting of the diesel engine can
cause a voltage drop of the starter battery.
– Avoid frequent starting of the diesel motor:
NOTICE!
Long starting processes can cause
Fig. 45: Pre-heating and damage to the starter.
starting
3. Let the diesel engine warm up for approximately
15 seconds before starting to operate the aerial
access platform.
Switching off
To switch off the diesel engine, turn the toggle
switch (Fig. 46/1) on the control panel to and
hold it until the diesel engine stops.
WARNING!
Danger of injury due to improper moving
of the aerial access platform!
There is a danger of severe injuries or even
death due to improper moving of the aerial
access platform.
– While in the working basket, always put on
a safety harness and hook into the attach-
ment points provided.
– Always perform all work with at least two
people, whereby one person must remain
on the ground in order to activate the
emergency control if necessary.
– Do not exceed maximum working basket
load of 200 kg.
– Heed openings in the floor when moving.
– Do not drive over materials with sharp
edges.
– Do not make any abrupt changes of direc-
tion.
– In case of stop on an incline, secure the
machine against rolling away.
– Make sure that the ladder is folded up and
locked.
– When moving across the slope (max.
10.5° or 20 %), do not stay on the down-
slope side next to the aerial access plat-
form.
– In case of moving on an incline (max.
14.5° or 26 %), no people may be on the
downslope behind the aerial access plat-
form.
– Only go up and down slopes forwards.
– Avoid contact of the rubber tracks with oil,
gasoline, diesel and salt, and clean if nec-
essary.
WARNING!
Danger of injury due to improper bracing!
With improper bracing, the machine can tip or
slide. This can cause severe injuries and sig-
nificant property damage.
– Always put the safety harness on when in
the working basket.
– Always perform all work with at least two
people.
– Ensure sufficient load capacity of the sub-
surface (Ä Chapter 3 „Technical
data“ on page 37).
– Heed maximum guard rail angle
(Ä Chapter 3 „Technical
data“ on page 37).
– If necessary, use base plates.
– Make sure that the base plates are
aligned horizontally (maximum deviation
of ± 8°).
– Do not anchor the outriggers with chains,
ropes, pegs, etc.
– Always observe the movement of the out-
riggers when extending.
– Make sure that no people, supply lines or
other objects are in the area around the
outriggers.
Press the left control lever (Fig. 50/2) for- Outrigger 3 extends
wards
Press the right control lever (Fig. 50/4) for- Outrigger 4 extends
wards
Automatic bracing
1. Switch on the machine (Ä Chapter 6.2 „Switching
the machine on/off“ on page 64).
WARNING!
Danger of injury due to uneven lifting!
With uneven lifting, the machine can tip or
slide. This can cause severe injuries and sig-
nificant property damage.
– In case of uneven lifting, cancel the
process immediately and align the
machine manually.
– Have the automatic bracing checked by
Service.
WARNING!
Danger of injury due to improper opera-
tion!
Improper operation can cause severe injuries
and significant property damage.
– While in the working basket, always wear
a safety harness, do not swing or move
jerkily.
– Always perform all work with at least two
people, whereby one person must remain
on the ground in order to activate the
emergency control if necessary.
– Make sure that the ladder is folded up and
locked.
– Do not climb onto the safety fence around
the basket.
– Do not work on or near high-voltage lines.
– Watch out for high obstacles.
– Make sure that when moving the working
basket, no body parts are crushed, e.g.
against a wall.
– At wind speeds above 12.5 m/s (wind
strength 6), stop work immediately.
CAUTION!
Property damage due to incorrectly-
aligned platform!
If the platform is not aligned correctly, the
transport attachments can be damaged when
moving in.
Fig. 61: Red arrows – Make sure that the red arrows (Fig. 61/1)
on the rotating assembly are aligned with
one another when moving into the trans-
port position.
WARNING!
Fig. 62: Transport position Danger of injury when lowering!
Due to uneven lowering of the outriggers, the
machine can tip or slide. This can cause
severe injuries and significant property
damage.
– Always put the safety harness on when in
the working basket.
– Always perform all work with at least two
people.
– Always observe the movement of the out-
riggers and of the chassis while retracting.
– Make sure that no limbs or supply lines
are underneath the crawler chassis.
– Lower the machine evenly.
Press the left control lever (Fig. 64/2) back- Outrigger 3 retracts
wards
Press the right control lever (Fig. 64/4) Outrigger 4 retracts
backwards
WARNING!
Danger of injury due to crushing between
crawler chassis and floor!
When operating the height adjustment, there
can be severe injuries due to crushing
between the crawler chassis and the floor.
– Make sure that there are no limbs
between the crawler chassis and the floor.
WARNING!
Danger of injury due to crushing between
crawler chassis and floor!
Fig. 76: Unload the crawler
chassis When operating the height adjustment, there
can be severe injuries due to crushing
between the crawler chassis and the floor.
– Make sure that there are no limbs
between the crawler chassis and the floor.
Removing the working basket 1. Put the machine in transport position (Ä Chapter
6.7 „Putting the machine in transport posi-
tion“ on page 81).
2. Pull the spring cotter pin (Fig. 79/1) out of the fas-
tening bolts (Fig. 79/2).
Attaching the floodlight mast 1. Put the machine in transport position (Ä Chapter
6.7 „Putting the machine in transport posi-
tion“ on page 81).
2. Remove the working basket (Ä Chapter 6.9
„Changing the working basket“ on page 89).
3. Remove the remote control from the control panel.
4. Unplug the 30-pin plug connector of the remote
control and plug in the included extension cable.
5. Connect the other end of the extension cable to
the remote control.
6. Insert the floodlight mast at an angle with the
adapter (Fig. 86/4) on the bolts (Fig. 86/3).
7. Press the floodlight mast in the direction of the
machine and move it with the attachments
(Fig. 86/1) on the bolts (Fig. 86/2).
Removing the floodlight mast 12. Switch off the floodlight mast (Ä Chapter 6.11
„Operating the floodlight mast
(optional)“ on page 95).
WARNING!
Danger of injury due to hot surfaces!
The floodlights of the floodlight mast can heat
up a lot in operation. Skin contact with hot
surfaces causes severe burns to the skin.
– Before removing the floodlight mast, make
sure that all surfaces have cooled off to
the ambient temperature.
13. Pull the spring cotter pin (Fig. 89/1) out of the fas-
tening bolts (Fig. 89/2).
CAUTION!
Property damage due to improper opera-
tion!
The simultaneous operation of the floodlight
mast and the aerial access platform causes
an overload of the mains supply or of the
generator.
– Do not operate the floodlight mast and
aerial access platform simultaneously.
WARNING!
Danger of injury due to hot surfaces!
The floodlights of the floodlight mast can heat
up a lot in operation. Skin contact with hot
surfaces causes severe burns to the skin.
– Before removing the floodlight mast, make
sure that all surfaces have cooled off to
the ambient temperature.
CAUTION!
Property damage due to incorrectly-
aligned platform!
If the platform is not aligned correctly, the
transport attachments can be damaged when
retracting.
Fig. 97: Red arrows – Make sure that the red arrows (Fig. 97/1)
on the rotating assembly are aligned with
one another when moving into the trans-
port position.
8.
The operation of the platform will be
explained in exemplary fashion below.
The operation of the outriggers takes
place in the same manner (Ä Chapter
6.14 „Valve settings“ on page 102).
WARNING!
Danger of injury due to uncontrolled
movements!
In case the valves are set incorrectly in
normal operation, there is a danger of
Fig. 104: Unscrewing the valves uncontrolled movements. This can cause
severe injuries.
– Make sure that for operation via con-
trol panel/remote control, the valves
(Fig. 104/1 to 3) are unscrewed com-
pletely.
Lift the lower Extend the Extend the Lift the upper Swivel the Tip working
boom lower boom upper boom boom platform anti- basket back-
clockwise wards
(seen from
above)
Lower the Retract the Retract the Lower the Swivel the Tip working
lower boom lower boom upper boom upper boom platform basket for-
clockwise wards
(seen from
above)
7 Maintenance
7.1 Safety instructions for maintenance
Electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When
switched on, electric components may be
subject to uncontrolled movements and may
cause grave injury.
– Switch off the power supply before starting
work and make sure that it cannot be
switched on again.
Improperly-executed mainte-
nance work WARNING!
Danger of injury due to improperly-exe-
cuted maintenance work!
Improper maintenance can cause severe inju-
ries and significant property damage.
– Before starting work, ensure that there is
sufficient assembly space.
– Make sure the assembly space is orderly
and clean! Loosely-stacked components
and tools or those left lying around are a
source of accidents.
– Do not loosen connections sealed with
yellow signal paint.
– If components have been removed, make
sure they are assembled correctly, re-fit all
fastening elements and adhere to screw
tightening torques.
– Before recommissioning, heed the fol-
lowing points:
– Make sure that all maintenance work is
performed and completed according to
the details and instructions in these
instructions.
– Make sure that there are no people in
the danger zone.
– Make sure that all covers and safety
equipment are installed and functioning
properly.
Exhaust gases
WARNING!
Danger to life through poisoning and suf-
focation by exhaust gases!
Exhaust gases can lead to suffocation if
inhaled, as also severe poisoning and
marked damage to the respiratory system.
– While operating the machine in diesel
mode, always ensure the supply of fresh
air.
– In case of inhalation of exhaust gases,
immediately take the affected person into
fresh air. Call a doctor in.
Batteries
WARNING!
Danger of injury due to incorrect handling
of batteries!
In case of batteries are improperly handled,
there is the danger that the batteries can
explode or that liquids that are hazardous to
health can egress from the batteries. The
liquid egressing can cause severe burns
upon skin contact, severe poisoning upon
swallowing and blindness in case it comes in
contact with eyes.
– Never short circuit the contacts (positive
and negative poles) of the batteries!
– Never use or store batteries in places
where the atmosphere is explosive or
where temperatures can rise excessively.
– Never attempt to solder batteries, to repair
them, to change their form, to remodel
them or to dismantle them.
– Always protect batteries from access by
unauthorised persons.
– In order to avoid fires, overheating, explo-
sions or escape of fluids, do not subject
batteries to heavy vibrations or shocks,
place heavy weights on them or subject
them to other damaging exposures. Liq-
uids which emanate from batteries can get
inflamed.
– Avoid contact with escaping liquids.
Hot surfaces
WARNING!
Danger of injury due to hot surfaces!
Surfaces of engine components can get
heated up considerably during operation.
Skin contact with hot surfaces causes severe
burns to the skin.
– Avoid contact with engine components
such as exhaust components, silencers,
coolers, radiators, pipes and engine
blocks.
– Check before all work on engine compo-
nents, as to whether these are hot. If nec-
essary, allow them to cool.
Engine oil
WARNING!
Danger of injury through engine oil!
Engine oil contains poisonous substances
which can cause inflammations and / or are
carcinogenic.
– Avoid all skin contact with engine oil.
– In case of accidental skin contact, wash
the hands or affected area immediately
with soap. Do not ever use petrol, gaso-
line, solvents or other chemical cleaning
agents.
NOTICE!
Property damage due to improper
cleaning!
Improper cleaning can cause damage to the
machine.
– Do not use any acidic or aggressive
cleaning agents.
– Remove all cleaning agents thoroughly
with clear water.
10. Put the sliding coupling (Fig. 118/2) back into the
bracket (Fig. 118/1).
Greasing the upper boom 1. Put the machine in broad work position (Ä Chapter
transport 6.5 „Putting the machine in working posi-
tion“ on page 73).
2. Lift the upper boom (Fig. 121/1) until it stands
approximately horizontal (Ä Chapter 6.6 „Oper-
ating the machine“ on page 78).
3. Support upper boom transport with a belt slip or
with a rolling cart.
WARNING!
Fig. 121: Lifting the upper boom
Danger of injury due to deactivated safety
equipment!
The further operation of the platform can only
take place in service mode (Ä Chapter 6.13
„Service operation“ on page 98). In service
mode, all safety equipment does not function.
– Follow the operating sequence below and
follow the instructions precisely.
NOTICE!
Property damage due to improper filling!
An incorrect oil level or incorrect hydraulic oil
can cause failure of and damage to the
hydraulic system.
– Check the oil level regularly.
– Only use prescribed oils (Ä Chapter 3.9
„Lubricants“ on page 42).
– Do not mix types of oil.
NOTICE!
Property damage due to improper filling!
An incorrect oil level or incorrect gearbox oil
can cause failure of and damage to the
gearbox.
– Check the oil level regularly.
– Only use prescribed oils (Ä Chapter 3.9
„Lubricants“ on page 42).
WARNING!
Danger due to incorrect tightening tor-
ques!
If screws are tightened with the incorrect
tightening torque, components can come
loose and cause personal injury and property
damage.
– Never exceed the maximum allowable
tightening torque.
– Check the tightening torques regularly.
– Always heed the relevant guidelines and
design criteria for screw connections.
8 Faults
The following section describes possible causes of
faults and the work to remedy them.
In case of faults that occur more than once, abbreviate
the maintenance intervals according to the actual uti-
lisation.
In case of faults that cannot be remedied using the fol-
lowing instructions, contact the manufacturer, see con-
tact data on page 2.
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear
fashion may cause serious injuries.
– Before carrying out any troubleshooting
work on moving parts, shut down the
machine and take precautions to prevent
restarting. Wait until all parts have
stopped moving.
– When in the danger zone, wear close-fit-
ting protective work clothing with low tear
strength.
Exhaust gases
WARNING!
Danger to life through poisoning and suf-
focation by exhaust gases!
Exhaust gases can lead to suffocation if
inhaled, as also severe poisoning and
marked damage to the respiratory system.
– While operating the machine in diesel
mode, always ensure the supply of fresh
air.
– In case of inhalation of exhaust gases,
immediately take the affected person into
fresh air. Call a doctor in.
Batteries
WARNING!
Danger of injury due to incorrect handling
of batteries!
In case of batteries are improperly handled,
there is the danger that the batteries can
explode or that liquids that are hazardous to
health can egress from the batteries. The
liquid egressing can cause severe burns
upon skin contact, severe poisoning upon
swallowing and blindness in case it comes in
contact with eyes.
– Never short circuit the contacts (positive
and negative poles) of the batteries!
– Never use or store batteries in places
where the atmosphere is explosive or
where temperatures can rise excessively.
– Never attempt to solder batteries, to repair
them, to change their form, to remodel
them or to dismantle them.
– Always protect batteries from access by
unauthorised persons.
– In order to avoid fires, overheating, explo-
sions or escape of fluids, do not subject
batteries to heavy vibrations or shocks,
place heavy weights on them or subject
them to other damaging exposures. Liq-
uids which emanate from batteries can get
inflamed.
– Avoid contact with escaping liquids.
Hot surfaces
WARNING!
Danger of injury due to hot surfaces!
Surfaces of engine components can get
heated up considerably during operation.
Skin contact with hot surfaces causes severe
burns to the skin.
– Avoid contact with engine components
such as exhaust components, silencers,
coolers, radiators, pipes and engine
blocks.
– Check before all work on engine compo-
nents, as to whether these are hot. If nec-
essary, allow them to cool.
Engine oil
WARNING!
Danger of injury through engine oil!
Engine oil contains poisonous substances
which can cause inflammations and / or are
carcinogenic.
– Avoid all skin contact with engine oil.
– In case of accidental skin contact, wash
the hands or affected area immediately
with soap. Do not ever use petrol, gaso-
line, solvents or other chemical cleaning
agents.
DANGER!
Danger to life due to electric current!
In case of contact with live components, there
is danger to life. Switched-on electric compo-
nents can make uncontrolled movements and
cause extremely severe injuries.
– Before starting work, switch off the power
supply and secure against switching on
again.
– When changing fuses, adhere to the cor-
rect amperage.
DANGER!
Danger to life due to electric current!
In case of contact with live components, there
is danger to life. Switched-on electric compo-
nents can make uncontrolled movements and
cause extremely severe injuries.
– Before starting work, switch off the power
supply and secure against switching on
again.
– When changing fuses, adhere to the cor-
rect amperage.
8.5 Fuses
8.5.1 Fuzzy control card
The fuzzy control card is in the control box on the left
side of the aerial access platform. The control boxes
are opened with a double bit key.
No Position Designation Type
.
1 - Voltage supply to fuzzy Glass fuse M
control card 1.25 A
2 A2.8 Fault light Glass fuse
FF 4 A
A2.9 Outrigger light
A2.10 Signal transmitter
(option)
A2.11 Changeover valve plat-
form/outriggers
3 A2.4 Release hydraulic Glass fuse
FF 4 A
A2.5 Electric motors
A2.6 Speed 1
A2.7 Speed 2
4 A2.0 Current regulating Glass fuse
valve FF 4 A
A2.1 Lower the upper boom
A2.2 Lift the upper boom
A2.3 Retract upper boom
5 A8.4 Chain right backwards Glass fuse
Fig. 145: Fuzzy control card FF 4 A
A8.5 Chain right forwards
A8.6 Chain left backwards
A8.7 Chain left forwards
6 A8.0 Outrigger 1 Glass fuse
FF 4 A
A8.1 Outrigger 2
A8.2 Outrigger 3
A8.3 Outrigger 4
9 Disposal
After the service life of the machine has ended, the
machine must be disposed of in environmentally-
friendly fashion.
WARNING!
Danger of injury through incorrect dis-
posal!
Improper disposal can cause severe injuries.
– Permit disposal only through authorised
specialist agencies.
NOTICE!
Danger to the environment due to incor-
rect disposal!
Improper disposal can present a danger to
the environment.
– Have electrical scrap, electronic compo-
nents, lubricants and other auxiliary mate-
rials disposed of by an approved opera-
tion.
– In case of doubt, obtain information about
environmentally-friendly disposal from the
local municipal authorities or a special dis-
posal operation.
10 Index
A Engine switch......................................... 51
Accident.................................................. 34 Environmental protection
Aerial access platform............................ 78 Cleaning liquids.................................. 35
Attachment points................................... 56 Cooling water..................................... 36
B Frost protection.................................. 36
Battery main switch................................ 29 Fuels.................................................. 36
Bracing Hydraulic oil........................................ 36
automatic...................................... 76, 84 Lubricants........................................... 36
manual......................................... 73, 81 F
C Fault table............................................. 132
Cable lengths.......................................... 41 FI circuit breaker................................... 142
Chain drive............................................. 48 Fire......................................................... 34
Chassis................................................... 48 First aid................................................... 34
Circuit breaker...................................... 142 Floodlight mast
Circular level........................................... 30 attaching/removing............................. 91
Connections............................................ 52 operating............................................ 95
Contact person....................................... 11 Fuses.................................................... 141
Control card.......................................... 141 Fuzzy control card................................ 141
Control lever..................................... 50, 51 H
Control panel.......................................... 50 Hand pump....................................... 30, 51
Copyright.................................................. 9 Hazards.................................................. 13
Crawler chassis................................ 48, 86 Height adjustment................................... 86
moving in............................................ 88 Honda iGX 440....................................... 40
moving out.......................................... 86 Hydraulics............................................... 18
Customer service.................................... 11 K
D Keys........................................................ 53
Danger zones......................................... 53 Kubota Z-602.......................................... 40
Diesel engine.................................... 40, 49 L
Disposal................................................ 143 Light
Double bit key......................................... 53 green.................................................. 51
E red...................................................... 51
Electric current........................................ 15 Lighting................................................... 52
Electric motor.................................... 40, 49 Light switch............................................. 52
Emergency............................................. 67 Limitation of rotation area....................... 31
Emergency operation............................. 51 Limit switch............................................. 29
Emergency Stop..................................... 67 Lubricants....................................... 42, 123
Emergency Stop button.................... 28, 51 Lubrication plan.................................... 123
M Storage................................................... 61
Main dimensions..................................... 37 Symbols
Motor...................................................... 49 in the instructions................................. 7
Moving.................................................... 69 on the machine................................... 32
Moving the machine............................... 69 T
O Tightening torque................................. 125
Oil recommendations.............................. 42 Tilt sensor............................................... 30
Operating conditions............................... 41 Toggle switch.......................................... 50
Operation................................................ 78 Transport
Otto engine....................................... 40, 49 crane.................................................. 57
Outriggers............................................... 47 Fork lift............................................... 58
Overview........................................... 45, 46 Trailer................................................. 59
Owner..................................................... 21 Transport inspection............................... 55
P Transport position................................... 81
Personnel............................................... 23 Type plate............................................... 43
Platform.................................................. 47 U
Platform operation.................................. 78 Use......................................................... 21
Pre-heating switch.................................. 51 V
Pre-selection lever.................................. 51 Valves
Proper use.............................................. 21 Emergency operation......................... 30
Protective equipment.............................. 25 Outrigger function............................... 30
R Platform function................................ 31
Remaining risks...................................... 13 Valve setting
Remote control....................................... 50 Outriggers........................................ 104
Rescue measures................................... 67 Platform............................................ 102
Rotating assembly................................ 125 W
S Warranty provisions................................ 10
Safety devices........................................ 26 Width adjustment.................................... 86
Safety equipment............................. 27, 28 Work areas............................................. 53
Safety harness........................................ 54 Work diagram......................................... 38
Screw tightening torque........................ 125 Working basket....................................... 48
Service.................................................... 11 changing............................................. 89
Service work........................................... 52 Working position..................................... 73
Appendix
A Circuit diagram
B Hydraulic plan
Your safety and the safety of others are very important. We have
provided important safety messages in this manual and on the CONTENTS
engine. Please read these messages carefully.
INTRODUCTION ........................1 SPARK PLUG .......................11
A safety message alerts you to potential hazards that could hurt SAFETY MESSAGES .................1 SPARK ARRESTER ..............11
you or others. Each safety message is preceded by a safety alert SAFETY INFORMATION ...........2 FUSE.....................................12
symbol and one of three words, DANGER, WARNING, or SAFETY LABEL LOCATION ......2 HELPFUL TIPS &
CAUTION. COMPONENT & CONTROL SUGGESTIONS .......................13
LOCATION .................................2 STORING YOUR ENGINE ....13
These signal words mean: FEATURES .................................3 TRANSPORTING .................14
You WILL be KILLED or SERIOUSLY BEFORE OPERATION TAKING CARE OF
HURT if you don’t follow instructions. CHECKS .....................................3 UNEXPECTED PROBLEMS .....14
OPERATION ...............................4 TECHNICAL INFORMATION ...15
You CAN be KILLED or SERIOUSLY SAFE OPERATING Serial Number Location ......15
HURT if you don’t follow instructions. PRECAUTIONS ......................4 Battery Connections for
STARTING THE ENGINE .......4 Electric Starter .....................16
You CAN be HURT if you don’t follow STOPPING THE ENGINE .......6 Carburetor Modifications for
instructions. SETTING ENGINE SPEED......6 High Altitude Operation ......16
SERVICING YOUR ENGINE ......6 Emission Control System
Each message tells you what the hazard is, what can happen, and THE IMPORTANCE OF Information ..........................17
what you can do to avoid or reduce injury. MAINTENANCE .....................6 Air Index ...............................17
MAINTENANCE SAFETY.......6 Specifications ......................18
DAMAGE PREVENTION MESSAGES SAFETY PRECAUTIONS ........6 Tuneup Specifications.........18
MAINTENANCE Quick Reference
You will also see other important messages that are preceded by SCHEDULE .............................7 Information ..........................19
the word NOTICE. REFUELING ............................7 Muffler Deflector Kit
ENGINE OIL............................8 Installation ...........................19
This word means: Recommended Oil .............8 Wiring Diagrams .................19
Your engine or other property can be damaged if you Oil Level Check...................8 CONSUMER INFORMATION ..23
don’t follow instructions. Oil Change ..........................9 DISTRIBUTOR/DEALER
AIR CLEANER.........................9 LOCATOR INFORMATION ..23
The purpose of these messages is to help prevent damage to your Inspection ...........................9 CUSTOMER SERVICE
engine, other property, or the environment. Cleaning .............................9 INFORMATION ....................23
SEDIMENT CUP ...................10
2005 - 2008 Honda Motor Co., Ltd. −All Rights Reserved Cleaning ...........................10
37Z3S605 GX440IU·GX440IR
00X37-Z3S-6050
ENGLISH 1
SAFETY INFORMATION COMPONENT & CONTROL LOCATION
Understand the operation of all controls and learn how to stop STANDARD TYPES
the engine quickly in case of emergency. Make sure the operator MUFFLER FUEL TANK FUEL FILLER CAP
receives adequate instruction before operating the equipment. LED
Do not allow children to operate the engine. Keep children and AIR CLEANER
pets away from the area of operation.
Your engine’s exhaust contains poisonous carbon monoxide.
Do not run the engine without adequate ventilation, and never RECOIL STARTER
run the engine indoors. (applicable types)
The engine and exhaust become very hot during operation.
Keep the engine at least 1 meter (3 feet) away from buildings
and other equipment during operation. Keep flammable
materials away, and do not place anything on the engine while it ECM
is running. STARTER GRIP
IGNITION COIL SPARK PLUG (applicable types)
(Inside ignition coil)
SAFETY LABEL LOCATION
OIL FILLER CAP/DIPSTICK
(STANDARD TYPES)
This label warns you of potential hazards that can cause serious
injury. Read it carefully.
If the label comes off or becomes hard to read, contact your Honda OIL EXTENSION
dealer for replacement. (applicable types)
ELECTRIC STARTER
(applicable types)
FUSE
(applicable types)
ENGINE
SWITCH
(applicable
types)
ENGINE
SWITCH
Gasoline is highly flammable and explosive. (applicable
Turn engine off and let cool before refueling. types)
STARTER GRIP
(applicable types)
Always check the following items before you start the engine:
MANUAL START LEVER CHOKE LEVER
Check the General Condition of the Engine
FEATURES 1. Look around and underneath the engine for signs of oil or
gasoline leaks.
OIL ALERT SYSTEM
‘‘Oil Alert is a registered trademark in the United States’’ 2. Remove any excessive dirt or debris, especially around the
The Oil Alert system is designed to prevent engine damage muffler and recoil starter.
caused by an insufficient amount of oil in the crankcase. Before
the oil level in the crankcase can fall below a safe limit, the Oil 3. Look for signs of damage.
Alert system will either shut off the engine or issue a warning.
Refer to the instructions provided by the equipment manufacturer. 4. Check that all shields and covers are in place, and all nuts, bolts,
and screws are tightened.
If the ECM is set to stop the engine:
Check the Engine
Engine type Oil Alert action
Electric start The LED on the ECM blinks twice. 1. Check the fuel level (see page 7 ). Starting with a full tank will
The engine stops. help to eliminate or reduce operating interruptions for refueling.
The engine will not restart.
Recoil start The engine stops. 2. Check the engine oil level (see page 8 ). Running the engine
The engine will not restart. with a low oil level can cause engine damage.
If the ECM is set to continue engine operation: If the oil level in the crankcase falls below a safe limit, the Oil
Alert system will either shut off the engine or issue a warning.
Engine type Oil Alert action However, to avoid the inconvenience of an unexpected
Electric start The LED on the ECM blinks twice. shutdown, always check the engine oil level before startup.
The engine continues to operate.
The engine will not restart. 3. Check the air filter element (see page 9, 10 ). A dirty air filter
Recoil start The engine continues to operate. element will restrict air flow to the carburetor, reducing engine
The engine will not restart. performance.
If the engine stops and/or will not restart, check the oil level (see 4. Check the equipment powered by this engine.
page 8 ) before troubleshooting in other areas.
Review the instructions provided with the equipment powered
by this engine for any precautions and procedures that should
If you continue to operate the engine after the Oil Alert system has be followed before engine startup.
been activated, you can damage the engine.
ENGLISH 3
OPERATION If the electric starter will not operate:
(with recoil starter types)
SAFE OPERATING PRECAUTIONS
1. Push the manual start lever.
Before operating the engine for the first time, please review the
SAFETY INFORMATION section on page 2 and the BEFORE STANDARD TYPES
OPERATION CHECKS on page 3 . MANUAL START LEVER
Push
Review the instructions provided with the equipment powered by
this engine for any safety precautions that should be observed
with engine startup, shutdown or operation.
If the engine fails to start 3. Pull the starter grip lightly until you feel resistance, then pull
within 5 seconds, release the briskly in the direction of the arrow as shown below. Return the
engine switch, and wait at starter grip gently.
least 10 seconds before
operating the starter again.
STARTER GRIP
2. Warm up the engine for 2 or 3 Do not allow the starter grip to snap back against the engine.
minutes. Return it gently to prevent damage to the starter.
4 ENGLISH
RECOIL STARTER TYPES: 4. Pull the starter grip lightly until you feel resistance, then pull
briskly in the direction of the arrow as shown below. Return the
1. Move the fuel valve lever (applicable types) to the ON position. starter grip gently.
FUEL VALVE LEVER Do not allow the starter grip to snap back against the engine.
(applicable types) Return it gently to prevent damage to the starter.
ON
STARTER GRIP
ON
2. To start a cold engine, move the choke lever to the CLOSED Direction to pull
position.
5. Warm up the engine for 2 or 3 minutes.
Some engine types use a remote-mounted choke lever. Refer to
the instructions provided by the equipment manufacturer. If the choke lever was moved to the CLOSED position to start the
engine, gradually move it to the OPEN position as the engine
STANDARD TYPES warms up.
CLOSE
OPEN
CHOKE LEVER
CLOSE
CHOKE LEVER
OPEN
To restart a warm engine, leave the choke lever in the OPEN
position.
ON
ENGINE SWITCH
ENGLISH 5
STOPPING THE ENGINE SERVICING YOUR ENGINE
To stop the engine in an emergency, simply turn the engine switch THE IMPORTANCE OF MAINTENANCE
to the OFF position. Under normal conditions, use the following Good maintenance is essential for safe, economical and trouble-
procedure. free operation. It will also help reduce pollution.
Some engine types use a remote-mounted throttle control. Refer Improper maintenance, or failure to correct a
to the instructions provided by the equipment manufacturer. problem before operation, can cause a malfunction in
which you can be seriously hurt or killed.
2. Turn the engine switch to the OFF position.
Always follow the inspection and maintenance
Some engine types use a remote-mounted engine switch. Refer recommendations and schedules in this owner’s
to the instructions provided by the equipment manufacturer. manual.
MIN To help you properly care for your engine, the following pages
include a maintenance schedule, routine inspection procedures,
and simple maintenance procedures using basic hand tools. Other
service tasks that are more difficult, or require special tools, are
best handled by professionals and are normally performed by a
OFF
THROTTLE CONTROL Honda technician or other qualified mechanic.
OFF
Failure to properly follow maintenance instructions
and precautions can cause you to be seriously hurt or
killed.
SETTING ENGINE SPEED Always follow the procedures and precautions in this
owner’s manual.
Adjust the throttle control for the desired engine speed.
SAFETY PRECAUTIONS
Some engine types use a remote-mounted throttle control, rather Make sure the engine is off before you begin any maintenance
than the engine-mounted throttle control shown here. Refer to the or repairs. This will eliminate several potential hazards:
instructions provided by the equipment manufacturer. −Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate
For engine speed recommendations, refer to the instructions the engine.
provided with the equipment powered by this engine. −Burns from hot parts.
Let the engine and exhaust system cool before touching.
−Injury from moving parts.
Do not run the engine unless instructed to do so.
Read the instructions before you begin, and make sure you have
the tools and skills required.
To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a non-flammable solvent,
not gasoline, to clean parts. Keep cigarettes, sparks and flames
away from all fuel related parts.
Remember that an authorized Honda servicing dealer knows your
MIN MAX engine best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new Honda
THROTTLE CONTROL Genuine parts or their equivalents for repair and replacement.
6 ENGLISH
MAINTENANCE SCHEDULE REFUELING (LOW PROFILE TYPES)
ENGLISH 7
2. Add fuel to the bottom of the maximum fuel level limit of the ENGINE OIL
fuel tank. Do not overfill. Wipe up spilled fuel before starting the Oil is a major factor affecting performance and service life. Use
engine. 4-stroke automotive detergent oil.
Check the engine oil level with the engine stopped and in a level
position.
Spilled fuel is not only a fire hazard, it causes environmental 4. Reinstall and tighten the oil filler cap/dipstick.
damage. Wipe up spills immediately.
DIPSTICK OIL FILLER CAP/DIPSTICK
UPPER LIMIT
Running the engine with a low oil level can cause engine damage.
This type of damage is not covered by the Distributor’s Limited
Warranty.
The Oil Alert system will stop the engine or issue a warning before
the oil level falls below a safe limit. Refer to the instructions
provided by the equipment manufacturer.
8 ENGLISH
Oil Change AIR CLEANER
Drain the used oil when the engine is warm. Warm oil drains A dirty air cleaner will restrict air flow to the carburetor, reducing
quickly and completely. engine performance. If you operate the engine in very dusty areas,
clean or replace the air filter more often than specified in the
1. Place a suitable container below the engine to catch the used oil, MAINTENANCE SCHEDULE.
then remove the oil filler cap/dipstick, oil drain plug and washer.
2. Allow the used oil to drain completely, then reinstall the oil drain Operating the engine without an air filter, or with a damaged air
plug and new washer, and tighten the oil drain plug securely. filter, will allow dirt to enter the engine, causing rapid engine wear.
This type of damage is not covered by the Distributor’s Limited
Please dispose of used motor oil in a manner that is compatible Warranty.
with the environment. We suggest you take used oil in a sealed
container to your local recycling center or service station for Inspection (standard types)
reclamation. Do not throw it in the trash, pour it on the ground,
or pour it down a drain. Remove the air cleaner cover and inspect the filter elements.
Clean or replace dirty filter elements. Always replace damaged
3. With the engine in a level position, fill with the recommended oil filter elements.
to the upper limit mark on the dipstick (see page 8 ).
Cleaning (standard types)
Running the engine with a low oil level can cause engine 1. Remove the nut from the air NUT
damage. This type of damage is not covered by the Distributor’s cleaner cover, and remove
Limited Warranty. the cover. AIR CLEANER
COVER
4. Install the oil filler cap/dipstick and push it in securely. 2. Remove the wing nut from
the air filter, and remove the WING NUT
filter.
OIL FILLER CAP/DIPSTICK PAPER FILTER
DIPSTICK 3. Remove the foam filter from ELEMENT
the paper filter.
FOAM FILTER
4. Inspect both air filter ELEMENT
UPPER LIMIT
elements, and replace them if
they are damaged. Always GASKET
replace the paper air filter
element at the scheduled
interval (see page 7 ).
Foam filter element: Clean in warm soapy water, rinse, and allow
to dry thoroughly. Or clean in non-flammable solvent and allow to
dry. Dip the filter element in clean engine oil, then squeeze out all
excess oil. The engine will smoke when started if too much oil is
left in the foam.
Dry
ENGLISH 9
6. Wipe dirt from the inside of the air cleaner case and cover using 5. Clean the foam filter element if it is to be reused.
a moist rag. Be careful to prevent dirt from entering the air duct
that leads to the carburetor. Clean in warm soapy water, rinse, and allow to dry thoroughly. Or
clean in non-flammable solvent and allow to dry.
7. Place the foam filter element over the paper element, and Dip the filter element in clean engine oil, then squeeze out all
reinstall the assembled air filter. Be sure the gasket is in place excess oil. The engine will smoke when started if too much oil is
beneath the air filter. Tighten the air filter wing nut securely. left in the foam.
8. Install the air cleaner cover, and tighten the nut securely.
Remove the air cleaner cover and inspect the filter elements. Soak Squeeze Oil Squeeze
Visually inspect the filter elements. Clean the foam filter element
or replace the dirty paper filter element. Always replace damaged
filter elements. 6. Wipe dirt from the inside of the air cleaner case and cover, using
a moist rag. Be careful to prevent dirt from entering the air duct
Cleaning (low profile types) that leads to the carburetor.
1. Loosen the cover screws and remove the air cleaner cover. 7. Put the air cleaner grid on the paper filter element and install
them to the air cleaner case.
2. Remove the foam filter element from the air cleaner cover.
8. Install the foam filter element to the air cleaner cover.
3. Remove the air cleaner grid and paper filter element.
9. Install the air cleaner cover and tighten the cover screw.
4. Inspect both filter elements, and replace them if they are
damaged. Always replace the paper filter element at the SEDIMENT CUP (applicable types)
scheduled interval (see page 7 ).
Cleaning
If the paper filter element is dirty, replace it with a new one.
Do not clean the paper filter element.
AIR CLEANER GRID Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when handling
fuel.
Stop engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
AIR CLENER
CASE
FOAM FILTER
ELEMENT FILTER
AIR CLEANER COVER
O-RING
SEDIMENT
CUP
10 ENGLISH
SPARK PLUG SPARK ARRESTER
Recommended Spark Plugs: BKR7E-E (NGK) The spark arrester must be serviced every 6 months or 100 hours
K22PR-UR (DENSO) to keep it functioning as designed.
The recommended spark plug has the correct heat range for If the engine has been running, the muffler will be hot. Allow it to
normal engine operating temperatures. cool before servicing the spark arrester.
NUT 2. Remove the three 6 mm bolts from the muffler protector, and
remove the muffler protector.
2. Remove the spark plug with a SPARK PLUG WRENCH 3. Remove the 5 × 8 mm screw from the spark arrester, and
5/8-inch spark plug wrench. remove the spark arrester from the muffler.
6. After the spark plug is seated, tighten with a 5/8-inch spark plug
wrench to compress the sealing washer.
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer.
ENGLISH 11
Spark Arrester Removal (low profile types)
6 mm BOLT 10 × 35 mm
1. Remove the three 6 mm bolts from the exhaust pipe protector FLANGE BOLT
and remove the exhaust pipe protector.
4. Remove the six 6 mm bolts from the lower muffler protector MUFFLER STAY
and remove the lower muffler protector.
6 × 16 mm
5. Remove the three 6 mm bolts from the muffler protector and BOLT WASHERS
slide the muffler protector to upside.
6. Remove the 5 × 8 mm screw from the spark arrester and Spark Arrester Cleaning & Inspection
remove the spark arrester from the muffler.
1. Use a brush to remove carbon
deposits from the spark arrester
6 mm BOLT EXHAUST PIPE PROTECTOR screen. Be careful not to damage
the screen. Replace the spark
arrester if it has breaks or holes.
2. Install the spark arrester to the
muffler. SCREEN
3. STANDARD TYPES
Install the muffler protector and air cleaner in the reverse order
of disassembly.
12 ENGLISH
HELPFUL TIPS & SUGGESTIONS Engine Oil
Stop engine and keep heat, sparks, and flame away. TRANSPORTING
Handle fuel only outdoors.
Wipe up spills immediately. If the engine has been running, allow it to cool for at least 15
minutes before loading the engine-powered equipment on the
transport vehicle. A hot engine and exhaust system can burn you
1. Place an approved gasoline container below the carburetor, and and can ignite some materials.
use a funnel to avoid spilling fuel.
Keep the engine level when transporting to reduce the possibility
2. Loosen the carburetor drain screw and drain the gasoline from of fuel leakage.
the carburetor.
TAKING CARE OF UNEXPECTED PROBLEMS
ELECTRIC STARTER TYPES:
Check the LED on the ECM
3. After all the fuel has drained into the container, tighten the drain
screw securely.
LED ECM
Storage Precautions
If your engine will be stored with gasoline in the fuel tank and
carburetor, it is important to reduce the hazard of gasoline vapor To perform the LED check, the engine must be connected to a
ignition. Select a well-ventilated storage area away from any battery and the engine switch must be in the ON position.
appliance that operates with a flame, such as a furnace, water
heater, or clothes dryer. Also avoid any area with a spark- ENGINE WILL Possible Cause Correction
producing electric motor, or where power tools are operated. NOT START
1. LED is not lit. Fuse burnt out. Replace fuse
If possible, avoid storage areas with high humidity, because that (p. 12).
promotes rust and corrosion. after replacing fuse,
turn the engine
Keep the engine level in storage. Tilting can cause fuel or oil switch to the ON
leakage. position once
again.
With the engine and exhaust system cool, cover the engine to 2. LED is lit. Fuel, engine oil, Check the BEFORE
keep out dust. A hot engine and exhaust system can ignite or melt spark plug, etc. OPERATION
some materials. Do not use sheet plastic as a dust cover. CHECKS (p. 3).
A nonporous cover will trap moisture around the engine, 3. LED blinks Engine oil level Fill with the
promoting rust and corrosion. twice. low. recommended oil
to the proper level
If equipped with a battery for electric starter types, recharge the (p. 8).
battery once a month while the engine is in storage. 4. LED blinks 3 or ECM, Take engine to an
This will help to extend the service life of the battery. more times. TE sensor, authorized Honda
power coil. servicing dealer, or
Removal from Storage refer to shop
Check your engine as described in the BEFORE OPERATION manual.
CHECKS section of this manual (see page 3 ). 5. Take engine to ECM, Replace or repair
an authorized sensors, etc. faulty components
Honda as necessary.
servicing
dealer, or refer
to shop
manual.
14 ENGLISH
ENGINE WILL Possible Cause Correction TECHNICAL INFORMATION
NOT START
1. Electric Battery Recharge battery. Serial Number Location STANDARD TYPES
starting discharged. Record the engine serial
(applicable number, engine type, and date
types): Fuse burnt out. Replace fuse. of purchase in the space below.
Check battery (p. 12). You will need this information
and fuse. when ordering parts and when
2. Check control Choke open. Move choke lever making technical or warranty
positions. (Recoil starter to CLOSED inquiries.
types) position unless the
engine is warm.
Engine switch Turn engine switch
OFF. to ON position.
3. Check engine Engine oil level Fill with the SERIAL NUMBER &
oil level. low. recommended oil ENGINE TYPE LOCATION
to the proper level ELECTRIC STARTER
(p. 8). (applicable types)
4. Check fuel. Out of fuel. Refuel (p. 7). LOW PROFILE TYPES
Bad fuel; engine Drain fuel tank and ELECTRIC STARTER
stored without carburetor (p. 14). (applicable types)
treating or Refuel with fresh
draining gasoline (p. 7).
gasoline, or
refueled with
bad gasoline.
5. Remove and Spark plug faulty, Gap or replace
inspect spark fouled, or spark plug (p. 11).
SERIAL NUMBER &
plug. improperly ENGINE TYPE LOCATION
gapped.
Spark plug wet Dry and reinstall
with fuel spark plug. Start Engine serial number: __ __ __ __ − __ __ __ __ __ __ __
(flooded engine). engine with
throttle lever in Engine type: ___ ___ ___ ___
MAX. position.
6. Take engine to Fuel filter Replace or repair Date Purchased: ______ / ______ / ______
an authorized restricted, faulty components
Honda carburetor as necessary.
servicing malfunction,
dealer, or refer ignition
to shop malfunction,
manual. valves stuck, etc.
ENGLISH 15
Battery Connections for Electric Starter (applicable types) Carburetor Modifications for High Altitude Operation
Recommended Battery At high altitude, the standard carburetor air-fuel mixture will be
iGX440 12 V−24 Ah too rich. Performance will decrease, and fuel consumption will
increase. A very rich mixture will also foul the spark plug and
Be careful not to connect the battery in reverse polarity, as this will cause hard starting. Operation at an altitude that differs from that
short circuit the battery charging system. Always connect the at which this engine was certified, for extended periods of time,
positive (+) battery cable to the battery terminal before may increase emissions.
connecting the negative (−) battery cable, so your tools cannot
cause a short circuit if they touch a grounded part while tightening High altitude performance can be improved by specific
the positive (+) battery cable end. modifications to the carburetor. If you always operate your engine
at altitudes above 1,500 meters (5,000 feet), have your servicing
dealer perform this carburetor modification. This engine, when
operated at high altitude with the carburetor modifications for
A battery can explode if you do not follow the correct high altitude use, will meet each emission standard throughout its
procedure, seriously injuring anyone nearby. useful life.
Keep all sparks, open flames, and smoking materials Even with carburetor modification, engine horsepower will
away from the battery. decrease about 3.5% for each 300-meter (1,000-foot) increase in
altitude. The effect of altitude on horsepower will be greater than
1. Connect the battery positive (+) cable to the starter solenoid this if no carburetor modification is made.
terminal as shown.
2. Connect the battery negative (−) cable to an engine mounting
bolt, frame bolt, or other good engine ground connection. When the carburetor has been modified for high altitude operation,
3. Connect the battery positive (+) cable to the battery positive (+) the air-fuel mixture will be too lean for low altitude use. Operation
terminal as shown. at altitudes below 1,500 meters (5,000 feet) with a modified
4. Connect the battery negative (−) cable to the battery negative carburetor may cause the engine to overheat and result in serious
(−) terminal as shown. engine damage. For use at low altitudes, have your servicing
5. Coat the terminals and cable ends with grease. dealer return the carburetor to original factory specifications.
POSITIVE (+)
BATTERY CABLE
16 ENGLISH
Emission Control System Information Replacement Parts
The emission control systems on your Honda engine were
Source of Emissions designed, built, and certified to conform with EPA, California
The combustion process produces carbon monoxide, oxides of (models certified for sale in California), and Canadian emission
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides regulations. We recommend the use of Honda Genuine parts
of nitrogen is very important because, under certain conditions, whenever you have maintenance done. These original-design
they react to form photochemical smog when subjected to replacement parts are manufactured to the same standards as the
sunlight. Carbon monoxide does not react in the same way, but it original parts, so you can be confident of their performance. The
is toxic. use of replacement parts that are not of the original design and
quality may impair the effectiveness of your emission control
Honda utilizes appropriate air/fuel ratios and other emissions system.
control systems to reduce the emissions of carbon monoxide,
oxides of nitrogen, and hydrocarbons. A manufacturer of an aftermarket part assumes the responsibility
Additionally, Honda fuel systems utilize components and control that the part will not adversely affect emission performance. The
technologies to reduce evaporative emissions. manufacturer or rebuilder of the part must certify that use of the
part will not result in a failure of the engine to comply with
The U.S., California Clean Air Acts and Environment Canada emission regulations.
EPA, California and Canadian regulations require all
manufacturers to furnish written instructions describing the Maintenance
operation and maintenance of emission control systems. Follow the maintenance schedule on page 7. Remember that this
schedule is based on the assumption that your machine will be
The following instructions and procedures must be followed in used for its designed purpose. Sustained high-load or high-
order to keep the emissions from your Honda engine within the temperature operation, or use in unusually wet or dusty conditions,
emission standards. will require more frequent service.
ENGLISH 17
Specifications (standard types) Tuneup Specifications
ITEM SPECIFICATION MAINTENANCE
PTO shaft type S Spark plug gap 0.7−0.8 mm Refer to page: 11
Length × Width × 407 × 505 × 456 mm (0.028−0.031 in)
Height (16.0 × 19.9 × 18.0 in) Valve clearance IN: 0.12 ± 0.02 mm See your
Dry mass [weight] 39.4 kg (86.9 lbs) (cold) EX: 0.15 ± 0.02 mm authorized
Engine type 4-stroke, overhead camshaft, single Honda dealer
cylinder Other No other adjustments needed.
Displacement 438 cm (26.7 cu-in) specifications
[Bore × Stroke] [88.0 × 72.1 mm (3.46 × 2.84 in)]
Net power 9.5 kW (12.9 PS, 12.7 bhp)
(in accordance with SAE J1349*) at 3,600 rpm
Max. Net torque 29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
(in accordance with SAE J1349*) at 2,500 rpm
Engine oil capacity 1.1 L (1.2 US qt, 1.0 lmp qt)
Fuel tank capacity 5.1 L (1.35 US gal, 1.12 lmp gal)
Cooling system Forced air
Ignition system CDI type magneto ignition
PTO shaft rotation Counterclockwise
18 ENGLISH
Quick Reference Information Wiring Diagrams
[1] FUSE 3 A [13] FUEL CUT SOLENOID
Fuel Unleaded gasoline (Refer to page 7) [2] FUSE 30 A [14] IGINITION COIL
U.S. Pump octane rating 86 or higher [3] FUEL CUT SOLENOID [15] SPARK PLUG
Except Research octane rating 91 or higher RECTIFIER [16] OIL LEVEL SWITCH
U.S. Pump octane rating 86 or higher [4] REGULATOR RECTIFIER [17] ECM
Engine oil SAE 10W-30, API SJ or later, for general use. [5] ENGINE GROUND [18] STEP MOTOR (GOV)
Refer to page 8. [6] BATTERY [19] STEP MOTOR (CHOKE)
Spark plug BKR7E-E (NGK) [7] STARTER MOTOR [20] PC CONNECTOR
K22PR-UR (DENSO) [8] POWER COIL [21] ENGINE TEMPERATURE
Maintenance Before each use: [9] FUEL CUT SOLENOID COIL SENSOR
Check engine oil level. Refer to page 8. [10] CHARGE COIL 20 A [22] THROTTLE CONTROL
Check air filter. Refer to page 9−10. [11] CHARGE COIL 3 A [23] COMBINATION SWITCH
First 20 hours: [12] CRANKSHAFT POSITION [24] RECTIFIER
Change engine oil. Refer to page 9. (CKP) SENSOR [25] ENGINE STOP SWITCH
Subsequent:
Refer to the maintenance schedule on page 7. Bl Black Br Brown
Y Yellow O Orange
Muffler Deflector Kit Installation (standard types) Bu Blue Lb Light blue
G Green Lg Light green
Muffler deflector (applicable types) R Red P Pink
W White Gr Gray
Turn the outlet of the muffler deflector downward and tighten the
three 4 × 6 mm screws securely.
ATTACHMENT POSITION
ENGLISH 19
ELECTRIC STARTER TYPES (20 A)
20 ENGLISH
ELECTRIC STARTER TYPES (3 A)
ENGLISH 21
RECOIL STARTER TYPES
22 ENGLISH
TECHNICAL & CONSUMER INFORMATION Canada:
Honda Canada, Inc.
DISTRIBUTOR/DEALER LOCATOR INFORMATION 715 Milner Avenue
Toronto, ON
United States, Puerto Rico, and U.S. Virgin Islands: M1B 2K8
Call (800) 426-7701
or visit our website: www.honda-engines.com Telephone: (888) 9HONDA9 Toll free
(888) 946-6329
Canada: (416) 299-3400 Local Toronto dialing area
Call (888) 9HONDA9 Facsimile: (877) 939-0909 Toll free
or visit our website: www.honda.ca (416) 287-4776 Local Toronto dialing area
United States, Puerto Rico, and U.S. Virgin Islands: All Other Areas:
If you are dissatisfied with the decision made by the dealership’s Please contact the Honda distributor in your area for assistance.
management, contact the Honda Regional Engine Distributor for
your area.
If you are still dissatisfied after speaking with the Regional Engine
Distributor, you may contact the Honda Office as shown.
《Honda’s Office》
When you write or call, please provide this information:
ENGLISH 23
Kubota diesel engine
3 SAFETY FIRST
This symbol, the industry's "Safety Alert Symbol", is used throughout
this manual and on labels on the machine itself to warn of the
possibility of personal injury. Read these instructions carefully. It is
essential that you read the instructions and safety regulations before
you attempt to assemble or use this unit.
ENGLISH
SAFE OPERATION
Careful operation is your best assurance against an accident. Read and understand this section carefully before
operating the engine. All operators, no matter how much experience they may have, should read this and other
related manuals before operating the engine or any equipment attached to it. It is the owner's obligation to provide
all operators with this information and instruct them on safe operation.
ENGLISH
6. EXHAUST GASES & FIRE PREVENTION
A Engine exhaust fumes can be very harmful if allowed to accumulate. Be
sure to run the engine in a well ventilated location and where there are
no people or livestock near the engine.
A The exhaust gas from the muffler is very hot. To prevent a fire, do not
expose dry grass, mowed grass, oil or any other combustible materials
to exhaust gas. Keep the engine and muffler clean at all times.
A To avoid a fire, be alert for leaks of flammable substances from hoses
and lines. Be sure to check for leaks from hoses or pipes, such as fuel
and hydraulic fluid by following the maintenance check list.
A To avoid a fire, do not short across power cables and wires. Check to
see that all power cables and wirings are in good condition. Keep all
electrical connections clean. Bare wire or frayed insulation can cause a
dangerous electrical shock and personal injury.
7. ESCAPING FLUID
A Relieve all pressure in the air, the oil and the cooling systems before
disconnecting any lines, fittings or related items.
A Be cautious of possible pressure relief when disconnecting any device
from a pressurized system that utilizes pressure. DO NOT check for
pressure leaks with your hand. High pressure oil or fuel can cause
personal injury.
A Escaping fluid under pressure has sufficient force to penetrate skin
causing serious personal injury.
A Fluid escaping from pinholes may be invisible. Use a piece of cardboard
or wood to search for suspected leaks: do not use hands and body. Use
safety goggles or other eye protection when checking for leaks.
A If injured by escaping fluid, see a medical doctor immediately. This fluid
can produce gangrene or severe allergic reaction.
4 SAFE OPERATION
ENGLISH
ENGLISH
10. ANTI-FREEZE & DISPOSAL OF FLUIDS
A Anti-freeze contains poison. Wear rubber gloves to avoid personal
injury. In case of contact with skin, wash it off immediately.
A DO NOT mix different types of Anti-freeze. The mixture can produce a
chemical reaction causing harmful substances. Use approved or
genuine KUBOTA Anti-freeze.
A Be mindful of the environment and the ecology. Before draining any
fluids, determine the correct way to dispose of them. Observe the
relevant environmental protection regulations when disposing of oil, fuel,
coolant, brake fluid, filters and batteries.
A When draining fluids from the engine, place a suitable container
underneath the engine body.
A DO NOT pour waste onto the ground, down a drain, or into any water
source. Dispose of waste fluids according to environmental regulations.
Part No.TA040-4957-1
Stay clear of engine
fan and fan belt
ENGLISH
SERVICING OF THE ENGINE
Your dealer is interested in your new engine and has the
desire to help you get the most value from it. After reading
this manual thoroughly, you will find that you can do some
of the regular maintenance yourself.
However, when in need of parts or major service, be sure
to see your KUBOTA dealer.
For service, contact the KUBOTA Dealership from which
you purchased your engine or your local KUBOTA dealer.
When in need of parts, be prepared to give your dealer the
engine serial number.
Locate the serial number now and record them in the
space provided.
NAMES OF PARTS
ENGLISH
PRE-OPERATION CHECK
BREAK-IN
During the engine break-in period, observe the following by all means:
1. Change engine oil and oil filter cartridge after the first 50 hours of operation (See "ENGINE OIL" in Periodic Service
Section).
2. When ambient temperature is low, operate the machine after the engine has been completely warmed up.
DAILY CHECK
To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.
ENGLISH
4. Insert the key into the key switch and COLD WEATHER STARTING
turn it "ON". If the ambient temperature is below* -5 C(23 F) and the
engine is very cold, start it in the following manner:
Take steps (1) through (4) left.
Check item
1. Check to see if there is any water leak;
2. Check to see if there is any obstacle around the
cooling air inlet or outlet;
3. Check to see if there is any dirt or dust between
radiator fin and tube;
4. Check to see if the fan belt is too loose;
5. Check to see if radiator water pipe is clogged;
6. Check to see if anti-freeze is mixed into coolant in
(1) Speed control lever (A) "IDLING" warm seasons.
(2) Engine stop lever (B) "OPERATION"
(C) "START"
(D) "STOP"
BOil pressure lamp
The lamp lights up to warn the operator that the engine oil
pressure has dropped below the prescribed level. If this
should happen during operation or should not go off even
after the engine is accelerated more than 1000rpm,
immediately stop the engine and check the following:
1. Engine oil level (See "ENGINE OIL" in Maintenance
Section).
2. Lubricant system (See "ENGINE OIL" in Maintenance
Section).
OPERATING THE ENGINE 7
ENGLISH
REVERSED ENGINE REVOLUTION AND
BFuel
REMEDIES
MAINTENANCE
ENGLISH
SERVICE INTERVALS
Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD lubricating oils of API classifi-
cation with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating
oil at shorter intervals than recommended in the table below depending on the operating condition.
A The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 After 6 times of cleaning.
*3 Consult your local KUBOTA Dealer for this service.
*4 Replace only if necessary.
A The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
Please see the Warranty Statement in detail.
10 MAINTENANCE
ENGLISH
A Lubricating oil
A Changing interval of Engine oil and oil filter With the emission control now in effect, the CF-4 and
cartridge. CG-4 lubricating oils have been developed for use of a
*Oil pan depth low-sulfur fuel on on-road vehicle engines. When an
off-road vehicle engine runs on a high-sulfur fuel, it is
101 mm 121 mm advisable to employ the CF, CD or CE lubricating oil
(3.98 in.) (4.76 in.)
with a high total base number. If the CF-4 or CG-4
50 Hrs (Initial) lubricating oil is used with a high-sulfur fuel, change
Z602-E Engine oil the lubricating oil at shorter intervals.
100 Hrs -
D902-E A Lubricating oil recommended when a low-
Oil filter cartridge 200 Hrs sulfur or high-sulfur fuel is employed.
50 Hrs (Initial) : Recommendable X : Not recommendable
Z482-E Engine oil
Lubricating Fuel
D662-E 75 Hrs 100 Hrs
Remarks
D722-E oil class Low-sulfur High-sulfur
Oil filter cartridge 150 Hrs 200 Hrs
50 Hrs (Initial) CF TBN 10
Engine oil
D782-E - 100 Hrs CF-4 X
ENGLISH
PERIODIC SERVICE
FUEL Distillation Viscosity
Viscosity
Fuel is flammable and can be dangerous. You should Temperatures, Kinematic
Saybolt,
handle fuel with care. C( F) cSt or
SUS at
90% mm /s at
37.8 C(100 F)
Point 40 C
[PROCEDURE]
1. Fill the fuel tank to the fullest extent. Open the fuel filter
lever.
2. Loosen air vent plug of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up
any more.
4. Open the air vent plug on top of the fuel injection
pump.
5. Retighten the plug when bubbles do not come up any
more.
A When the fuel pipes are not installed, plug them at A Entrance of dust and dirt can cause a malfunction of
both ends with clean cloth or paper to prevent dirt from the fuel injection pump and the injection nozzle. Wash
entering. Dirt in the pipes can cause fuel injection the fuel filter cup periodically.
pump malfunction.
PERIODIC SERVICE 13
ENGLISH
ENGINE OIL
4. If the oil level is too low, remove the oil filler plug, and
add new oil to the prescribed level. BChanging engine oil
5. After adding oil, wait more than 5 minutes and check
the oil level again. It takes same time for the oil to
come down to the oil pan.
To avoid personal injury:
Engine oil quantity A Be sure to stop the engine before draining
engine oil.
Oil pan depth A When draining engine oil, place some
Models
*101 mm (3.98 in.) 121 mm (4.76 in.) container underneath the engine and dispose it
according to local regulations.
2.1 L 2.5 L A Do not drain oil after running the engine. Allow
Z482-E
(0.55 U.S.gals.) (0.66 U.S.gals.) engine to cool down sufficiently.
D662-E 3.2 L 3.8 L
D722-E (0.84 U.S.gals.) (1.0 U.S.gals.) 1. Change oil after the initial 50 hours of operation and
every 100 hours thereafter.
3.6 L 2. Remove the drain plug at the bottom of the engine,
D782-E -
(0.95 U.S.gals.) and drain all the old oil. Drain oil easier and completely
101 mm (3.98 in.) while the engine is hot.
Z602-E 2.5 L -
(0.66 U.S.gals.)
101 mm (3.98 in.)
D902-E 3.7 L -
(0.98 U.S.gals.)
ENGLISH
RADIATOR
BReplacing the oil filter cartridge Coolant will last for one day's work if filled all the way up
before operation start. Make it a rule to check the coolant
level before every operation.
To avoid personal injury:
A Be sure to stop the engine before changing the
oil filter cartridge. To avoid personal injury:
A Allow engine to cool down sufficiently, oil can A Do not stop the engine suddenly, stop it after
be hot and cause burns. about 5 minutes of unloaded idling.
A Work only after letting the engine and radiator
1. Replace the oil filter cartridge after the initial 50 hours cool off completely (more than 30 minutes after
of operation and every 200 hours thereafter. it has been stopped).
2. Remove the old oil filter cartridge with a filter wrench. A Do not remove the radiator cap while coolant is
3. Apply a film of oil to the gasket for the new cartridge. hot. When cool to the touch, rotate cap to the
4. Screw in the cartridge by hand. When the gasket first stop to allow excess pressure to escape.
contacts the seal surface, tighten the cartridge enough Then remove cap completely.
by hand. Because, if you tighten the cartridge with If overheats should occur, steam may gush out
wrench, it will be tightened too much. from the radiator or reserve tank; Severe burns
could result.
Models Quantity
Z482-E, Z602-E 2.8L (0.74 U.S.gals.)
D662-E, D722-E,
3.1L (0.82 U.S.gals.)
D782-E, D902-E
ENGLISH
1. If hose clamps are loose or water leaks, tighten hose 3. The procedure for mixing of water and anti-freeze
clamp securely. differs according to the make of the anti-freeze and the
2. Replace hoses and tighten hose clamps securely, if ambient temperature. Refer to SAE J1034 standard,
radiator hoses are swollen, hardened or cracked. more specifically also to SAE J814c.
Replace hoses and hose clamps every 2 years or earlier, 4. Mix the anti-freeze with water, and then fill in to the
if checked and found that hoses are swollen, hardened or radiator.
cracked.
A When the anti-freeze is mixed with water, the anti-
freeze mixing ratio must be less than 50%.
BPrecaution at overheating
Take the following actions in the event the coolant Vol % Freezing Point Boiling Point *
temperature be nearly or more than the boiling point, what Anti-freeze
is called "Overheating". Take these actions if the engine's
40 -24 -12 106 222
alarm buzzer sounds or the alarm lamp lights up. 50 -37 -34 108 226
1. Stop the engine operation in a safe place and keep the
engine unloaded idling. *At 1.013 x 10 Pa (760 mmHg) pressure
2. Do not stop the engine suddenly. Stop it after about 5 (atmospheric). A higher boiling point is obtained by
minutes of unloaded idling. using a radiator pressure cap which permits the
3. If the engine stalls within about 5 minutes of running development of pressure within the cooling system.
under no load, immediately leave and keep yourself
away from the machine. Never open the hood and any
other part. A The above data represent industry standards that
4. Keep yourself and others well away from the engine necessitate a minimum glycol content in the
for further 10 minutes or while the steam blown out. concentrated anti-freeze.
5. Checking that there gets no danger such as burn, get A When the coolant level drops due to evaporation, add
rid of the causes of overheating according to the water only to keep the anti-freeze mixing ratio less
manual, see "Troubleshooting" section. And then, start than 50%. In case of leakage, add anti-freeze and
again the engine. water in the specified mixing ratio before filling into the
radiator.
BAnti-freeze A Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
A Do not use radiator cleaning agents when anti-freeze
has been added to the coolant. (Anti-freeze contains
To avoid personal injury: an anti-corrosive agent, which will react with the
A When using anti-freeze, put on some protection radiator cleaning agent forming sludge which will
such as rubber gloves. affect the engine parts.)
A If should drink anti-freeze, throw up at once
and take medical attention.
BRadiator cement
A When anti-freeze comes in contact with the
skin or clothing, wash it off immediately. As the radiator is solidly constructed, there is little
A Do not mix different types of anti-freeze. possibility of water leakage. Should this happen, however,
A Keep fire and children away from anti-freeze. radiator cement can easily fix it. If leakage is serious,
A Be mindful of the environment and ecology. contact your local KUBOTA dealer.
Before draining any fluids, find out the correct
way of disposing by checking with local codes.
A Also, observe the relevant environmental
protection regulations when disposing of oil,
fuel, coolant, brake fluid, filters and batteries.
AIR CLEANER
As the element of the air cleaner employed on this engine BFor the air cleaner with a dust cup
is a dry type, never apply oil to it. (optional)
1. Open the evacuator valve once a week under ordinary Remove and clean out the dust cup before it becomes half
conditions-or daily when used in a dusty place-to get full with dust; usually once a week, or even every day if the
rid of large particles of dust and dirt. working surroundings are dusty.
2. Wipe the inside air cleaner clean with cloth or the like Install the air cleaner dust cup with "TOP" indicated on the
if it is dirty or wet. rear of the cup in the upside. (However, it may be installed
3. Avoid touching the element except when cleaning. in either direction when the cover is placed at the lower
4. When dry dust adheres to the element, blow
part.)
compressed air from the inside turning the element.
Pressure of compressed air must be under 205kPa
(2.1kgf/cm , 30psi).
5. When carbon or oil adheres to the element, soak the
element in detergent for 30 minutes, then wash it
several times in water, rinse with clean water and dry
it naturally.
6. After element is fully dried, inspect inside of the
element with a light and check if it is damaged or not.
(referring to the instructions on the label attached to
the element.)
7. Replace the element every year or every six
cleanings.
(1) Element
(2) Air cleaner body
(3) Dust cup
(4) Wing bolt
(5) "TOP" mark
ENGLISH
2. To slow charge the battery, connect the charger
BBattery charging positive terminal to the battery positive terminal, and
negative to the negative.
3. Quick recharging charges the battery at a high rate in
a short time. As this is only for emergencies.
The battery comes in two types: refillable and non- 4. Recharge the battery as early as possible, or battery
refillable. life will be extremely shortened.
A For using the refillable type battery, follow the 5. When exchanging an old battery into new one, use
instructions below. battery of equal specification shown in page 26.
Do not use or charge the battery if its fluid level
stands below the LOWER (lower limit level)
mark.
Otherwise, the battery component parts may
deteriorate earlier than expected, which may
shorten the battery's service life or cause an
explosion.
Immediately, add distilled water until the
battery's fluid level is between the UPPER and
LOWER levels.
FAN BELT
BDirection for long term storage
1. When storing the engine for long periods of time, BAdjusting Fan Belt Tension
remove the battery, adjust the electrolyte to the proper
level, and store in a dry and dark place.
2. The battery naturally discharges while it is stored. To avoid personal injury:
Recharge it once a month in summer, and every 2 A Be sure to stop the engine and remove the key
months in winter. before checking the belt tension.
A Be sure to reinstall the detached safety shield
ELECTRIC WIRING after maintenance or checking.
A deflection of between 7 to 9 mm
Proper fan belt
(0.28 to 0.35 in.) when the belt is
tension
To avoid personal injury: pressed in the middle of the span.
C Shorting of electric cable or wiring may cause
a fire. 1. Stop the engine and remove the key.
A Check to see if electric cables and wiring 2. Apply moderate thumb pressure to belt between the
are swollen, hardened or cracked. pulleys.
A Keep dust and water away from all power 3. If tension is incorrect, loosen the alternator mounting
connections. bolts and, using a lever placed between the alternator
Loose wiring terminal parts, make bad and the engine block, pull the alternator out until the
connections. Be sure to repair them before deflection of the belt falls within acceptable limits.
starting the engine. 4. Replace fan belt if it is damaged.
ENGLISH
CARRIAGE AND STORAGE
CARRIAGE STORAGE
1. Use carrier such as crane when carrying the engine, or Before storing the engine for more than a few months,
hurt your waist and yourself. Support the engine remove any dirt on the machine, and:
securely with rope not to fall while carrying it. 1. Drain the coolant in the radiator. Open the cock at the
2. When lifting the engine, put the hook securely to metal bottom of the radiator, and remove the pressure cap to
fittings attached to the engine. Use strong hook and drain water completely. Leave the cock open. Hang a
fittings enough to hang the engine. note written "No water" on the pressure cap. Since
water may freeze when the temperature drops below
0 C (32 F), it is very important that no water is left in
the machine.
2. Remove dirty engine oil, fill with new oil and run the
engine for about 5 minutes to let the oil penetrate to all
the parts.
3. Check all the bolts and nuts, and tighten if necessary.
4. Remove the battery from the engine, adjust the
electrolyte level, and recharge it. Store the battery in a
dry and dark place.
5. When the engine is not used for a long period of time,
run it for about 5 minutes under no load every 2 to 3
months to keep it free from rust. If the engine is stored
without any running, moisture in the air may condense
into dew over the sliding parts of the engine, resulting
in rust there.
6. If you forget to run the engine for longer than 5 to 6
months, apply enough engine oil to the valve guide
and valve stem seal and make sure the valve works
smoothly before starting the engine.
7. Store the engine in a flat place and remove the key
from engine.
8. Do not store the engine in a place where has
flammable materials such as dry grass or straw.
9. When covering the engine for storage, let engine and
muffler cool off completely.
10. Operate the engine after checking and repairing
damaged wirings or pipes, and clearing flammable
materials carried by mouse.
22 TROUBLESHOOTING
ENGLISH
TROUBLESHOOTING
If the engine does not function properly, use the following chart to identify and correct the cause.
B When it is difficult to start the engine B When output is insufficient
Cause Countermeasures Cause Countermeasures
*Check the fuel tank and fuel filter. *Clean orifice and needle valve, being
*Remove water, dirt and other impurities. Carbon stuck very careful not to damage the nozzle
Fuel is thick and *As all fuel will be filtered by the filter, if around orifice of orifice.
doesn't flow. there should be water or other foreign nozzle piece *Check nozzle to see if good. If not,
matters on the filter, clean the filter with replace with new parts.
kerosene.
*Bad valve and excessive wear of rings,
Compression is
*If air is in the fuel filter or injection lines, pistons and liners cause insufficient
insufficient.
the fuel pump will not work properly. To compression. Replace with new parts.
Leaking valves
attain proper fuel injection pressure, *Grind valves.
Air or water mixed check carefully for loosened fuel line
Fuel is insufficient. *Check fuel system.
in fuel system coupling, loose cap nut, etc.
*Loosen air vent screws stop fuel filter *Check lubricating oil system.
and fuel injection pump to eliminate all *Check to see if lubricating oil filter is
the air in the fuel system. working properly.
*Filter element deposited with impurities
*This is caused when water or dirt is
would cause poor lubrication. Change
mixed in the fuel. Clean the nozzle Overheating of
element.
Thick carbon injection piece, being careful not to moving parts
*Check the clearance of bearing are
deposits on orifice damage the orifice.
within factory specs.
of injection nozzle. *Check to see if nozzle is working
*Check injection timing.
properly or not. If not, install a new
*Adjust timing 0.366 rad(20 ) before top
nozzle.
dead center.
*Adjust valve clearance to 0.145-
Valve clearance is *Adjust to proper valve clearance of
0.185mm(0.0057-0.0072in) when the Valve clearance is
wrong. 0.145 to 0.185 mm(0.0057 to 0.0072 in.)
engine is cold. wrong.
with engine cold.
Leaking valves *Grind valve.
*Clean the element every 100 hours of
Air cleaner is dirty
*Adjust injection timing operation.
Fuel injection timing
*The injection timing is 0.366 rad(20 )
is wrong. Fuel injection *Adjust to proper pressure. 13.7Mpa
before top dead center.
pressure is wrong. (140 kgf/cm ; 1991 psi)
Engine oil becomes
*Do not use poor quality fuel for it will
thick in cold *Change grade of oil according to the
cause wear of the pump. Only use No.
weather and engine weather (temperature.)
Injection pump 2-D diesel fuel.
cranks slow.
wear *Check the fuel injection pump element
*Bad valve or excessive wear of rings, and delivery valve assembly and
Low compression pistons and liners cause insufficient replace as necessary.
compression. Replace with new parts.
Battery is *Charge battery.
discharged and the *In winter, always remove battery from
engine will not machine, charge fully and keep indoors.
crank. Install in machine at time of use.
A If the cause of trouble can not be found, contact your KUBOTA dealer.
TROUBLESHOOTING 23
ENGLISH
B When engine suddenly stops B When engine must be stopped immediately
Cause Countermeasures Cause Countermeasures
*Check the fuel tank and refill the fuel, if Engine revolution
necessary. suddenly *Check the adjustments, injection timing
Lack of fuel
*Also check the fuel system for air or decreases or and the fuel system.
leaks. increases.
*If necessary, replace with a new Unusual sound is
Bad nozzle *Check all moving parts carefully.
nozzle. heard suddenly.
*Check amount of engine oil with oil Color of exhaust
Moving parts are *Check the fuel injection system,
level gauge. suddenly turns
overheated due to especially the fuel injection nozzle.
*Check lubricating oil system. dark.
shortage of
*At every 2 times of oil change, oil filter
lubrication oil or Bearing parts are
cartridge should be replaced. *Check the lubricating system.
improper overheated.
*Check to see if the engine bearing
lubrication.
clearances is within factory specs. *Check the lubricating system.
*Check, if the engine bearing
clearances are within factory specs.
A When the engine has suddenly stopped, decompress Oil lamp lights up
*Check the function of the relieve valve
the engine by the decomp and turn the engine lightly during operation.
in the lubricating system.
by pulling on the fan belt. If the engine turns easily *Check pressure switch.
without abnormalities, the cause of the trouble is *Check filter base gasket.
usually lack of fuel or bad nozzle.
B When engine overheats
B When color of exhaust is especially bad Cause Countermeasures
Cause Countermeasures Engine oil *Check oil level. Replenish oil as
insufficient required.
Fuel governing
*Contact dealer for repairs.
device bad Fan belt broken or
*Change belt or adjust belt tension.
elongated
Fuel is of extremely *Select good quality fuel.
poor quality. Use No. 2-D diesel fuel only. Coolant insufficient *Replenish coolant.
Nozzle is bad. *If necessary, replace with new nozzle. Excessive
*Add water only or change to coolant
concentration of
*Cause is poor atomization, improper with the specified mixing ratio.
antifreeze
injection timing, etc. Because of trouble
Combustion is in injection system or in poor valve Radiator net or
incomplete. adjustment, or compression leakage, radiator fin clogged *Clean net or fin carefully.
poor compression, etc. with dust
Check for the cause.
Inside of radiator or
coolant flow route *Clean or replace radiator and parts.
corroded
Fan or radiator or
radiator cap *Replace defective parts.
defective
Thermostat *Check thermostat and replace if
defective necessary.
Temperature gauge *Check temperature with thermometer
or sensor defective and replace if necessary.
Overload running *Reduce load.
Head gasket
defective or water *Replace parts.
leakage
Incorrect injection
*Adjust to proper timing.
timing
Unsuitable fuel
*Use the specified fuel.
used
24 SPECIFICATIONS
ENGLISH
SPECIFICATIONS
Model Z482-E Z602-E D662-E D722-E D782-E D902-E
Type Vertical, water-cooled, 4-cycle diesel engine
Number of cylinders 2 3
Bore and stroke 67 x 68 72 x 73.6 64 x 68 67 x 68 67 x 73.6 72 x 73.6
mm (in.) (2.64 x 2.68) (2.83 x 2.90) (2.52 x 2.68) (2.64 x 2.68) (2.64 x 2.90) (2.83 x 2.90)
Total displacement 0.479 0.599 0.656 0.719 0.778 0.898
L (cu.in.) (29.23) (36.55) (40.03) (43.88) (47.46) (54.80)
Combustion chamber Spherical Type (ETVCS)
SAE NET Intermittent
kW / rpm 9.32 / 3600 11.6 / 3600 12.9 / 3600 14.0 / 3600 13.5 / 3200 17.5 / 3600
H.P. (SAEJ1349) (12.5 / 3600) (15.6 / 3600) (17.3 / 3600) (18.8 / 3600) (18.1 / 3200) (23.5 / 3600)
(HP / rpm)
SAE NET Continuous
kW / rpm 8.05 / 3600 10.1 / 3600 11.18 / 3600 12.15 / 3600 11.7 / 3200 15.2 / 3600
H.P. (SAEJ1349) (10.8 / 3600) (13.5 / 3600) (15.0 / 3600) (16.3 / 3600) (15.7 / 3200) (20.4 / 3600)
(HP / rpm)
Maximum bare speed
3800 3850 3800 3450 3850
rpm
Maximum bare idling
800 to 900 900 to 1000 800 to 900 900 to 1000
speed rpm
Order of firing 1-2 1-2-3
Direction of rotation Counter-clockwise (viewed from flywheel side)
Injection pump Bosch MD Type mini pump
Injection pressure 13.73 MPa, 1991 psi(140 kgf/cm )
Injection timing
0.366rad(20 ) 0.35rad(20 ) 0.366rad(20 ) 0.35rad(20 )
(Before T.D.C.)
Compression ratio 23.5 : 1 24 : 1 23.5 : 1 24 : 1
Fuel Diesel Fuel No.2-D
Lubricant
above CC grade
(API classification)
351 x 389 x 520 385 x 421 x 544 467 x 421 x 544
Dimension mm (in.) 426 x 389 x 520
(13.82 x 15.31 x (15.16 x 16.57 x (18.39 x 16.57 x
(length x width x height) (16.77 x 15.31 x 20.47)
20.47) 21.42) 21.42)
Dry weight
53.1 (117.1) 57.0 (125.7) 63.7 (140.4) 63.1 (139.1) 63.5 (140.0) 72.0 (158.7)
(BB Spec.) kg (lbs.)
Starting system Cell starter (with glow plut)
Starting motor 12 V, 0.8 kW 12 V, 1.0 kW 12 V, 0.8 kW 12 V, 1.2 kW
Charging generator 12 V, 150 W 12 V, 480 W 12 V, 150 W 12 V, 480 W
Recommended battery 12 V, 28 AH, 12 V, 52 AH,
12 V, 36 AH, equivalent
capacity (5Hr capacity) equivalent equivalent
ENGLISH
WIRING DIAGRAMS
EU standard for Alternator (Energize to stop)