CanyCom BP415 Operator'S Manual Download

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OPERATOR'S MANUAL

July 2003, 3558 7002 000

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

Off-Road Rubber Track Carrier

BP416/BP416D

BP415/BP415D

Summary of Contents for BP415

Page 1: ...afety 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 Off Road Rubber Track Carrier BP416 BP416D BP415 BP415D ...

Page 2: ...al thoroughly before using your machine This will enable you to use it correctly 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 in...

Page 3: ...ent Names and Functions 9 5 Product Specifications 10 5 1 Specifications of this Product 10 5 2 Details of Tool Bag 11 6 Operation 12 6 1 Preparation Before Operation 12 6 1 1 Checking Fuel and Adding Fuel 12 6 1 2 Checking Engine Oil Level and Adding Oil 12 6 2 Method of Starting 13 6 3 Method of Operating 15 6 4 Stopping 17 6 5 Operating Dump 18 6 5 1 Operating Dump Manual Dump 18 6 5 2 Operatin...

Page 4: ... Dump 27 7 5 Lubricating 28 7 6 Cleaning 29 7 6 1 Air Cleaner Element 29 7 6 2 Ignition Plug 29 7 6 3 Fuel Cock Fuel Filter 30 7 7 Adjustments 31 7 7 1 V belt 31 7 7 2 Clutch 31 7 7 3 Brake 32 7 7 4 Side Clutch 33 7 7 5 Track Tension 34 7 7 6 Belt Stopper 35 7 8 Maintenance After Use 35 8 Storage Long term Storage 36 8 1 Machine 36 8 2 Engine 37 8 2 1 Fuel Cock 37 8 2 2 Cleaning Air Cleaner Elemen...

Page 5: ...rantee 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: ...e followed when operating or using this machine 4 Explanation of Components This section explains the names and functions of the parts of the machine 5 Product Specification 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 operation ...

Page 7: ...ree of the failure the following four signal words are used to identify the safety messages in this manual Their meanings are as follows 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 NOTICE ...

Page 8: ... using the Off road Rubber Track Carrier 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 3559M 0103 020 BP415...

Page 9: ... 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 B1 001 A1 001 B1 002 B1 003 Do Not Carry Passengers on this Machine Driving the Off Road Rubb...

Page 10: ...ith an Observer in Dangerous Situations When operating the machine where there is poor visibil ity rugged terrain hills or limited maneuvering room use an observer to help direct the machine s move ment The observer should be able to see the machine and its immediate surroundings and should use pre arranged signals to direct the driver s actions No Quick Starting Acceleration Turning or Braking Dr...

Page 11: ...he bridge or overpass carefully at a con stant speed Observe the Machine s Load Limit on a Slope Driving on slopes can be dangerous This is particularly true when you are driving with a load Do not exceed 150kg when traveling on slopes of 15 to 20 If you must drive on slopes of more than 20 the machine must not carry a load Do Not Drive Across a Slope to Drive on the Slope Always travel straight u...

Page 12: ...eld of view Do Not Park on Unstable or Inclined Surfaces Check for Safety at Parking and Enforcement of Chock on Slope When parking move the running clutch lever to the STOP position Brake ON and stop the engine Avoid parking on a slope If the vehicle must be parked unavoidably ensure to chock up the wheels Do Not Park on Unstable or Inclined Surfaces Park the machine on a stable level flat surfac...

Page 13: ...ilate Properly when Operating Indoors When operating engine indoors always ensure that there is adequate ventilation to prevent poisoning by exhaust gas Never carry out maintenance with engine running Do not carry out maintenance with the engine running Always stop the engine before starting maintenance ...

Page 14: ...lever This is used to interrupt the transmission of power from the engine to the transmission When the lever is lowered the operation mode becomes RUN travel When the lever is raised the operation mode becomes STOP stop The lever is interlocked with the brake When the lever is at the STOP position the brake is applied Gear shift lever This is used to select the running speed Before operating this ...

Page 15: ...180 165 Maximum payload capacity kN kg BP415 2 45 250 BP416 2 94 300 Minimum turning radius mm 1200 Minimum ground clearance mm 90 Height of bed floor mm 370 380 370 Without load 25 With Max load 15 Bucket capacity m3 0 066 0 066 Left 41 Right 39 Left 25 Right 25 F1 2 0 F2 4 5 R1 1 5 R2 3 5 Clutch Belt tension system Brake lnner expansion system Dump angle 5 0 55 63 57 63 BP415 BP416 Model Measure...

Page 16: ...oduct Specifications 11 No Part Name Q ty Remarks 1 OperationandMaintenanceManual thismanual 1 2 Instruction manual for engine 1 3 Engine tools 1 For engine maintenance and repair 5 2 Details of Tool Bag ...

Page 17: ...01 010 3558M 0601 020 6 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 When adding fuel keep open flames lighted cigarettes etc away from fuel and en...

Page 18: ... and L on the dipstick 3560M 0602 040 3560M 0601 030 3558M 0602 010 3560M 0602 020 3560M 0602 030 6 2 Method of Starting Before starting the engine remove any flammable material from around the engine Area around the engine should be well venti lated DANGER 1 Move the drive clutch lever to the STOP position 2 Move the gear shift lever to the NEUTRAL N position 3 Turn the fuel cock to OPEN 4 Move t...

Page 19: ...ine via a throttle cable 5 Move the choke lever to FULL CLOSE position The choke lever should not be operated after the engine is warmed up NOTICE 6 Pull out the starter knob 7 After the engine is started move the throttle lever to the LOW position 8 Return the choke lever to the FULL OPEN position and perform the warm up operation for 3 to 5 minutes The first week about 40 to 50 hours use time af...

Page 20: ... in the STOP posi tion 3 Firmly move the gear shift lever to any forward or reverse gear shift position Partially engaged gears may cause failures or accidents When the shift gears cannot be fully engaged do not force gears into posi tions Move the drive clutch lever slightly to the RUN position then slowly repeat gear shifting DANGER 4 Move the drive clutch lever slowly to the RUN position to sta...

Page 21: ... gears during traveling Always stop the vehicle before shifting gears CAUTION If the side clutch levers on both right and left sides are operated simultaneously the vehi cle will abruptly stop Operate the right and left side clutch levers at the same time only in emergencies CAUTION Right Turning 6 Grasp the right side clutch lever Avoid turning abruptly except for an emergency CAUTION Left Turnin...

Page 22: ...throttle lever to the LOW position 2 Release the drive clutch lever to return it to the STOP position In an emergency grasp both right and left side clutch levers simultaneously The vehicle stops urgently On sloped ground perform these oper ations carefully since the vehicle may rise from the ground CAUTION 3 Move the engines switch to OFF 4 Turn the fuel cock to CLOSE ...

Page 23: ... injury or death If dumping on a slope is necessary make the machine as level as possible by posi tioning on a large immobile object such as a rock or fallen tree WARNING When performing the inspection opera tion under the deck ensure to stop the engine Lowering the load deck suddenly with a load can damage the machine chassis Always lower the load deck slowly to pre vent damage to the machine cha...

Page 24: ...g Dump Hydraulic Dump Raising Dump Body 1 Start the engine move the throttle lever to the HI position and increase the engine speed 2 Release the lock plate for the hydraulic dump lever 3 Tilt the hydraulic dump lever to RAISE position 4 When the dump body is raised to the upper limit a hiss sound is heard Quickly return the dump lever to the NEUTRAL position Lowering Dump Body 1 Move the dump lev...

Page 25: ...ne stall or knocking Check speed at low idling and at high idling Check that rotation is smooth Warm up engine thoroughly then check for abnormal exhaust gas color or exhaust sound low idling to high idling Check if glow plug works prop ery Check for cracks deformation of case looseness of cover or connecting piping Check for looseness of nuts and bolts at tightening portion of cylinder head and m...

Page 26: ...perating conditions for disengagement of gears abnormal noise and abnormal heating Check the oil level in the case Check for fuel leakage from fuel tank injection pump hoses pipes Engine compression Engine mount Lubrication system Inspection interval Inspection interval Monthly Annually Checks before starting Engine proper If the engine is operating abnormally or if the exhaust condition at idle o...

Page 27: ...res for damage and the mounting parts for looseness Operate the brake repeatedly to check for looseness and rattling of connection parts and missing split pins Rods links and wires There must be no rattling or rusting Traction system Brake system Item Content of inspection Remarks Operate the lever to check for play and pulling tolerance Operate the lever to check clearance in rods links bearing s...

Page 28: ...es There must be no abnormal vibration abnormal noise or abnormal heating There must be no excessive contamination of oil There must be no oil leakage Check hose joints and seals for oil leakage Operate the pump to check for abnormal vibration abnormal noise and abnormal heating in unloaded and loaded conditions With the pump loaded check for delivery amount and delivery pressure under loading If ...

Page 29: ... parts Please contact your Canycom distributor or our Service Center Inspect every 50 hours weekly and replace if defective Inspect every 200 hours monthly and replace if defective Item Replacement interval Q ty Page Parts number Air cleaner element Fuel filtter 08521300031 79531213100 35442021000 35496008000 35176021000 08520000019 See page 30 See page 30 1 1 2 1 1set The entire set is replaced 1...

Page 30: ...oil filler cap and pour in the specified oil See item Inspection Adding above 1 Remove the oil filler plug 2 Visually check the engine oil level and the condition of dirt in the oil Add or remove oil until oil level is between F and L lines on the dipstick If the oil is extremely dirty change the oil Oil to use See page 24 Oil amount Between F and L on the dipstick 3 Replace the fluid filler plug ...

Page 31: ...l and the condition of dirt in the fluid If the level is low add transmission fluid If the fluid is extremely dirty change the fluid Oil to use See page 24 3 Replace the fluid filler plug Changing 1 Prepare a suitable container to catch the drained fluid 2 Remove the drain plug to drain the fluid Note Fluid will drain faster with fluid filler plug removed Dispose of the drained oil properly NOTICE...

Page 32: ...els may decrease dump perfor mance Check the fluid level every 100 hours NOTICE When the engine is first started and the bed of the truck is raised after adding fluid knock ing may occur due to entrapped air To elimi nate knocking repeat above steps 2 to 3 times NOTICE 3 Replace the oil tank 4 Open the fluid filler cap and pour in the fluid See item Inspection Adding Fluid above Dispose of the dra...

Page 33: ...in the figure Grease to use See page 24 Reference When a manual grease pump is used strike it five to six times When the pump handle becomes heavy halfway stop greasing at once When a pneumatic grease pump is used a few seconds are enough To lubricate swing remove the outside nut tighten the fur nished grease fitting with a spanner and apply grease to the rollers through the grease fitting After g...

Page 34: ...g for the following points and clean or replace it as necessary Presence or absence of breakage of the insulator Worn electrode Carbon deposit Damage to and breakage of gasket Degree of burning of insulator in spark section Do not pull on the cable when removing the igni tion plug cap Always hold the cap body NOTICE A dirty air cleaner element will reduce engine performance and life Clean every 50...

Page 35: ...wire brush or plug cleaner 1 Grind the electrode with sandpaper to adjust the gap as specified Standard clearance 0 7 mm 3 Replace the ignition plug 7 6 3 Fuel Cock Fuel Filter Cleaning 1 Check that the fuel cock is positioned at CLOSE 2 Remove the fuel filter pot and wash clean the inside of the pot and the filter with kerosene ...

Page 36: ...ment bolt 3 Turn the V belt tension adjustment bolt to adjust the V belt tension so that the belt is deflected about 10 mm when the V belt between the pulleys is pressed at the center position by the finger Adjust the tension taking care so that the V belt is not slipped NOTICE 7 7 2 Clutch 1 Move the drive clutch lever to the STOP lower side position to free the clutch wire 2 Loosen the lock nuts...

Page 37: ...justment nut 3560M 0707 040 3560M 0707 050 7 7 3 Brake Proper brake performance is critical for safety Always keep brakes adjusted for maximum performance NOTICE 1 Move the drive clutch lever to the RUN position to disengage the brake 2 Loosen the lock nut for the brake adjuster C 3 Turn the adjustment nut to adjust the brake adjuster When the effectiveness of the brake is poor Turn the adjustment...

Page 38: ...ission to the brake wire is extended by about 5 mm with the running clutch lever set to STOP lower side 4 After the adjustment tighten the lock nut firmly 7 7 4 Side Clutch When the amount of play of the side clutch lever becomes large or when turning cannot be done smoothly adjust the amount of play by means of the adjustment screw for the side clutch cable NOTICE 1 Loosen the lock nut for the si...

Page 39: ...d as part of monthly inspections as specified in the Regular Inspection Chart NOTICE 1 Jack up the front and rear of the chassis to raise the crawler on one side and make it horizontal to the ground surface Perform this step with extra care so that the jack does not move from the specified positions NOTICE 7 7 5 Track Tension 2 Raise the deck See page 19 3 Loosen the lock nut of the crawler tensio...

Page 40: ...nce After Use Maintenance After Use in Normal Conditions After using the machine remove any mud water or other foreign matter stuck to the machine Do not wash the engine or control panel with water This will allow water to enter and lead to rust When leaving the machine outdoors cover it with a waterproof cover Maintenance After Use in Cold Weather After using the machine remove any mud water or o...

Page 41: ...he engine to cool down then cover the machine with a waterproof sheet NOTICE 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 8 1 Machine 1 Loosen the crawler tension bolts See Page 34 2 Clean the outside surface of the machin...

Page 42: ...e for a long period drain the fuel in the carburettor and the fuel tank Do not use fuel which has been left for a long period For details about engine storage refer to the furnished Engine Operation Manual provided NOTICE 8 2 Engine 1 Remove the air cleaner element and clean it See page 28 8 2 3 Replacing Engine Oil 8 2 1 Fuel Cock 1 Turn the fuel cock to the CLOSE position to cut off the fuel sup...

Page 43: ...dure 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 WARNING Location Engine related Problem Main causes Remedy Engine does not start or is difficult to start Add fuel See page 12 Wait for a while before starting Add fuel See page 25 Clean or replace See page 29 Foll...

Page 44: ...ne oil level is too high Improper fuel Worn cylinder piston ring Large amounts of black smoke are emitted defective exhaust condition White smoke or blue smoke is emitted defective exhaust condition Excessive consumption of engine oil Leakage of engine oil Check and repair Add oil see page 25 Engine overheats Lack of engine oil Check and repair please contact your Canycom distributor Clean or repl...

Page 45: ...butor Gears disengage Gears not smoothly shifting Worn gear Excessive loading Firmly shift gears Please contact your Canycom distributor Reduce loading The side clutch is loose Improper adjustment Adjust See page 33 Turning cannot be done smoothly Improper adjustment Adjust See page 33 Shift the gears completely The brake is applied Adjust the brake See page 32 Engage the V belt or adjust please c...

Page 46: ...roper adjustment Adjust See page 34 Location Roller upper roller and idler Lift and dump system Problem Main causes Remedy Replace the defective part Please contact your Canycom distributor Replace the defective part Please contact your Canycom distributor Add or replace See page 27 Inspect and repair Adjust See page 35 The dump or lift equipment does not operate or mal functions Oil in the power ...

Page 47: ...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 Height Ramp Length of 3 times height or longer 3560M 1000 010 When loading and unloading the machine do not allow any one to come near the machine or the ramps Do not change direction on the ramps There is a danger that the machine will fall off When dri...

Page 48: ...ce and explanations as to the safe operation as well as handling and control and I have received this guarantee certificate Address Customer Signature Name Model Product name purchased Production number Remarks Dealer Duplicate Delivery Person in charge inspection Dealer Explainer Date of explanation Person who received explanations Dealer name ...

Page 49: ...ve 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 Address Customer Signature Name Model Product name purchased Production number Remarks Delivery Person in charge inspection Dealer Explainer Date of explanation Person who received explanations Dealer name ...

Page 50: ...here a failure results from carelessness in use and handling negligence or imperfection checking 2 A case where a failure results from the use in which the limit of the specifications specified by our company is exceeded 3 A case where a modification or alteration which is not approved by our company causes a failure 4 A case where a failure results from the use of parts other than our company s g...

Page 51: ...552 6288 Sendai Center 022 281 1255 FAX 281 3141 Saitama Center 0495 77 4511 FAX 77 4511 Osaka Center 0790 42 6031 FAX 42 6035 Hiroshima Center 0824 34 5996 FAX 34 5997 Matsuyama Center 0899 83 2701 FAX 83 5749 Fukuoka Center 09437 6 2583 FAX 5 5126 Kagoshima Center 0995 58 3011 FAX 58 2344 CHIKUSUI CANYCOM INC We prohibit unauthorized reprinting and reproduction of this document ...

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