IHI 55N3 User manual

SERIAL NUMBER
WP003001 ～
55N3
PUB.1
OPERATION MANUAL
0903 ENG

CONTENTS
Page
FOREWORD ........................................................................................... 0-1
SAFETY INFORMATION ........................................................................ 0-2
1. SAFETY .................................................................................................. 1-1
1-1 General .............................................................................................................. 1-1
1-2 Mounting and Dismounting ................................................................................ 1-5
1-3 Before Starting the Engine ................................................................................. 1-6
1-4 Starting the Engine ............................................................................................. 1-6
1-5 Before Operating the Machine ........................................................................... 1-7
1-6 Operating the Machine ....................................................................................... 1-8
1-7 Safe Travel ....................................................................................................... 1-22
1-8 Towing .............................................................................................................. 1-25
1-9 Safe Transportation .......................................................................................... 1-26
1-10 Parking the Machine ........................................................................................ 1-27
1-11 Safe Maintenance ............................................................................................ 1-28
1-12 Warning Signs and Labels ............................................................................... 1-33
2. Operation ............................................................................................... 2-1
2-1 Nomenclature ..................................................................................................... 2-1
2-2 Controls and Instruments ................................................................................... 2-2
2-3 Before Starting the Engine ............................................................................... 2-11
2-4 Starting Engine ................................................................................................. 2-12
2-5 Jumper Cable Starting...................................................................................... 2-13
2-6 After Starting the Engine .................................................................................. 2-14
2-7 “Break-in”Operation ........................................................................................ 2-14
2-8 Control System ................................................................................................ 2-15
2-9 Operating the Special Attachments and Actuators (If Equipped) ...................... 2-18
2-10 Traveling the Machine ...................................................................................... 2-20
2-11 Towing .............................................................................................................. 2-23
2-12 Lifting the Machine ........................................................................................... 2-24
2-13 Loading and Unloading the Machine................................................................ 2-25
2-14 Precaution on Use of Rubber Track Shoe ........................................................ 2-26
2-15 Boom Lowering with the Engine Stopped ........................................................ 2-27
2-16 Parking the Machine ........................................................................................ 2-28
2-17 Emargency Engine Stop................................................................................... 2-28

Page
3. MAINTENANCE ..................................................................................... 3-1
Maintenance Intervals ........................................................................................ 3-1
3-1 Lubrication Chart Maintenance and Checks ...................................................... 3-2
3-2 Recommended Lubricant Table ......................................................................... 3-3
3-3 When Required Maintenance and Checks......................................................... 3-4
3-4 Daily Maintenance and Checks........................................................................ 3-10
3-5 50 Hours Maintenance and Checks ................................................................. 3-14
3-6 250 Hours Maintenance and Checks ............................................................... 3-15
3-7 500 Hours Maintenance and Checks ............................................................... 3-20
3-8 1000 Hours Maintenance and Checks ............................................................. 3-23
3-9 2 Years Maintenance and Checks ................................................................... 3-26
3-11 Unusual Operating Conditions ......................................................................... 3-28
3-12 Long Term Storage ........................................................................................... 3-31
4. TROUBLE SHOOTING .......................................................................... 4-1
4-1 Trouble and Action ............................................................................................. 4-1
5. HYDRAULIC SYSTEM DIAGRAM ......................................................... 5-1
5-1 Hydraulic System Diagram ................................................................................. 5-1
6. ELECTRICAL SYSTEM DIAGRAM ....................................................... 6-1
6-1 Electrical Wiring System Diagram ...................................................................... 6-1
7. SPECIFICATIONS .................................................................................. 7-1
7-1 General Specifications ....................................................................................... 7-1
7-2 Overall Dimensions ............................................................................................ 7-3
7-3 Working Range .................................................................................................. 7-4
7-4 Rated Object Handling Capacities Table ............................................................ 7-6
7-5 Noise Level ........................................................................................................ 7-7

0 – 1
FOREWORD
This manual contains safety, operation, maintenance, and adjustment information.
The procedures are designed to provide the best performance of the machine in an
effective and economical way. In order to obtain it, remember the next basic rules.
• This manual should be stored in the operator’s compartment in the literature
holder or seat back literature storage area.
• Before inspection, maintenance or operating the machine, read and
understand this manual completely.
• Since all of the explanations in this manual may not be thoroughly understood
at first, repeat reading it until abilities as an operator are obtained and
developed for proper operation.
• Further abilities as an operator outside of descriptions in this manual can be
obtained from the experience during normal operations and under proper
supervision.
• The illustrations in this manual are used first of all to let you pay attention.
They do not show all of illustrations in this manual. Because of continuing
improvement and advancement of product design, the shape of machine in
the illustrations may be partly different from your machine. Please understand
it. Whenever a question arises regarding your machine, or this publication,
please consult your local IHI distributor for the latest available information.

0 – 2
SAFETY INFORMATION
We offer you basic and important rules and precautions for safe operations.
Read, understand, and observe them before starting operation. This is the most essential
way to prevent accidents.
Wrong operation, inspection, or maintenance can cause personal injury or death.
Throughout this manual and on the machine, precautions are provided with marks
and classified by the words “DANGER”, ‘’WARNING”, and “CAUTION” according to
their extent of danger.
The classification is as follows :
Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury. It may also be used to alert against
possible damage to the machine and its components.
We have made every effort for you to prevent accidents during operation, however, we
cannot be held responsible for predicting every kind of danger in all operating conditions.
It is the owner or user of the machine who is responsible for ALWAYS paying attention to
operate the machine; as well as reading and understanding this manual enough to obtain
the essential knowledge and skills fundamental to correct machine operation.
•BEFORE inspection, operation, or maintenance of the machine, be sure to
read and understand this manual.
• Incorrect operation or maintenance of the machine can cause the accident
and serious injury or death.
• Keep this manual on hand during operation so that you can immediately
consult it when necessary. If it should be missing or damaged, place an order
from lHI distributor for a replacement.
• There are various kinds of federal, state, and local regulations that effect
construction and industrial machinery. Since the regulations are subject to
change, and differ from one locale to another, it is impossible for us to provide
such information in this manual.
It is the responsibility of the owner or user to be familiar with the regulations.
• Specifications and materials of the machine are subject to change without
any obligation on the part of the manufacturer.
DANGER
WARNING
CAUTION
WARNING

1 – 1
ᵏ
SAFETY
SAFETY TIPS
This section explains safety tips which you
will find throughout this manual and on the
machine.
Periodically check labels and plates
containing those tips for damage.
If they are damaged, clean or replace them.
For replacement, contact your local IHI dealer
with their Parts Numbers in the Parts
Catalogue.
Remember that the safety tips that we
provide cannot cover every kind of danger
that you may encounter during operation.
1-1 GENERAL
OBSERVE THE BASICS FOR SAFE AND
EFFECTIVE OPERATION.
The operator's knowledge, skills, and
experience are the most important to utilize
the machine. Therefore, be sure to
understand operation procedures and to take
necessary training.
OPERATOR SHOULD BE QUALIFIED.
Only qualified operators should be authorized
to operate the machine, and those so
authorized should do so only when physically
and mentally alert.
The operator should be to be familiar with the
hazards and necessary safety measures
unique to the operation of hydraulic
excavators.

1 – 2
ᵏ
SAFETY
READ AND UNDERSTAND THE
INSTRUCTIONS AND WARNINGS.
This manual, plates, and labels on the
machine contain necessary instructions and
warnings for safe operation. You are supposed
to read and understand them first.
If you should ignore them, injury or death may
occur. Do not leave what you do not
understand as it is. Your IHI distributor is glad
to answer any question.
If the manual, plate, or label is missing or
damaged, contact lHl distributor for
replacement.
OPERATOR SHOULD BE IN GOOD
HEALTH.
Operator should be physically and mentally
alert, which is one of the best insurance
against an accident.
NEVER operate the machine under the
influence of alcohol, medication or intoxication.
WEAR PROPER WORKING CLOTHES.
Wear working clothes that closely fit
operators. Avoid loose jackets, shirt sleeves,
rings, and other jewelry which may be caught
in moving parts. Avoid also oil stained or
damaged garments. Shoes should be clear of
grease or mud before operation.
Always wear required protective items such
as hard hats, safety glasses, reflective
clothing. safety shoes, and ear protection as
required.

1 – 3
ᵏ
SAFETY
PERFORM “WALK-AROUND”
INSPECTION.
Walk around the machine to check safety
guards, plates, and other related parts are set
in place. Do not attempt to operate the
machine when any unsafe condition is
detected.
NEVER ASSUME ANYTHING
GUARANTEED.
Never assume that everything is all right at
the start of a work day just because it seemed
satisfactory at the end of the previous work
day. Before beginning each days operation,
thoroughly inspect the entire excavator for
signs of vandalism.
MAKE A WORK PLAN.
Prior to operation, investigate your job site
sufficiently. When any obstruction or hazards
are detected, mark it so that all personnel are
aware of it. Avoid any oversight that may cause
serious accident.
Observe a local weather forecast and discuss
well work procedures and let all personnel
know them without exception.

1 – 4
ᵏ
SAFETY
WATCH FOR UNDERGROUND UTILTIES.
Mark the location of underground utilities
such as gas lines, sewers, and power lines
before any digging operations.
If necessary, the utilities should be
temporarily discontinued.
CHECK THE JOB SITE.
ALWAYS check the job site for grade and
stability of the ground, ventilation, depth of
water and ambient obstructions.
Avoid operating your equipment too close to
an overhang.
Since this machine is not provided with anti-
explosion design, NEVER use it inside a
tunnel or in explosive environment to avoid
hazard caused by an explosion.
CLEAR ALL PERSONNEL FROM THE
MACHINE AND AREA.
Be sure to barricade the job site to prevent
entry of the unauthorized. Confirm that there
is no one around the machine before starting
the engine or operating the machine.

1 – 5
ᵏ
SAFETY
MAINTAIN GOOD VENTILATION.
Take a countermeasure to vent the exhaust
gas to the outside to start and operate the
engine, in a pit, tunnel, or trench. In such a
place, the air trends to stagnate. It is very
dangerous to inhale the exhaust gas.
Remember, exhaust gas can kill you.
DO NOT MODIFY THE ROPS/TOPS.
Do not modify the ROPS/TOPS unless
instructed to do so in installation instructions.
Modifications such as welding, drilling or
cutting can weaken the structure and reduce
the protection it provides.
A damaged ROPS/TOPS can not be repaired
– it must be replaced.
1-2 MOUNTING AND DISMOUNTING
CAREFULLY MOUNT AND DISMOUNT
THE MACHINE.
ALWAYS use steps and handholds to mount
and dismount the machine.
Hold the handholds with both hands and face
the machine keeping a contact with at least
three points of the steps and handrails.
NEVER hold control levers at mounting and
dismounting.
NEVER not try to mount or dismount the
moving machine.
NEVER jump off the machine.
Do not try to climb on or off the machine with
implements or supplies in your hand.

1 – 6
ᵏ
SAFETY
1-3 BEFORE STARTING THE ENGINE
FOLLOW THE NEXT PRECAUTIONS.
• Clear all personnel from the machine and
the area.
• Move all control levers to the NEUTRAL
position before starting the engine.
• Inspect the condition of the seat belt and
mounting hardware.
Replace any damaged or worn parts.
• Fasten the seat belt (if equipped) securely.
• Adjust the operator’s seat to be able to
depress the pedal completely.
1-4 STARTING THE ENGINE
Fasten the seat belt. Adjust the
operator’s seat
•ALWAYS start the engine only from the
operator’s seat following the starting
procedure in this manual.
• When the start switch or controls are
tagged with “Do Not Operate”,do not start
the engine or move any of the controls.
•NEVER short across the starter terminals
or across the battery.
NEUTRAL

1 – 7
ᵏ
SAFETY
1-5 BEFORE OPERATING THE MACHINE
FOLLOW THE NEXT PRECAUTIONS RIGHT
AFTER STARTING THE ENGINE.
• Clear all personnel from the machine and the
area.
• Make sure the machine horn and all other
warning device are working properly.
• Be sure all Windows are clean.
• Check for proper operation of all controls and
protective devices while moving slowly in an
open area.
• When any defect is detected, immediately report
it.
CONDUCT WARM-UP BEFORE OPERATION.
It is ESSENTIAL to conduct warm-up operation
after starting the engine in order to run the
hydraulic fluid smoothly.
The pumps may squeak because of the cold and
thick hydraulic fluid, which results in the damage to
the pumps.
ALWAYS take a time to warm up the fluid with
running the engine at a low speed to maintain the
FREE FLOW OF OIL.
BE SURE TO LOCK DOORS AND OTHERS.
Be sure to lock doors, front windows, and lids
before starting operation.
Operating with unlocked doors may cause
personal injury.
Crushing of finger or hands.

1 – 8
ᵏ
SAFETY
1-6 OPERATING THE MACHINE
KEEP EACH OPERATION SECURED FOR
SAFETY.
Conduct every operation with great care for
safety. If you operate the machine roughly, It
may cause damage to the machine, degrade
the machine performance, and result in
serious accidents.
OPERATE CONTROL LEVERS IN A WISE
WAY.
Do not get angry with the control levers when
you cannot operate the machine as desired.
It may degrade the machine performance
and damage the machine instead of
improving the situation.
ALWAYS consider the machine capacity and
take a time to clear problems in the best way.
OBSERVE THE NEXT PRECAUTIONS
FOR SAFE OPERATlON.
• Do not read.
• Do not drink.
• Do not eat.
• Do not be distracted. If you have to divert
yourself from the machine operation, stop
the operation first.
ALWAYS OPERATE THE MACHINE ONLY
FROM THE OPERATOR’S SEAT.
NEVER attempt to operate the excavator
from any position except the operator’s seat.
lf you operate the machine from any other
position, such as standing by the window or
door, you may operate the machine
inaccurately, which can cause serious injury.
Remember that you should not get on or get
off the moving machine to be seated or to
leave the machine.

1 – 9
ᵏ
SAFETY
WATCH FOR OVERHEAD WIRES.
Care must be taken that the boom does not
contact, or even close to, overhead wires.
Know the maximum height and around of the
machine. When working near overhead
electrical lines, keep a distance of at least 10
feet (3 m) plus an additional 4 inches (100 m)
for each 1,000 volts over 50,000 volts.
Check for local and state codes, which may
require a greater distance for safety. Treat all
lines as energized.
NEVER LEAVE LOAD SUSPENDED IN
THE AIR.
NEVER leave the load suspended in mid air,
when the machine is out of service, or you
have to leave the machine. ALWAYS put
down the bucket or load onto the ground.
Should a malfunction occur, it could fall,
striking equipment or personnel.
Should contact occur, stay on the machine
until the boom is cleared or until the current
is turned off. Keep all personnel off the
machine. lf you must leave the machine,
JUMP, DO NOT STEP OFF.
Electrical shock / erectrocution
DANGER

1 – 10
ᵏ
SAFETY
NEVER ALLOW ANYONE TO RIDE THE
ATTACHMENT OR THE LOAD
NEVER attempt to lift personnel using the
attachment since the machine is designed to
excavate and move NOT personnel BUT
materials. If you lose control of the attachment
in such a trial, the personnel will be dropped
down, which is likely to occur.
NEVER LIFT, SWING, OR LOWER A LOAD
OVER ANYONE OR ALLOW ANYONE TO
RIDE TEE ATTACHMENT OR THE LOAD.
PROVIDE ADEQUATE TAILSWING
CLEARANCE
Confirm that there is a sufficient clearance
around the machine for swinging operation.
The operator tends to be unconscious of the
area behind the machine. Before tailswing,
make sure that there no personnel or objects
in such area.
CAUTION
ALWAYS check for personnel or objects
around the machine before swinging.
NEVER SWING OVER PERSONNEL
Be sure that no personnel are working
around the machine before swinging.
Pay attention to invisible workers in a trench
or pit in particular. Follow the signal person’s
direction not to swing over such workers.

1 – 11
ᵏ
SAFETY
CAREFULLY TRUCK LOADING
Load the truck from the rear whenever
possible. NEVER swing the load over the
truck cab. “High altitude” dumping into the
truck is a dangerous practice. Use the bucket
wrist action for precise dumping.
NEVER dump over truck cab. ALWAYS be
sure truck driver is OUT OF TRUCK CAB
and clear of the dumping bed when lifting.
ALWAYS OBSERVE THE BUCKET AND
LOAD.
ALWAYS watch the moving bucket or load
carefully. Moving bucket or load without care
may cause injury to personnel or materials.
If you have to look away from it, stop the
machine.
NEVER CAUSE PHYSICAL SHOCK TO
HYDRAULIC CYLINDERS.
Be careful to protect the cylinder from any
damage during operation. The hydraulic
cylinder is not immune to physical shock. If
the cylinder is collided or bumped, it may be
distorted.

1 – 12
ᵏ
SAFETY
TAKE SIGNALS FROM ONE SIGNAL
PERSON EXCLUSIVELY.
Use only signals which are predetermined
and common to all personnel.
Only one signal person should exclusively
direct and give signals to personnel
NEVER ALLOW PERSONNEL RIDE ON
THE MACHINE OTHER THAN OPERATOR.
Only operator is authorized to be on the
machine during operation.
Never let unauthorized personnel ride on the
machine.
CAREFULLY OPERATE THE BUCKET.
Slow down the operation when controlling the
bucket or moving the filled bucket close to the
operator’s cab in particular. which prevents
the load from being dropped into the cab.

1 – 13
ᵏ
SAFETY
PREVENT THE BUCKET FROM HITTING
THE DITCH.
Be careful that the bucket will not hit the walls
of ditch or the bank during swinging operation.
This is likely to occur when conducting digging
and dumping alternately.
Move the bucket slowly.
NEVER SWEEP WITH THE BUCKET.
Avoid sweeping the bucket like a broom in
order to level off ahead of machine. This
causes side strains and wear on the boom,
arm, and bucket.
DO NOT MOVE THE ATTACHMENTS TO
THE EXTREME ENDS OF THE STROKE.
If the rod is extended to the stroke end of the
cylinder, the shock applies a large force to the
cylinder, which may cause a damage to the
boom or arm.
Operate the machine without moving the
cylinder to the extreme end of the stroke.
It is recommended to operate the attachments
near the stroke end of the cylinder.
USE AN EXCLUSIVE MACHINE TO DIG OR
BREAK EXTREMELY HARD MATERIALS.
Do not use the bucket to dig or break very
hard materials like concrete. This will cause
damage to the machine.

1 – 14
ᵏ
SAFETY
DO NOT OVERLOAD TO CYLINDER.
Do not forcefully conduct digging operation
beyond the capacity, which may overload any
cylinder and open its relief valves.
This causes damage to the hydraulic system
and machine.
NEVER CONDUCT DIGGING OPERATION
WITH FALLING FORCE OF MACHINE.
Do not raise off the rear of the machine from
the ground and drop it down for digging up.
This will cause excessive shock and damage
to the machine.
MEASURE DEPTH OF WATER AND
CHECK CONDITIONS OF RIVERBED
BEFORE FORDING.
Before fording, measure the depth of water
and check the riverbed for holes, bumps, and
any dangerous condition by following the
next:
• Measure the depth of water first.
• Stop the machine and swing the bucket
under the water to detect any bump or
obstacle.
• Lower the bucket to measure the depth of
water and detect holes occasionally.
OBSERVE THE ALLOWABLE WATER
DEPTH.
Allowable depth of water is limited up to the
center of the upper rollers.
Be sure to lubricate long-soaked parts until
old grease comes out of the bearings. Allowable water depth