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Off-Road Rubber Track Carrier
BP416/BP416D
BP415/BP415D
OPERATOR'S MANUAL
Read this manual completely before operating or maintaining this machine.
Failure to follow safety precautions could result in serious injury or death.
Keep this manual for future reference for you and for all those who operate and
maintain this machine.
WARNING
CHIKUSUI CANYCOM, INC.
90-1 Fukumasu, Yoshiimachi,
Ukihagun,Fukuoka,Japan839-1396
Tel.(09437)5-2195 Fax.(09437)5-4396
July 2003, 3558 7002 000
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Table of Contents
Related Manuals for CanyCom BP416
Summary of Contents for CanyCom BP416
- Page 1 Failure to follow safety precautions could result in serious injury or death. Keep this manual for future reference for you and for all those who operate and maintain this machine. July 2003, 3558 7002 000 CHIKUSUI CANYCOM, INC. 90-1 Fukumasu, Yoshiimachi, Ukihagun,Fukuoka,Japan839-1396 Tel.(09437)5-2195 Fax.(09437)5-4396...
- Page 2 Warning Words Used in this Manual To indicate the level of danger (or the degree of the failure), the following four signal words are used to identify the safety messages in this manual. Their meanings are as follows. Signal word Meaning Indicates an imminently hazardous situation which, if not avoided by following these instructions and precautions, will result in death...
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Page 3: Table Of Contents
Contents Introduction 1.1 Purpose of this Manual ..........1.2 Structure of this Manual . - Page 4 Maintenance 7.1 Periodic Inspection Table ......... 7.2 Fuel, Lubricant, and Coolant Chart .
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Page 5: Troubleshooting
Troubleshooting Transporting Machine < Guarantee Certificate > Attached to end of this manual. * Receive the guarantee certificate together with a receipt after you have received instructions for handing this machine. < Appendix > "Instruction manual for engine" * Be sure to read it together with this manual. -
Page 6: Introduction
Introduction Introduction 1.1 Purpose of this Manual The purpose of this manual is to provide detailed information needed for the safe and effective use of this machine to those who operate or maintain the machine. 1.2 Structure of this Manual This manual contains the following chapters. -
Page 7: Warning Labels Attached To This Machine
Introduction 1.3 Warning Words Used in this Manual To indicate the level of danger (or the degree of the failure), the following four signal words are used to identify the safety messages in this manual. Their meanings are as follows. NOTICE Replace these labels immediately if they have been removed, fallen off, or have become illegible. -
Page 8: Warranty And After-Sales Service
Warranty and After-sales Service 2. Warranty and After-sales Service Warranty Chikusui Canycom, Inc. provides a warranty to you through their local dealers. Consult your local dealer regarding the details of warranty. After-sales Service Please contact your Canycom distributor from whom you purchased your machine or our Service Center regarding service orders or any questions or problems that may arise when using the Off-road Rubber Track Carrier. -
Page 9: Rules For Safe Operation And Maintenance
Rules for Safe Operation and Maintenance 3. Rules for Safe Operation and Maintenance This chapter describes general safety precautions that must be followed during operation and mainte- nance. Be sure that all users and maintenance personnel are familiar with these rules and that they follow them. Safety Precautions before Operation Pre-work Check Perform the daily pre-operation check before starting... - Page 10 Rules for Safe Operation and Maintenance Do Not Drive Recklessly Do not operate this machine when under the influence of alcohol or when fatigued. No one under age18 should operate this vehicle. B1-004 Do Not Start, Accelerate, Turn, or Brake Quickly Maintain Safe Speed When driving the machine, always drive at a safe speed suitable for the load in the dump body and the condi-...
- Page 11 Rules for Safe Operation and Maintenance Engine Brake on Downhill Before a downhill, temporarily stop and move the gearshift lever to the low speed position. Ensure to apply the engine brake for deceleration. If the vehicle is stopped without decelerating sufficiently, the vehicle body may be lifted.
- Page 12 Rules for Safe Operation and Maintenance Load Vehicle Properly Load cargo on the load deck so it is evenly distributed and strap the cargo to the load deck to avoid cargo weight imbalance and shifting. Do not load cargo on the load deck to a height that obstructs the operator's field of view.
- Page 13 Rules for Safe Operation and Maintenance Precautions When Performing Maintenance Ventilate Properly when Operating Indoors When operating engine indoors, always ensure that there is adequate ventilation to prevent poisoning by exhaust gas. B5-001 Never carry out maintenance with engine running Do not carry out maintenance with the engine running.
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Page 14: Component Names And Functions
Component Names and Locations Component Names and Locations Locations 3558M-0400-010E Component Names ① Throttle lever ..... . . This is used to increase or decrease the speed of the engine. ②... -
Page 15: Product Specifications
Product Specifications 5. Product Specifications 5.1 Specifications of this Product NOTICE Read and understand the specifications of this machine to use and maintain the machine properly. BP415 / BP416 Model Manual dump Hydraulic dump Flat-bed type Sliding panel Bucket type... -
Page 16: Details Of Tool Bag
Product Specifications 5.2 Details of Tool Bag Part Name Q'ty Remarks Operation and Maintenance Manual (this manual) Instruction manual for engine Engine tools For engine maintenance and repair – 11 –... -
Page 17: Operation
Operation Operation • Before reading this section, be sure to read Section 3 "Rules for Safe Operation and Maintenance"(see pages 4-8). • When operating the machine, always follow the instructions in this section. Do not operate the machine unless you are familiar with the operation of all controls and safety devices. 6.1 Preparation Before Operation 6.1.1 Adding Fuel DANGER... -
Page 18: Method Of Starting
Operation 2. Visually check the engine oil level. If it is not within the specified levels, add engine oil. Dipstick Oil to use: See page 23 Engine oil quantity : Between "F" and "L" on the dipstick. 3560M-0601-030 6.2. Method of Starting Drive clutch lever DANGER Before starting the engine, remove any... - Page 19 Operation 4. Move the throttle lever to the halfway point between Throttle lever "LOW" and "HI". Reference: The throttle lever of the vehicle is connected to the throttle lever of the engine via a throttle cable. 3560M-0602-050 5. Move the choke lever to "FULL CLOSE( )"...
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Page 20: Method Of Operating
Operation 6.3 Method of Operating 1. Check that all areas around the machine are safe. Drive clutch lever 2. Check that the drive clutch lever is in the "STOP" posi- tion. 3558M-0602-010 3. Firmly move the gear shift lever to any forward or reverse gear shift position. - Page 21 Operation When Changing Speeds 5. After the vehicle is stopped, follow the steps 1 to 3 on page 15. (For stopping the vehicle, refer to Section 6.4 Gear shift lever "Stopping". p.17) CAUTION Do not shift gears during traveling. Always stop the vehicle before shifting gears.
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Page 22: Stopping
Operation 6.4 Stopping Throttle lever 1. Move the throttle lever to the "LOW" position . 3560M-0602-080 2. Release the drive clutch lever to return it to the "STOP" position. Drive clutch lever CAUTION In an emergency, grasp both right and left side clutch levers simultaneously. -
Page 23: Operating Dump
Operation Operating Dump DANGER • Falling load deck can cause injury or death • Always fix load deck support bar before doing any work under the load deck • Do not raise or lower load deck or dump load when anybody is standing near load deck. -
Page 24: Operating Dump (Hydraulic Dump)
Operation 2. Raise the deck in upper forward direction. 3558M-0605-020 Lowering Dump Body 1. Manually tilt the deck backward until the deck is locked. 2. Raise the deck without operating the dump lever to check that the deck is locked firmly. 3558M-0605-030 6.5.1 Operating Dump (Hydraulic Dump) -
Page 25: Maintenance
Some inspection and maintenance procedures in the table below require technical knowledge or specific tools and mea- suring instruments. If you have difficulty performing these pro- cedures, or do not have the correct tools or instruments, contact your dealer or a Canycom service center. Inspection Inspection interval... - Page 26 If you hear valve noise or Please contact your Engine or if the exhaust condition at idle the engine is not running Canycom distributor compression or at high RPM is abnormal, check smoothly, check valve clear- for inspection the engine compression.
- Page 27 Maintenance Inspection Inspection interval interval Item Content of inspection Remarks The side clutch must operate Check that the side clutch functions correctly correctly without generating without generating any abnormal noise any abnormal noise. when the side clutch lever is operated during traveling.
- Page 28 Must be within reference With the pump loaded, check for Please contact your values. delivery amount and delivery Canycom distributor pressure under loading. for inspection * If any abnormality is not found in the inspection of the previous item, this inspection may be omitted.
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Page 29: Fuel, Lubricant, And Coolant Chart
Lower side 35176021000 (Replace if defective) of cylinder Special replacement parts Please contact your Canycom distributor (or our Service Center). NOTICE Rubber parts such as hydraulic hoses will deteriorate even when not used. Replace them every 2 years, or whenever damaged. -
Page 30: Adding Oil
Maintenance Adding Oil NOTICE Oil level must be maintained and proper oil must be used, for smooth rotation. Improper maintenance and oil will cause failures and reduce the service of the machine. Always use the specified high quality oil and maintain oil at proper levels. 7.4.1 Engine Oil Inspection/Adding 1. -
Page 31: Transmission Fluid
Maintenance 7.4.2 Transmission Fluid Inspection/Adding 1. Remove the fluid filler plug. 2. Visually check the transmission fluid level and the condition of dirt in the fluid. If the level is low, add transmission fluid. If the fluid is extremely dirty, Fluid filler plug change the fluid. -
Page 32: Power Package Fluid (Fluid For Hydraulic Dump)
Maintenance 7.4.3 Hydraulic Pump Power Package Fluid Inspection/Adding NOTICE Low fluid levels may decrease dump perfor- mance. Check the fluid level every 100 hours. 1. Remove the fluid filler cap. 2. Visually inspect the oil level. If oil is short, remove Fluid filler cap the oil filler cap and replenish oil. -
Page 33: Lubricating
Maintenance 7.5 Lubricating NOTICE Proper Iubrication will prevent seizures and rust, and ensure smooth operation. Lubricate every 6 months. 1. Using a commercially available manual grease pump or pneumatic grease pump, grease the areas as shown in the figure. Grease to use: See page 24. Reference: When a manual grease pump is used, strike it five to six Roller(Swing) -
Page 34: Cleaning
Maintenance 7.6 Cleaning 7.6.1 Air Cleaner Element CAUTION • A dirty air cleaner element will reduce engine performance and life. Clean every 50 hours of operation. • Depending on the types of engines, air cleaner elements of dry type, semi-wet type, and oil bath type are available. -
Page 35: Fuel Cock (Fuel Filter)
Maintenance Cleaning 1. Clean the ignition plug using a wire brush or plug cleaner. 3560M-0706-040 1. Grind the electrode with sandpaper to adjust the gap as specified. Standard clearance: 0.7 mm 3. Replace the ignition plug. 3560M-0706-050 7.6.3 Fuel Cock (Fuel Filter) Cleaning Filter 1. -
Page 36: Adjustments
Inspection (Engine V-belt) V-belt 1. Visually check the traveling V-belt for damage. If it is damaged, replace. Changing: Contact your Canycom distributor. 3560M-0707-010 Inspection (Power Package V-belt) 1. Loosen the power package mounting bolts (4 pcs). Lock nut V-belt tension 2. -
Page 37: Brake
Maintenance (BP416) 7.7.2 Clutch Brake wire 1. Move the drive clutch lever to the "STOP" (lower side) position to release the clutch wire. Clutch wire 2. Loosen the clutch wire lock nut. 3. Turn the adjustment nut to adjust the clutch wire. -
Page 38: Side Clutch
Maintenance (BP416) 7.7.3 Brake Brake wire NOTICE Clutch wire If the effectiveness of the brake is lowered, adjust it immediately even if it is very small so that safety can be assured at all times. 1. Move the drive clutch lever to the "RUN" position to release the brake. -
Page 39: Track Tension
Maintenance 7.7.5 Track Tension NOTICE Loose track tension can cause the tracks to come off the machine, causing damage to the machine and possibly serious injury or death to the operator or bystanders. During the first 100 hours of use, the tracks stretch and the track tension loosens. Check track tension during the preoperation inspection and as part of monthly inspections, as specified in the Regular Inspection Chart. -
Page 40: Belt Stopper
Use warm or hot water to melt the frozen parts or wait for the ice to melt. Be careful when moving the machine. If the machine is moved by force, Canycom does not take responsibility for damage or failure. – 35 –... -
Page 41: Storage (Long-Term Storage)
Storage (Long-term Storage) 8. Storage (Long-term Storage) When storing for a long time,it is necessary to take suitable action to prepare for the next time that the machine is used. When preparing for long-term storage, carry out "Maintenance after use" (see page 35), then do as follows. -
Page 42: Engine
Storage (Long-term Storage) 8.2 Engine NOTICE • If fuel is left in the carburetor for a long period, it will deterio- rate, and problems with starting and rotational fluctuation may occur. To prevent these problems, when storing the engine for a long period, drain the fuel in the carburettor and the fuel tank. - Page 43 If you can not resolve the problem or do not have the correct tools or knowledge, take the machine to your dealer or Canycom service center for repair, adjustment, or part replacement. Troubleshooting Chart...
- Page 44 Engine overheats Lack of engine oil Add oil (see page 25) Engine Check and repair ( please Leakage of fuel from fuel related contact your Canycom system Excessive consumption of distributor ) fuel Clean or replace (See page Clogged air cleaner...
- Page 45 Vehicle will not move even V-belt disengaged or Engage the V-belt, or adjust when the clutch is engaged excessively loosened (please contact your Canycom distributor) Failure of transmission Please contact your Canycom distributor Clutch disengagement is Improper adjustment Adjust (See page 31)
- Page 46 Main causes Remedy Adjust nut loosened Adjust (See page 31) Brake lining worn Replace the lining (Please contact your Canycom distributor) Oil in brake drum Replace the oil seal Brake (Please contact your Poor braking Canycom distributor) Water in brake drum...
- Page 47 Transporting Machine 10. Transporting Machine When loading and unloading this machine onto a truck for transportation, follow these safety precautions. 1. Use ramps that have ample strength (that can hold the total weight of the machine and operator), width (at least 1.2 times the width of the crawler), and length (at least 3 times the height of the bed of the truck), and are fitted with no-slip pads.
- Page 48 Dealer (Duplicate) Accountable receipt of guarantee certificate Based on the instruction manual for the following product I have purchased, I have been given guidance and explanations as to the safe operation as well as handling and control and I have received this guarantee certificate.
- Page 49 Customer (Duplicate) Accountable receipt of guarantee certificate Based on the instruction manual for the following product I have purchased, I have been given guidance and explanations as to the safe operation as well as handling and control and I have received this guarantee certificate.
- Page 50 (2) A case where a failure results from the use in which the (9) Even if the guarantee certificate is lost, we will not reissue limit of the specifications specified by our company is exceeded CHIKUSUI CANYCOM, INC. 90-1 Fukumasu, Yoshii-machi, Ukiha gun, Fukuoka, Japan...
- Page 51 CHIKUSUI CANYCOM, INC. 09437(5)2195 FAX (5)4396 ■Osaka Center 0790(42)6031 FAX (42)6035 Sales Headquarters ■ 03(3552)6255 FAX (3552)6288 0824(34)5996 FAX (34)5997 Tokyo Headquarters Hiroshima Center ■ ■ ■Foreign Trade Center 03(3552)6255 FAX (3552)6288 0899(83)2701 FAX (83)5749 Matsuyama Center ■ ■Sendai Center 022(281)1255 FAX (281)3141 ■Fukuoka Center...
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