Kyoeisha Baroness HMA1560 User manual

HAMMER KNIFE MOWER
Service Manual 2005
KYOEISHA

This service manual explains the specifications and maintenance procedures for our Hammer
Knife Mower, HMA1560/HMA1720.
Notes
1. This manual was prepared in January 2005. Its contents are subject to change for
improvement without notice.
2. Carefully read “Owner's Handling Manual” and understand the contents well to ensure safety
during maintenance and repair.
3. Maintain the machine sufficiently to allow the machine to deliver better performance.
4. All rights reserved
Introduction

- -1
1. Specifications 2
2. Maintenance schedule 2
3. List of major power transmission parts 3
4. Wiring diagram 4
5. Electrical equipment 5
5-1. Electrical equipment box 5
5-2. Fuse box 5
6. Hydraulic circuit and equipment 6~7
7. Maintenance of each part 8~17
7-1. Hydraulic system 8
7-2. Engine 9
7-3. Fuel system/radiator 10
7-4. Air cleaner/battery 11
7-5. Step 12
7-6. Belt adjustment 13
7-7. Adjustment and detachment of rubber crawler 14
7-8.
Adjustment of the neutral position of piston pump 15
7-9. Greasing of friction parts 16
7-10. Hammer knife 17
8. Troubleshooting 18~23
8-1. Engine trouble 18~19
8-2. Traveling system trouble 20
8-3. Hammer knife trouble 21~22
8-4. Overheating 23
8-5. Step trouble 23
9. Checklist 24
CONTENTS
Engine
P. 9
Electrical equipment
P. 5
Step
P.12 Adjustment of
neutral position
P.15
Hydraulic system
P.6~8
Crawler
P.14
Power transmission
P.3 & P.13
Hammer knife
P.17

- -2
1. Specifications
HMA1560 HMA1720
1,717mm 1,910mm
30 7.2cm(51P)
Forward: 0-6.5 km/h
Backward: 0-4.5 km/h
Belt tension type
3-28 cm(max. 42 cm)
(Mowing width Operation speed 0.7)
30
35 7.2cm(51P)
120 blades 140 blades
154cm 170cm
70 are/h (6.5 km/h) 77 are/h (6.5 km/h)
16.6kPa
1,470kg
1,535kg
14.6kPa
1,510kg
1,575kg
Dimensions
Total length
Total width
Total height
Engine
Rubber crawler
Speed change
(Hydraulic variable speed)
Hammer knife
Knife clutch
Mowing height
Mowing width
Efficiency
Max. operating inclination
Ground pressure
Dry weight
Curb weight
3,000mm(3,200mm Foot step)
1,350mm
Mitsubishi Diesel S4L2-E231KM 1.758L (1,758 cm3)
Max. output: 26.5 kW/2,800 rpm (36 PS/2,800 rpm)
Fuel tank: 33 L (dm3)
2. Maintenance schedule
Inspection, adjustment, replenishment and cleaning
Replacement
Engine Main unit
Knife section
Others
Maintenance
Engine oil
Oil filter
Fuel filter
Electromagnetic pump filter
Air cleaner element
Air cleaner urethane
Cooling water (qty, leakage, etc.)
Fuel (qty, leakage, etc.)
Hydraulic oil (qty, leakage, etc.)
Hydraulic oil filter
Tightening of hydraulic hose/joint
Electrolyte
Radiator core
Side brake
Traveling lever
Neutral position
Emergency switch operation
Step operation
Operation of respective switches and meters
Lighting of pilot lamp
Knife tension operation
Strength of knife tension
V-belt tension
Crawler tension
Breakage of hammer knife
Looseness of knife mounting bolt
Knife shaft bearing
Dust-proof cover and protection plate
Greasing each section
Looseness of screw in each section
Accumulation of dust
Visible damage
Initial
After 10 hr
Hydraulic motor oil Initial
After 200 hr
Before
use
10hrs every
50hrs
every
200hrs
every
500hrs Page
9
9
10
10
11
11
10
10
8
8
-
8
11
10
-
-
15
-
12
-
-
-
13
13
14
17
16
-
-
-
Repair or replace the abnormal part immediately irrespective of the above schedule.

- -3
3. List of major power transmission parts

- -4
Starter switch connection 4-pole ON-ON switch
521189126310 741 163452
Electric
cylinder
Fan
control
unit
Solenoid valve
for fan rotation
Solenoid valve
for mowing height
Safety
switch
Fuel
pump
Fuel
gauge
Starter Thermo
switch
12V 80Ah/20HR
95D31R battery
Oil
pressure
switch
Alternator
Engine
Charge
lamp
Solenoid Glow plug
Flat connector
(AV0.85)
Red
and
black Red
White Blue
Flat connector
Tank
unit
Alarm
buzzer
Water
temperature gauge
Water
temperature gauge
Thermo
switch
Glow
lamp
Glow
timer
Emergency
switch
Safety relay
Glow relay Relay
Oil
pressure
lamp
Brake release
solenoid
Horizontal
controller
box
Inclination
sensor
Glow timer
4
4
44
2
22
857
3
53
3
3
1
11
6RPLES
Control timer
Relay N.C. relay
N.C.
relay
Safety relay
2-pole ON-OFF-ON switch
Solenoid valve for
single-/double-acting
changeover
Control timer
– CAUTION –
The wires with the same numberd
mark are connected to one wire
inside the wiring system.
The single wires with mark without
number and the wires connecting
the wires of the same numberd
mark are connected to a grounding
wire at the back of the electric
equipment box.
B
OFF
1
2
MSG2
Yellow and red
(AV1.25)
Yellow and red
(AV1.25)
Yellow
and red
(AV2)
Yellow
and red
(AV1.25)
Yellowand red
(AV1.25)
Yellow
(AV5)
Black(AV1.25)
Green and red
(AV1.25)
Blue(AV2)
Orange(AV0.85)
Red(AV0.85)
(AV1.25)
50A 5A 5A 5A 5A 5A 5A
20A 20A 20A 5A
(M6)
Red
(AV5)
(M5)
(M5)
G2
G1
(M4)
(M4)
B
SM
Red(AV2)
Red(AV2)
Red(AV1.25)
Gray(AV1.25)
Black and yellow(AV0.85)
Red and white(AV0.85)
Red and black(AV0.85)
White(AV2)
Red(AV5)
Black(AV30)
Pink(AV3)
White and yellow(AV0.85)
Blue(AV5)
1
65
1
1
2
2
3
4
3
4
7
5
6
43
243 12 4 3
Green(AV5)
Yellow(AV0.85)
Blue(AV5)
Black
(AV30) Black
(AV5)
Black
(AV0.85)
Black
(AV0.85)
Green
(AV0.85)
Red and white
(AV0.85)
Red and white(AV0.85)
Yellow and black
(AV0.85)
Black
(AV0.85)
Black(AV0.85)
Black(AV3)
Yellow and blue(AV0.85)
Yellow and red(AV0.85)
White(AV0.85)
Black(AV1.25)
Black(AV1.25)
Yellow and black(AV0.85)
Blue(AV0.85)
Green(AV0.85)
Red(AV1.25)
Blue and white(AV0.85)
Yellow and red
(AV0.85)
White and black
(AV0.85)
Yellow
and blue
(AV0.85)
(M12)
(M4)
(M5)
(M6)
(M6)
(M6)
(M8)
(M6)
L
B
P
R
L
R
L
R
PS
E
(M6)
(AV0.85)
Yellow
(AV5)
50A
Red and white(AV1.25)
White(AV5)
White(AV0.85)
Black(AV1.25)Black(AV1.25)
Black(AV3)
Black(AV2)
Black(AV1.25)
Black(AV1.25)
Black
Brown(AV5)
Brown(AV1.25)Brown(AV1.25)
Red(AV1.25)
Red(AV3)
Red and yellow(AV2)
White and
red(AV2)
White and red(AV2)
Red(AV2)
Red(AV0.5)
White(AV0.5)
Black and
white(AV0.5)
Black(AV0.5)
Green(AV0.5)
Brown(AV0.5)
Sky blue(AV0.5)
Red(AV2)
Black(AV2)
White and red(AV2)
White(AV2)
White(AV2)
Black(AV2)
White
(AV2)
Blue(AV1.25)
Blue(AV1.25)
Blue(AV1.25)
Blue
Blue
Blue
White
Black
Blue
Green
Green
Green
White
Black
Red
Green
Blue(AV1.25)
Green(AV1.25)
Green(AV1.25)
Green(AV1.25)
Brown(AV0.85)
Blue and yellow
(AV0.85)
Black
(AV1.25)
Black
(AV0.85)
Black
(AV0.85)
Red and yellow(AV0.85)
(M6) T(M6)
E
B1(M5)
M(M8)
(M8)
(M5) (M5)
(M5)
(M6)
(M6)
(M4)
(M5)
+E
S
B
-
(M6)
(M6)
(M6)
(M6)
(M6)
(M6)
(M6)
(M6)
(M6)
(Flat connector)
4. Wiring diagram

- -5
No. Part name Application
1 Horizontal controller box Horizontal control of step
2 Fan control unit Control of direction of cooling fan rotation
3 Fusible link Main fuse of electric circuit (50A)
4 Relay Step control 2 ; fan control 2
5 Glow relay Relay for engine glow relay
6 Starter relay Engine starting relay
7 Relay Fuel shutoff solenoid relay
8 Control timer Control of electric circuit of engine
9 Safety relay Emergency stop relay
10 Glow timer Engine glow control
11 Fusible link Engine glow fuse (50A)
5. Electrical equipment
5-1. Electrical equipment box 5-2. Fuse box
No. A Location
15Alarm buzzer
25Oil pressure lamp
35Fuel gauge and water temperature gauge
420Step changeover switch
520Fan control unit
65Control timer unit
75Charge lamp
85Safety switch
95Solenoid valve
10 5 Fuel pump
11 5 Spare fuse
12 20 Spare fuse
13 - Fuse puller
Fusible link installation position

- -6
Knife frame up/down (45-70-250 double-acting 2)
EDV1-02T-12V-00
KES-VU02T-00
B
PT
a2 a1
A
VPF-06
KP1009
MAG-18P-150 SP08
(10 m)
Hydraulic tank
PSV2-16A
A
TP
IN PF
EF T
P
T1
T1
P1 P4
P2 P3
B1 B2
T2
P2
P1
A
P
B
T
P2
ab
MAG-18P-150
HD-02413
MA6AD661
T2
P1
166/151 Eng
S
R/G
pPp
R/G
VRD-03-05
6. Hydraulic circuit and equipment

- -7
Hydraulic pump
Traveling piston pump
+
Hydraulic equipment driving gear pump
Flow priority
Flow dividing valve
(flow volume control valve)
Valve unit
.Mowing height adjustment control
(Up/down of hammer knife)
.Single-double changeover of hydraulic
cylinder
Relief valve
Protection of gear pump
Solenoid valve
Control of direction of cooling fan rotation
Solenoid valve
Control of brake in traveling motor
MAG motor : Traveling motor
Hydraulic cylinder : Up/down of hammer knife
Gear motor : Cooling fan motor
Oil filter : Removal of contamination and impurities
Oil cooler : Cooling unit

- -8
A. Hydraulic tank
The tank is at the front of the center
of the machine. The oil filler port and
oil level gauge are at the left side of
the machine.
Remove the seal of the oil filler port,
and carefully supply hydraulic oil so
that dust or other impurities will not
enter.
Hydraulic oil : Shell Tellus ST46
D. Traveling motor (MAG motor)
0.35 L of gear oil is in the speed
reducer of the traveling motor.
Change oil after 50 hr of initial
operation and every 200 hr thereafter.
Gear oil : VG140
B. Hydraulic tank drain
The drain is at the bottom of the right
side of the hydraulic tank.
The drain plug itself has no sealing
function.
Be sure to apply seal tape.
C. Oil filter
It is at the left side of the back of the
machine.
Refer to “6. Hydraulic circuit and
equipment.”
7. Maintenance of each part
7-1. Hydraulic system
(Supplement) Direction of port when changing gear oil
Waste oil Oil supply