CanyCom BP416 User manual

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.[phone] Fax.[phone]
Off-Road Rubber Track Carrier
BP416/BP416D
BP415/BP415D

The machine can be very dangerous if the safety precautions in this
manual and on the labels attached to this machine are not followed.
Always follow the instructions and safety precautions, or serious injury
or death could result.
This machine should only be used for its intended purpose: hauling and
dumping.
Any other use could be dangerous.
Also driving this machine on a public road or a road regarded as a pub-
lic road may be illegal.
WARNING
Do not modify this machine. Also do not remove the safety cover of the
body before running. A serious accident could result.
WARNING
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.
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
or serious injury.
Indicates a potentially hazardous situation which, if not avoided by
following these instructions and precautions,
could result in death or serious injury.
This word is used for precautions that are recommended or to
emphasize the importance of information.
Indicates a potentially hazardous situation which, if not avoided by
following these instructions and precautions, may result in minor or
moderate injury.
WARNING
CAUTION
DANGER
NOTICE

Contents
1. Introduction 1
1.1 Purpose of this Manual ............................................. 1
1.2 Structure of this Manual ............................................ 1
1.3 Warning Labels Attached to this Machine ......................... 2
2. Warranty and After-sales Service 3
3. Rules for Safe Operation and Maintenance 4
4. Component 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 Operating Dump (Hydraulic Dump) ................................... 19

7. Maintenance 20
7.1 Periodic Inspection Table ......................................... 20
7.2 Fuel, Lubricant, and Coolant Chart .............................. 24
7.3 Replacement Parts Chart ......................................... 24
7.4 Adding Oil .......................................................... 25
7.4.1 Engine Oil ......................................................... 25
7.4.2 Transmission Fluid ................................................. 26
7.4.3 Power Package Fluid (Fluid for Hydraulic 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 Element ....................................... 37
8.2.3 Replacing Engine Oil ............................................... 37

9. Troubleshooting 38
10. Transporting Machine 42
< 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.

Introduction
– 1–
1. 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.
1. Introduction
This section explains the purpose and structure of the manual and the warnings used in the
manual. It also describes the warning labels attached to the machine.
2. Warranty and After-service
This section covers items related to the warranty and after- service for this machine.
3. Points to Remember for Safe Operation
This section covers general safety items that must be 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.
7. Maintenance
This section gives information about periodic inspection, use of coolant, lubricants. and
grease, and cleaning, replacing, adjusting, and maintenance of the machine after use.
8. Storage (Long-term Storage)
This section gives information about storage (long-term storage) of the machine.
9. Troubleshooting
This section describes the action to take if any problem occurs.
10. Transporting Machine
This section explains the methods and precautions when transporting the machine.

Introduction
– 2–
3558M-0103-030
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.
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

– 3–
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.
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
Product model
Serial number
< Location of Model Label > < Model Label >
Availability of Repair Parts
Repair parts for this product will be available for seven years after manufacturing of this machine is dis-
continued.

Protective Clothing
Wear clothes suitable for the operation of heavy equip-
ment. 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.
– 4–
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
B1-001
A1-001
B1-002
B1-003
Do Not Carry Passengers on this Machine
Driving the Off-Road Rubber Track Carrier with a pas-
senger or passengers can change the center of gravity
and make the machine difficult to handle.
This product was designed to be operated carrying only
one person-the driver.Driving with passengers are
extremely dangerous.

– 5–
Rules for Safe Operation and Maintenance
B1-004
Do Not Start, Accelerate, Turn, or Brake Quickly
B2-003
B2-002
B2-001
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.
Maintain Safe Speed
When driving the machine, always drive at a safe speed
suitable for the load in the dump body and the condi-
tions of the road surface and grade of the road.
Work with 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
Drive safely and avoid sudden changes 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.

– 6–
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.
Precautions When Carrying a Load
150 kg
15°〜20°
B2-004
B2-005
B3-001
B3-002
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 over-
pass.
Then cross the 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 up and down a slope. Never travel
across a slope or along a contour line. Driving across a
steep slope or along a contour line is dangerous and
may cause the machine to tip over causing serious injury
or death. Do not operate the side clutch lever when the
vehicle is positioned on sharply sloping ground. If use of
the lever cannot be avoid, do so quickly and carefully,
taking care not to cause a reverse turn.

– 7–
Rules for Safe Operation and Maintenance
Precautions when parking
B3-003
B3-004
B4-001
B4-002
Never Overload
Do not load the machine in excess of the working
capacity of 150kg.
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.
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 surface.
If parking 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 operating the
machine and transporting a load on a slope.

– 8–
Rules for Safe Operation and Maintenance
Precautions When Performing Maintenance
B5-001
B5-002
Ventilate 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.

4. Component Names and Locations
Locations
Component Names
①Throttle lever .......................This is used to increase or decrease the speed of the engine.
②Side clutch lever ...................This is used when changing the running direction. The vehicle
is turned to the side on which the clutch lever is grasped by
hand. When the right and left levers are grasped at the same
time, the vehicle is stopped immediately.
③Clutch 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.
④Gear shift lever .....................This is used to select the running speed. Before operating this
lever, move the clutch lever to the " STOP" position (upper
side) to stop the vehicle.
⑤ Hydraulic lever .....................This is used to raise or lower the deck.
Component Names and Locations
– 9–
3558M-0400-010E

Product Specifications
– 10 –
5. Product Specifications
5.1 Specifications of this Product
Manual dump Hydraulic dump
Flat-bed type Sliding panel Bucket type Flat-bed type Bucket type
Overall length 1790 1650(1810) 1750 1775 1750
Overall width 830 620(975) 620 830 620
Overall height 980
Length 1050 950(1110) 1080 1050 1080
Width 745 520(900) 550 745 550
Height 200 420 260 200 260
Grand contact length 700
Shoe width 180
Tread 440
Engine Continuous rated output 2.1kW/1800min-1
Machine weight (kg) 160 150 155 180 165
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 angle5 0°55°63°57°63°
BP415 / BP416
Model
Measurement
(mm)
Bed inner size
(mm)
Crawler
(mm)
Gradeability
Stability
Without load
With Max. load
Speed
Reverse (kw/h)
Forward(kw/h)
* These specifications are subject to change without notice, for product improvement.
Read and understand the specifications of this machine to use
and maintain the machine properly.
NOTICE

Product Specifications
– 11 –
No. Part Name Q'ty Remarks
1 Operation and Maintenance Manual (this manual) 1
2Instruction manual for engine 1
3 Engine tools 1 For engine maintenance and repair
5.2 Details of Tool Bag

6.1 Preparation Before Operation
6.1.1 Adding Fuel
1. Visually check the oil level gauge. If fuel is low, open
the fuel tank cap, and add fuel.
Fuel to use: Lead free gasoline for cars
Fuel tank capacity: 2.2 liters
6.1.2 Checking Engine Oil Level and Adding Oil
1. Remove the engine oil filler plug (this plug has a
dipstick).
Oil level gauge
Fuel tank cap
Oil filler plug
– 12 –
Operation
3558M-0601-010
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 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 spilt before starting engine.
DANGER

Gear shift lever
Engine switch
Fuel cock
OPEN
Drive clutch lever
Dipstick
– 13 –
Operation
2. Visually check the engine oil level. If it is not within
the specified levels, add engine oil.
Oil to use: See page 23
Engine oil quantity : Between "F" 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 the engine switch to the "ON" position.

Choke lever
OPEN CLOSE
Throttle lever
LOW
Starter knob
Choke lever
OPEN CLOSE
Throttle lever
LOW

– 14 –
Operation
3560M-0602-050
3560M-0602-060
3560M-0602-080
3560M-0602-090
3560M-0602-070
4. Move the throttle lever to the halfway point between
"LOW" and "HI".
Reference:
The throttle lever of the vehicle is connected to the
throttle lever of the engine 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) after
starting machine operation is the breaking-in period.
・Do not apply excessive loads to the machine when
operating during this period.
NOTICE

Drive clutch lever
Throttle lever
HI
LOW
Gear shift lever
– 15 –
Operation
When moving the vehicle backward, start the
vehicle slowly after sufficiently checking for safety.
WARNING
Drive clutch lever
3558M-0602-010
3558M-0603-020
3558M-0603-010
3560M-0603-030
6.3 Method of Operating
1. Check that all areas around the machine are safe.
2. Check that the drive clutch lever is 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 start the vehicle.
Do not move the drive clutch lever abruptly.
The engine may stall.
NOTICE
5. Adjust the speed by moving the throttle lever slowly
from "LOW" toward "HI" position.