CanyCom S100 Operator'S Manual Download

Page: 63 / 66

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Troubleshooting

Location

Problem

Main causes

Remedy

Dump

device

Dump device does not
operate

･

Oil leakage from hydraulic

system

･

Foreign matter clogged in

control valve

→ Inspect and repair

Rotating

device

Rotating device does not
operate

･

Oil leakage from hydraulic

system

･

Forein matter clogged in

control valve

→ Inspect and repair

Summary of Contents for S100

Page 1: ...achine 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 Feb 2004 3677 5101 001 CHIKUSUI CANYCOM INC 90 1 Fukumasu Yoshiimachi Ukihagun Fukuoka Japan 839 1396 Tel 0943 75 2195 Fax 0943 75 4396 ...

Page 2: ... injury This word is used for precautions that are recommended or to emphasize the importance of information Notice to Users and Maintenance Personnel Thank you for purchasing this machine Always be sure to read and understand this manual thoroughly before using your machine This will enable you to use it correctly The machine can be very dangerous if the safety precau tions in this manual and on ...

Page 3: ...Be sure that everyone who uses this machine including those who rent or lease this machine receives a copy of the Operator s Manual and understands the importance of reading and following the information in this manual ...

Page 4: ... Names and Functions 10 5 Product Specifications 12 5 1 Specifications of This Product 12 5 2 Details of Tool Bag 13 6 Operation 14 6 1 Preparation Before Operation 14 6 1 1 Adding Fuel 14 6 1 2 Cheking Engine Oil Level and Adding Oil 15 6 1 2 Cheking Engine Cooling Water Level and Adding Water 15 6 2 Method of Starting 16 6 2 1 Preparation of Starting 16 6 2 2 Normal Starting 17 6 2 3 Starting in...

Page 5: ...4 2 HST Fluid Hydraulic Fluid 36 7 5 Lubricating 37 7 6 Adding Water 38 7 6 1 Engine Cooling Water 38 7 6 2 Battery Electrolyte 39 7 7 Cleaning and Replacement 41 7 7 1 Air Cleaner Element 41 7 7 2 Engine Oil Filter 42 7 7 3 Suction Filter and Line Filter 43 7 7 4 Fuel Filter 43 7 8 Adjustments 44 7 8 1 Bleeding Air from Fuel System 44 7 8 2 Parking Brake 44 7 8 3 V belt for Traveling 45 7 8 4 V b...

Page 6: ...lement 52 8 3 2 Replacing Engine Oil 53 8 3 3 Fuel Cock 53 9 Troubleshooting 54 9 1 Troubleshooting Chart 54 10 Transporting Machine 58 10 1 Truck Loading and Unloading 58 10 2 Lifting by Crane 59 Guarantee Certificate Attached to the end of this manual Receive the guarantee certificate together with a receipt after you have received instructions for handing this machine Appendix Instruction manua...

Page 7: ...must be followed when operating or using this machine 4 Component Names and Functions This section explains the names and functions of the parts of the machine 5 Product Specifications This section gives the specifications of this machine It also gives details about the tool bag 6 Operation This section explains the preparations before operating the machine the order of operation and the method of...

Page 8: ...ng Labels Attached to This Machine Replace these labels immediately if they have been removed fallen off or have become illegible Use the part numbers on the label to order replacement labels from dealer One way dump 3677M0104010 ...

Page 9: ... 3 Introduction 1 Swivel dump 3677M0103050 ...

Page 10: ... Rubber Track Dumper Please inform us of the product model that you own or use and the product serial number specified on the model label See illustration below for location of the label Please refer to the Specifications in Chapter 5 for the name of the manufacturer of the engine installed in your machine as well as the engine model Location of Model Label Model Label S100 Product model Location ...

Page 11: ...parts before starting the machine 3 002 Fuel Handling Do not handle fuel or grease service the engine or recharge the battery while smoking or when near an open flame 3 003 Protective Clothing Wear clothes suitable for the operation of heavy equipment Protective footwear long pants and long sleeved shirts are recommended A1 001 Do Not Carry Passengers on This Machine 3 58 Driving the Off Road Rubb...

Page 12: ...the conditions of the road surface and grade of the road 3 007 Precautions of Crumbling Ground Beware of driving trenches and banks There is a danger of the ground crumbling due to the machine weight If travelling on soft ground drive slowly and safely 3 060 No Quick Starting Acceleration Turning or Braking 3 006 Drive safely and avoid sudden changes of speed or direction Make sure the area around...

Page 13: ...ces The machine may slip even on a gentle slope causing a serious accident Stopping suddenly when driving down a slope can throw the operator from the machine or make the machine turn over causing serious injury or death Observe the Machine s Load Limit on a Slope 15 20 Driving on slopes can be dangerous This is particularly true when you are driving with a load Do not exceed 500kg when traveling ...

Page 14: ...a height that obstructs the operator s field of view 3 014 Observe Weight Limit of a Bridge or Overpass Before crossing a bridge or overpass be sure that the total combined weight of the machine and the load does not exceed the stated weight limit for the bridge or overpass Then cross the bridge or overpass carefully at a constant speed 3 012 Precautions When Parking Do Not Park on Unstable or Inc...

Page 15: ...ark ing on a slope is unavoidable apply the parking brake and block the rubber tracks at the lower end of the machine Observe all precautions for driving and operat ing the machine and transporting a load on a slope 3 015 Precautions When Performing Maintenance Ventilate Properly When Operating Indoors When operating engine indoors always ensure that there is adequate ventilation to prevent poison...

Page 16: ... 10 4 Component Names and Functions 4 Component Names and Functions Locations One way dump Swivel dump 3667M 0400 020E ...

Page 17: ...tch is turned to the I position it lights up and if the conditions are normal it will go out after the engine starts This displays the total number of hours that the machine has been work ing in units of 0 1 hour Press this button to sound the horn This is used when warning during traveling and signaling during operation Turn this key to start and stop the engine This is used to switch the traveli...

Page 18: ...m3 kg 0 54 1080 0 50 1000 Engine Model Kubota D 722 Type Water cooled 4 cycle diesel Cylinder bore stroke mm 67 68 Total displacement cm3 cc 719 719 Maximum output 1 PS rpm 11 0 3000 15 0 3000 Maximum torque N m min 1 kg m rpm 37 0 2200 3 77 2200 Starting system Electric starter Fuel used Light oil Fuel consumption g kW h g PS h 312 7 230 Fuel tank capacity liters 15 0 Lubricating oil capacity lit...

Page 19: ...aximum rotational speed rpm 2700 Maximum discharge ℓ min 11 0 Relief setting pressure MPa kg cm2 14 7 150 Cylinder bore stroke mm 60 400 Performance Maximum lifting angle deg 90 Lifting time sec About 6 0 About 6 3 Lowering time sec About 4 0 About 5 1 Hydraulic fluid capacity liters 1 6 Combination with HST fluid Rotating device Rotating system Hydraulic pressure twin cylinder Maximum rotating an...

Page 20: ...etc away from fuel and engine Flames will cause the fuel to ignite Always stop the engine before adding fuel Do not overfill so that fuel spills out of filler cap Wipe up any spillt before starting engine Fuel gauge Checking fuel level Visually check the fuel level gage If fuel is low open the fuel tank cap and add fuel Adding fuel 1 Open the fuel tank cover 3677M 0601 060 Fuel tank cover Fuel tan...

Page 21: ...ut the dipstick Line upper Line lower Carefully insert the stay bar in the holding hole If the stay bar comes out of the hole the engine cover may close causing serious personal injury Carefully remove and replace dipstick If it is pulled out too strongly personal injury may result or parts may be damaged 4 Check the engine oil level If the engine oil is not at the specified level open the oil fil...

Page 22: ... liters Reservoir tank capacity 0 7 liters Mixing of antifreeze See page 37 6 2 Method of Starting Before starting the engine check that there is no flammable material around the engine and that the area around the engine has good ventilation 6 2 1 Preparation for Starting 1 Open the engine cover and lock it with the stay bar See page 15 2 Turn the fuel cock to ON Fuel cock Neutral Steering lever ...

Page 23: ...the lock plate 6 2 2 Normal Starting 1 Push the clutch lever to the ON position Clutch lever Parking brake pedal 2 Depress the parking brake pedal When the steering lever is in the NEUTRAL position and the parking brake pedal is in lock a safety switch is engaged and engine will not start ...

Page 24: ...d to preheat if the engine is already warm 5 Turn the key in the ignition switch to the START position and start the engine When the engine starts release the key immediately The key will automatically return to the ON position START If the engine does not start do not crank the starting motor continuously for more than 15 seconds Return the key to the ON posi tion wait for 30 seconds then try to ...

Page 25: ...remain lit after the engine has started go to Section 9 Troubleshooting and take the appro priate action Reference See pages 54 to 57 7 Continue the warming up operation for about 5 min utes under no load Always perform the warming up operation in win ter or in cold areas If the machine is operated before the engine is properly warmed up the life of the engine and hydraulic equipment will be reduc...

Page 26: ...the throttle lever to the HIGH SPEED position 4 Insert the engine key in the ignition switch and turn it to the PREHEAT position to warm up the engine 5 Turn the key in the ignition switch to the START position to start the engine When the engine starts release the key immediately The key will automati cally return to the ON position 6 Check that the warning lamps oil lamp charge lamp and cooling ...

Page 27: ...around the machine when turning Do not make sudden turns when driving the machine The operator may be thrown from the machine or the machine may also turn over resulting in serious injury or death of the operator or bystanders Parking brake pedal Preparation for Moving 1 Check that all areas around the machine are safe 2 Check that parking brake is unlocked 3 Push the throttle lever to the HIGH SP...

Page 28: ... reverse The machine travel speed can be adjusted by moving the steering levers Steering lever Normal Right Turn Steering lever To turn right when traveling forward push the left steering lever slowly to the front To turn right when traveling backward push the left steering lever slowly to the rear Normal Left Turn Turning left Turning right To turn left when traveling forward push the right steer...

Page 29: ...eft steering lever to the front 3677M 0603 120 Do not operate the steering levers with the brake pedal depressed Always release the steering levers at the neutral position Do not turn the engine key to the OFF position while moving The balance of the machine may be upset and the front or rear of the machine may rise 6 4 Stopping Neutral Steering lever 1 Return both steering levers to the neutral N...

Page 30: ...ing brake pedal 4 With the parking brake pedal depressed pull out the parking brake lock lever to lock the brake 5 Turn the key in the ignition switch to the OFF position then remove the key 6 Open the engine cover and lock it with the stay bar See page 15 7 Turn the fuel cock to the OFF position Fuel cock 3667M 0604 050 ...

Page 31: ...may be turned over resulting in a seri ous accident 3677M 0605 090 Do not perform dumping operation on a sharp slope The body becomes unstable and it may cause a serious accident If the dumping operation must be performed unavoidably on the slope operate the vehicle carefully Do not perform the tilting operation of the bed on a slope The body becomes unstable and it may cause a serious accident Ra...

Page 32: ... Lowering the load deck suddenly with a load can damage the machine chassis Always lower the load deck slowly to prevent damage to the machine chassis Lowering Dump Body 1 Remove the lock plate from the dump lever 2 Move the dump lever gradually to the LOWER position 3 When the dump body is lowered to the lower limit a hiss sound is heard Quickly return the dump lever to the HOLD position ...

Page 33: ...d deck body is turn to the maximum angle of rotation a hiss sound is heard Quickly return the turn lever to the HOLD position When turning the load deck clockwise 1 Unlock the lock plate 2 Tilt the turn lever in the direction of reverse clockwise turn Maximum angle of rotation 90 3 When the load deck body is turn to the maximum angle of rotation a hiss sound is heard Quickly return the turn lever ...

Page 34: ...tching of accel erator lever when accelerating engine stall or knocking There must be no catching stalling of engine or knocking Exhaust gas condition Warm up engine thoroughly then check for abnormal exhaust gas color or exhaust sound low idling to high idling Exhaust gas color and exhaust sound must be normal Check for gas leakage from exhaust pipe or muffler There must be no gas leakage Air cle...

Page 35: ...heck for dirty or clogged fuel filter cartridge There must be no dirt or clogging Cleaning See page 43 Check for any abnormality in injection pressure or spray con dition of injection nozzle If there is no abnormality in the exhaust or rotation condition when idling or accelerating this inspection can be omitted Must be specified injec tion pressure and spray must be normal Please contact your Can...

Page 36: ...nspection replacement See page 36 Check for oil leakage from around hydraulic tank There must be no oil leakage Traction system Sprocket Idler Roller Upper roller Check for cracks deformities wear No cracks deformities or noticeable wear Drive machine and check for abnormal noise or abnormal generation of heat from shaft area No abnormal noise or heat Check for loose or missing mounting bolts and ...

Page 37: ...al sections for oil leakage There must be no oil leakage Stop the cylinder by applying a load Then check the cylinder for extension amount Extension amount must be within a standard value specified by the manufacture Check the cylinder tube and the cylinder rod for dents cracking bend and scratch Any dent crack bent and scratch must not occur Check the cylinder mounting pins for wear and damage Ex...

Page 38: ...tor to check for cracks There must be no cracks or damage Overall test Operate travel and loading system and check function All system must work correctly there must be no abnormal noise abnormal vibration or abnormal generation of heat 7 2 Fuel Lubricant and a Cooling Water Chart Item Interval Recommended product Capacity Page Fuel Whenever needed Light oil 15 0 liters See page 14 Engine oil Fill...

Page 39: ...defective 1 See page 43 One way dump Hydraulic 0852 1300 029 Replace if defective 1 See page 45 Swivel dump 0852 1300 028 Brake lining 7301 4007 000 Replace if defective 2 Replace it with an assembly Hydraulic hose For HST See the Parts List Every 2 years Replace if a defect occurs 1 Please contact your Canycom distributor for replacements For oil cooler 1 For dump 1 For rotation 1 Crawler OHTSU m...

Page 40: ...he oil dipstick and wipe off oil with clean cloth 3 Insert the oil dipstick and pull it again 4 Check the oil level If it is low add oil to between the upper limit and lower limit positions on the oil dipstick 5 Visually check oil for amount and dirt If oil level is low or dirty change all oil Line upper Line lower Avoid contact with high temperature oil to avoid burns Dispose of the drained oil p...

Page 41: ...d trans mission fluid If the fluid is extremely dirty change the fluid 4 Remove the fluid filler plug and add the specified fluid 5 Check the fluid level and install the fluid filler plug Fluid to use See page 32 6 Install the safety cover Replacement 1 Prepare a suitable container to collect drain fluid 2 Remove the drain plug and drain fluid from crank case Avoid contact with high temperature oi...

Page 42: ...the load deck with the support bar 2 Check the hydraulic fluid level gauge If the fluid level is low add fluid 3677M 0704 120 Drain plug Fluid filler cap Replacement 1 Prepare a suitable container to catch the drained fluid 2 Remove the drain plug to drain the fluid 3677M 0704 130 Avoid contact with high temperature oil to avoid burns Dispose of the drained fluid properly 3 Replace the drain plug ...

Page 43: ... Clutch lever pivot 2 3 Hydraulic cylinder pivot Slewing ring 2 7 4 Swing roller pivot 2 5 Roller shaft 10 6 Upper roller 2 7 Idler 2 8 Bessel pivot 1 1 Throttle lever pivot 1 Oil 2 Hydraulic V belt tension arm 1 3 Dumper lever pivot 1 Reference To lubricate the roller shaft remove the outside nut tighten the furnished grease fitting with a spanner and apply grease to the rollers through the greas...

Page 44: ... lock it firmly with the stay bar See page 15 2 When the engine is cold check the engine cooling water level in the reservoir tank If the level is below the FULL mark add water Reservoir tank capacity 0 7 liters 3 Open the radiator cap 4 Check the engine cooling water level If the level is low add water Cooling water amount 1 8 liters Radiator cap Ambient temperrature Proportion antifreeze 10 C 30...

Page 45: ...Treat the cooling water properly 7 6 2 Battery Electrolyte Keep open flames away from battery Battery gases can easily ignite Avoid skin or clothing contact with battery electrolyte to avoid burns Always stop engine and turn the ignition switch to the O OFF position when inspecting or removing the battery Inspection Adding Electrolyte 1 Open the battery box cover 2 Check the electrolyte level If t...

Page 46: ...site order may cause a short circuit When reinstalling the battery connect the and to their original positions Avoid contact between terminals and other surrounding parts The rapid charging method is a method of charging with a large current in a short time to partially compensate for battery discharge This method is used in emergencies After completing operations perform compensation charging qui...

Page 47: ... cover and lock it firmly with the stay bar See page 15 2 Remove the air cleaner element 3 Hit the air cleaner element lightly to remove the dust or blow the element with compressed air while rotat ing it If the air cleaner element is contaminated with carbon and oil immerse it in water with solvent for about 30 minutes and then wash it clean rinse it with fresh water and let it dry in the air Rep...

Page 48: ...e oil filter wrench turn the oil filter cartridge to the left and remove it 5 Clean the filter housing base on the engine side 6 Coat the seal portion of the new oil filter cartridge thinly with clean engine oil 7 Install the new oil filter and tighten it fully Do not use a filter wrench tighten by hand only 8 Add engine oil See page 34 9 After starting the engine check that there is no leakage of...

Page 49: ...all a new suction filter cartridge 3677M 0707 060 Line filter Coat the filter cartridge seal thinly with clean engine oil when installing 7 7 4 Fuel Filter 1 Open the engine cover and lock it with the stay bar See page 15 2 Tune the fuel cock to the OFF position 3 Remove the fuel filter cap Fuel cock Fuel filter cup 4 Remove dirt and water accumulated at the bottom of the fuel filter cup 5 Slowly ...

Page 50: ...on to ON start the fuel pump for about 5 seconds automatic air bleeding system 7 8 2 Parking Brake Proper brake performance is critical for safety Always keep brake adjusted for maximum performance Use the brake with the steering lever in the neutral position Safety cover Turnbuckle Spring 1 Remove the safety cover 2 Surely lock the parking brake pedal 3 Loosen the lock nut and adjust the spring h...

Page 51: ...st the spring hook inner dimension to 114 to 118 mm by turning the turnbuckle Replacement Contact your Canycom distributor 7 8 4 hydraulic pressure V belt Adjustment nut Lock nut Spring Tension arm Inspection 1 Open the engine cover and lock it with the stay bar See page 15 2 Visually check the hydraulic pressure V belt for damage If it is damaged replace Slippage of V belt After loosening the loc...

Page 52: ...t and move the alternator to adjust the tension of the belt Clawler tension bolt Lock nut 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 opera tor or bystanders During the first 100 hours of use the tracks stretch and the track tension loos ens Check track tension during the pre operation inspection and as ...

Page 53: ...justed 1 Start the engine and push the throttle lever to the HIGH SPEED position to increase the speed of the engine 2 On level ground tilt the steering lever for movement If the right and left crawlers move forward or backward when the steering lever is released the crawlers must be adjusted Before Adjustment 1 Raise the load deck of the truck and lock the dump lever to the lock plate 2 Secure th...

Page 54: ...e distance L between two link balls C becomes shorter If the crawler moves backward adjust the rod so the distance L between two link balls C becomes longer Link ball C Lock nut A Rod B Link ball F Lock nut D Rod E 3 Tighten two lock nuts A If Left Crawler Moves 1 Loosen two link ball lock nuts D 2 Rotate rod E slowly until crawler does not move 3 Tighten two lock nuts D Lock nut A Lock nut D Link...

Page 55: ...rical problems occur Slow blow fuse Fuse Open the battery box cover and check that no fuse is blown Slow Blow Fuse 30A Main glow 40A Alternator Fuse 5A Hour meter alarm monitor fuel pump 5A Horn Replacement If a fuse is blown investigate the cause then replace the fuse with another cor rect capacity fuse Correct capacity fuse must be used for warranty to apply ...

Page 56: ... other foreign matter stuck to the machine Then park the machine on concrete or firm dry ground or set it on blocks If water or mud stuck to the machine freezes it may cause failure In extremely cold areas put wooden blocks under the crawlers at right angles to the machine When leaving the machine outdoors cover it with a waterproof cover If the machine freezes and it is impossible to operate it d...

Page 57: ...high There is a danger of fire Avoid storing the machine in a place where there is high humidity or excessive dust When storing wait for the engine to cool down then cover the machine with a waterproof sheet 8 1 Machine 8 1 1 Crawler Clawler tension bolt Lock nut 1 Loosen the lock nut of the crawler and loosen the tension bolt See page 46 2 Clean the outside surface of the machine with an oily clo...

Page 58: ... level If the level is low add electrolyte 3 Store the battery in a cool dry place Battery box cover Reference When the battery is not being used it will remain charged for about 6 months but if it is charged before it has been removed it is possible to extend the life of the battery 8 3 Engine Refer to the engine operation manual for more details about long term storage of the engine 8 3 1 Cleani...

Page 59: ... 8 8 3 2 Changing Engine Oil Drain the engine oil then fill with fresh engine oil See page 32 Oil drain plug 3677M 0704 030 8 3 3 Fuel Cock Turn the fuel cock to the OFF position to cut off the fuel supply Fuel cock 3667M 0604 050 ...

Page 60: ...nect cable Replace Repair Please contact your Canycom distributor Add fuel See page 14 Bleed air See page 44 Wait for a while before re starting Add or change oil See page 31 Add battery electrolyte Charge battery See page 40 Please contact your Canycom distributor Clean the fuel stop valve Engine stops immedi ately No fuel Air in fuel hose Insufficient warming up Add fuel See page 14 Bleed air Se...

Page 61: ...e of engine cooling water Clogged radiator Add oil See page 34 Add water See page 38 Inspect and repair Please contact your Canycom distributor Clean Excessive consumption of fuel leakage of fuel from fuel system Clogged radiator Defective function of injection pump Improper injection timing Insufficient engine compression Check and repair Please contact your Canycom distributor Clean or replace S...

Page 62: ...sened Brake lining worn Water in brake drum Overload Adjust See page 44 Replace the lining Please contact your Canycom distributor Apply the brake several times to eliminate water Reduce load Crawler Crawler does not rotate smoothly Improper adjustment Adjust See page 46 Safety device related Lamp does not light Defective wiring Blown bulb Blown fuse Connect Replace Replace See page 49 Warning lam...

Page 63: ...es not operate Oil leakage from hydraulic system Foreign matter clogged in control valve Inspect and repair Inspect and repair Rotating device Rotating device does not operate Oil leakage from hydraulic system Forein matter clogged in control valve Inspect and repair Inspect and repair ...

Page 64: ... the machine 2 Fit the hooks of the ramps to the bed of the truck so that they do not slip and so that there is no height difference from the bed of the truck 3 When unloading the machine operate the machine from the outside of the machine Height When loading and unloading the machine do not allow anyone to come near the machine or the ramps Do not change direction on the ramps There is a danger t...

Page 65: ...g 1 Hitch the wire rope to the lifting hooks 4 places attached to the frame at right and left side front and rear positions and lift the machine from the lateral center of the machine 2 Slinging work attachments wire rope chain etc should have sufficient strength and equal lengths Hook ...

Page 66: ... 281 3141 Saitama Center TEL 0495 77 4511 FAX 77 1561 Osaka Center TEL 0790 42 6031 FAX 42 6035 Hiroshima Center TEL 0824 34 5996 FAX 34 5997 Matsuyama Center TEL 089 983 2701 FAX 983 5749 Fukuoka Center TEL 0943 76 2583 FAX 75 5126 Kagoshima Center TEL 0995 58 3011 FAX 58 2344 Memo of address and telephone number Name of dealer We prohibit unauthorized reprinting and reproduction of this document...

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