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

- -9
A. Engine oil change
Drain engine oil through the drain
hose near the crawler at the left side
of the machine.
Keep the drain hose inserted in the
holder usually when engine oil
change is not necessary.
B. Engine oil supply
Supply engine oil through the oil
filler port atop the engine. Use the
accompanying funnel to supply oil.
.Engine oil specification
API standard: Grade CC or above
.Quantity of engine oil
7.9 L
(Supplement) Actual oil supply
Clean the machine to prevent dust from
entering the engine before oil supply.
The photo shows the condition when
the left side cover is removed.
7-2. Engine
C. Engine oil gauge
A saber type oil gauge is used for the
machine.
D. Engine oil quantity
Be sure to check the oil quantity when
changing or supplying oil.
The machine is to be operated on a
slope as well, so supply oil to the
maximum.
E. Oil filter
The oil filter is at the front side of the
engine (between the engine and
hydraulic oil tank).
Before changing the oil filter, stop the
engine and cool it sufficiently.

- -10
A. Water sedimenter
Primary fuel filter
When the red float at the bottom of
the cup rises, water is mixed with the
fuel. Change the whole quantity of
the fuel.
B. Fuel pump
Fuel supply electromagnetic pump
+
Secondary fuel filter
C. Exploded view of fuel pump
There is a filter also in the fuel pump.
Unlike other filters, this filter cannot
be checked from outside. Exercise
care.
7-3. Fuel system/radiator
D. Fuel filter
Tertiary fuel filter
Air bleeding is automatically
conducted by the engine itself, but
when air bleeding is incomplete,
bleed air with the bolt atop the filter.
E. Radiator
It is at left side of the machine.
(Right side of photo)
High-pressure cleaning will damage
the heat sink, reducing the cooling
effect.
Low-pressure air blowing is
recommended.
F. Reserve tank
It is at the right side of the machine.
The volume of water is approx. 11 L
in the circulation section, and it is
approx. 0.8 L in the reserve tank.
Adjust the quantity of coolant
according to the environment.

- -11
A. Air cleaner
It is atop the hydraulic tank at the
front of the machine. The cover is at
the left side of the machine.
Pay attention to the installation
direction of the cover.
Be sure to stop the engine before
maintaining the air cleaner.
B. Air cleaner element
Remove the cover and wing bolt, and
the element can be removed.
When the filter is extremely dirty or
broken, change it immediately.
C. Air cleaner cap
It is at the center of the top of the
machine.
A cleaner cover and urethane for the
cleaner are provided for dust control.
D. Cleaner cover and urethane
The air cleaner cap consists of these
parts shown in the photo.
Check that the machine is in the
condition shown in Photo C before
mowing operation.
E. Battery
It is at the front of the radiator box at
the left side of the machine.
Be sure to remove the grounding wire
(-) before maintaining the electrical
equipment.
7-4. Air cleaner/battery

- -12
A. Step
It is a simple riding unit provided at
the back of the machine.
The electric cylinder is at the right
side of the disc at the center.
The photo shows the step without the
cover.
B. Step operation switch
.Step control changeover switch
(Photo: Top)
AUTO :
The step automatically swings
according to the angle of inclination.
MANUAL :
Use the switch shown at the bottom
of the photo to swing the step.
.Step control manual switch
(Photo: Bottom)
Manual operation switch to be used
when the switch shown at the top of
the photo is set in the “MANUAL”
position.
7-5. Step
C. Horizontal sensor
(Analog sensor, Slope Eye 30)
It is at the front of the disc at the
center.
This horizontal sensor senses the
angle of inclination.
D. Horizontal controller box
It is in the lower section of the back
inside the electrical equipment box.
The signal from the horizontal sensor
is transmitted to the electric cylinder.
Refer to “5. Electrical equipment.”
E. Relay
(Two relays - front and back - at the
far left of the photo)
External relays for the horizontal
controller box
Refer to “5. Electrical equipment.”

- -13
7-6. Belt adjustment
A. Engine pulley ~ Hydraulic pump
(V-belt W4SB72 2 pcs)
Adjust the hydraulic tension bar
spring.
Appropriate spring length : 52-55 mm
B. Engine pulley ~ Sextuple pulley
(V-belt W4SB64 3 pcs)
Adjust the knife tension rod spring.
Appropriate spring length : 52-55 mm
C.
Sextuple pulley ~ Intermediate shaft pulley
(Low-edge cogged belt H-PXSB54 3 pcs)
Adjust the tension lever spring.
Appropriate spring length : 47-50 mm
D. Intermediate shaft pulley ~
Knife shaft pulley
(V-belt W4SB59 3 pcs)
1. Adjust the tension pin and M8 nut
at the tension pulley adjusting bolt
section.
Loosen the tension pin and tighten
M8 nut , and the belt will be
stretched.
After adjustment, be sure to tighten
and secure the tension pin.
2 . Measurement of belt tension
(Reference)
Pull the center of the belt between
pulleys with a spring scale.
Check the tension by the belt
pulling force and the quantity of
belt distortion.
3 . Belt tensions (Reference)
Appropriate values
Belt pulling force : 5 kg
Qty of belt distortion : 20 mm
The circumferential length of the
V-belt changes according to the
time and environment of use.
Try to keep appropriate tension at
all times.

- -14
7-7. Adjustment and detachment of rubber crawler
A. Stretching the rubber crawler
Supply grease to the grease nipple of
the grease cylinder at the back of the
rubber crawler to tension the crawler.
B. Loosening the rubber crawler
1. Loosen the bolt (width across flats:
22 mm) on the grease nipple.
2mm
C. Detaching the rubber crawler
After loosening the rubber crawler,
jack up the machine and lift the
rubber crawler above the ground.
Remove the front portion of the
crawler first. It is convenient to use a
long crowbar shown in the photo.
When attaching the crawler, fit the
sprocket side first, and then fit the
front roller side.
D.
Adjustment of the rubber crawler tension
Refer to the figure at left, and adjust
the tension.
Looseness or excessive tension will
cause the rubber crawler to come off.
2. Grease will leak from the loosened
bolt section, and the rubber crawler
will be loosened.
E. Configuration of rubber crawler parts

- -15
Lock nut
(left-hand thread)
Lock nut
(right-hand thread)
Lock shaft
Groove
Groove
Traveling lever
Neutral stopper
M10 right-/left-hand thread rods
Pump
Mounting bolt
Left neutral lever
mounting base for pump
Right neutral lever
mounting base for pump
7-8. Adjustment of the neutral position of piston pump
A. Adjustment of neutral position
.
When the machine will not stop even if the traveling lever is released, adjust the neutral position in the manner shown below.
Secure the machine so that the rubber crawlers at right and left will be lifted above the ground, and release the side
brake. (When the rubber crawler is out of place, lift the sprocket above the ground.)
After loosening the mounting bolts (Fig.B), start the engine and move the neutral lever right and left to find the neutral
position.
The engine is running. Be careful of the rotating parts and hot parts.
When the neutral position is found, tighten the mounting bolts, and recheck that the machine is in the neutral position.
Adjustment of the neutral position is finished.
Then while keeping the machine in the neutral position, pull the side brake and make adjustment so that the lock shaft of
the traveling lever is set in the grooves of the neutral stopper. (Fig.A)
Loosen the lock nuts of the M10 rods at right and left. (Fig.A: 4 locations in total)
Rotate the rods to adjust the length of them and make adjustment so that the lock shaft will be set naturally in the
grooves.
Confirm appropriate setting of the lock shaft and grooves by repeat of lock and unlock of the side brake several time.
After adjustment, tighten the lock nuts and check again the locational relationship between the lock shaft and grooves.
Now all the processes are finished.
.If the side brake cannot be pulled (the lock shaft and grooves are not in position) although the machine is at rest when the
traveling lever is released, continue operations from .
B. Q&A about neutral position
Q : What will happen when the neutral position is not correct?
A : Even if the operation lever is released in an emergency, the machine will not stop, which is very dangerous.
Q : What will happen when the lock shaft and groove are not in position.
A : You cannot pull the side brake, and you cannot park the machine correctly. When you pull the side brake forcibly and
align the lock shaft with the grooves by force, the traveling machine will be forcibly stopped by the brake; therefore, the
relief valve will be activated, raising the oil temperature suddenly.
When the oil temperature rises, the hydraulic equipment will be damaged.
Fig. A
Fig. B

- -16
7-9. Greasing of friction parts
Apply grease to respective joints in good time to prevent rusting.
Supply grease every 50 hours to grease nipples.
A. Greasing section
.Crawler section [26 locations]
.Operation lever & parts relating to the neutral position [8 locations]
.Tensioning section [3 locations]
.Knife frame support [2 locations]
.Both sides of knife shaft [2 locations]
Greasing of both ends of the knife shaft is not for lubrication but for protection
(waterproofing and dustproofing) of the bearing.
Exercise care so as not to apply pressure when greasing.

- -17
7-10. Hammer knife
The knife shaft is rotating at high speed, and slight loss of balance will cause substantial
vibration. Machine operation with loss of balance may cause an unexpected accident or
failure. Maintain the knife shaft most carefully.
A. Maintenance of knife shaft
B. Protective device
No.
1
2
3
4
5
6
7
Part
Knife blade
Mounting pin
Mounting hitch
Balance weight
Support shaft
Bearing
Knife shaft
Inspection item
Missing blades
Breakage, curvature, or uneven abrasion
Wrong direction
Looseness
Curved or open
Breakage or uneven abrasion
Missing
Abrasion
Uneven abrasion
Unsmooth rotation
Twining of vines or cords
Distortion as a whole
Correction
Attach.
Replacement
Attach correctly.
Tightening (*1)
Correction
Repair or replacement (*2)
Repair by specialist (*2)
Repair or replacement
by specialist (*2)
Replacement
Removal
Replacement
The protection cover, protection plate, and knife guard are
protective devices. Attach them correctly before work. Replace
them immediately if they are damaged in any degree.
An anti-scattering chain is provided as an option. Use it
according to the working environment.
*1 The tightening torque of the knife mounting pin is 32-36 Nm (equivalent to M10
ordinary bolt). Excessive tightening will damage the thread of the mounting pin.
*2 Special correction by balancing machine may be required.

The engine will not start.
(The starter motor does not work.)
Is the knife clutch disengaged?
Are respective fuses normal?
Is the battery output normal?
Are respective connections
of wiring normal?
Is the starter relay normal?
Disengage the knife clutch. See page 10 of the handling manual.
See pages 4 and 5 of this manual.
Refer to the battery operation manual.
See page 4 of this manual.
See pages 4 and 5 of this manual.
Use of fire prohibited during fuel supply.
See page 10 of this manual.
See page 11 of this manual.
Refer to the engine operation manual.
Change fuses.
Charge or replace the battery.
Connect the wire again.
Change the relay.
Supply fuel.
Change filters.
Clean or change the element.
Change solenoid.
Failure of main switch
Failure of control timer
Defective compression
Failure of main switch
Failure of starter motor
Defective grounding
Is fuel in the tank?
The engine will not start.
(The starter motor works.)
Is the fuel filter normal?
Is the air element normal?
Is the fuel shut-off solenoid
normal?
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
See page 4 of this manual.
See pages 4 and 5 of this manual.
Refer to the engine operation manual.
See page 4 of this manual.
Refer to the engine operation manual.
See page 4 of this manual.
NO
NO
NO
NO
NO
NO
NO
NO
- -18
8. Troubleshooting
8-1. Engine trouble