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Troubleshooting

9. Troubleshooting

* Stop using machine immediately after any malfunction or abnormal operation occurs. Use

troubleshooting chart (below) to identify problems and corrective actions. Please contact dealer or

CANYCOM service center for problems not listed in chart.

* Contact dealer or CANYCOM service center for service requiring special tools or knowledge.

Area

Malfunction

Possible cause

Corrective action

Engine

Engine does not start

* Blade clutch lever is not

in "OFF". (Safety device is

actuated.)

→ Put the lever to "OFF".

* Brake pedal is not

depressed. (Safety device is

working.)

→ Depress brake pedal.

* Battery is over-discharged. → Charge battery.

(See page 40)

→ Replace battery.

(See page 40)

* Battery cable is

disconnected.

→ Connect cable.

* Fuse is blown.

→ Replace.

* Open circuit or contact failure

of wiring

→ Repair. (Consult dealer.)

Difficulty starting

* Lack of fuel

→ Add. (See page 15)

* Air or water in fuel

→ Check pipe and tightening

band. Repair or replace.

* Excessive intake of fuel

→ Start after interval.

* Engine oil too low or poor

quality (High oil viscosity)

→ Add or replace.

(See page 34)

* Poor ignition due to dirt on

spark plug or poor sparking

→ Clean or replace.

(See page 41)

* Insufficient capacity of

battery (Poor electric

starting)

→ Replenish battery fluid.

→ Charge battery.

(See page 39)

* Impurities in fuel circuit

→ Replace the fuel filter.

(Consult dealer.)

Engine stalls soon

* Lack of fuel

→ Add. (See page 15)

Engine stops abruptly

* No fuel

→ Add. (See page 15)

* Burn due to insufficient or

deteriorated engine oil

→ Check and add oil.

(See page 34)

Improper idling

(lrregular engine speed)

→ Ask dealer for service.

Poor power or acceleration

* V-belt loosened

→ Adjust.

* Improper accelerator

adjustment

→ Ask dealer for service.

* Clogging of air cleaner

→ Clean or replace.

(See pages 40)

Troubleshooting Chart

Содержание CM 2103

Страница 1: ...s injury or death Keep this manual for future reference by you and by all those who operate and maintain this machine CHIKUSUI CANYCOM INC 90 1 Fukumasu Yoshii machi Ukiha shi Fukuoka Japan 839 1396 Tel 81 0 943 75 2195 Fax 81 0 943 75 4396 Original Instructions in English Ride on Brushcutter CM 2103 Operator s Manual 5314 5205 001 ...

Страница 2: ...uarters TEL 81 0 943 75 2195 FAX 81 0 943 75 4396 Foreign Trade Center TEL 81 0 3 3552 6277 FAX 81 0 3 3552 6288 All rights reserved Unauthorized use or reproduction of this material is prohibited Authorized Dealer CHIKUSUI CANYCOM INC ...

Страница 3: ...t Names and Locations 11 5 Product Specifications 13 5 1 Specifications of This Product 13 5 2 Details of Tool Bag 14 6 Operation 15 6 1 Preparation Before Operation 15 6 1 1 Adding Fuel 15 6 1 2 Checking Engine Oil Level and Adding Oil 16 6 2 Starting 17 6 3 Operation Procedure 20 6 4 Stopping 21 6 5 How to Park 21 6 6 Emergency Transferring 22 6 7 How to Avoid Slippage of Rear Wheels 23 6 8 How ...

Страница 4: ...s Chart 33 7 4 Adding Oil 34 7 4 1 Engine Oil 34 7 4 2 Transmission Oil 35 7 4 3 Differential Oil and Knuckle Oil 36 7 4 4 HST Oil 37 7 5 Lubrication and Greasing 38 7 6 Adding Water to Battery 39 7 7 Cleaning 40 7 7 1 Air Cleaner Element 40 7 7 2 Ignition Plug 41 7 7 3 Fuel Filter 42 7 7 4 Fan Housing and Cooling Fan 42 7 8 Adjustments 43 7 8 1 Driving V Belt 43 7 8 2 Blade Rotary V Belt 43 7 8 3...

Страница 5: ... Appendix together with this manual 7 8 6 Tire Pressure 45 7 9 Replacement 46 7 9 1 Oil Filter 46 7 9 2 HST Oil Filter 46 7 9 3 Fuel Pipe Engine Oil Drain Pipe and HST Oil Tank Connection Hose 46 7 9 4 Cutter Blade 47 7 10 Maintenance After Use 48 8 Storage Long term Storage 49 8 1 Vehicle Body 49 8 2 Battery 50 8 3 Engine 50 8 3 1 Cleaning Air Cleaner Element 50 8 3 2 Replacing Engine Oil 51 9 Tr...

Страница 6: ...ine Also do not remove the safety cover of the body before running A serious accident could result 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 ...

Страница 7: ...ting or using this machine 4 Component Names and Locations 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 required before operating the machine the order of operation and the method of operation 7 Mainte...

Страница 8: ...04 010E 1 3 Warning Labels Attached to This Machine Replace these labels immediately if they have been removed have fallen off or have become illegible Use the part numbers on the label to order replacement labels from dealer ...

Страница 9: ...Introduction 3 5310M 0104 020E ...

Страница 10: ... 4 Introduction 5305 5327 000 5310M 0104 030E ...

Страница 11: ... using the Ride on Brush cutter Please refer to the product model that you own or use the product serial number specified on the model label see illustration below for location of the label the name of the manufacture of the engine installed in your machine and the engine model listed in chapter 5 of this manual Specifications Location of Model Label Model Label Warranty and After sales Service Av...

Страница 12: ...Protective footwear long pants and long sleeved shirts are recommended Pre work Check Perform the daily pre operation check before starting the machine Repair or replace damaged parts before starting the machine Fuel Handling Do not handle fuel or grease service the engine or recharge the battery while smoking or when near an open flame Do Not Carry Passengers on This Machine This machine has one ...

Страница 13: ...nges of speed or direction Make sure the area around the machine is safe for driving Do not make sudden maneuvers or turn sharply when driving on soft or wet ground this can cause the machine to lose traction or turn over Maintain Safe Speeds Always drive at a safe speed Do Not Drive Recklessly Do not operate this machine when under the influence of alcohol or drugs or when fatigued No one or unde...

Страница 14: ...e at a low speed Let the engine speed help decelerate the machine Travel at a low speed on wet steel plates and in muddy places 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 Avoid Driving Across Slopes Always travel straight up o...

Страница 15: ...g When parking always apply brake and stop engine Always remove key Do Not Park on Unstable or Inclined Surfaces Park the machine on stable level flat surfaces Do not park on unstable or inclined surfaces CM3 003 CM4 001 CM4 002 CM4 003 Precautions When Parking Avoid Parking on Slopes Avoid parking the machine on slopes If there are no other options apply the parking brake securely and block the w...

Страница 16: ...arry Out Maintenance with Engine Running Do not carry out maintenance with the engine running Always stop the engine before starting maintenance Ventilate Properly When Operating Indoors When operating engine indoors always ensure that there is adequate ventilation to prevent poisoning by exhaust gas ...

Страница 17: ...Component Names and Locations 11 4 Component Names and Locations Locations 5314M 0400 000E Component Names and Locations ...

Страница 18: ...lips When the lever is moved to ON the differential lock is engaged When the lever is moved to OFF the differential lock is disengaged normal driving position During normal driving always put the lever to OFF position 9 Blade height adjusting switch Adjusts the cutter blade height 10 Blade clutch lever Turns blade power on and off When pushing this lever to OFF the cutter brake pulley is engaged a...

Страница 19: ...verall width mm 1110 Overall height mm 980 Wheel base mm 1460 Tread mm Front 810 Rear 900 Minimum freeboard mm 115 Engine Model KAWASAKI FH641V Type Air cooled 4 cycle gasoline Cylinder Bore Stroke mm 75 2 76 0 Total displacement cm3 cc 675 Maximum output KW ps rpm 14 7 3600 21 3600 Starting system Self starter type Fuel used Gasoline Fuel tank capacity liters 15 Ignition plug no BPR4ES Electrical...

Страница 20: ... 36 Power transmission device Main speed shift HST Steering device Rack and pinion type round steering wheel Brake type Internal expanding type brake Tire Front wheel 4 00 7 Rear wheel 17 8 00 8 Cutter blade Cutter blade width mm 900 Cutter blade height mm 20 100 free stage Blade type Free knife stepped stay Amount of slide of cutter blade mm 150 These specifications are subject to change without ...

Страница 21: ...Maintenance See pages 6 10 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 engine Flames will cause the fuel to ignite Always stop the engine before adding fuel Do not overfill so that fuel spi...

Страница 22: ...lean cloth Reinsert to measure oil level 3 Check the add engine oil level If it is not in the range A see illustration add engine oil through the refueling port Fuel to be used See page 32 Engine cover Knob bolt 5310M 0601 030E Filler cap 5310M 0601 040E Oil level gauge 5310M 0601 050E After checking and refueling are completed replace and firmly tighten the oil gauge and filler cap ...

Страница 23: ...602 010E HST pedal 5314M 0602 040E 2 Push the blade clutch lever to OFF Auxiliary speed change lever L H N 5314M 0602 050E 3 Release foot from the HST pedal Always start engine in area with adequate ventilation to prevent poisoning from exhaust gas 4 Confirm that the auxiliary speed change lever is at NEUTRAL When blade clutch lever is ON a safety switch is engaged and engine will not start ...

Страница 24: ...imes to prolong motor life If the engine fails to start after 15 seconds wait about 1 minute before trying again When the engine fails to start turn key switch to OFF and then try restarting the engine Quick restarting may damage the starter gear Engine will start only when brake pedal is fully depressed due to a safety switch 8 Insert the key into the main switch 9 Turn the main switch to START t...

Страница 25: ... C About 10 minutes 0 C to 10 C 10 to 20 minutes 10 C to 20 C 20 to 30 minutes Under 20 C More than 30 minutes Warm up engine before using in cold environments to avoid engine seizure During the first 40 to 50 hours of new machine use only use light loads and avoid severe operations Never turn the key to START when the engine is running This will damage the starting motor or cause failure of the e...

Страница 26: ... Auxiliary speed change lever 5314M 0603 040E 5 To accelerate press the HST pedal slowly To move forward Push the pedal top To move backward Push the pedal bottom 3 Shift the accelerator lever to HIGH to increase the engine speed 4 Shift the auxiliary speed change lever to LOW to decrease engine speed To change speeds When conditions require speed changes shift the auxiliary speed change lever bet...

Страница 27: ...he brake pedal depressed pull the parking brake lock lever toward operator to lock the parking brake 2 Move foot off the HST pedal to stop the machine 6 5 How to Park 1 Stop the machine under the procedures shown in item 6 4 Stopping Procedure 2 Push the blade clutch lever to OFF Blade may still turn after brake is in OFF position due to inertia Always confirm that blade has stopped turning before...

Страница 28: ...toward operator to lock the parking brake 6 6 Emergency Transferring If the machine does not operate with normal control due to engine failure or other problems do not force the machine to move Transport the machine with the following procedures If the main switch is left ON after the engine is stopped current will continue to flow from the battery to the circuits and the battery will drain 1 Shif...

Страница 29: ... to the Low speed position and drive the machine slowly 3 After you regain wheel control return the differential lock lever to the OFF position 6 8 How to Operate Blade 5314M 0608 010 Keep legs and arms away from cutter blade covers during operations The cutter blade rotates close to each cover during operation When using machine for the first time select flat ground and operate slowly so that cut...

Страница 30: ... Start the engine and shift the accelerator lever to the intermediate position between HIGH and LOW ON OFF Blade clutch lever When the rotary cutter is in highest position the cutting blade clutch cannot be shifted ON Slightly lower rotary cutter before shifting blade clutch 3 Push the blade clutch lever slowly to ON 5314M 0608 030E ...

Страница 31: ...onitor 8cm Blade height Monitor 6cm Blade height Monitor 4cm Blade height Monitor 2cm 5 Shift the accelerator lever to HIGH and increase the rotation speed of the engine 6 Shift the auxiliary speed change lever to LOW and start the cutting work at low running speed Adjust the running speed according to work conditions 7 When the working load is heavy due to cutting a large amount of material reduc...

Страница 32: ...tch lever to OFF 2 Pull the cover locking pin 3 There are three round holes in the lock plate Insert the cover locking pin into any one of these round holes The opening of the cover can be adjusted by changing the hole into which the cover locking pin is inserted Do not open or close the grass outlet cover while the cutter blade is rotating 5314M 0609 010E Cutter blade Grass outlet cover opened 8 ...

Страница 33: ... of the grip and pull the rotary out of the machine 3 Insert the deck sliding lock lever into the outer pin to lock the rotary in the slide position Slide position of rotary Normal position of rotary 5314M 0610 010E 5314M 0610 020E During normal work use the machine without sliding the rotary The deck sliding mechanism makes it possible to perform close cutting work around obstacles on the right s...

Страница 34: ...use Never wash an extinguisher with water Never use fire extinguishers with rust defects or deformations Avoid breaking the extinguisher to prevent injuries from fire fighting chemicals 2 Direct the nozzle toward the fire base 3 Hit the push button on the head strongly and spray fire fighting chemicals in direction of fire 5314M 0611 010 5314M 0611 020 5314M 0611 030 ...

Страница 35: ...gas color noise Check for gas leak from muffler exhaust pipe etc No gas leak Air cleaner Check case for cracks and deformation looseness at lid or connecting pipe No cracks or deformation in case No looseness at lid and pipe Check urethane foam paper element for contamination and damage No severe dirt No damage Cleaning Replacement See Page 40 Tightening Check cylinder head and manifold retaining ...

Страница 36: ...posit Inspection Cleaning See page 41 Battery Check electrolyte level Proper amount Inspection Adding See page 39 Check terminals for looseness and corrosion No looseness or severe corrosion Wiring harness Check connections for looseness No damage Check wiring harness for damage No looseness Power train V belt Check appearance for cracks damage and dirt No cracks damage or grease deposit Inspectio...

Страница 37: ... link and wires Check rod link wires for damage and looseness at connection No damage or looseness Repeatedly operate brake and check connection for looseness and missing split pins No looseness at connection or missing split pins Body Body cover Check body and cover for cracks deformation and loose missing bolts nuts No cracks deformation or loose missing bolts nuts Lamp system Head lamp Start en...

Страница 38: ...Oil for the cutter blade counter case Gear oil API class GL4 or 5 SAE class 80 0 39 liters Oil for upper case for blade Gear oil API class GL4 or 5 SAE class 80 0 83 liters Front differential gear oil center Gear oil API class GL4 or 5 SAE class 80 0 36 liters See page 36 Front knuckle gear oil both sides Gear oil API class GL4 or 5 SAE class 80 Each 0 05 liters See page 36 Each area to be lubrica...

Страница 39: ...5314 2205 000 1 Rear R 5314 2301 000 1 Rear L 5314 2302 000 1 HST tank Element Assembly 5310 2053 100 Replace the element assembly for every replacement of HST oil 1 See page 46 Fuel hose Fuel tank to fuel pump 5310 0344 000 Every 3 years or replace if defective 2 Wire Throttle wire 5310 0102 000 Replace if defective 1 Choke wire 5310 0105 000 1 Blade cutter wire 5310 2406 000 1 Brake wire 5310 33...

Страница 40: ...ed into poor viscosity Fuel to be used See page 32 Amount of engine oil Within the range A on the oil gauge 6 Reinsert oil gauge and tighten filler cap Check the amount of oil before the engine is started or at least 10 minutes or more after the engine has stopped Immediately after the engine is stopped oil still remains in parts of the engine so oil checks are not accurate Filler cap Oil level ga...

Страница 41: ...Oil Oil level check bolt 5314M 0704 020E Lubricating plug 5314M 0704 030E Inspecting Oil 1 Park the machine on level ground 2 Remove the oil level check bolt from the oil checking port and confirm that oil drains from the port Confirm that the oil level reaches the oil checking port Amount of oil See page 32 Add oil until oil reaches the oil level check bolt hole Adding Oil 1 Remove the lubricatin...

Страница 42: ...k oil level and color When oil level is too low or oil is dirty add or change oil Oil to be used See Page 32 3 Replace the lubricating plug Replacing Oil 1 Position a suitable container to collect drained oil under drain plug 2 Remove the drain plug and drain oil Note Oil will drain faster after lubricating plug is removed 3 Replace the drain plug 4 Open the oil cap and pour oil pour proper amount...

Страница 43: ... below the specified value open the cap of the oil tank and add HST oil until it reaches the oil checking plug position Oil to be used See page 32 Amount of HST oil Fill to oil checking plug position level when oil is cold Replacing Oil 1 Position a suitable container to collect drained oil under drain plug 2 Remove the drain plug and drain oil Oil level gauge Cap Drain plug HST oil tank 5314M 060...

Страница 44: ...pe 1 Front axle mounting pin section 1 Grease 2 HST pedal fulcrum 1 3 Steering rod fulcrum 4WS 2 4 Drive shaft 4WD 2 5 Cutting blade drive shaft 1 6 Auxiliary speed change lever Cutting blade clutch lever fulcrum 2 Oil Grease point Oil point 5314M 0705 010E When using a manual type grease pump push its handle five to six times When resistance becomes heavy immediately stop pushing When using a pne...

Страница 45: ...y in a short time with a large amount of current This method should be used only in emergencies Quick charging will extremely shorten battery life After quick charging always fully recharge the battery with the normal method as soon as possible Always remove the battery from the machine before charging it to avoid damaging electrical components and wiring Connect battery cables to the correct posi...

Страница 46: ... or deforming Air cleaner case nut Wing bolt Foam element Paper element 5310M 0707 010E 1 Remove the air cleaner case nut and detach the case 2 Remove the wing bolts and detach the elements Wash the foam element in a vessel filled with detergent and water and blow compressed air against it or shake it to dry Then soak the element with clean engine oil and squeeze it to remove excess oil drying it ...

Страница 47: ...ith a plug wrench 3 Check for the following defects or damage Replace plug if damaged or cannot be cleaned See page 13 lgnition plug No BPR4ES Damage to insulator Worn electrodes Carbon deposits on electrodes Damage or breakage of gasket Burned insulator Cleaning Ignition Plug 1 Clean the ignition plug with a wire brush and plug cleaner 2 Adjust the electrode spark clearance with sandpaper to keep...

Страница 48: ...an A B 5310M 0707 070E Fuel filter 5310M 0707 060E Always stop the engine before cleaning of the cooling fan housing and fan Remove the cooling fan housing after the engine has cooled Inspecting Fuel Filter 1 Check the fuel filter color The normal color of the filter is light brown 2 When the fuel filter is severely dirty black colors ask a CHIKUSUI CANYCOM dealer to replace the filter 7 7 3 Fuel ...

Страница 49: ...ut changing V belt tension Adjust V belt tension only after it slips Inspecting V belt Visually check for damage on V belt Replace any damaged V belt Adjusting V belt Inspecting V belt Visually check for damage on V belt Replace any damaged V belt Adjusting V belt After replacing V belt make adjustment as follows 1 Set the clearance A between the V belt and the guides A and B at 2 to 4 mm 2 Shift ...

Страница 50: ...g Rotary Stopper When the rotary cutter does not stop within about 4 seconds after shifting the cutting blade clutch lever to OFF and after the rotary stopper is replaced adjust the rotary cutter brake according to the following procedure 1 Confirm that the engine stops 2 Adjust the length of the spring F to 125 mm with adjusting nut G when shifting the blade clutch lever to OFF 3 Adjust the lengt...

Страница 51: ...skills and tools to adjust HST pedal Machine operaor tar should not attempt to adjust HST pedal 7 8 5 Brake Pedal Turn adjusting nut to make play 10 to 15 mm at pedal back when brake pedal is slightly depressed Adjust brake pedal if play increases Excessive brake play may cause accidents Adjustment nut 5314M 0708 040E 5313M 0708 070E 1 Check the air pressure of the front and rear tires Adjust if r...

Страница 52: ... before removing again and confirming the level 5 Start engine and check for oil leakage Cap Oil tank connection hose Oil filter position Oil tank cover 5314M 0709 020E 7 9 2 HST Oil Filter Replace the HST oil filter every 500 operating hours 1 Drain oil in the tank 2 Remove the oil tank connection hose 3 Take off the oil tank cover and replace the inside oil filter with a new oil filter 4 Install...

Страница 53: ...river into the hole I of the cutting blade stay Check and replace the cup square neck bolt after heavy wear 3 Using a closed wrench or socket wrench remove the nut K and the nut L in that order and then remove the cutting blade 4 Place a new cutting blade under the stay and insert the square spherical head bolt into the blade from the underside 5 Place the collar M and the cap N onto the cup squar...

Страница 54: ...ng it outdoors In cold season Remove all dirt water and foreign objects from the body Any remaining dirt will freeze and may cause malfunctions Place the vehicle on a concrete floor dry firm ground or wooden blocks Cover the vehicle with a water proof sheet when placing it outdoors If the vehicle freezes do not operate or force movement Melt ice with hot water or wait until the vehicle is not froz...

Страница 55: ...htly higher than the standard value 4 Apply blocks in front of and behind the front wheels 5 Lubricate and grease areas to be lubricated and greased See Page 38 6 Remove key from the main switch 8 Storage Long term Storage When storing the vehicle for a long time appropriate maintenance is required for future use After performing the after use maintenance see page 48 follow the instructions below ...

Страница 56: ...sary 3 Store the battery in a cool and dry area Reference Completely recharge battery before storage to maintain battery life Remove all fuel from the carburetor and fuel tank before storing the vehicle for a long time Fuel in the carburetor will deteriorate if left unused for a long time causing poor starting or unstable operation of the engine Do not use fuel which has been left unused for a lon...

Страница 57: ...Storage 51 8 3 2 Replacing Engine Oil Filler cap 5310M 0601 040E Oil level gauge 5310M 0601 050E Drain all engine oil and refill engine with new engine oil See Page 34 ...

Страница 58: ...tact failure of wiring Repair Consult dealer Difficulty starting Lack of fuel Add See page 15 Air or water in fuel Check pipe and tightening band Repair or replace Excessive intake of fuel Start after interval Engine oil too low or poor quality High oil viscosity Add or replace See page 34 Poor ignition due to dirt on spark plug or poor sparking Clean or replace See page 41 Insufficient capacity o...

Страница 59: ...l volume See page 34 Improper fuel Replace fuel Worn cylinder or piston ring Check and repair Consult dealer Power transmission system Unit does not move with HST lever in forward or reverse Insufficient HST oil Add See page 37 Parking brake is applied Release parking brake lock lever Unit moves even when HST lever is in neutral position HST speed shift neutral position adjustment not correct Adju...

Страница 60: ...s into the soil Mowing height too low Set the mower to a higher mowing height See page 23 High swing speed Reduce swing speed Ground contours Change the mowing pattern mowing direction etc Too many bumps and dips in the ground Set the mower to a higher mowing height Bent mowing blade Replace the blade with a new one See page 47 Rotary cutter blade does not rotate Broken driving pin for cutter blad...

Страница 61: ...n truck loading body height and abrasive surface for traction Place the boards as shown below so that the boards will not shift positions when the machine rides on them 2 Securely hook the running boards to truck so boards are flush with truck s loading bed Keep people away from the machine truck and running boards while loading or unloading the machine Do not turn on the running boards The machin...

Страница 62: ... evaluated based on factory standard NOISE LEVEL Model Engine Rated revolution Vibration Mower Blade Clutch Steering wheel top Steering wheel bottom Seat CM2103 3600 rpm ON 17 0 m s2 14 0 m s2 1 2 m s2 OFF 12 0 m s2 14 0 m s2 1 1 m s2 VIBRATION evaluated based on factory standard VIBRATION ...

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