IHI 55N3, Operation Manual

Page 1: ...SERIAL NUMBER WP003001 55N3 PUB 1 OPERATION MANUAL 0903 ENG ...

Page 2: ......

Page 3: ... 2 Operation 2 1 2 1 Nomenclature 2 1 2 2 Controls and Instruments 2 2 2 3 Before Starting the Engine 2 11 2 4 Starting Engine 2 12 2 5 Jumper Cable Starting 2 13 2 6 After Starting the Engine 2 14 2 7 Break in Operation 2 14 2 8 Control System 2 15 2 9 Operating the Special Attachments and Actuators If Equipped 2 18 2 10 Traveling the Machine 2 20 2 11 Towing 2 23 2 12 Lifting the Machine 2 24 2 ...

Page 4: ...nce and Checks 3 20 3 8 1000 Hours Maintenance and Checks 3 23 3 9 2 Years Maintenance and Checks 3 26 3 11 Unusual Operating Conditions 3 28 3 12 Long Term Storage 3 31 4 TROUBLE SHOOTING 4 1 4 1 Trouble and Action 4 1 5 HYDRAULIC SYSTEM DIAGRAM 5 1 5 1 Hydraulic System Diagram 5 1 6 ELECTRICAL SYSTEM DIAGRAM 6 1 6 1 Electrical Wiring System Diagram 6 1 7 SPECIFICATIONS 7 1 7 1 General Specificat...

Page 5: ...ly understood at first repeat reading it until abilities as an operator are obtained and developed for proper operation Further abilities as an operator outside of descriptions in this manual can be obtained from the experience during normal operations and under proper supervision The illustrations in this manual are used first of all to let you pay attention They do not show all of illustrations ...

Page 6: ...e for predicting every kind of danger in all operating conditions It is the owner or user of the machine who is responsible for ALWAYS paying attention to operate the machine as well as reading and understanding this manual enough to obtain the essential knowledge and skills fundamental to correct machine operation BEFORE inspection operation or maintenance of the machine be sure to read and under...

Page 7: ...of danger that you may encounter during operation 1 1 GENERAL OBSERVE THE BASICS FOR SAFE AND EFFECTIVE OPERATION The operator s knowledge skills and experience are the most important to utilize the machine Therefore be sure to understand operation procedures and to take necessary training OPERATOR SHOULD BE QUALIFIED Only qualified operators should be authorized to operate the machine and those s...

Page 8: ...utor for replacement OPERATOR SHOULD BE IN GOOD HEALTH Operator should be physically and mentally alert which is one of the best insurance against an accident NEVER operate the machine under the influence of alcohol medication or intoxication WEAR PROPER WORKING CLOTHES Wear working clothes that closely fit operators Avoid loose jackets shirt sleeves rings and other jewelry which may be caught in ...

Page 9: ...rk day just because it seemed satisfactory at the end of the previous work day Before beginning each days operation thoroughly inspect the entire excavator for signs of vandalism MAKE A WORK PLAN Prior to operation investigate your job site sufficiently When any obstruction or hazards are detected mark it so that all personnel are aware of it Avoid any oversight that may cause serious accident Obs...

Page 10: ...the ground ventilation depth of water and ambient obstructions Avoid operating your equipment too close to an overhang Since this machine is not provided with anti explosion design NEVER use it inside a tunnel or in explosive environment to avoid hazard caused by an explosion CLEAR ALL PERSONNEL FROM THE MACHINE AND AREA Be sure to barricade the job site to prevent entry of the unauthorized Confir...

Page 11: ... drilling or cutting can weaken the structure and reduce the protection it provides A damaged ROPS TOPS can not be repaired it must be replaced 1 2 MOUNTING AND DISMOUNTING CAREFULLY MOUNT AND DISMOUNT THE MACHINE ALWAYS use steps and handholds to mount and dismount the machine Hold the handholds with both hands and face the machine keeping a contact with at least three points of the steps and han...

Page 12: ...orn parts Fasten the seat belt if equipped securely Adjust the operator s seat to be able to depress the pedal completely 1 4 STARTING THE ENGINE Fasten the seat belt Adjust the operator s seat ALWAYS start the engine only from the operator s seat following the starting procedure in this manual When the start switch or controls are tagged with Do Not Operate do not start the engine or move any of ...

Page 13: ...etected immediately report it CONDUCT WARM UP BEFORE OPERATION It is ESSENTIAL to conduct warm up operation after starting the engine in order to run the hydraulic fluid smoothly The pumps may squeak because of the cold and thick hydraulic fluid which results in the damage to the pumps ALWAYS take a time to warm up the fluid with running the engine at a low speed to maintain the FREE FLOW OF OIL B...

Page 14: ...on ALWAYS consider the machine capacity and take a time to clear problems in the best way OBSERVE THE NEXT PRECAUTIONS FOR SAFE OPERATlON Do not read Do not drink Do not eat Do not be distracted If you have to divert yourself from the machine operation stop the operation first ALWAYS OPERATE THE MACHINE ONLY FROM THE OPERATOR S SEAT NEVER attempt to operate the excavator from any position except t...

Page 15: ...ay require a greater distance for safety Treat all lines as energized NEVER LEAVE LOAD SUSPENDED IN THE AIR NEVER leave the load suspended in mid air when the machine is out of service or you have to leave the machine ALWAYS put down the bucket or load onto the ground Should a malfunction occur it could fall striking equipment or personnel Should contact occur stay on the machine until the boom is...

Page 16: ...T OR THE LOAD PROVIDE ADEQUATE TAILSWING CLEARANCE Confirm that there is a sufficient clearance around the machine for swinging operation The operator tends to be unconscious of the area behind the machine Before tailswing make sure that there no personnel or objects in such area CAUTION ALWAYS check for personnel or objects around the machine before swinging NEVER SWING OVER PERSONNEL Be sure tha...

Page 17: ...OF TRUCK CAB and clear of the dumping bed when lifting ALWAYS OBSERVE THE BUCKET AND LOAD ALWAYS watch the moving bucket or load carefully Moving bucket or load without care may cause injury to personnel or materials If you have to look away from it stop the machine NEVER CAUSE PHYSICAL SHOCK TO HYDRAULIC CYLINDERS Be careful to protect the cylinder from any damage during operation The hydraulic c...

Page 18: ...o personnel NEVER ALLOW PERSONNEL RIDE ON THE MACHINE OTHER THAN OPERATOR Only operator is authorized to be on the machine during operation Never let unauthorized personnel ride on the machine CAREFULLY OPERATE THE BUCKET Slow down the operation when controlling the bucket or moving the filled bucket close to the operator s cab in particular which prevents the load from being dropped into the cab ...

Page 19: ...d wear on the boom arm and bucket DO NOT MOVE THE ATTACHMENTS TO THE EXTREME ENDS OF THE STROKE If the rod is extended to the stroke end of the cylinder the shock applies a large force to the cylinder which may cause a damage to the boom or arm Operate the machine without moving the cylinder to the extreme end of the stroke It is recommended to operate the attachments near the stroke end of the cy...

Page 20: ...he machine MEASURE DEPTH OF WATER AND CHECK CONDITIONS OF RIVERBED BEFORE FORDING Before fording measure the depth of water and check the riverbed for holes bumps and any dangerous condition by following the next Measure the depth of water first Stop the machine and swing the bucket under the water to detect any bump or obstacle Lower the bucket to measure the depth of water and detect holes occas...

Page 21: ...s at an angle to the ground or touches the ground partially it may be damaged or loose its balance To avoid this level the ground first Do not use the blade to excessively raise the tracks Lower the blade only within a range where the tracks behind the blade lift slightly to ground the blade as a stabilizer MAINTAIN A CORRECT BLADE POSITION lf you need to conduct the deep digging with the blade do...

Page 22: ... as option Consult your local lHl dealer THE FRONT GUARD PROTECTS AN OPERATOR FROM FLYING OBJECTS THE FRONT When braking materials with the machine and objects are likely to fly from the front the front guard shall be equipped If it is not equipped flying objects may cause injury or death The front guard is avoidable as option Consult your locaI IHI dealer FOPS TOP GUARD PROTECTS AN OPERATOR FROM ...

Page 23: ...the heavy bucket and swing the boom slowly to prevent a turnover Also watch for buried objects during digging operation to prevent a turnover AVOID UNDERCUTTING THE MACHINE Do not try to dig close to the machine lf you undercut the machine the footing may easily collapses Recede from the digging site enough to keep a distance EMERGENCY ESCAPE If the machine tips over and the cab door will not open...

Page 24: ... the width of each track is shorter than its length stability is poorer over side than on the blade side On a grade operate the machine slowly with the retracted arm in a reduced working radius OBSERVE PRECAUTIONS WHEN OPERATING WITH LONG ARM Observe the following precautions to use the long arm c Do not use any combination of arm and bucket that we do not specify d Do not use the breaker attachme...

Page 25: ... serious accidents like a turnover 2 Use of attachment c When using the longer arm great care should be taken If tends to reduce the machine stability and limits the bucket size Slowly operate the machine with the longer arm and watch the ground condition d When using the larger bucket great care should be taken It tends to reduce the machine stability Slowly operate the machine with the larger bu...

Page 26: ...Lifting capacity in excavators is usually determined by hydraulic and structural fitness not tipping load Before making a list ALWAYS consult the load rating chart in the operator s cab Stay within the lifting limits when laying pipes Remember you may be able to lift the pipe close in at ground level but as you reach out and down the lifting capacity decrease If the machine is not on level ground ...

Page 27: ...tracks either parallel with or at right angle with the machine POSITION THE ARM VERTICALLY Do not try to lift up the front end of the tracks with the arm cylinder or bucket cylinder fully extended Position the arm vertically against the ground for lifting NEVER USE THE BLADE TO EXTRACT PILES Do not use the blade to lift up the machine to extract a pile The great force of the blade cylinder overloa...

Page 28: ... on the alert for overhead obstacles and be sure there is adequate side clearance when traveling Get the assistance of the man on the ground when clearances cannot be ascertained from the operator s position CAREFULLY TRAVEL THE MACHINE IN A NARROW AREA AND LOW CLEARANCE NEVER travel in an area where persons are coming and going or there are many objects ALWAYS keep a safety distance around the ma...

Page 29: ...to the ground and slowly travel When traveling uphill or on a slope keep the boom on the uphill side of the machine NEVER STEER ON A GRADE NEVER steer on a grade or unstable ground which causes a turnover NEVER travel across a grade When traveling on a grade travel up and down in parallel with the grade Be careful to travel on the frozen ground since the machine tends to skid or fall down CHECK BR...

Page 30: ...avel with the drive sprocket to rear Keep the drive sprocket to rear in long travel in particular If you position tt to front wear at the lower structure will be enhanced UTILIZE MATS AT A SPECIAL JOB SITE Use mats made of lumbers to support the machine on the soft ground or in a marsh Use the clean and level mats for safe operation Remember that the mats cannot support the machine in every condit...

Page 31: ...f a wire rope should be attached to the rear axle and the machine should be towed by a towing machine NEVER attach the wire rope to the towing hook at the rear axle which causes damage to the axle and the hook and personal injury may occur WRONG RIGHT USE THE TOWING HOOK PROPERLY The towing hook is used to tow for lightweight material The maximum allowable towed weight is 500kg NEVER tow the machi...

Page 32: ...ing and unloading NEVER LOAD AND UNLOAD THE MACHINE WITHOUT RAMPS TO PREVENT TURNOVER NEVER lift up the machine using the boom to load and unload the machine on and out of the truck This is very dangerous ALWAYS ensure that a ramp has sufficient strength and length to accommodate the size and weight of the machine OBSERVE PRECAUTIONS ON TRANSPORTATION Be sure to engage the swing lock Block tracks ...

Page 33: ... PARK THE MACHINE ON A GRADE If you have to park the machine on a grade ALWAYS lower the bucket and the blade onto the ground and block the machine OBSERVE PRECAUTIONS WHEN PARKING THE MACHINE ON THE ROAD If you have to park the machine on the road use appropriate flags barriers flares and warning signals OPERATOR LEAVING MACHINE ALWAYS lower attachments to rest on ground and stop engine before le...

Page 34: ...g controls should be TAGGED the tag should be removed only by someone who is aware of the circumstances and who can assure that it is safe to do so ALWAYS CLEAN THE MACHINE Maintain the machine clean for safe operation Remove dirt grease maintenance tool from the operator s cab for secured control Clean the window to obtain good sight Do not place anything flammable around the machine SET HYDRAULI...

Page 35: ... cab The boom may fall down onto you if the boom control lever is accidentally pressed If the window is missing or broken replace immediately SUPPORT THE UNDERCARRIAGE WHEN WORKING UNDER TRACKS NEVER allow anyone to work undercarriage that is lifted and not properly blocked Check that the machine is supported sufficiently by the blocks and will not fall down Do not keep the machine lifted up only ...

Page 36: ...after handling Battery acid will burn skin eat holes in clothing and cause blindness if splashed into eyes If you spill acid on yourself flush skin immediately with lots of water Apply baking soda to help neutralize the acid If acid gets in your eyes flush immediately with large amount of water and seek proper medical treatment immediately When servicing battery remember that a lead acid storage b...

Page 37: ...and that lines pipes and hoses are in good condition before starting the engine Fluid escaping from a small hole can be almost invisible Use a piece of cardboard or wood instead of your hands to search for suspected leaks If you are struck by escaping hydraulic fluid under pressure serious reactions can occur if proper medical treatment is not administered immediately NEVER WATCH THE RELIEF VALVE ...

Page 38: ... the engine is running or right after the engine is stopped lf the cap is open the very hot steam will blow out which causes serious burns Wait until the coolant temperature goes down Slowly open the filler cap to release the pressure Do not touch the engine coolant directly It may cause injury to your skin Wear gloves or use a cloth to handle it NEVER drink it or NEVER let it come in contact with...

Page 39: ...e sure that you can read all safety signs Clean or replace these if you cannot read the words or see the pictures When cleaning the labels use a cloth water and soap Do not use solvent gasoline etc You must replace a label if it is damaged missing or cannot be read If a label is on a part that is replaced make sure a new label is installed on the replaced part See your IHl dealer new labels 1 12 W...

Page 40: ...ating parts such as fan Turn off before inspection and maintenance Part No D405 509 00 c Warning Read manual before operation maintenance disassembly assembly and transportaion Part No D405 359 00 e Sign indicates a hazard of being crushed or run over by unexpected moving of stopped machine Lower working device to ground move safety lever to lock position and take engine key with you before leavin...

Page 41: ...rd by rotation of upper structure of the machine Keep away from swinging area of machine Part No D406 022 00 l Sign indicates a hazard of flying plug from track adjuster that could cause injury Read manual before adjusting track for safe and proper handling Part No D405 505 00 11 Sign indicates a hazard from falling window After raising window be sure to lock it in place with lock pins Part No D40...

Page 42: ...1 36 ᵏ SAFETY This page left intentionally blank ...

Page 43: ... Battery 12 Hydraulic Oil Tank 13 Return Filter 14 Radiator and Oil Cooler 15 Cab 16 Engine 17 Muffler 18 Air Cleaner 19 Fuel Tank 20 Hydraulic Pump 21 Swing Device 22 Swing Bearing 23 Travel Drive with motor 24 Control Valve 25 Upper Roller 26 Lower Roller 27 Rotary Joint 28 Track Adjuster 29 Front Idler 30 Blade Cylinder 31 Blade 32 Track Shoe Typical Example ...

Page 44: ... Lamp 9 Engine Start Switch 10 Horn Switch 11 Engine Throttle Lever 12 Control Shut Off Lever 13 High Speed Travel Pedal 14 Left Travel Lever 15 Right Travel Lever 16 Blade Lever 17 Left Operating Lever 18 Right Operating Lever 19 Boom Swing Pedal 20 Operator s Seat 21 Seat Belt Typical Example ...

Page 45: ...Warning Lamp This indicates a malfunction in the electrical charging system If the light comes on while the engine is running check the electrical system e Heat Indicator Lamp Hold the engine start switch in the HEAT position for approximately 15 seconds The air heater is activated and the indicator comes on j Engine Fail Lamp The lamp flashes if the engine abnormality occurs while the engine is r...

Page 46: ...ange is the normal operating temperature The Red range indicates overheating If the gauge indicate red range reduce machine operating speed and keep the engine at low idle until the engine is cooled down Stop the engine Check the coolant Check the fan drive belt Have any necessary repair made h Service Hour Meter Indicates the total operating hours of the machine It should be used to determine ser...

Page 47: ...art the engine Turn the key switch to the OFF position to stop the engine ON Turn the key clockwise to active the electrical system The key will return to the ON position when released from the START position START Turn the key to the START position to crank the engine Release the key as soon as the engine starts l Horn switch Push down on the top of the right operating lever to activate the horn ...

Page 48: ...to the locked position This makes all hydraulic activation controls inoperable Unlocked Move the lever forward to the unlocked position This makes all hydraulic activation controls operable 13 High Speed Travel Pedal NEVER high speed travel on a grade or loading and unloading the machine When control shut off lever is locked does not change to high speed travel Low Speed Travel Release the pedal t...

Page 49: ...ward Direction Travel Move the both travel levers forward to move the machine forward direction Stop Release the travel levers to stop the machine and apply the brakes Reverse Direction Travel Move the both travel levers rear to move the machine reverse direction Refer to Traveling the Machine section of this manual 16 Blade Lever The blade falls with its self weight if pushing this lever to forwa...

Page 50: ...tion Arm or swing movement will stop Two Functions may be performed at the same time by moving the lever diagonally 18 Right Operating Lever Bucket and boom controls 1 Boom Lower Move the lever forward to lower the boom 2 Boom Raise Move the lever back to raise the boom 3 Bucket Dump Move the lever right to dump the bucket 4 Bucket Dig Move the lever left to close the bucket 5 Hold When the lever ...

Page 51: ...o Adjust the Seat Suspension if equipped Turning nob c clockwise increases suspension stiffness and turning it counterclickwise decreases suspension stiffness To Adjust the Seat Forward or Backward with Right and Left Control Levers Pull up and hold lever d and move the seat and control levers to the desired position from the travel levers Release the lever to hold the seat in the selected positio...

Page 52: ...eck for worn or damaged buckle extrusion and mounting hardware Replace them if they worn or damaged To Fasten the Belt With gripper c held and insert extrusion d into buckle e until correctly latched Adjust the seat belt length according to your body size Slightly pull the belt fand confirm the belt is fastened To Unfasten the Belt Push in button g of buckle e and extrusion d will be released from...

Page 53: ...a and cylinder mounting brackets Repair if damaged Refer to Walk Around Inspection in the Maintenance Section Lubrication Perform the daily lubrication as required by the Lubrication Chart Pre start Checks Check all of oil coolant and fuel levels Refer to the Daily in the Maintenance Section for more detailed information Seat and Seat Belt Checks Adjust the seat to allow full travel of the levers ...

Page 54: ... engine for more than 15 seconds Allow the starter to cool for seconds before cranking again 6 Release the switch key after the engine starts 7 Move the engine throttle lever to position LOW to allow the engine to warm Starting In Cold Weather This engine has an inlet manifold heater for cold weather starting Do not use other types of starting aids such as ether Such use could result in an explosi...

Page 55: ... Stop the engine on boost machine 3 On stalled machine turn the start switch key to OFF Turn of all accessories 4 Connect POSITIVE jumper cable red POSITIVE cable terminal of discharged battery Do not allow positive cable clamp to touch any metal other than battery terminals 5 Connect POSITIVE jumper cable red POSITIVE cable terminal of boost battery 6 Connect one end of NEGATIVE jumper cable blac...

Page 56: ...ive minutes while intermittently holding the bucket control lever in the bucket dump position Operate the bucket control lever for 10 to 15 seconds and then return the control lever HOLD position to ten seconds 3 Move the engine throttle lever to maximum engine speed Run the engine for an additional five minutes while intermittently holding the bucket dump position This will allow the oil to reach...

Page 57: ...kward Forward C 2 levers Bucket dump L LEFT RIGHT Boom hoist R Bucket dig Swing left Swing right Arm out Arm in LEFT RIGHT Boom lowering Forward Backward D 2 levers Bucket dump L LEFT RIGHT Boom hoist R Bucket dig Swing left Swing right Arm out Arm in LEFT RIGHT Boom lowering Forward Backward F 2 levers Ｌ LEFT RIGHT Arm out Arm in R Bucket dump Bucket dig Boom lowering Boom hoist LEFT RIGHT Backwa...

Page 58: ...2 16 ᵐ OPERATION OPERATIONS DIRECTION OF LEVER DIRECTION OF MACHINE BOOM BUCKET ARM SWING When leaving the operator s seat stop the engine lower the bucket and the blade on the ground 2 Pattern A ...

Page 59: ...2 17 ᵐ OPERATION OPERATIONS DIRECTION OF LEVER DIRECTION OF MACHINE BOOM SWING BLADE Always locked pedal when is not in use ...

Page 60: ...ore starting operation confirm each specification to ensure safety of workers and the machine CAUTION 1 SINGLE ACTION OPERATION Hydraulic Breaker and Other Controls If the marked of the valve is set in horizontal position the pressure of returned oil becomes higher and the breaker does not function efficiently ALWAYS set the marked in vertical position Switching the attachment hydraulic circuit Ch...

Page 61: ...port B 3 SINGLE ACTION OPERATION USED FOR POWER PORT WORKS The engine cannot be started if the power port is ON locked status with the pedal depressed Be sure to set the pedal at the neutral position before starting the engine 1 Fold the pedal into double layers 2 Turn the pedal lock lever to the unlocked position and release the pedal lock 3 Push down the pedal and turn the pedal lock lever to th...

Page 62: ...o the unlocked position 3 Raise the boom and the blade enough to provide sufficient ground clearance 4 Control right and left travel levers e as follows Forward Direction Travel Move the both travel levers e forward to move the machine forward The machine will always travel toward the BLADE Stop Slowly move both the travel levers e to the stop position to stop the machine and apply the brakes Reve...

Page 63: ...the two travel levers as follows Pivot Left Turn Move the right lever c forward to travel forward and left and move it rear to travel reverse and left pivoting on the left track Pivot Right Turn Move the left lever d forward to travel forward and right and move it rear to travel reverse and right pivoting on the right track SPOT TURN Spot Left Turn Move the left travel lever d rear and move the ri...

Page 64: ...vel speed ranges while going downhill Work up and down slopes rather then sideways whenever possible Do not travel across a grade by all means Avoid changing the direction of travel on a slope which could result in tipping or side slipping of the machine Keep the arm in and carry the boom in a low position When starting up a steep grade or breaking over a rise keep the boom lowered as close to the...

Page 65: ...ow line angle to a minimum Do not exceed a 30º angle from the straight ahead position 1 If the machine sinks down on a soft ground and cannot crawl up by itself a wire rope should be attached to the rear axle and the machine should be towed by a towing machine To prevent the damage of the wire rope be sure to place a protector at the corner of the axle Use the towing wire rope with sufficient stre...

Page 66: ...r 2 Position the machine on the level ground with the boom arm and bucket cylinders fully extended 3 Position the boom at the center of the machine with the boom swing pedal 4 Stop the engine 5 Install the cable to the two lifting eyes on the blade with shackles Install the cable to the lifting eye on the boom of the center with shackle 6 Install the cables to the crane hook 7 Confirm that no obst...

Page 67: ...ps and the truck bed before loading NEVER operate the high speed travel switch when loading the machine on a trailer or loading lamps Perform warm up the machine before loading and unloading under cold weather Do not raise the boom excessively at loading and unloading NEVER make a turn on a ramp To make a turn get off the machine from the ramp first MACHINE LOADING ONTO A TRUCK 1 Block the truck w...

Page 68: ...iron core extremely Excessive tension increases travel resistance which prevents proper travel force and speed It also causes damages and extreme wear at undercarriage as well as overextension of the rubber track shoe 2 To prevent damages of the rubber track shoe avoid the following in travel as much as possible Pointed rocks or quarry Craggy place such as riverbed or path through woods CAUTION St...

Page 69: ...e is shut down or the hydraulic system disabled 1 Remove the floor cover under the operator s station floor 2 Remove the lock nut dof the boom raise relief valve located inside the control valve c 3 Slowly loosen adjusting screw e until boom start lower The boom will start to lower slowly 4 After making sure that the front implement has lowered completely on to the ground install the lock nut d 5 ...

Page 70: ...ons If freezing temperature are expected each crawler frame should be cleaned of mud and dirt and the machine parked on wood planks Engine Stopping 1 Operate the engine at LOW IDLE for five minutes This gives the engine a chance to cool off gradually before they are stopped 2 Turn the start switch key to OFF Remove the key Leaving the Machine 1 Use the steps and handhold use both handles and face ...

Page 71: ... Service Hours Coolant Interval given applies only to initial period of use Break in Check and Adjust Tension Check Rubber Shoes Replace Replace Clean and Check Electrolyte Level Change Bucket Check Oil Level Check Coolant Level Check Hydraulic Oil Level Check Fuel Level Check Servise Signal Check Level and Drain Water Drain Water and Sediment Lubricate Fitting with Grease Lubricate Fitting with G...

Page 72: ...Symbol G Grease L Gear oil H Hydraulic fluid E Engine oil W Coolant Change Check Maintenance Supply Remarks Attachment pins Lubricate with grease G Drain water and sediment Check oil level H Drain water and sediment Wash and clean strainer Change filter Change engine oil E Change fuel filter Change oil filter Clean or Change air filter Check coolant level W Bearing lubricate with grease G Ring gea...

Page 73: ... Swing Gear 11 5 liter 1000 Hrs Lubricate the Fitting Swing Bearing Attachment pins etc API Class CD SAE15W 40 API GL 4 ISO VG 320 SAE 90 Gear Oil EP2 Lithium Grease Tropical Regions Wear Proof Hydraulic Fuluid ISO VG 46 Ambient Temperature 5 C Wear Proof Hydraulic Fuluid ISO VG 32 Ambient Temperature Below 5 C LOCATIONS USE REFILL CAPACITIES APPROXIMATE CHANGE INTERVALS LUBRICANT VISCOSITIES Note...

Page 74: ...l have approximately 10 to 20 mm slack with rubber shoes In case of steel shoes approximately 30 to 50 mm Track Tightening 1 Add grease through check valve fitting c until the correct track tension is reached 2 Move the tracks forward and reverse to equalize the pressure 3 Check the amount of track sag again and adjust as necessary Track Loosening 1 Remove soil deposited on front idler bearing 2 L...

Page 75: ...one 2 Exposure of Steel Cords If steel cord is exposed because of weary rubber or damage replace it with brand new one 3 Break of Steel Cords When break of steel cord is detected replace it immediately If you leave it as it is the rubber track shoe can be break without expectation which causes a serious accident 4 Crack of Covering Rubber If a crack is 30 mm or more long and 8 mm or more deep repa...

Page 76: ... The following circuit protected by each fuse includes the fuse amperage c Fuel pump Control shut off and Travel speed select solenoid 20 amps d Horn Cigarette lighter and Room lamp 20 amps e Front light 20 amps f OK Monitor Radio Heater and Wiper 20 amps g Main Relay 10 amps FUSIBLE LINK The fusible link is provided between the positive terminal of the battery and the starter switch to prevent el...

Page 77: ...ssible If battery is out of use for a long time it must not be allowed to run down completely The battery should be given a small recharge sufficient to bring it back to fully charged state about every one or two months Trickle charging is not recommend and during charging as before care must be taken that temperature of electrolyte does not rise above 40ºC for temperate climates and 52ºC for batt...

Page 78: ...sition as illustrated 3 Connect the arm into the hole A and the link into the hole B with pins 4 Install a stopper bolt to each pin securely 5 Adjust the bucket clearance 6 Move the O rings for sealing into the regular position 7 Lubricate each pins with grease 8 After install the bucket start the engine and low speed rotate the bucket to the stroke end Check if anything interrupts the bucket rota...

Page 79: ...in into the tooth 4 Install the new tooth over the adaptor 5 Drive the lock pin through the tooth until the pin is flush with the tooth surface NOTICE After driving the lock pin make sure the lock pin fits snugly into the hole of the tooth Replacement of Side Cutters 1 Remove the mounting bolts and remove the side cutters 2 Clean the mounting surfaces Install the new side cutters WARNING Change Ov...

Page 80: ...stick c Add oil if necessary 4 Remove the oil fill plug d and add oil Clean and install the oil fill plug d 5 Close the access door Check the Coolant Level Steam generated by hot fluid under pressure in radiator can cause personal injury Remove filler cap only when cool enough to touch with bare hand 1 Open the access door on the rear of the machine 2 Always check the coolant level in the reserve ...

Page 81: ...tall the fill plug To pressurize the hydraulic tank refer to Change Hydraulic Oil section Fill Fuel Tank Fuel can be added to the tank by removing the fill cap on top of the fuel tank Do not remove strainer in the fill port when fill fuel tank After completion of refueling be sure to lock the fuel tank cap to protect against vandalism Dust Indicator Check the air filter dust indicator If the indic...

Page 82: ...ill the tank with fuel 1 Stop the engine 2 Turn the drain valve counterclockwise to open 3 Drain water and sediment into suitable container NOTE Always dispose of drained fluids as established by local regulations 4 Close drain valve 5 Priming the sytem There should be enough fuel in the system to allow the engine to start Keep the engine start switch key at ON for a period of 20 seconds which ope...

Page 83: ...damage or excessive wear Repair if damaged Inspect and remove any trash build up in the engine compartment Inspect the cooling system for leaks faulty hose and trash built up Correct any leaks and remove any trash from the radiator Inspect the hydraulic system for leaks Inspect the tank cylinder rod seals tubes plugs joints and fittings Correct any leaks Inspect and repair travel drive leaks Check...

Page 84: ...and sediment into suitable container NOTE Always dispose of drained fluids as established by local regulations 3 Close the drain valve Lubrication Perform the 50 hours lubrication as required by the Lubrication Chart Be sure to lubricate all cylinder mounting bushings and pins The following maintenance and checks should be made in 50 hours for the initial time only Interval given applies only to p...

Page 85: ...rear of machine 4 Remove the used filter d by the filter wrench Clean the filter housing base 5 Apply a light coat of engine oil to the gasket of the new filter 6 Install the new filter by hand When the seal contacts the base tighten the filter 3 4 turn more by filter wrench Do not overtighten 7 Remove the oil fill plug e Fill the crankcase with oil Refer to Recommended lubricant table Clean and i...

Page 86: ...UTION Service the Primary Element Cleaning Every 250 hours or when indicated the red signal in the dust indicator Replacement After cleaning five times after one year or damaged pleats or seals 1 Stop the engine 2 Release the two latches and remove the service cover c 3 Remove the primary element d from the air cleaner housing e Do not remove the secondary element f when service the primary elemen...

Page 87: ...dust seen inspect if there are foreign substances on the inside and outside of the housing seal tube 7 Install a clean primary element d Install and secure the service cover c with the valve g at the bottom NOTE Insert a new element correctly When the element seal unit is inserted into the seal tube its seal surface is extended uniformly to seal the element To seal the element more accurately push...

Page 88: ... the primary element d from the air cleaner housing e 2 Remove the secondary element f from the air cleaner housing e Cover the engine intake opening 3 Clean the inside of the air cleaner housing e and service cover c Remove the covering from the intake opening NOTE Clean the seal tube in the cleaner housing Dust on the seal tube causes dust leak 4 Install the new secondary element f 5 Install the...

Page 89: ...inward by hand apply 98 N 10 kg force midway between the pulleys Correctly adjusted belt will deflect 10 mm Adjust 1 To adjust the belt loosen mounting bolt c and adjust plate bolt d 2 Move the alternator in or out as required to obtain the correct adjustment by turn adjusting screw e 3 Tighten mounting bolts c adjust plate bolt d 4 Check the belt adjustment again after 5 minutes of engine operati...

Page 90: ...ue 2 General torque specifications Other than above mentioned refer the next table for torques Items Tighten point Wrench size Thread size Tighten torque mm metrie N m c Travel drive 24 M16 245 d Sprocket 22 M14 157 e Lower roller 30 M20 490 f Swing bearing 24 M16 245 g Swing motor 24 M16 245 Newton meter N m is approximately the same as 0 1 kg m Tighten torque Metric Metric fine coarse H T H T bo...

Page 91: ...ilter wrench Clean the filter base d NOTE This is a cartridge type element It cannot be reused 5 Coat the gasket f of new filter with clean hydraulic oil 6 Install the new filter e by hand When the seal contacts the base tighten an additional 3 4 turn by filter wrench 7 Start and run the engine to fill the filter Stop the engine Maintain the oil level between marks on the level gauge Add oil if ne...

Page 92: ... 5 There should be enough fuel in the system to allow the engine to start Keep the engine start switch key at ON for a period of 20 seconds which operates the fuel pump and priming automatically Check the Travel Reduction Gear Oil Level When the quantity of oil is found to have increased abnormally it is necessary to check the oil seal of the travel motor If the seal is leaking contact a IHI deale...

Page 93: ...ulation 3 Clean and install the drain plug 4 Fill the oil to bottom of level plug opening Refill capacities 5 Clean and install the oil level plug and oil fill plug 6 Perform procedure on the other travel reduction gear 7 Start the engine and allow the travel reduction gear to turn through several cycles 8 Stop the engine check the oil level 9 Check the drained oil for metal chips or particles If ...

Page 94: ... as shown Stop the engine 2 Relieve the internal pressure from the hydraulic tank by loosening the fill plug c 3 Clean area thoroughly to keep dirt out of strainer cover unit d and fill plug c 4 Remove the oil drain plug e Drain oil into a container Drain oil in all parts of the hydraulic system thereafter NOTE Always dispose of used oil as established by local regulation 5 Remove the pipe joint f...

Page 95: ...ground with the arm and bucket cylinder fully retracted and stop the engine 15 Maintain the oil level between FULL and ADD marks on the level gauge k 16 Pressurize the hydraulic oil tank Raise the boom with the arm boom and bucket cylinder fully extended Remove the fill plug c and then install fill plug again 17 Lower the bucket on the ground and stop the engine Hydraulic Oil Change Intervals for ...

Page 96: ...the radiator drain valve d and allow the coolant to drain into a container 4 Remove the drain plug e allow the coolant to drain into a container Drain plug is located under the injection pump on the front side of cylinder body 5 Close the drain valve and drain plug Fill the system with clean water and cleaning solution 6 Start and operate the engine for 1 2 hour Stop the engine and drain the clean...

Page 97: ...ing effects will maintain the machine free from coolant exchange for 2 years through summer and winter seasons The Long Life Coolant is therefore recommended for use with this machine when exchanging its coolant Mixing Rate of Long Life Coolant The mixing ratio of Long Life Coolant with water determines the freezing point Select the mixing ratio for a freezing point lower by 5º than the expected l...

Page 98: ...o be defective 2 Condensation in the fuel tank contaminates the fuel supply with water which can freeze in the fuel lines and block the fuel flow to the engine To minimize this possibility keep the tank as full as is practical during cold weather This may entail refilling the tank more frequently than usual but the inconvenience is small compared to clearing a blocked fuel line If water should be ...

Page 99: ...t will most often be corrected by SLOWLY adding coolant while the engine is running at FAST IDLE Should this fail to correct the problem drain and flush the system and refill with fresh coolant 50 solution of ethylene glycol and a corrosion inhibitor Allow the engine to cool before draining and flushing the cooling system Water containing more than small concentrations of salt or minerals should n...

Page 100: ...d to the deteriorating effects of salt moisture or both To protect exposed metallic surfaces wiring paint and other items keep them dry and well lubricated where salt or high humidity are encountered Follow the recommendations below when operating in these conditions 1 Make frequent inspections for rust and corrosions and remove them as soon as they are detected Dry and paint exposed surfaces afte...

Page 101: ...s Store the battery after move the negative terminal and covering it or dismounting the battery from the machine Lock the control levers and pedals with the lock lever and pedal lock During Storage If you have to operate the machine indoors to prevent rust keep good ventilation and gas poisoning by window or entrance During storage operate the machine once a month to maintain films of oil at the l...

Page 102: ...3 32 ᵑ MAINTENANCE This page left intentionally blank ...

Page 103: ...ow Control valve damaged Clogging foreign matter such as stone Defective travel motor or reduction Defective brake valve Clogging foreign matter Shoe tension unequal Defective pump Loosen travel lever stopper Defective motor or brake valve Fail lubricate of swing bearing Defective motor Defective brake valve Defective cushion valve Low hydraulic oil Improper viscosity hydraulic oil Main relief val...

Page 104: ...4 2 ᵒ TROUBLE SHOOTING This page left intentionally blank ...

Page 105: ...tion relief valve P2 Pump 24 5 250 OR1 Overload relief valve Boom 22 6 230 OR2 Overload relief valve Arm 22 6 230 OR3 Overload relief valve Bucket 24 5 250 OR4 Overload relief valve Blade 24 5 250 SWR Swing relief valve 17 7 180 RER Remote control relief valve 3 4 35 Relief valve set pressure Tank level capacity 75 liters Total system volume 110 liters Pump flow rate Max P1 64 6 liter min P2 64 6 ...

Page 106: ...5 2 ᵓ HYDRAULIC SYSTEM DIAGRAM This page left intentionally blank ...

Page 107: ...㫃㪸㫅㪼䋮 䌎䌯䌴䌥 㪇㪅㪏㪌㪙 㪇㪅㪏㪌㪩㪮 㪇㪅㪏㪌㪩㪮㩿㪙㪀 㪇㪅㪏㪌㪩㪮㩿㪚㪀 㪇㪅㪏㪌㪩㪮㩿㪙㪀 㪇㪅㪏㪌㪩㪮㩿㪚㪀 㪥㪚 㪙 㪦 㪊㪅㪇㪩 㪈㪅㪉㪌㪩㪣 㪇㪅㪏㪌㪧 㪇㪅㪏㪌㪩㪰 㪣 㪣 㪇㪅㪏㪌㪞㪙 㪇㪅㪏㪌㪙 㪈㪅㪉㪌㪩㪞 㪇㪅㪏㪌㪙 㪇㪅㪏㪌㪩㪞 㪇㪅㪏㪌㪩㪞 㪈㪅㪉㪌㪩㪞 㪊㪅㪇㪩 㪊㪅㪇㪩 㪊㪅㪇㪩 㪊㪅㪇㪙㪩 㪉㪅㪇㪩㪰 㪈㪅㪉㪌㪩㪰 㪙 㪈㪅㪉㪌㪩㪞 㪇㪅㪏㪌㪩㪙 㪇㪅㪏㪌㪮㪙 㪇㪅㪏㪌㪮㪙 㪣㪮 㪇㪅㪏㪌㪩㪰 㪣㪙 㪣㪩 㪊㪅㪇㪞 㪊㪅㪇㪞 㪊㪅㪇㪮㪙 㪍㪇㪙 㪇㪅㪌㪩㪙 㪇㪅㪌㪩㪙 㪊㪅㪇㪩 㪌㪅㪇㪙㪩 㪇㪅㪏㪌㪙㪩 㪇㪅㪏㪌㪩㪙 㪇㪅㪏㪌㪩㪰 㪇㪅㪏㪌㪩㪰 㪇㪅㪌 㪣㪮 㪇㪅㪌 㪞㪣 㪇㪅㪏㪌 㪩㪰 㪇㪅㪏㪌 㪩㪙 㩿㪚㪘㪭㪪㪀 㩿㪚㪘㪭㪪㪀 㩿㪚㪘㪭㪪㪀 㩿㪚㪘㪭㪪㪀 㩿㪚㪘㪭㪪㪀 㪉 㪇㪅㪌 㪣㪮 㪇㪅㪌 㪞㪣 㪇㪅㪏㪌 㪩㪰 㪇㪅㪏㪌 㪩㪙 㪩㪰 㪙 ...

Page 108: ...gine proper L 4 2 Total amount L 8 5 Engine model YANMAR 4TNV98 Vertical 4 cycle water Engine type cooled diesel engine Direct injection system No of cyl bore storoke mm 4 98 110 Total piston displecement L 3 318 Rated output kW min 1 ps rpm 40 8 2400 55 5 2400 DIN6271 40 4 2400 Max torque N m min 1 kgf m rpm 205 8 1550 20 99 1550 Canopy Cabin Total operation weight Rubber shoe kg 5200 5330 Steel ...

Page 109: ...g arm Number of teeth 4 4 3 3 4 ISO m3 Slope bucket Heaped Struck 0 18 0 18 0 11 0 14 0 19 0 14 0 14 0 085 0 11 0 15 Combinations Remarks Remarks 150 155 120 135 148 152 Standard OPT OPT OPT OPT OPT General digging Reinforced Ditch digging Ditch digging Loading Slope finishing Std applicable Applicable Not applicable ...

Page 110: ...ructure Cabin 1880 1880 E Overall height Canopy 2500 2500 Cabin 2500 2500 F Rear end swing radius 1560 1560 G Rear end ground clearance 695 695 H Ground clearance 340 340 I Overall length of undercarriage 2950 2940 J Blade height 370 370 K Blade width 2000 2000 L Overall length Blade in front 5710 5710 Blade in rear 5850 5850 M Front end mini Canopy 2220 2220 radius at center Cabin 2220 2220 N Arm...

Page 111: ...7 4 ᵕ SPECIFICATIONS 7 3 WORKING RANGE OFFSET DIGGING WORKING RANGE Canopy Specification OFFSET DIGGING WORKING RANGE Cabin Specification ...

Page 112: ...of max digging depth 2370 2370 2370 2370 E Max digging height 5950 6190 5950 6190 F Radius of max digging height 3265 3430 3265 3430 G Max dumping height 4110 4340 4110 4340 H Radius of max digging height 2960 3160 2960 3160 I Min dumping height 1540 1250 1540 1250 J Radius of min dumping height 1930 2010 1930 2010 K Max vertical digging depth 2950 3270 2950 3270 L Radius of max vertical digging d...

Page 113: ...ed for operation on a level and firm ground If the machine is operated on an unleveled or unstable ground the capacity decreases CAUTION There may be some local government regulations regarding the use of excavators to lift heavy objects Please observe those regulations where they apply Outreach in m Loads in kg Outreach m 6 0 6 5 5 0 4 5 4 0 3 5 3 0 2 5 2 0 Z2 500 600 700 900 1100 1300 1700 Z1 40...

Page 114: ...7 7 ᵕ SPECIFICATIONS 7 5 NOISE LEVEL Unit dB A Measured 97 Guaranteed 98 Cabin model Open 77 At operator s head Close 78 Canopy model At exterior measurement position distance 10m ...

Page 115: ...arch 2009 55N3 取 扱 説 明 書 OPERATION MANUAL 236 8611 神奈川県横浜市金沢区昭和町 3174 3174 Syowa machi Kanazawa ku Yokohama Kanagawa 236 8611 Japan 不許複製 All rights reserved TIS 編集及び発行所 プロダクトサポート部 Editing Publishing Office Product Support Department ...