FOUR ASHES MACHINERY LTD.

KIT 360 ASSEMBLY INSTRUCTIONS

For information regarding the assembly procedures please contact:

contact@four-ashes.com

1- Contents Remove one panel of the crate to facilitate the inventory. The crate can be re used once

the machine is assembled for onward shipping of the completed machine if required.

Heavy components such as the main chassis will require a minimum of two people or

the use of lifting equipment. Please wear appropriate footwear and take care when

lifting heavy parts.

Once all the parts have been removed from the crate, you can now start the inventory

as per the list below. Please check that everything is present before starting assembling

the machine.

2x Rubber Tracks

2x Side Fenders

6x Rollers

2x Cog Wheels

2x Cog Wheels Spacers 25mmØ

2x 160cc Hydraulic Orbital Motors

1x Chassis Base

1x Front Wheels Axle

2x Track Tensioners

1x Front Dozer Blade

1x Dozer Blade Axle

6x 25mmØ x 35mm Bushes

1x 7 Ports Hydraulic Rotating Manifold

1x Manifold Support Plate

1x Underside Skid Plate

1x Main Body Platform

1x Seat

1x Hydraulic Orbital Motor 315cc

1x Slew Ring

1x Gear

2x Control Valve Units

1x Set of Hoses (Refer to Hydraulic Paragraph for Listing)

1x 6.5hp Gasoline Engine

1x Gear Pump 3.2cc

1x Bell Housing and Coupling

1x Hydraulic Reservoir Inspection Plate, Gasket and Cap

1x Oil Level Gauge

6x Hydraulic Rams

1x Boom Housing

1x Boom

1x Dipper Arm

2x Pivot Brackets

1x Set of Pins (diameter and minimum length):

Ø20mm x 9

1x 150mm for the centre axis of the two direction cylinders

1x 70mm for left hand direction cylinder head

1x 70mm with round head for dozer blade cylinder head

1x 80mm with round head for dozer blade cylinder body

2x 90mm on dipper arm for bucket cylinder

1x 130mm with round head for bucket bracket pivot

2x 200mm for bucket

Ø25mm x 7

1x 270mm for boom housing

2x 140mm for boom and boom cylinder body

2x 110mm for boom cylinder head and dipper cylinder body

1x 120mm boom to dipper pivoting axis

1x 90mm for dipper cylinder head

4x Ø20mm x 25mm bushes / spacers for bucket

1x Bag of Mechanical Fittings:

M5 or M6 Lynch pins x3

M12 x 120 bolts x 4

M12 x 70 bolts x 2

M12 x 50 bolts x 4

M12 x 30 bolts x 40

M12 nylon insert nuts x 6

M12 nuts x 4

M12 washers x 28

M10 nylon insert nuts x 4

M8 x 60 bolts x 6

M8 x 50 bolts x 1

M8 x 30 bolts x 14

M8 x25 bolts x 6

M8 x 20 bolts x13

M8 nylon insert nuts x 12

M8 washers x 19

M8 x 40 Ø flat washers x 6

M6 x 40 bolts x 4

M6 x 20 bolts x 8

M6 washers x 8

Circlips x 2

M20 washers x 12

M24 washers x 12

M10 male/male rubber dampers x 2

M8 male/female rubber dampers x 4

M6 grease nipples x 20

1x Bag of Hydraulic Fittings:

Banjo screws size ¼ x 16 (Hydraulic rotating manifold and motor drain)

Connectors ¼ Male x ¼ Female x 8 (Top of hydraulic manifold)

Washers size ¼ x 40 (For above)

Banjo screws size ⅜ x 22 (Bottom row control valves, rams, return to tank)

Union ⅜ Male / ⅜ Male x 10 (Top row control valves, left/right rams)

Washers size ⅜ x 54 (For above)

T connectors ⅜ x 3 (Left/right rams connection, case drain)

Banjo screws size ½ x 11 (Hydraulic motors, flow in/out control valves)

Washers size ½ x 22 (For above)

Carry over ½ valve x 1 (top hole of control valve fed by pump)

Fluted connector ⅜ x 19mm x1 (Flow in to pump/hose no.1)

Valve ¾ x1 (Exit of reservoir)

Fluted connector ¾ x 19mm x1 (Exit reservoir/hose no.1)

Washer size ¾ (For above)

3x Buckets

1x Ripper Tooth

2- Introduction

These instructions are to help you in the assembly process of the first machine(s). They are a

guideline only reflecting our own experience in machine assembly. Please take all the necessary

steps to ensure your personal safety and of others during the assembly process.

Our machines are in constant evolution and our aim is to reduce the assembly time to a minimum. It

is possible that the machines you received is slightly different than the one above and we will update

these instructions whenever possible. Your feedback would be appreciated to help improve our

services and products.

We recommend the use of hydraulic thread lock fluid when fitting hydraulic connectors or in some

cases PTFE tape. Thread lock fluid is also recommended for bolts which are not used in conjunction

with a nylon insert nut or spring washer. Check all bolts after a few hours of use and again at regular

intervals.

You will also need a good selection of tools including a set of flat spanners in metric sizes (10, 13, 17,

18, 19, 22, ….), adjustable wrench, hex keys, hammer, mallet, hammer, metal file, drill, angle grinder

with metal cutting disc, M6 and M8 taps… And other consumables like hydraulic oil (20L of ISO

HVI46), 4 stoke engine oil (1L of 10W40), grease and grease gun, cable ties, hose wrap, etc….

3- Rolling Chassis

Once you have identified all the parts, place the chassis base on the floor with a piece of cardboard

or similar to avoid damaging the paint work.

Position the slew ring and fix using 12 M12 x 30 bolts.

Then assemble the front track tensioners and axle. Excess paint may have to be removed first to

facilitate the assembly. 4 M12 x 120 bolts are used to tension the tracks, together with 4 M12 nuts

to lock the bolts in position, once the rubber tracks are tensioned.

The slew ring is sealed and already greased, however grease can be added prior to assembly.

Although the front roller axle doesn’t need to rotate in the square blocks, this can also be greased to

facilitate future removal, if needed. To do so, place a grease nipple in the tapped hole, grease and

remove the nipple. This operation can be repeated during servicing to avoid seizing up.

Next, prepare the hydraulic rotating manifold with all the 7 hoses - nos. 25 to 31 – connected to the

sides using the corresponding letters (A to G). Refer to the hydraulic diagram. Each hose is fixed to

the side of the manifold using a banjo screw size ¼ BSP and one washer on either side of each banjo

hose fitting.

Position the manifold so the two dozer blade hoses, nos. 25 and 30, are facing towards the front of

the machine, as per the pictures below.

Bolt on the retaining plate to the hydraulic rotating manifold using 6 M8 x 30 bolts and washers.

Then fix the whole assembly to the bottom of the chassis using 2 rubber dampers and 4 M10 nylon

insert nuts, so the top of the hydraulic rotating manifold is flush with the top of the slew ring. You

may find this procedure easier by fixing the rubber dampers to the chassis tabs first. Please note the

length of the threaded ends of the dampers are a standard size and may need shortening to fit.

Once the rotating manifold is in place, run the hoses through the holes on either end of the chassis

and fix the two 160cc tracking motors using 4 M12 x 50 bolts and 4 M12 nylon insert nuts.

With the machine still on its back as per the pictures, position the 4 rollers and push them into

position onto the fixed axles until fully inserted. Note the stub axle closest to the hydraulic motor

doesn’t have a roller and is simply used to fix the side protection plate.

Before inserting the front rollers, you need to fit the dozer blade and its axle. The dozer blade axle

slides through the chassis holes and is secured with 2 M12 flat washers and 2 M12 x 30 bolts.

Once the dozer blade in position – and facing the right way as per the pictures – you can now insert

the remaining 2 rollers in the front axle.

Now you are ready to fit the rubber tracks. The direction of the rubber tracks thread is not

important. To fit the rubber tracks, it is easier to do as follow: place one rubber track over all the

rollers and insert the cog wheel inside the track. Then pull on the cog wheel until it reaches the track

motor shaft and slide the cog onto the shaft with the key way in place. Please note the motor shaft

can be greased to facilitate future removal if needed.

Repeat on the other side.

Fit all the spacers: 6 x 35mm by 25mm Ø bushes on the end of each roller axle. For securing the cog

wheels, insert a spacer tube and secure with 2x M8 x 60mm bolts and 2x M8 x 40mm flat washers.

Use thread lock fluid on the bolt and tighten fully

Repeat on the other side. With the machine still upside down, you can now fix the bottom protecting

plate with 4 M12 x 30 bolts

Spacer

tube

Bush

The rolling chassis can now be flipped back onto its tracks.

Hoses nos. 26 to 29 for the tracking motors can now be fixed using 4 ½ banjo screws with washers,

one on either side of each banjo hose fitting.

Hoses 32A and 32B for the case drain can also be attached. Just remove the case drain plug with a

hex key and fit the hoses with 2 ¼ banjo screws and one washer on either side of each banjo hose

fitting. Please note, in some case, to obtain a better fit, you may have to remove the thin metal plate

from the motor first.

Next, position the dozer blade hydraulic ram with the ports facing down, secure with pins on either

ends and 2 M6 lynch pins and attach hoses nos. 25 and 30 with their banjos screws and washers

Case drain

Thin metal plate

Tension the tracks using the 4 M12 x 100 bolts and securing nuts leaving about 1 inch of slack. Do

not over tension. Once the tracks are tensioned, fix the side protection plates using 8 M12 x 30 bolts

and washers. The rolling chassis is now completed.

Please note that the two middle holes on the side protection plates may not align with the axles, this

is due to heat deformation during welding and this varies from machine to machine. The holes can be

enlarged to fit or alternatively, just two bolts can be used on each plate to secure it: one at the front

and one at the end.

4- Rotating Platform

The rotating platform is heavy and requires two people or the use of lifting equipment.

The platform needs to be positioned exactly above the slew ring and the rotating hydraulic manifold.

Some wriggling is needed to align all the holes into position. Only hand tighten the bolts, 14 M12 x

30 bolts for the slew ring and 6 M8 x 25 bolts for the rotating manifold, until all the bolts are in

place. Tip: plug in the hydraulic port holes A to G on top of the rotating to avoid dirt and scraps of

paint falling in.

Once fitted the platform should rotate 360 degrees freely on top of the rolling chassis.

Next fit the small gear onto the shaft of the 315cc hydraulic motor using 1 M8 x 50 bolt and 1 M8 x

40 flat washer. Tip: you can make a tab washer with a large M8 x40mm penny washer to lock the

securing bolt so the gear doesn’t slide off the shaft, alternatively use a spring washer and thread lock

fluid to tighten the bolt.

Place the motor with its gear through the platform and engage the gear against the slew ring, keep

into position whilst tightening with 2 M12 x 70 bolts and 2 M12 nylon insert nuts and washers. Make

sure the ports to fit the hoses are facing forward.

Hand-made tab

washer

Fit the two control valves onto the platform bulkhead. You will need 4 M8 x 60 bolts and 4 M8 nylon

insert nuts.

Attach hoses no. 5 to 10 to the top of the rotating manifold onto their corresponding holes (A to F)

using for each hose, one ¼ adaptor Male / Female – which acts as a spacer – a washer and one ¼

banjo screw with two washers. The centre hole, G, requires two adaptors on top of each other,

before hose no. 32 can be fitted.

Refer to the hydraulic diagram to connect hoses 5 to 10 onto the control valves. Hose 32 connects

the rear of the reservoir using one 3/8 banjo screw with two washers, as per the picture below.

Please note that the two other holes on this picture will be for the return from the control valves

hoses no.4

5- Boom Housing and Arms

For the boom housing, main boom and dipper arm assembly we recommend that you first identify

all the relevant pins and if necessary rub the excess paint off. Make sure all the pins fit freely into

their bushes or holes and clear any swards of metal if necessary using a metal file. Re-tap and fit all

the grease nipples into their location prior assembly. Secure the pins with 3x M6 lynch pins and 13

M8 x 20 bolts.

Please note that the pins may be over-sized in length. These can be cut flush, if required, or left as

they are. Only the pins with a round head need a lynch pin to secure them, all the other pins are

secured with an M8 bolt. Use thread lock fluid and check all bolts at regular intervals.

First fit the boom housing and the two digging arms.

Secure with pin.

Place an M24 washer between the boom housing

and support before fitting the boom housing.

Then position the two left and right hydraulic rams with the port holes facing inwards, secure with

the two pins and some M20 washers to level them.

Connect the directions hoses nos. 11-16 and the two connecting T’s, using banjo screws at the front

of the rams and two unions male 3/8 x male 3/8 to fit the elbow fittings at the rear of the ram.

Please note that when fitting a union connector, only one washer is needed between the union

connector male / male and the flat surface it is mating on (i.e. no washer on the hose side needed)

You can now connect the hoses for the 315cc hydraulic rotating motor using two ½ banjo screw and

washers. Then position the foot platform. This may need cutting, depending on the weld and heat

distortion, if any. Then secure with 4 M6 x 20 bolts.

T connectors. No

washer required there

Assemble the main boom and dipper arm and use M24 washers to reduce lateral play. Secure with

pins.

Assemble the bucket pivot bracket again using M20 washers to limit play. Once in place, secure all

the pins.

Position the three remaining hydraulic rams – the thinner one is for the bucket – and connect all the

hoses using six 3/8 banjo screws and twelve washers.

This M8 bolts will need 2

washers so it doesn’t foul

with the bracket during

bucket curling

6- Hydraulic Components and Hose Diagram

Start by connecting the 10mmØ hoses nos. 2, 3 and 4 (time 2) which feed the oil to and from

the control valves.

For a neater, more compact arrangement, remove the ½ inch plugs on the front of the

controls and fit to the sides. IMPORTANT: THE CONTROL VALVES ARE NOW 4 BANK ON EACH

WITH A TOTAL OF TWO JOYSTICKS AND 4 LEVERS AS PER DRAWINGS

Remove the four ½ plugs and place on the sides of both control valves instead of the orange plastic

caps. Hose no. 3 connects the two control valves together and must be fitted as per the above

picture.

Insert carry over

valve here and

connect hose

No3

Remove this

plug and fit it on

the side instead

of orange plastic

one. Connect

other end of

hose No.3 Remove this plug and fit it on

the side instead of orange

plastic one. Connect hose No.2

from the pump

Remove this plug and

fit it on the side

instead of orange

plastic one. Connect

hose No.4 and return

to reservoir

Remove this plug and fit it

on the side instead of

orange plastic one. Connect

hose No.4 and return to

reservoir

½ inch BSP carry over valve to

connect one control valve to the

other with hose No.3

Hose listing:

No. Diameter / Length (mm) Hydraulic Crimped Fittings Function

1 19 / 450 None Feed to Pump

2 10 / 1750 Banjo ⅜ / Banjo ½ Pump Feed to Control Valve

3 10 / 600 Banjo ½ / Banjo ½ Carry Over Valve to Valve

4 10 / 1800 (2 of) Banjo ½ / Banjo ⅜ Return to Reservoir

5 8 / 1020 Banjo ⅜ / Banjo ¼ Position D Top

6 8 / 960 Banjo ⅜ / Banjo ¼ Position B Top

7 8 / 900 BSP ⅜ x90 / Banjo ¼ Position E Top

8 8 / 930 BSP ⅜ x90 / Banjo ¼ Position F Top

9 8 / 910 Banjo ⅜ / Banjo ¼ Position A Top

10 8 / 1030 BSP ⅜ x90 / Banjo ¼ Position C Top

11 8 / 370 BSP ⅜ x90 / BSP ⅜ x90 T connector

12 8 / 330 Banjo ⅜ / BSP ⅜ x90 T connector

13 8 / 860 Banjo ⅜ / BSP ⅜ xStraight T connector Boom Direction

14 8 / 330 Banjo ⅜ / BSP ⅜ x90 T connector

15 8 / 1300 BSP ⅜ x90 / BSP ⅜ x90 T connector

16 8 / 100 BSP ⅜ x90 / BSP ⅜ xStraight T connector Boom Direction

17 8 / 1150 Banjo ⅜ / Banjo ½ Slew Motor Right

18 8 / 1120 BSP ⅜ x90 / Banjo ½ Slew Motor Left

19 8 / 1500 Banjo ⅜ / Banjo ⅜ Main Boom

20 8 / 1400 Banjo ⅜ / BSP ⅜ x90 Main Boom

21 8 / 1800 Banjo ⅜ / Banjo ⅜ Dipper

22 8 / 1600 Banjo ⅜ / BSP ⅜ x90 Dipper

23 8 / 2400 Banjo ⅜ / Banjo ⅜ Bucket

24 8 / 2700 Banjo ⅜ / BSP ⅜ x90 Bucket

25 8 / 610 Banjo ⅜ / Banjo ¼ Position A Side

26 8 / 710 Banjo ½ / Banjo ¼ Position C Side

27 8 / 730 Banjo ½ / Banjo ¼ Position E Side

28 8 / 780 Banjo ½ / Banjo ¼ Position B Side

29 8 / 720 Banjo ½ / Banjo ¼ Position D Side

30 8 / 530 Banjo ⅜ / Banjo ¼ Position F Side

31 6 / 300 Banjo ¼ / BSP 3/8 xStraight Position G Side

32 6 / 650 Banjo ⅜ / Banjo ¼ Position G Top

31A 6 / 300 Banjo ¼ / BSP 3/8 x90 T to Case Drain

31B 6 / 300 Banjo ¼ / BSP 3/8 x90 T to Case Drain

Notes: banjo fittings go on the lower row of the control valves, elbow fittings go on the top row. Each

banjo screw requires two washers. For the top row of the control valves, you will need to fit one

union connector ⅜ male x ⅜ male with a washer on the control valves side before fitting the elbow

end of the hoses.

Clean the inside of the reservoir – we use a hoover extension followed by a magnet to pick up any

metal residues. Make sure the reservoir is clean as there is no filter on the kit and the oil must be

changed once a year. An optional in line filter can be purchased if required. Fit the inspection cover

with its rubber gasket and cap using 4x M6x20mm bolts.

7- The Gasoline Engine and Hydraulic Pump Assembly

Instructions for the maintenance for the engine are included in the box. Don’t forget to fill up with

oil. Follow the sequence of pictures below for the pump assembly.

Plate not

necessary

Fix the pump with 4 M6 x 40mm bolts and the bell housing with 4 M8 x 30 bolts

Install the engine into position and fix with the 4 rubber vibration dampers using 4 M8 bolts and 4

M8 nylon insert nuts. Very important: Make sure that the pump is facing as per the picture so the

feed into the pump (hose no.1, 19mm Ø) is facing upwards on this picture.

7. Finishing the Hydraulic System and Test the Machine

Connect all the remaining hoses to the hydraulic rams, the return to the reservoir and plug in the 3rd

hole

Fit the service valve to the reservoir as per picture. The washer is not necessary and PTFE tape can

be used. Very important: always keep the valve in the open position when the engine is running to

avoid damaging the pump. If necessary remove the red handle to avoid the valve being switch off by

accident.

Hose no.1 fitted to the pump (pictures taken show the engine and pump mounted sideways)

Connect all the hoses and secure with cable ties and / or plastic hose wrap to ensure that they don’t

rub on any part of the machine during operation.

Fill up the reservoir with hydraulic fluid to approximately 2 inches from the top to avoid overspill

through the breather cap. Fill up the petrol tank of the engine with unleaded and start the machine.

Air will be chased gradually through the system until it reaches the reservoir. It is self-bleeding. Let

the engine warm up fully and operate the digging at low engine speed to avoid jerky movements.

Check the hydraulic oil level and top up as necessary.

Operation manuals can be downloaded from http://four-ashes.com/servicing/