Menzi Muck Menzi IHI 45v4, Menzi IHI 55v4, Menzi IHI 60v4 Operator's Manual

Menzi Muck AG Telefon +41 (0)71 727 12 12 9451 Kriessern/Switzerland Fax +41 (0)71 727 12 13 www.menzimuck.com info@menzimuck.com

Operator’s manual

Menzi IHI 45v4 Menzi IHI 55v4 Menzi IHI 60v4

45V4 55V4 60V4

WG010001~

WY010001~

WZ010001~

45V4 55V4 60V4 0988405EN-02

45V4 • 55V4 • 60V4 ENG

CONTENTS

FOREWARD ............................................. 0-1

INTRODUCTION .................................... 0-1

MACHINE NUMBER ............................... 0-2

MACHINE DIRECTION .......................... 0-3

SAFETY .................................................... 1-1

SAFETY INFORMATION ........................ 1-1

SAFETY PRECAUTIONS ....................... 1-2

PRECAUTIONS BEFORE

OPERATION ........................................ 1-2

Precautions during Operation .............. 1-4

PRECAUTIONS FOR TRAVELING ..... 1-8

Precautions for Transporting ................ 1-9

Precautions for Maintenance ............. 1-10

SAFETY SIGNS AND LABELS ............ 1-14

OPERATION ............................................. 2-1

NAMES OF COMPONENTS .................. 2-1

CONTROLS AND INSTRUMENTS ........ 2-2

Right Control Box ................................. 2-3

Left Control Box ................................. 2-10

Travel Levers ..................................... 2-11

Boom Swing Pedal ............................. 2-11

Operator's Seat .................................. 2-12

Seat belt ............................................. 2-12

AUX Pedal (Option) ........................... 2-12

Operator’s Cabin ................................ 2-13

Air conditioner (Option) ...................... 2-16

Heater (Option) .................................. 2-17

STARTING ENGINE ............................. 2-18

Check before Starting Engine ............ 2-18

Normal Starting .................................. 2-19

Starting in Cold Seasons ................... 2-19

Starting Engine with Booster

Cables ................................................ 2-20

Check after Starting Engine ............... 2-21

Warming Up Engine ........................... 2-21

STOPPING ENGINE ............................ 2-22

EMERGENCY ACTIONS IF ENGINE

STOPS .................................................. 2-23

RUNNING IN NEW MACHINE.............. 2-24

LEVER OPERATIONS ......................... 2-25

Operation Mode ................................. 2-25

Operation Mode Plate ........................ 2-26

AF Multi-selection Method

(for Machine with AF Multi-

selector Valve) ................................... 2-27

ABG Multi-selection Method

(for Machine with ABG Selector

Valve) ................................................. 2-28

ABCD Multi-selection Method (for

Machine with ABCD Selector Valve) .. 2-29

BLADE OPERATION ............................ 2-30

BOOM SWING OPERATION ............... 2-30

SWING OPERATION ........................... 2-31

TRAVELING ......................................... 2-32

Starting, Traveling and Stopping ........ 2-32

Changing Direction ............................ 2-33

High Speed Traveling ........................ 2-34

Precautions While Traveling

on Slope ............................................. 2-34

WORK INSTRUCTIONS ....................... 2-35

Digging ............................................... 2-35

Ditching .............................................. 2-35

Loading .............................................. 2-35

Gutter Digging .................................... 2-35

PRECAUTIONS FOR WORKS ............. 2-36

PRECAUTION ON USE OF RUBBER

TRACK .................................................. 2-39

AUX WHEN USING SPECIAL

ATTACHMENT ..................................... 2-42

No. 1 AUX .......................................... 2-43

When Using Breaker .......................... 2-44

When Using Iron Fork ........................ 2-45

No. 2 AUX .......................................... 2-46

45V4 • 55V4 • 60V4 ENG

No. 3 AUX .......................................... 2-47

TOWING ............................................... 2-48

TRANSPORT ........................................ 2-49

Loading and Unloading the Machine . 2-49

Fixation at Transport .......................... 2-50

LIFTING THE MACHINE ...................... 2-51

MAINTENANCE ........................................ 3-1

PERIODIC REPLACEMENT OF THE

IMPORTANT PARTS .............................. 3-1

MAINTENANCE INTERVALS ................. 3-2

RECOMMENDED LUBRICATION

TABLE .................................................... 3-6

LUBRICATE THE GREASE ................... 3-7

Attachment ........................................... 3-7

Boom Swing ......................................... 3-8

Blade .................................................... 3-8

Swing Bearing ...................................... 3-9

Ring Gear ............................................. 3-9

MAINTENANCE OF BUCKET .............. 3-10

Replace the Tooth .............................. 3-10

Change the Bucket ............................ 3-11

Adjust the Bucket Clearance .............. 3-12

CRAWLER TRACK ............................... 3-13

Rubber Track Maintenance ................ 3-13

Inspection of Crawler Track ............... 3-14

Adjustment of Crawler Track .............. 3-15

TRAVEL REDUCTION GEAR .............. 3-16

Check Oil Level and Refilling ............. 3-16

Change Oil ......................................... 3-16

HYDRAULIC SYSTEM ......................... 3-17

Hydraulic Oil Level and Refilling ........ 3-17

Replace Return Filter Cartridge ......... 3-18

Change the Hydraulic Oil and

Clean the Strainer .............................. 3-19

Air Breather Element Replacement ... 3-20

ENGINE OIL ......................................... 3-21

Check the Engine Oil Level

and Refill ............................................ 3-21

Replace the Engine Oil and Engine

Oil Filter .............................................. 3-22

FUEL SYSTEM ..................................... 3-23

Check Fuel Quantity and Refilling ...... 3-23

Check and Clean Water Separator

and Replace Element ......................... 3-24

Replace Fuel Filter ............................. 3-25

How To Discharge Air ........................ 3-25

COOLING SYSTEM ............................. 3-26

Check the Coolant Level and Refill .... 3-26

Change the Coolant ........................... 3-26

Check the Fan Belt ............................ 3-28

Inspect and Clean Radiator Fins

and Oil Cooler Fins ............................ 3-29

INTAKE AIR SYSTEM .......................... 3-30

Inspect Dust Indicator ........................ 3-30

Inspect and Clean Air Cleaner

Element .............................................. 3-31

Replace Air Cleaner Element ............. 3-31

ENGINE ................................................ 3-32

Adjust Intake Valve and Exhaust

Valve Clearance ................................. 3-32

Check of Fuel Injection System .......... 3-32

ELECTRIC SYSTEM ............................ 3-33

Replace the Fuses ............................. 3-33

Replace the Fusible Link .................... 3-33

Check the Battery .............................. 3-34

TIGHTEN BOLTS ................................. 3-35

Special Tightening Positions .............. 3-35

Standard Tightening Torques............. 3-37

HANDLING IN COLD WEATHER ......... 3-38

LONG TERM STORAGE ...................... 3-39

HYDRAULIC SYSTEM DIAGRAM ....... 3-40

ELECTRIC SYSTEM DIAGRAM........... 3-42

SPECIFICATIONS .................................... 4-1

SPEED AND GRADEABILITY ................ 4-1

ENGINE .................................................. 4-1

MASS ...................................................... 4-1

CAPACITY .............................................. 4-2

45V4 • 55V4 • 60V4 ENG

BUCKET ................................................. 4-2

DIMENSIONS ......................................... 4-4

WORKING RANGE ................................ 4-7

WORKING RANGE FOR OFFSET

DIGGING .............................................. 4-10

RATED OBJECT HANDLING CAPACITIES

TABLE .................................................. 4-12

45V4 • 55V4 • 60V4 ENG

FOREWORD

45V4 • 55V4 • 60V4 ENG 1

0FOREWARD

INTRODUCTION

This manual contains the safety, operation, maintenance and adjustment procedures of this

machine.

Read it and have good understanding before using the machine.

Contact our dealer immediately if you lose or damage this manual.

See the “Operation Manual of the Engine” for the engine.

If you hand over this machine to any third party, this manual should also be handed over to it.

The specifications of the machine may be improved and differ from descriptions of this manual. Please contact our dealer if you have some problems or questions.

FOREWORD

45V4 • 55V4 • 60V4 ENG 2

MACHINE NUMBER

The machine No. and engine No. are marked at the positions shown below.

FOREWORD

45V4 • 55V4 • 60V4 ENG 3

MACHINE DIRECTION

The front, rear, right and left directions of the machine are determined based on the orientation

when the operator is seated on the operator's seat with the blade frontward, as shown below.

Blade

Front

Rea

Right

Left

FOREWORD

45V4 • 55V4 • 60V4 ENG 4

This page is intentionally left blank

45V4 • 55V4 • 60V4 ENG

SAFETY

Most accidents occur during works when preventive measures

against danger are neglected or basic safety instructions are

not observed.

Such accidents may be avoided by paying careful attention in

advance.

This manual describes the basic safety instructions to be

observed in daily operation, inspection and maintenance of

the machine.

Observe these instructions carefully for safety.

Check the safety with great care for any other matters not

described in this manual.

45V4 • 55V4 • 60V4 ENG

SAFETY

45V4 • 55V4 • 60V4 ENG 1-1

11 SAFETY

SAFETY INFORMATION

Read and understand the operation manual, safety signs and labels before using or maintaining

this machine.

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety

messages that follow this symbol to avoid possible injury or death.

The signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. All are used as attention-getting devices throughout this manual as well as on

labels fixed to the machine to assist in potential hazard recognition and prevention.

This safety alert symbol and signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This safety alert symbol and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

This safety alert symbol and signal word indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or serious damages of the machine.

This signal word indicates a potentially hazardous situation which, if not avoided, could result in damages of the machine or reduction of the service life.

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.

NOTICE

SAFETY

45V4 • 55V4 • 60V4 ENG 1-2

SAFETY PRECAUTIONS

PRECAUTIONS BEFORE OPERATION

Read and understand the safety signs and labels

x There are several specific safety signs on your

machine. Please read and understand the safety signs and labels.

x You must replace a label if it is damaged, missing or

cannot be read.

Make a work plan

Start the work only after discussing with the person in

charge at the site.

Wear proper working clothes

For the sake of safety during working, wear clothes that

match your body.

Always wear required protective items such as protective

cap, protective goggles, reflective clothing, safety shoes,

and ear protection as required.

Watch for underground utilities

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.

WC-C100620

SAFETY

45V4 • 55V4 • 60V4 ENG 1-3

Perform "walk-around" inspection

Be sure to walk around the machine and inspect it before

starting work. If some defects are found, repair them

without fail.

Prevent a fire

x Do not leave oiled waste cloth, dead leaves, paper

trash or other flammable objects around the engine.

Such matters may cause a fire. Always inspect and

remove such matters.

x Stop the engine and do not bring fire close to it while

refilling fuel.

x Check if fuel, oil or hydraulic oil does not leak. If some

defects are found, repair them and wipe off leaked oil.

x Check the installation position and usage of the fire

extinguisher.

Install the ROPS canopy

We recommend that the ROPS canopy should be

installed to avoid accidents, which may result in injury, if a

machine with a canopy should fall down.

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.

Start the engine at the operator's seat

If the engine is started from a position other than sitting in

the operator's seat, there is the danger that the machine

starts moving suddenly.

Start the engine only after carrying out checks while

sitting in the operator's seat.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-4

PRECAUTIONS DURING OPERATION

Stay seated while operating

Never attempt to operate the excavator from any position

except the operator's seat. If 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 off the moving machine to be seated or to leave

the machine.

Fasten the seat belt

If the machine falls down, you may be thrown out of the

operator's seat or pressed under the machine. Such an

accident may result in serious injury or death.

Sit on the operator's seat and fasten the seat belt all the

time while operating the machine.

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.

Prevent accidents while moving

Always sound the horn to signal others nearby that you

are moving the machine. Check that no one is within the

working area of the machine before attempting to move it.

WC-C100630

Keep Out

SAFETY

45V4 • 55V4 • 60V4 ENG 1-5

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.

Never leave the bucket in the raised position

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 of load onto the

ground. Should a malfunction occur, it could fall, striking

equipment or personnel.

Do not swing above the truck cab

If you swing the bucket above the truck cab, the driver

may be injured by dropped soil and sand or the bucket

contacting the truck cab.

Do not swing the bucket above the truck cab when

loading soil and sand.

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 are

no personnel or objects in such area.

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.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-6

Never allow unauthorized personnel to ride on the

machine

Only operator is authorized to be on the machine during

operation. Never let unauthorized personnel ride on the

machine. Any person riding as a passenger can fall off

and suffer injury.

Danger for electric power line

If the machine should contact with an electric power line,

move the machine apart from the cable.

If it is impossible to move the machine, shout “Never

touch the shovel” to give a warning to the workers around

the machine.

Do not put on the step when you get off the shovel. Jump

down onto the ground.

Do not operate the engine in an enclosed area without

adequate ventilation

Diesel engine exhaust contains products of combustion

which may be harmful to your health. Always start and

operate the engine in a well ventilated area. If in an

enclosed area, vent the exhaust to the outside.

Do not dig near the machine

Do not dig the ground deep near the machine to prevent

falling due to collapse of the ground.

Do not dig at the base of a cliff

If you dig at the base of a cliff, it may collapse or stones

may drop, causing a danger. Do not dig a cliff.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-7

Never exceed the machine performance

If you use a large bucket that exceeds the machine

performance, the machine may be broken or injury or

death may result.

Be sure to use a bucket or attachment that meets the

specifications.

Never lean out of the window

Do not lean out of the window, enter between the

attachment and cylinder or put your hand or arm between

them.

If the attachment moves, you may be caught by the

attachment, resulting in serious injury or death.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-8

PRECAUTIONS FOR TRAVELING

Check the direction

If forward movement and backward movement are

mistaken in operation with the travel lever, serious

accidents may result.

Check the blade position before traveling. If the blade is

behind the machine, operations of the travel levers are

reversed.

Travel up and down the slope

Traveling sideways or parallel to a slope while on it may

cause the machine to slide and fall over.

To prevent such accidents, only travel up and down the

slope at a right angle.

Do not steer on the slope

Avoid changing the direction on a slope, which could

result in tipping or side slipping of the machine.

When it is inevitable to change the direction, carry it out in

a hard ground where the slope is gradual.

Travel on the slope

x Keep the bucket at as low position as 20 to 30 cm from

the ground and travel the machine at low speed when

traveling on a slope.

x Lower the bucket onto the ground and stop traveling if

the machine becomes unstable.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-9

PRECAUTIONS FOR TRANSPORTING

Load and unload the machine

x Always load and unload the machine on the level

ground.

x Use a ramp board that has sufficient strength, width,

length, and thickness.

x Remove ice, snow, or slippery material from the ramp

board and truck deck before loading.

x Never swing the machine on a ramp board. Otherwise,

it may fall down.

Never load or unload the machine without ramp board

Never load or unload the machine by jacking up the

attachment. Otherwise, the machine may fall down.

Precautions at transportation

Apply stoppers in front of and behind the crawlers.

Apply wire ropes to the machine body and attachment

and fix them firmly to the load carrying platform.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-10

PRECAUTIONS FOR MAINTENANCE

Keep routine maintenance

You must read and understand the warnings and

instructions contained in this manual, before performing

any operation or maintenance procedures.

Wear protective tools

In grinding or when detaching the pin or tooth, fragments

may be put in eyes, resulting in injury.

Wear protective goggles and protective cap before

starting work.

Put the "maintenance signboard"

Put the “Maintenance signboard” on an easy-to-see

position of the operation lever in order to prevent any

other person from touching the machine carelessly.

Never perform maintenance of the moving machine

Lower the bucket onto the ground and stop the engine to

prevent an accident of being crushed or caught by the

machine.

Keep in good contact with the operator if it is necessary to

perform maintenance of the moving machine.

DANGER

do not

operate

Operation Manual

SAFETY

45V4 • 55V4 • 60V4 ENG 1-11

When working under tracks

If the machine is merely jacked up with the attachment,

you may be caught by the machine when it lowers.

Place the supporting blocks under the crawler and make

sure that it is supported firmly.

Hold the attachment

If the hydraulic hose is disconnected or the pin is drawn

out in the condition where the attachment is raised in the

air, oil may spout out or the attachment may drop.

Be sure to lower the attachment onto the ground or keep

it with safety supports, blocks, etc.

Never watch the check valve when adjusting crawler

tracks

Never watch the check valve when servicing the crawler

tracks. Position yourself not to be splashed with grease.

Grease used to adjust the crawler tracks is highly

pressurized and can cause serious injury or death.

Carefully read and understand the maintenance

procedure for track adjustment.

Never perform maintenance with engine running

Touching rotating parts such as the fan belt, etc., can get

your hand crushed and there is the danger of your hand

being cut off.

Always perform maintenance with the engine shut off.

Be careful with hot engine

Never touch the engine or muffler right after the machine

is stopped. It is very hot and causes burns.

Danger

Do Not

Operate

SAFETY

45V4 • 55V4 • 60V4 ENG 1-12

Never open a radiator cap when it is hot

Never try to open the radiator cap while the engine is

running or right after the engine is stopped. If the cap is

open the very hot steam will blow out, which causes

serious burns.

Wait until the coolant temperature goes down.

Slowly open the cap to release the pressure.

Always release inner pressure from hydraulic system

Pressurized oil may spout out if the hydraulic line is

disconnected without releasing the inner pressure of the

hydraulic system. Release the inner pressure before

disconnecting a hydraulic line.

Precautions for high pressure oil

It is very dangerous if the high pressure oil enters your

skin or eyes.

If oil enters your skin, immediately go to the doctor and

get medical attention.

Precautions for battery

When maintaining the electrical system or carrying out

welding, remove the lead connected to the negative

terminal (-) of the battery.

The battery can generate flammable gases and there is

the danger of the gases catching fire and exploding. Also,

dilute sulfuric acid is used for the battery liquid. Take

sufficient care while handling.

Prevent fire or explosions

Keep away fuel, lubricant and coolant from any fire or

heat. Most of them are very flammable.

Never place flammable materials or objects close to fire or

heat.

WC-C300020

SAFETY

45V4 • 55V4 • 60V4 ENG 1-13

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SAFETY

45V4 • 55V4 • 60V4 ENG 1-14

SAFETY SIGNS AND LABELS

There are several specific safety signs on your machine. Following is a listing of Safety Decals and locations. Clean or replace these if you cannot read the words. Check the part number for the safety sign against this manual or the actual object before placing an order.

WG-C105000

10 11

View A

(When the cover is opened)

Detail B

SAFETY

45V4 • 55V4 • 60V4 ENG 1-15

(Operator's cab inside right)

(Side view of hydraulic oil tank)

Cabin specification

(Operator's cab inside left)

View C

(Detail of counterweight section)

(Detail of operator's seat)

14 (Put in storage

box when not used.)

SAFETY

45V4 • 55V4 • 60V4 ENG 1-16

1. Safety operation (440645800)

2. Read manual! (D405 359 00) Read manual before operation, maintenance, disassembly, assembly and transportation.

3. Crush hazard (D405 508 00) Sign indicates a hazard of being crushed or run over by unexpected moving of stopped machine. Lower working device to ground, move safety lever to lock position and take engine key with you before leaving machine.

4. Electric power lines (D405 506 00) Sign indicates an electrocution hazard if machine is brought too near electric power lines. Keep a safe distance from electric power lines.

5. Precautions during adjustment of the hydraulic circuit (D408 424 00)

SAFETY

45V4 • 55V4 • 60V4 ENG 1-17

6. Hazard of rotating parts (D405 509 00)

Sign indicates a hazard of rotating parts,

such as fan. Turn off before inspection and maintenance.

7. Hazard of rotating parts (D405 366 00)

Sign indicates a hazard of rotating parts,

such as belt. Turn off before inspection and maintenance.

8. Keep away from swing area (D405 507 00) Sign indicates a crush hazard by rotation of upper structure of the machine. Keep away from swinging area of machine.

9. Keep away from machine (D405 511 00) Sign indicates a hazard of being hit by the working device of the machine.

10. Burn hazard (D405 503 00)

Sign indicates a burn hazard from spurting

hot water or oil if radiator or hydraulic tank is uncapped while hot. Allow radiator or hydraulic tank to cool before removing cap.

11. Electrical hazard (D405 504 00)

Sign indicates an electrical hazard from handling the cable. Read manual for safe and proper handling.

SAFETY

45V4 • 55V4 • 60V4 ENG 1-18

12. Warning for track adjuster (D405 505 00)

Sign indicates a hazard of flying plug from track adjuster that could cause injury. Read manual before adjusting track for safe and proper handling.

13. Hazard from falling window (D405 510 00)

Sign indicates a hazard from falling

window. After raising window, be sure to lock it in place with lock pins.

14. Do not operate (D405 323 00)

Operation prohibition during inspection and

servicing. Hang this sign on the control lever during inspection and servicing not to allow any other worker to start the engine or operate the machine.

45V4 • 55V4 • 60V4 ENG

OPERATION

This section describes the proper operation procedures of this

machine.

Always look to the safety and observe the given operation

instructions and cautions to carry out works safely.

45V4 • 55V4 • 60V4 ENG

OPERATION

45V4 • 55V4 • 60V4 ENG 2-1

22 OPERATION

NAMES OF COMPONENTS

No. Name No. Name No. Name

1 Bucket 12 Battery 23 Travel unit

2 Bucket link 13 Return filter 24 Upper roller

3 Arm link 14 Radiator and oil cooler 25 Lower roller

4 Bucket cylinder 15 Canopy 26 Track adjusting device

5 Arm 16 Air cleaner 27 Swing bearing

6 Arm cylinder 17 Engine 28 Front idler

7 Boom 18 Muffler 29 Blade cylinder

8 Boom cylinder 19 Swing unit 30 Blade

9 Boom swing cylinder 20 Rotary joint 31 Crawler track

10 Fuel tank 21 Hydraulic pump

11 Hydraulic oil tank 22 Control valve

Right

Rea

Left

Front

OPERATION

45V4 • 55V4 • 60V4 ENG 2-2

CONTROLS AND INSTRUMENTS

No. Name No. Name

1 Right control box 4 Boom swing pedal

2 Left control box 5 Operator's seat

3 Travel lever 6 No. 1 AUX. pedal (Option)

OPERATION

45V4 • 55V4 • 60V4 ENG 2-3

Right Control Box

No. Name No. Name

1 OK monitor 9 Mode select switch

2 Right operation lever 10 Horn switch

3 Blade lever 11 Auto idle selector

4 Travel speed select switch 12 No. 1 AUX. proportional lever (E Grip)

5 Throttle dial 13 No. 1 AUX. bottum (E Grip)

6 Engine key switch 14 No. 1 AUX. flow limit switch (E Grip)

7 Power outlet 15 No. 1 AUX. hold switch (E Grip)

8 Light switch

* The switches of the No. 2 AUX and No. 3 AUX hydraulic power are shown in the section “AUX

WHEN USING SPECIAL ATTACHMENT”.

Front of machine

Right operation lever(Option)

OPERATION

45V4 • 55V4 • 60V4 ENG 2-4

1. OK monitor

When the engine key switch is set to the ON position, the engine oil pressure warning indicator

and battery charge warning indicator turn on. Make sure, after the engine starts, that all warning indicators are off before starting work.

No. Name

1 No use

2 Travel speed indicator

3 Glow indicator

4 Battery charge warning indicator

5 Engine oil pressure warning indicator

6 Water temperature warning indicator

7 Auto idle indicator

8 Control lock warning indicator

9 Water separator warning indicator

10 ECO mode indicator

11-14 No use

15 Water temperature gauge

16 Fuel gauge

17 Hour meter

x If some trouble occurs in the machine, the corresponding warning indicator turns on to

indicate the trouble. If a warning indicator turns on during work, stop the engine immediately and check and repair the abnormal position.

x The OK monitor does not always warrant the machine condition. Take indication of the

OK monitor and carry out startup inspection and daily inspection.

x Be sure to check the levels and contamination of the engine oil, cooling water, fuel tank

and hydraulic oil tank visually.

x If the engine oil temperature is low, the hydraulic pressure becomes higher and the

engine oil pressure warning indicator may turn on. It turns off when the engine is warmed up. Stop the engine and carry out inspection and repair work if the indicator does not turn off even after warming up.

OK monitor

OPERATION

45V4 • 55V4 • 60V4 ENG 2-5

Travel speed indicator

This indicator turns on, when the high speed is selected. When

the switch is pressed again, the travel speed is changed into the low speed and the indicator turns off.

Glow indicator

This indicator turns on when the engine key switch is set to the

ON position, indicating that preheat. The indicator turns off after preheat completion.

Battery charge warning indicator

This indicator turns on if some trouble occurs in the charging

system while the engine is running. If it turns on while the engine is running, the fan belt may be slack. Stop the engine and check

it.

Engine oil pressure warning indicator

This indicator turns on if the lubricating oil pressure lowers while

the engine is running. Stop the engine and check the lubrication

system and lubricating oil quantity if this indicator turns on while the engine is running.

Water temperature warning indicator

This indicator turns on if the water temperature is higher

abnormally. Stop the engine and check the cooling system if this indicator turns on while the engine is running.

Auto idle indicator

This indicator turns on when the Auto idle switch is on and turns off when the Auto idle switch is off.

Control lock warning indicator

This indicator turns on if the engine key switch is set to the START position though the control lock lever is not at its locked position. The engine cannot be started in such a condition. Put the gate lock lever in its locked position to start the engine.

WC-C200050

WC-C200060

WC-C200070

WC-C200080

WC-C200090

n/min

WC-C200120

WC-C200110

OPERATION

45V4 • 55V4 • 60V4 ENG 2-6

Water separator warning indicator

This indicator turns on if water is collected up to the specified level

in the water separator. Stop the engine and discharge water from the water separator when this indicator turns on.

Eco mode indicator

This indicator lights up when the Eco switch is ON and goes OFF when the Eco switch is OFF.

Water temperature gauge

x This gauge indicates the temperature of engine

cooling water.

x It is proper if the pointer indicates a temperature in

the white range during operation.

x After starting the engine, carry out warming up

operation of the engine until the needle points in the horizontal direction.

x Idle the engine and wait until the temperature lowers

to the white range if the pointer indicates a temperature in the red range during operation. Check the water level in the subtank, water leak from the engine and radiator and fan belt.

Fuel gauge

x This gauge indicates the fuel level in the fuel tank.

F: The fuel tank is full. E: Fuel is insufficient. Refill the tank with fuel.

Hour meter

This meter indicates the accumulative running time in units of 1/10 hour (six minutes). It advances as long as the engine is running, even if the machine is not working.

White

Red

WC-C200100

White

Red

OPERATION

45V4 • 55V4 • 60V4 ENG 2-7

2. Right operation lever

Use this lever to operate the boom and bucket.

The standard pattern at the time of shipment from the factory is the pattern A.

x Boom raise: Pull the lever backward. x Boom lower: Push the lever forward. x Bucket dig: Turn the lever to the left. x Bucket dump: Turn the lever to the right. x Stop: Release your hand from

the lever. The lever returns to the neutral position automatically and operation stops.

x Simultaneous operation: Turn the lever diagonally to

operate the boom and bucket simultaneously.

3. Blade lever

Use this lever to raise and lower the blade.

x Raising the blade: Pull the lever backward. x Lowering the blade: Push the lever forward.

4. Travel speed select switch

Use this switch to select the low and high travel speeds. Press the switch during traveling at the low speed to change it into the high speed. Press the switch again to change the high speed into the low speed. Every time this switch is pressed, the travel speed changes from high into low, and vice versa, alternately. A selected speed is maintained. Becomes low speed when the engine is stopped.

5. Throttle dial

Use this dial to adjust the engine speed.

x Low speed: Turn the dial to the left.

x High speed: Turn the dial to the right.

Front of machine

WK-C200040

High

OPERATION

45V4 • 55V4 • 60V4 ENG 2-8

6. Engine key switch

Use this switch to start and stop the engine.

HEAT (preheat)

Set the switch to this position to preheat the engine if the engine is cold in cold seasons.

Keep the switch at the HEAT position for maximum 10

seconds. Preheating is complete and the glow indicator turns off. Turn the key to the START position

to start the engine when the glow indicator turns off.

OFF (stop)

The key may be inserted and removed at this position. Power of all electrical systems is cut off and the

engine stops.

ON (run)

Power is supplied to the electrical systems and the OK monitor indicator turns on.

START (start)

Set the switch to this position to start the engine.

Release the fingers from the key immediately after the engine starts.

The key returns to the ON position automatically.

7. Power outlet

This is a power socket for standby power source. Use it within the following capacity. Capacity: 12 V, 120 W Always keep the cap closed when this socket is not used.

8. Light switch

Use this switch to turn on and off the front light of the boom.

x Turning on: Press the ON side of the switch.

x Turning off: Press the OFF side of the switch.

9. Mode select switch

Change the operation mode x “ECO” Mode: This is a mode in which fuel consumption

is suppressed. The ECO mode is started by putting the selector to the ECO side.

x “Vmax” Mode: This is a mode specialized to speed of

work. The Vmax mode is started by putting the selector to the Vmax side.

WC-C200200

WC-C200230

ECO mode Vmax mode

WC-C200190

OPERATION

45V4 • 55V4 • 60V4 ENG 2-9

10. Horn switch

Press this switch to turn on the horn.

11. Auto idle switch

When the Auto idle. switch is set to the ON position, the engine revolution changes into low automatically to reduce fuel consumption approximately four seconds after the operation lever is returned to the neutral position. The previous engine revolution is restored when some operation lever is moved again. Every time this switch is pressed, the auto idle indicator on the OK monitor turns on and off alternately.

If the lever is operated in the condition where the Auto idle. switch is set to the ON position and the engine revolution is reduced, the engine revolution increases quickly, the operation speed changes suddenly, and a serious accident may occur. Set the Auto idle. switch to the OFF position in works that may cause dangerous accidents if the operation speed changes suddenly such as loading or unloading of the machine, turning, etc.

12. No. 1 AUX. proportional lever (E Grip)

Sliding to left: Pressurized oil is supplied to the left AUX

pipe of the arm.

Sliding to right: Pressurized oil is supplied to the right

AUX pipe of the arm.

13. No. 1 AUX. botton (E Grip)

When this switch is pressed, pressurized oil is supplied to the left AUX pipe of the arm. Supply of pressurized oil stops when the finger is released from the switch.

14. No. 1 AUX. flow limit switches (E Grip)

Use this switch to operate the No. 1 AUX. proportional lever. ON: The supply flow is reduced to approximately half. OFF: The switch is reset.

15. No. 1 AUX. hold switch (E Grip)

When this switch is made ON (the indicator lights up) and the No. 1 AUX. botton is operated, it will be possible to

continue to supply compressed oil to the left side spare

piping.

S grip specification E grip specification

(Option)

Front of machine

E grip specification

(Option)

OPERATION

45V4 • 55V4 • 60V4 ENG 2-10

Left Control Box

1. Left operation lever

Use this lever to operate the arm and swing. The standard pattern at the time of shipment from the

factory is the pattern A.

x Arm in: Pull the lever backward. x Arm out: Push the lever forward.

x Swing left: Turn the lever to the left.

x Swing right: Turn the lever to the right. x Stop: Release your hand from the lever.

The lever returns to the neutral

position automatically and operation stops.

x Simultaneous operation:

Turn the lever diagonally to operate the arm and swing

simultaneously.

2. Control lock lever

Use this lever to lock all operations. The control lock lever moves together with the control box.

x Lock: Pull up the control lock lever.

x Unlock: Push down the control lock lever.

x If the operation lever is touched carelessly in the condition where the control lock lever

is not at the locked position, the machine may move unexpectedly, resulting in a dangerous accident.

x Stop the engine and put the control lock lever in its locked position when you leave the

operator's cabin.

x Be careful not to touch the left operation lever when using the control lock lever.

Front of machine

Unlock

Lock

OPERATION

45V4 • 55V4 • 60V4 ENG 2-11

Travel Levers

Use these levers to control traveling.

Forward: Push the right and left travel levers forward.

Backward: Pull the right and left travel levers backward.

Stop: Release your hands from the levers. The

levers return to the neutral positions

automatically and operation stops.

x If forward movement and backward movement are mistaken during traveling, a serious

accident may result.

x Forward movement means forward movement with the blade in the front position. If the

blade is at the rear position, the traveling directions are contrary to the lever operations.

x Check if the blade is in the front or rear position before operating the travel levers.

Boom Swing Pedal

Use this pedal to swing the boom.

Open the pedal cover to the unlocked position.

Left boom swinging: Step on the left side of the pedal. Right boom swinging: Step on the right side of the pedal.

Put the pedal cover over the pedal to disable pedaling when boom swinging is not carried out.

Forward

Backward

Unlocked

Pedal cove

Left swing

Right swing

Locked

OPERATION

45V4 • 55V4 • 60V4 ENG 2-12

Operator's Seat

Sit on the operator's seat and adjust it to the condition where the operation levers and pedals may be used smoothly. Back and forth adjustment: Move the seat back and forth while pulling the slide lever (1) to adjust the seat position. Reclining adjustment: Move the back seat (3) back and forth while pulling the reclining lever (2) to adjust the back seat angle. Suspension adjustment: Adjust the hardness of suspension according to the body weight with the suspension lever (4). The applicable body weight is displayed in the display panel (5).

Lower the bucket onto the ground and stop the engine before adjusting the operator's seat.

Seat belt

Hold the grip (1), insert the tongue plate (2) into the

buckle (3) to the end, and make sure that it is locked.

x Fasten the seat belt during operating.

x Be sure to check the belt, tongue plate, buckle,

etc. before starting operating. Replace the damaged belt, tongue plate and/or buckle with new one(s).

AUX Pedal (Option)

Use this for making the No. 1 AUX hydraulic operation.

Put the pedal lock lever in the unlock position.

Supply of pressure to the left side of the arm: Step on the front side of the pedal.

Supply of pressure to the right side of the arm: Step on

the rear side of the pedal.

When the No. 1 AUX hydraulic operation is not to be made, move the pedal lock lever to the lock position and put it in a state in which it cannot be operated.

Pedal lock leve

Left pipe pressure supply

Right pipe pressure supply

Lock

Unlock

OPERATION

45V4 • 55V4 • 60V4 ENG 2-13

WG-C200180

WG-C200190

Operator’s Cabin

Door lock

x The door may be locked at the fully opened or closed

position.

Push the door until it is locked completely.

x Press the Unlock lever (1) to unlock the door. The

door is unlocked and may be opened and closed.

Opening and Closing the Front Window of the Cabin

x Move down the front window slowly, when

closing it, with care not to pinch your hand, etc.

x Be sure to fix the front window with the right and

left lock pins (2), in addition to the automatic lock (4), when opening and storing it on the ceiling.

Opening

1. Release the locking device by pressing down the left

and right locking device release levers (2).

2. Pull and push up the front window by holding the right

and left handles (3) and move the window to the ceiling.

3. When pushing up the front window by holding the

handles, the window can be completely locked by the locking device. Push it up until completely locked.

Closing

1. Push down the left and right lock releasing levers and

release the locking device.

2. Gradually lower the bottom window with the locking

device maintained in the released state.

3. If the bottom window is pressed inward while the

locking device is maintained in the released state, since it butts against the locking device (6), always release the locking releasing leaver and put it back in the locked state.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-14

Opening and Closing the Bottom Window of the Cabin

x Move down the bottom window slowly, when

closing it, with care not to pinch your hand, etc.

x Be sure to fix the bottom window with the right

and left lock pins (4), in addition to the automatic lock, when opening and storing it on the ceiling.

Opening

1. Release the locking device by pressing down the left

and right locking device release levers (4).

2. Pull to the front the locking device still in the released

state and move the bottom window.

3. Lift up the bottom window while the locking device is

still in the released state, and release the locking lever when it touches the locking device of the front window (5) and be sure to put that lever back in the locking position.

When the front window is at the roof, it will be

possible to remove the bottom window by lifting it up.

Closing

1. Push down the left and right lock releasing levers and

release the locking device.

2. Gradually lower the bottom window with the locking

device maintained in the released state.

3. If the bottom window is pressed inward while the

locking device is maintained in the released state, since it butts against the locking device (6), always release the locking releasing leaver and put it back in the locked state.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-15

WG-C200200

Wiper switch

Press the mark side to activate the wiper.

x Do not start the wiper in the condition where the

window is dry, muddy or snowy.

x Never turn on the wiper switch when the cabin

front window (upper) is stored on the ceiling.

Window washer switch

Press the mark side further. Washer liquid spouts out of

the nozzle while the mark side is kept depressed.

Do not operate the switch if window washer liquid is lacking. If the window washer liquid is exhausted, put washer liquid in the washer liquid tank.

Window washer tank

Wiper switch Window washer switch

OPERATION

45V4 • 55V4 • 60V4 ENG 2-16

Air conditioner (Option)

The air conditioner is on the right side of the operator’s seat inside the cabin. Operate this for adjusting the temperature inside the cabin.

1. Air conditioner switch

Pressing the switch starts the air conditioner. The indicator blinks when this switch is ON.

2. Fan speed controlling knob

This knob is for switching ON or OFF the fan and for adjusting the air flow speed. The air flow rate is controlled by three levels

3. Temperature control knob

This knob is for controlling the temperature of the air coming out of the air blow outlets.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-17

Heater (Option)

The heater is on the right side of the operator’s seat inside the cabin. Operate this for heating inside the cabin.

• “LOW” or “HIGH”

Starts the fan and blows warm air into the cabin. The air flow rate of the fan can be selected by putting this switch to the “LOW” or the “HIGH”

side.

• “OFF”

Stops the fan.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-18

STARTING ENGINE

Check before Starting Engine

1. Sit on the operator's seat and adjust it to the condition

where the operation levers and pedals may be used

smoothly.

2. Make sure that the control lock lever is set at the

locked position.

3. Make sure that each lever is set at the neutral position.

4. Insert the key into the engine key switch. Turn it to the

ON (run) position and make sure of the following.

x The engine oil pressure warning indicator (1) and

battery charge warning indicator (2) are lit continuously.

(It is normal if the engine oil pressure warning

indicator and battery charge warning indicator turn off when the engine starts.)

x Push the light switch and make sure that the front

lights are turned on.

x Push the horn switch and make sure that the horn

sounds.

Unlock

Lock

Front of machine

OPERATION

45V4 • 55V4 • 60V4 ENG 2-19

WK-C200090

Normal Starting

1. Set the throttle dial to the middle speed.

2. Turn the key to the START position to start the engine.

3. Release your fingers from the key when the engine

starts. The key returns to the ON (run) position automatically.

4. Push the control lock lever down to the release position

to start work.

x Check if there are no persons or obstacles

around the machine, turn on the horn, and start then.

x Be sure to sit on the operator’s seat and start

the engine.

x Set the control lock lever to the lock position

and restart the engine, if the engine stops with the gate lock lever set at the release position.

Do not turn the starting motor for 15 seconds or more. If the engine fails to start, return the key to the OFF position, wait for 30 seconds, and try to start the engine again.

Starting in Cold Seasons

Preheat the engine in cold seasons to make it easy to start the engine.

1. Set the throttle dial to the middle speed.

2. Turn the key counterclockwise and keep it at the ON

(run) position. Preheating starts and the glow indicator (3) turns on. Wait until it turns off (10 seconds at the maximum, the value of which depends on the cooling water temperature). The engine oil pressure warning indicator (1) and battery charge warning indicator (2) also turn on when the key is set at the ON (run) position. However, this does not imply any abnormality.

3. Turn the key to the START position to start the engine

after the glow indicator turns off.

4. Release your fingers from the key after the engine

starts. The key returns to the ON (run) position automatically.

Middle speed

OPERATION

45V4 • 55V4 • 60V4 ENG 2-20

Starting Engine with Booster Cables

Follow the instructions shown below to start the engine using the booster cables.

x If the booster cables are connected improperly, the battery will be shorted, resulting in

a dangerous accident. Never connect the + and

terminals.

x The battery produces flammable hydrogen gas, which is explosive. Do not bring fire

close to it or produce sparks near it.

The electrical circuits of this machine run on 12 V. Use a 12 V auxiliary battery.

Order of connecting booster cables

1. Set the engine key switches of the normal machine

and machine in trouble to the OFF positions.

2. Connect the clip of the booster cable (red) to the

terminal of the machine in trouble. Connect the other

clip to the

terminal of the normal machine.

3. Connect the clip of the booster cable (black) to the -

terminal of the normal machine. Connect the other clip

to the upper frame of the machine in trouble.

Starting engine

1. Make sure that the cable clips are connected to the

battery terminals and upper frame firmly.

2. Start the engine of the normal machine and keep the

engine running at high revolution.

3. Start the engine of the machine in trouble.

Disconnecting booster cables

1. Disconnect the clip of the black cable from the upper

frame first. Then, disconnect the clip from the

terminal of the normal machine.

2. Disconnect the clip of the red cable from the

terminal of the normal machine first. Then, disconnect the clip

from the + terminal of the machine in trouble.

WC-C200410

Never connect the + and - terminals.

WC-C200420

(Red)

(Black)

Battery of normal machine

Battery of machine in trouble

Upper frame of machine in trouble

Order of connecting booster cables

Order of disconnecting booster cables

OPERATION

45V4 • 55V4 • 60V4 ENG 2-21

Check after Starting Engine

1. Checking operation of the OK monitor Make sure that all indicators on the OK monitor are off.

2. Check if the engine exhaust color, sound and vibrations are proper.

x Do not accelerate the engine or apply loads to it

quickly when the cooling water temperature is low.

x Stop the engine immediately, find the cause and

repair troubles, if some troubles are found.

Warming Up Engine

1. Idle the engine to warm it up for approximately 10 minutes after the engine starts.

2. Lift the bucket from the ground and repeat cycles of moving the bucket lever to the digging or dumping

position for 10 to 15 seconds and keeping it at the

neutral position for about 10 seconds for five minutes to raise the hydraulic oil temperature, if the hydraulic oil

temperature is low.

3. Then, repeat all operations, including turning, traveling

and moving the attachment, three to five times to warm

up all devices.

Do not carry out high-speed operation quickly when the hydraulic oil temperature is low (below 20ºC).

The proper hydraulic oil temperature is 50ºC to 80ºC. Warm up hydraulic oil up to 20ºC or so and then carry out operation, if it is necessary to start operation at low temperature.

WC-C200430

Warming up

OPERATION

45V4 • 55V4 • 60V4 ENG 2-22

STOPPING ENGINE

If you touch the operation lever by mistake without locking the control lock lever, the machine may move unexpectedly, resulting in a dangerous accident.

Lower the attachment onto the ground, stop the engine and set the control lock lever to the lock position before you leave the operator's seat.

x Stopping machine

1. Park the machine on a safe, flat and rigid ground not in

danger of stone dropping, landslide, etc.

2. Raise the arm and lower the bucket onto the ground with its bottom horizontal.

3. Lower the blade onto the ground.

4. Set the control lock lever to the locked position.

Stopping engine

1. Idle the engine for five minutes or so to lower the

engine temperature.

2. Set the engine key switch to the OFF (stop) position to stop the engine.

3. Pull out the key from the engine key switch.

Inspection and locking after engine stops

1. Check each part for oil leak, water leak and damages. Carry out repair work if leak or some abnormality is

found.

2. Refill the fuel tank fully.

3. Remove soil and sand from around the crawlers and

bucket.

4. Lock all the lockable parts such as the fuel port, engine cover, etc.

Lock the front and rear windows, if the machine has a

cabin. Lock the door.

WC-C200440

WC-C200450

OPERATION

45V4 • 55V4 • 60V4 ENG 2-23

EMERGENCY ACTIONS IF ENGINE STOPS

If the machine stops due to an engine trouble in the

condition where the boom is raised, the boom will not lower even though the boom operation lever is set to the

low position. If the machine is left in this condition, the

boom is in danger of dropping. Lower the boom by one of the methods shown below.

If the starting motor runs though the engine does

not start

In the state in which the operation lock lever is pressed

down, push down the boom operation lever and retain it in that state, and put the START switch to the START

position, and lower the boom while rotating the engine by

the starter motor.

Do not rotate the starting motor for 15 seconds or more. Wait two minutes or so and restart the motor then.

x If the engine does not rotate at all

1. Open the cover (1).

2. Loosen the lock nut (3) of the overload relief valve (2) for lifting the boom above the control valves (1).

Loosen the adjust screw (4) gradually.

3. Stop loosening the adjust screw when the boom begins to lower. Wait until the bucket moves down to the

ground.

Do not turn back the adjust screw. It requires special adjustment technique accompanied by pressure measurement. Ask our service office to repair the engine and adjust the screw.

(In the case of the accumulator specification – Option)

If it is within about 30 seconds, if the starter switch is put to the “ON” (ACC) position, and the

boom operation lever is lowered while the operation lock lever is kept pushed down, then the

boom can be lowered.

If the boom does not come down, lower the boom using the above method.

Overload relief valve

WC-C201180

Machine outside Machine center side

OPERATION

45V4 • 55V4 • 60V4 ENG 2-24

RUNNING IN NEW MACHINE

If a new machine is used by force, the performances may be deteriorated earlier and the service life may be shortened. Run in the machine for the initial 50 hours.

Follow the instructions below and run in the new machine.

1. Warm up the machine sufficiently.

2. Do not run the machine with heavy loads or at high

speed. Run the machine at about 80% of the maximum engine

revolution.

3. Do not apply the full load to the machine. The adequate load is 80% or so.

Do not run the machine by force.

4. Do not start, accelerate or stop the machine quickly or change the direction quickly.

5. Do not apply shocks such as quick stopping of the

boom when lowering it to the machine.

6. Grease the pins of the attachment everyday.

WC-C200430

WC-C200460

WC-C200470

Warming up

OPERATION

45V4 • 55V4 • 60V4 ENG 2-25

LEVER OPERATIONS

Operation Mode

Six operation patterns are available. The handling methods of the operation levers and machine movements differ with these patterns.

Check the operation mode before using the levers. The operation mode plate is stuck on the

right of the operator's seat. The standard pattern at the time of shipment from the factory is the pattern A.

Operation

direction

Operation mode

Pattern A Pattern B Pattern C Pattern D Pattern F Pattern G

1 Boom raising Boom raising Arm in Arm out Arm in Boom raising

2 Boom lowering Boom lowering Arm out Arm in Arm out Boom lowering

3 Bucket digging Bucket digging Left swing Left swing Bucket digging Left swing

4 Bucket dumping Bucket dumping Right swing Right swing Bucket dumping Right swing

5 Arm in Left swing Boom raising Boom raising Boom raising Arm in

6 Arm out Right swing Boom lowering Boom lowering Boom lowering Arm out

7 Left swing Arm out Bucket dumping Bucket dumping Left swing Bucket dumping

8 Right swing Arm in Bucket digging Bucket digging Right swing Bucket digging

Check the action of each operation lever and movement of the machine before starting work in order to prevent accidents, which may result in injury or death, due to improper operations.

Bucket dumping

Arm out

rm in

Bucket digging

Boom

lowering

Boom raising

Right swing

Left swing

Operation mode plate

OPERATION

45V4 • 55V4 • 60V4 ENG 2-26

Operation Mode Plate

The corresponding operation mode plate shown below is stuck on the right of the operator’s seat.

Operation mode Operation mode plate

Pattern A

D40662200

Pattern B

D40662300

Pattern C

D40662400

Pattern D

D40662500

Pattern F

D40662600

Pattern G

D40662700

OPERATION

45V4 • 55V4 • 60V4 ENG 2-27

AF Multi-selection Method (for Machine with AF Multi-selector Valve)

Two operation patterns A and F can be changed with the selector valve. Lower the attachment onto the ground and stop the engine before changing the operation mode.

1. The selector valve is inside the front left cover.

2. Loosen the wing bolt that fixes the selector valve lever. Set the lever to the intended position.

3. Fix the selector valve lever with the wing bolt after changing the operation mode.

When changing the operation mode, a serious accident may occur due to improper operations. Check the action of each operation lever and movement of the machine before starting work.

Position

Wing bolt

Position F

Selector valve

Operation mode plate (pattern A, F)

Cabin model

OPERATION

45V4 • 55V4 • 60V4 ENG 2-28

ABG Multi-selection Method (for Machine with ABG Selector Valve)

Three operation patterns A, B and G can be changed with the selector valve. Lower the attachment onto the ground and stop the engine before changing the operation mode.

1. The selector valve is inside the front left cover.

2. Remove the bolt that fixes the selector valve lever. Set the lever to the intended position.

3. Fix the selector valve lever with the bolt after changing the operation mode.

When changing the operation mode, a serious accident may occur due to improper operations. Check the action of each operation lever and movement of the machine before starting work.

Lever fixing bolt

Selector valve

Operation mode plate (patterns A, B, G)

Cabin model

OPERATION

45V4 • 55V4 • 60V4 ENG 2-29

ABCD Multi-selection Method (for Machine with ABCD Selector Valve)

Four operation patterns A, B, C and D can be changed with the selector valve. Lower the attachment onto the ground and stop the engine before changing the operation mode.

1. The selector valve is inside the front left cover.

2. Remove the bolt that fixes the selector valve lever. Set the lever to the intended position.

3. Fix the selector valve lever with the bolt after changing the operation mode.

When changing the operation mode, a serious accident may occur due to improper operations. Check the action of each operation lever and movement of the machine before starting work.

Lever fixing bolt

ABCD multi-selection

Operation mode plate (patterns A, B, C, D)

Cabin model

OPERATION

45V4 • 55V4 • 60V4 ENG 2-30

BLADE OPERATION

Move the blade lever forward or backward.

BOOM SWING OPERATION

Set the pedal cover to the unlocked position before swinging the boom. Step on the right or left

side of the boom swing pedal to swing the boom.

When boom swing is not carried out, put the pedal cover on the pedal and lock it to prevent an improper operation.

Lowering blade

Raising blade

Raising

Lowering

Blade

Pedal cove

Unlocked

Left boom swing

Right boom swing

Locked

Swing bracket

Right boom swing

Left boom

swing

OPERATION

45V4 • 55V4 • 60V4 ENG 2-31

SWING OPERATION

Use the left operation lever to swing.

Turn the lever to the right to swing to the right. Turn the lever to the left to swing to the left.

Return the lever to the neutral position to stop swinging.

Do not let any persons enter the swinging operation range.

Check the safety around the machine before swinging.

Left swing

Right swing

Left operation leve

Right swing

Left swing

OPERATION

45V4 • 55V4 • 60V4 ENG 2-32

TRAVELING

Starting, Traveling and Stopping

x If forward movement and backward movement

are mistaken in operation with the travel lever, serious accidents may result.

x Check the blade position before traveling. If the

blade is behind the machine, operations of the travel levers are reversed.

x Make sure that there are no people around the

machine and turn on the horn before starting.

1. Pull the throttle dial to raise the engine speed to the

proper speed to traveling.

2. Lower the control lock lever to unlock it.

3. Raise the bucket and blade to certain height that allow

smooth traveling without hitting them.

4. Operate the right and left travel levers as shown below.

x Forward

Push both travel levers forward to move the machine

forward. (The machine always moves toward the blade when the

travel levers are pushed forward.)

Backward

Pull back both travel levers to move the machine

backward.

(The machine always moves toward the sprocket when the travel levers are pulled back.)

The traveling speed of the machine can be controlled by

the amount of turning the travel levers.

Stopping

Set both travel levers to the neutral positions to stop the

machine. When the machine stops, the parking brake is applied automatically.

Control lock leve

Travel levers

Throttle dial

Left travel leve

Right travel leve

Forward

Backward

Forward Backward

OPERATION

45V4 • 55V4 • 60V4 ENG 2-33

Changing Direction

Turning during traveling

Return the travel lever toward the neutral position a little to change the direction during forward (or backward)

traveling.

When the lever of the intended turning direction is returned a little, the machine turns slowly in that direction.

Pivot turning (when blade is in front of machine)

Drive a single crawler to change the direction.

1. Pivot turn to the left Push the right travel lever (1) to turn the machine

forward. Pull it back to turn the machine backward.

2. Pivot turn to the right Use the left travel lever (2) in the same way.

Spin turning (when blade is in front of machine)

Drive the right and left crawlers in the reverse directions

to change the direction without traveling the machine.

1. Spin turning to the left

Push the right travel lever forward and pull back the left

lever.

2. Spin turning to the right

Pull back the right travel lever and push the left lever

forward.

Forward turning to left

Backward turning to right

Pivot turn to left

Forward turning to right

Backward turning to left

Pivot turn to right

Spin turning

OPERATION

45V4 • 55V4 • 60V4 ENG 2-34

High Speed Traveling

Push the travel speed select switch (1) of the blade lever to change the travel speed into the high speed. Push it

again to change the high speed into the low speed.

Do not change the travel speed into the high speed while unloading from a truck or traveling down a slope. It is very dangerous if the travel speed changes during traveling.

Precautions While Traveling on Slope

1. The gradeability of this machine is 30º (58%).

2. Travel up or down a slope at the low speed.

3. Travel up a 15º or more slope in the posture shown on

the right.

4. Reduce the engine speed and operate the travel levers slowly when traveling down a 15º or more slope.

Move down the slope in the forward traveling posture

as shown on the right. Lower the bucket onto the ground to stabilize the

machine if it becomes unstable.

x Do not change the direction on a slope.

Otherwise, the machine may slide sideways.

x When the machine moves across a slope, it

may slide sideways. Move down the slope onto a flat ground, turn the machine, and travel safely.

x Do not travel on a 30º or more slope.

WC-C200670

OPERATION

45V4 • 55V4 • 60V4 ENG 2-35

WORK INSTRUCTIONS

Digging

The digging force of the arm cylinder is maximized when the angle between the arm cylinder and arm is 90

degrees.

The digging force of the bucket cylinder is maximized when the angle between the bucket cylinder and the arm

link is the same as the angle between the arm link and

bucket link. Improve the digging work efficiency, making use of these

angles properly.

In digging, pull the arm to dig with the bucket. Raise and lower the boom to adjust the depth.

Ditching

Place the machine along the ditch direction and travel it backward with the progress of ditching.

After digging, raise the boom, swing and load soil onto the dump truck.

Gutter Digging

It is possible to dig gutters in narrow spaces by swinging the boom.

WC-C200700

WC-C200710

When being the same angle

WC-C200720

WC-C200730

WC-C200740

OPERATION

45V4 • 55V4 • 60V4 ENG 2-36

WC-C200770

WC-C200780

WC-C200790

WC-C200800

WC-C200810

PRECAUTIONS FOR WORKS

Never stop swinging by hitting

Never stop swinging by hitting or pressing the bucket

against the wall of the ditch. Otherwise, strong impacts are applied to the machine and the service life is

shortened.

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.

Precautions for works at the cylinder stroke end

At the stroke end of the cylinder, the bucket moves faster. Thus, operate the bucket slowly with care not to allow soil

and sand to drop.

When the cylinder is moved to the stroke end, large forces are applied to the cylinder piston and the service

life is shortened. Give some margins to the cylinder in

works.

Hammering is prohibited

Never use the bucket instead of picks or for hammering or

piling. Otherwise, excessive forces are applied to the

machine, resulting in dangerous accidents.

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.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-37

Do not crawl with the bucket

Do not drag the bucket on the ground by crawling. Level

the ground with proper equipments in a correct way.

Bring both sides of the blade into contact with the

ground

Bring both sides of the blade into firm contact with the flat

ground when using the blade as a stabilizing plate in

digging work. If a single side of the blade contacts the ground, the blade

may be damaged.

Pay attention to the blade when digging deep ditches

The cylinder may hit against the blade. Thus, the boom cylinder may contact with the blade when digging a deep

ditch.

Be very careful in operation.

Works in damp grounds

Place mats or the like to protect the footing in advance

when carrying out works in damp grounds or muddy

places. Drive the machine with great care not to enter muddy

places.

WC-C200820

WC-C200830

WC-C200840

Contacts

WC-C200850

OPERATION

45V4 • 55V4 • 60V4 ENG 2-38

Escape from a muddy place

If a single side enters a muddy place, lower the bucket

onto that muddy ground to lift the crawler, place logs, wood. under the crawler and escape from that place.

If both sides enter a muddy place and the machine cannot

be driven, place logs or wood under crawlers one by one in the same way as shown above, bite the front ground

with the bucket, pull the arm in the same way as digging

to move the machine, and escape from that place.

Works in water

x The allowable water depth is up to the center of the

upper roller or the top of the slide pad.

Check the water depth and ground before working in water or traveling the machine across the river. Do not

go into water deeper than the allowable water depth.

The machine may sink little by little if the ground is soft. Pay great attention to the footing in work.

If the bucket is dipped in water for long, grease the

pins around the bucket sufficiently until used grease oozes out.

x The engine may get wet with water and the radiator fan

may be broken if the machine climbs a steep slope when going out of water. Be very careful.

Countermeasures if the machine is buried up to the

super structure

If the machine is buried with water, soil or sand up to the

super structure by mistake the swing bearing may wear abnormally. It is necessary to change grease in the

turning structure or overhaul and repair the turning

structure immediately. Stop operation and ask greasing, overhaul or repair works from the nearest service office.

WC-C200860

WC-C200870

WC-C200880

WC-C200890

WC-C200140

OPERATION

45V4 • 55V4 • 60V4 ENG 2-39

WC-C200900

PRECAUTION ON USE OF RUBBER TRACK

The rubber track may be damaged or worn faster depending on working conditions. Be sure to

observe the prohibitions and instructions shown below.

Structure of Rubber Track

As shown in the figure to the right, the rubber track

consists of steel cord to sustain tension, iron core to

support it, and covering rubber to them.

If a crack reaches the steel cord, it may be rusted and cut off by moisture. When any crack is detected, immediate repair is essential. Please contact your local IHI distributor.

Cautions while working and traveling

Do not travel or work on rocky site

This causes damage of the lug and breakage of the steel

cord.

Do not travel or work on riverbed

This causes damage and slipping off of the track.

Lug

Iron core

Steel cord

Covering rubbe

WC-C200910

WC-C200920

OPERATION

45V4 • 55V4 • 60V4 ENG 2-40

Do not travel or work on steel or scrap material

This causes damage of the lug and breakage of the steel

cord.

Do not travel on large step

While traveling up the large step, do not change the

course.

Otherwise, the tracks may be slipped off.

Do not travel or work while spanning a ditch

This causes damage of the lug and breakage of the steel

cord.

Do not forcibly press soil while rubber tracks are

slipping

Slipping of the rubber tracks promotes wear of the lugs.

Do not travel over high heat locations

Do not travel over place subjected to high heat such as

bonfires or steel plate under scorching heat.

This causes serious abrasion or damage and breakage of the lug.

WC-C200930

WC-C200940

WC-C200950

WC-C201010

WC-C201020

OPERATION

45V4 • 55V4 • 60V4 ENG 2-41

WC-C201050

WC-C201060

Do not hit the bucket

Be careful not to damage the rubber tracks with the

bucket. Otherwise, the iron cores may be broken or the steel

cords may be cut off.

Do not let oil, solvents and salt adhere to the rubber

tracks

x If fuel, hydraulic oil and paint should adhere to the

rubber tracks, wipe it away quickly.

x Wash away with water after working in locations with a

large salt content. Salt can cause the iron core to rust or peel.

Always keep proper tension on the track

If the rubber track is slack, it may damage the rubber

track or cause them to come off the rollers. This causes damage and slipping off of the track.

Oil

Solvent

Salt

WC-C201030

OPERATION

45V4 • 55V4 • 60V4 ENG 2-42

AUX WHEN USING SPECIAL ATTACHMENT

It is possible to provide the machine with three spare pipe systems as the AUX hydraulic power

for the special attachment.

x Select the proper special attachments such as hydraulic breakers, iron forks, special

hydraulic devices and so forth that fit the capability of this machine.

x Some special attachments require reinforcement of the arm. Inquire our dealer about

reinforcement.

x Be sure to read the manuals issued by the manufacturers and have good

understanding before using special attachments.

x When a special attachment is attached to the machine, the stability, transport

dimensions, etc. of the machine may change. Be careful.

No. 1 AUXpipe

No. 2 AU

pipe

No. 3 AU

pipe

OPERATION

45V4 • 55V4 • 60V4 ENG 2-43

No. 1 AUX

Names of Switches and Applicable Works

Operating lever

Specifications

No. Name

Work

Breaker Iron fork

S Grip 1 No. 1 AUX. pedal

{ {

E Grip

(Option)

No. 1 AUX.

proportional lever

{ {

3 No. 1 AUX. button

{ {

No. 1 AUX. flow

limit switch

{

No. 1 AUX. hold

switch

- {

Be sure to set the hold switch and slow mode switch to

the OFF positions when they are not used.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-44

When Using Breaker

• S Grip specification (standard)

1. Connect the supply side hose to the pipe on the left side of the arm and the return side hose to the pipe on

the right side.

2. Set the selection valve so that the mark (6) is vertical.

3. Put the pedal lock lever to the free position.

4. Press on the front side of the No. 1 AUX. pedal (1)

thereby activating the breaker.

5. The breaker stops when the foot is removed.

6. If the pedal lock lever is put in the locked position while

pressing the spare pedal towards the front, the hydraulic pressure is supplied continuously.

• E Grip specification (option)

1. Connect the supply side hose to the pipe on the left side of the arm and the return side hose to the pipe on

the right side.

2. Set the selection valve so that the mark (6) is vertical.

3. Press the No. 1 AUX. button (3) and operate the

breaker.

It is also possible to operate the breaker by sliding the No. 1 AUX. proportional lever (2) to the left.

4. The breaker stops when the hand is released.

5. The No. 1 AUX. flow limit switch (4) is used when supplying the hydraulic pressure continuously.

ON (Lamp lit up): Continuous operation becomes

possible, if the No. 1 AUX onetouch button is pressed once, it is

possible to continue to supply

compressed oil to the left side spare piping.

OFF (lamp is off): Released.

Be sure to set the mark on the selector valve as described above.

If it is set improperly, the machine and/or breaker may be damaged.

Pedal lock lever

Lock

Unlock

Breaker

model

OPERATION

45V4 • 55V4 • 60V4 ENG 2-45

When Using Iron Fork

• S Grip specification

1. Connect the hoses to the left and right piping of the arm.

2. Set the mark (6) of the selection valve to the horizontal

position.

3. Step on the front and back of the spare pedal (1) and

operate the dismantling fork.

When stepped on the front side:

Compressed oil is fed to the arm left side piping.

When stepped on the rear side:

Compressed oil is fed to the arm right side piping.

• E Grip (Option)

1. Connect the hoses to the left and right pipes of the arm.

2. Set the mark (6) of the selection valve to the horizontal

position.

3. Operate the dismantling fork by sliding to the left or right the No. 1 AUX. proportional lever (2).

Sliding to the left:

Compressed oil is supplied to the arm left side

pipe.

Sliding to the right:

Compressed oil is supplied to the arm right side

pipe.

The flow rate changes according to the amount

of sliding.

It is also possible to operate the dismantling fork by

pressing the No. 1 AUX. button (3).

4. When making fine operations

After pressing the “ON” side of the No. 1 AUX. hold

switch (5), operate the No. 1 AUX proportional lever. The lever returns to the original position when the

“OFF” side is pressed.

Be sure to set the mark on the selector valve as described above.

If it is set improperly, pressurized oil is not supplied to the pipe on the right of the arm.

Iron fork

model

Pedal lock leve

Lock

Unlock

OPERATION

45V4 • 55V4 • 60V4 ENG 2-46

No. 2 AUX

Use the No. 2 AUX select switch (1) to change oil flowing toward the boom swing cylinder to the

No. 2 AUX pipe, which is a spare pipe of the double-action circuit operated with the boom swing

pedal (2).

1. Connect the special attachment hose to the No. 2 AUX pipes on the right and left of the arm.

2. Push the ON position of the No. 2 AUX select switch (1) to

change the circuit into the No. 2 AUX pipe.

2nd PTO select switch

x Pushing the ON position: The circuit is changed into the

No. 2 AUX pipe.

x Pushing the OFF position: The circuit is changed into the

boom swing cylinder. This is

the normal position.

3. Open the pedal cover and operate the boom swing pedal (2).

Pedal operations

x Stepping on the left side: Pressure oil is supplied to the

AUX pipe on the left of the arm.

x Stepping on the right side: Pressure oil is supplied to the

AUX pipe on the right of the arm.

No. 2 AUX select switch

Pedal cove

Boom swing pedal

OPERATION

45V4 • 55V4 • 60V4 ENG 2-47

No. 3 AUX

Use the No. 3 AUX hydraulic power for the detachable quick hitching

device such as a bucket.

1. Connect the bucket releasing hose of the quick hitching device to

the No. 3 AUX pipe on the right of the arm.

Connect the bucket grasping hose of the quick hitching device to

the No. 3 AUX pipe on the left of the arm.

2. Turn on the No. 3 AUX power switch (1).

No. 3 AUX power switch

ON: Once the switch is pushed, it is depressed, the switch lamp

goes on, and the buzzer sounds. Operation is possible in

this case.

OFF: When the switch is pushed again, it is pushed back, the

switch lamp goes out, and the buzzer stops. Operation is

not possible in this case.

3. Operate the quick hitching device with the No. 3 AUX operation

switch (2).

No. 3 AUX operation switch

Pushing the FREE position: Pressure oil is supplied to the

pipe on the right of the arm and

the quick hitching device

releases the bucket.

Pushing the LOCK position: Pressure oil is supplied to the

pipe on the left of the arm and

the quick hitching device grasps the bucket.

4. Be sure to set the No. 3 AUX operation switch to the LOCK

position after operating the quick hitching device, now matter how the bucket is released or grasped.

5. Turn off the No. 3 AUX power switch (1). The switch lamp goes

out and the buzzer stops.

x Do not touch the No. 3 AUX power switch or No. 3 AUX operation switch if the quick

hitching device is not used. If you touch the switch by mistake, the quick hitching device may move during work and release the bucket.

x Keep the No. 3 AUX operation switch at the LOCK position all the time when the quick

hitching device is not used.

x If No. 3 AUX power switch is turned on by mistake and the buzzer sounds, turn it off

immediately.

x Read thoroughly the instruction manual of quick hitch.

No. 3 AUX power switch

No. 3 AU

operation

switch

OPERATION

45V4 • 55V4 • 60V4 ENG 2-48

TOWING

x It is very dangerous if the wire rope is disentangled during towing. Do not stand

between the towing machine and the towed machine.

x Use wire ropes and shackles for towing that are strong enough for the towing weight. x The machine is provided with a pulling hook at the back of the lower frame to pull light

objects. Never pull the machine itself or other heavy objects using this pulling hook.

Towing the machine or heavy objects

Apply a wire rope to the rear frame and pull the machine by another machine if it enters a muddy place and cannot escape from it by itself. Never use the pulling hook for light objects to pull the machine itself.

1. Start the engine.

2. Select the low speed mode with the travel speed select switch.

3. Move the travel lever in the travel direction slowly when towing starts.

Put a patch at the corner in contact with the wire rope to prevent the wire rope from being damaged.

When the engine is defective and does not start, the crawler tracks do not rotate and pulling is disabled.

Pulling light objects

Apply a wire rope to the pulling hook at the back of the lower frame using a shackle.

x The maximum pulling load should be 500 kg or

less.

x Do not pull diagonally.

Light-duty towing hook

WC-C100290

OPERATION

45V4 • 55V4 • 60V4 ENG 2-49

TRANSPORT

Observe the loading and unloading methods and the anchoring method for transportation as well

as the laws and regulations concerned when transporting the machine.

Loading and Unloading the Machine

x Carry out operation on a flat and firm ground.

x Set the travel speed select switch to the low speed mode and load or unloading the

machine at low engine speed.

x Be sure to use ramp boards or loading platform for loading and unloading. Never use

the attachment to load or unload the machine. It is very dangerous.

x Use wide, long and thick enough ramp board that ensures safe loading and unloading.

x Remove mud from the crawlers and grease, oil, water and other adhered matters from

the ramp boards to prevent slipping.

x Never change the direction on the ramp boards. It is very dangerous. Move down from

the ramp boards once and change the direction.

x The center of gravity moves quickly at the border of the truck and the ramp boards.

Travel the machine slowly.

x Warm up the machine sufficiently before loading or unloading it in cold seasons.

1. Apply the brake of the truck securely. Apply blocks to

the tires to fix the tires.

2. Adjust the center line of the machine to the center line of the truck. Adjust the ramps boards to the crawler

width.

3. The angle of the ramp boards should be 15° or less.

4. Load the machine from the front if it has an

attachment. Load it from the rear if no attachment is

mounted.

5. Adjust the machine to the ramp board direction, raise

the blade and travel the machine slowly with care not

to hit the attachment against the truck.

6. Load the machine properly in the designated position

on the truck.

WC-C201130

Ramp board

15º or less

Block

djust to the

machine width.

OPERATION

45V4 • 55V4 • 60V4 ENG 2-50

Fixation at Transport

If the machine falls down during transportation, it can cause personal injury or death.

Fix the machine firmly on the platform of the truck with wheel blocks and wire ropes.

1. Lower the blade onto the platform of the truck.

2. Fold the arm and bucket fully. Lower the attachment

onto a wooden block, etc.

3. Stop the engine and pull out the key from the engine

key switch.

4. Apply stopper blocks to the front and rear positions of the crawlers.

5. Apply wires to the crawler frame and bucket and fasten

them to the platform of the truck.

If wire ropes are applied to the rubber tracks directly when fixing the machine, the rubber tracks may be damaged. Put patches on the front and rear positions of the crawler frame and fix with the wire ropes.

Wire rope

Patch

OPERATION

45V4 • 55V4 • 60V4 ENG 2-51

LIFTING THE MACHINE

x Always lift the machine on a flat and firm ground.

x Never lift the machine loaded with any personnel.

x Make sure the lifting cables and other lifting devices are strong enough to support the

machine.

x Do not perform crane operation including slinging work unless you are not qualified.

1. Set the blade at the rear position.

2. Raise the blade to the highest position.

3. Raise the boom to the highest position and fold the arm and bucket fully.

4. Make the boom straight if it has swung to the right or

left.

5. Fasten wire ropes to the lifting holes at the back of the

boom using the shackle.

6. Stop the engine and get off the machine.

7. Fasten the wire ropes to the lifting holes at both ends

of the blade using shackles.

8. Apply the wire ropes from the boom and blade to the hook of the crane. Apply patches to the positions

where the wires contact with the machine when

tensioning the wires.

9. Lift the machine slowly until it is lifted slightly apart

from the ground, stop lifting once, check the machine

balance, and lift the machine to the intended height.

Wire length: 1.5 m

Wire length: 4.0 m (two wires)

Boom lifting hole

Blade lifting hole

OPERATION

45V4 • 55V4 • 60V4 ENG 2-52

This page is intentionally left blank

45V4 • 55V4 • 60V4 ENG

MAINTENANCE

Proper maintenance is needed to maintain the machine

performances for long and prevent damages and troubles in

advance.

This section describes the proper maintenance procedures of

this machine. Carry out maintenance safely and properly in

accordance with the instructions described below.

45V4 • 55V4 • 60V4 ENG

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-1

33 MAINTENANCE

PERIODIC REPLACEMENT OF THE IMPORTANT PARTS

Replace the following parts, which are related to the safety and a fire, periodically.

These parts are subject to aged deterioration and wear, and it is hard to judge the service life by

means of appearance inspection. Replace them periodically even though they have no apparent

defects, in particular.

Type Parts to be replaced periodically Qty

Replacement

interval

Fuel hose

Fuel tank - Water separator 1

Every 2 years

Water separator - Fuel pump 1

Fuel pump - Fuel filter 1

Fuel filter - Engine 1

Engine - Fuel cooler 2

Fuel cooler - Fuel tank 1

Coolant hose

Radiator hose (upper) 1

Every 2 years Radiator hose (lower) 1

Radiator - Sub tank 1

Hydraulic hose

Hydraulic pump - Control valve 6

Every 2 years

C/V - Boom cylinder 4

C/V - Arm cylinder 4

C/V - Bucket cylinder 4

C/V - Boom swing cylinder 2

C/V - Blade cylinder 6

C/V - Swing motor 3

C/V - Travel motor 8

Repair or replace these parts immediately if some abnormalities or defects are found in them

even before the replacement interval.

Also check the fuel hoses, cooling water hoses and hydraulic hoses in daily check, monthly

check and yearly check.

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-2

MAINTENANCE INTERVALS

Periodic maintenance is most important to operate the machine safely and demonstrate its

performances fully.

Take special care when using the machine under severe condition.

ǻ: Check. {: Replace.

Maintenance

point

Maintenance

work

Maintenance interval

Daily 50h 100h 250h 500h 1000h 1500h 2000h

Irregular

Greasing

Attachment

Grease

Boom swing ǻ

Blade ǻ

Swing bearing ǻ

Ring gear ǻ

Bucket

Bucket tooth Check wear ǻ

{

Bucket

Check damage

{

Clearance Adjust ǻ

Crawler

Rubber track

Check wear & deterioration

{

Track tension

Check and adjust

Reduction gear

Travel reduction gear

Check oil leak ǻ

Check oil qty & refill

Change oil

{ First time

{

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-3

Maintenance

point

Maintenance

work

Maintenance interval

Daily 50h 100h 250h 500h 1000h 1500h 2000h

Irregular

Hydraulic system

Hydraulic oil tank

Check oil qty & refill

Drain water ǻ

Change hydraulic oil

Clean the tank

{

Suction strainer

Clean ǻ

Return filter Replace cartridge

{ First time

{

Air breather

Element replacement

{

Hydraulic devices

Check oil leak ǻ

Hydraulic equipment

Check oil leak ǻ

Lubrication system

Engine oil

Check oil qty & refill

Change

{ First time

{

Oil filter Replace

{ First time

{

Fuel system

Fuel tank

Check oil qty & refill

Water separator

Check & drain water

Clean Replace element

{

Fuel filter Replace

{

(Breaker specification 600h)

(Breaker specification 100h)

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-4

Maintenance

point

Maintenance

work

Maintenance interval

Daily 50h 100h 250h 500h 1000h 1500h 2000h

Irregular

Cooling system

Sub tank

Check coolant qty & refill

Radiator

Clean ǻ

Change coolant

{ or

1 year

Radiator fins Oil cooler fins

Check & clean ǻ

Fan belt

Check tension & adjust

ǻ First time

Check cracks

ǻ First time

{

Intake system

Air cleaner

Check dust indicator

Check element & clean

ǻ First time

Replace element

{

Hoses

Fuel hose

Radiator hose

Hydraulic hose

Leak inspection, replacement

{

or 2

years

Engine

Intake valve & exhaust valve head

Adjust clearance

z At every 800 hours

Fuel injection system

Check, clean & check functioning

z At every 3000 hours

z: Contact our dealer.

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-5

Maintenance

point

Maintenance

work

Maintenance interval

Daily 50h 100h 250h 500h 1000h 1500h 2000h

Irregular

Electric system

Fuse Replace

{

Fusible link Replace

{

Battery

Check battery liquid qty & refill

Clean terminals

Bolt tightening Retightening ǻ First

time

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-6

RECOMMENDED LUBRICATION TABLE

Lubrication

points

Oil type Grade

Temp. & application (ºC)

Qty required

-30 -20 -10 0 10 20 30 40

Engine oil pan

Engine oil API-CF

H: 9.7 L L: 6.7 L

Hydraulic oil tank

Hydraulic oil

Abrasionresistant

System: 75 L Tank level: 56 L

Travel reduction gear

Gear oil API-GL-4

0.9 L

Fuel tank Diesel fuel –

66 L

Cooling system

Coolant – Long-life coolant (LLC) added Total qty: 10.1 L

Greasing Grease – Lithium grease EP2 Proper qty

x The oil with the * marks is used for the machine before shipment.

* SAE10W-30

* SAE15W-40

* SAE90

* ISO-VG46

ISO-VG32

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-7

LUBRICATE THE GREASE

Attachment

1. Lower the attachment in the greasing posture onto the ground and stop the engine.

2. Fill grease using a grease gun through all grease nipples.

3. Wipe off old grease that oozes out of the grease nipples completely after greasing.

No. Name Qty

1 Boom foot pin 1 2 Boom cylinder foot pin 1 3 Boom cylinder rod pin 1 4 Arm foot pin 1 5 Arm cylinder foot pin 1 6 Arm cylinder rod pin 1 7 Bucket pin 1 8 Bucket cylinder foot pin 1

9 Bucket cylinder rod pin 1 10 Arm link and bucket link pin 1 11 Arm link pin 1 12 Bucket link pin 1

Boom and swing

bracket

Boom and

arm

Bucket and

arm

Arm link and

bucket link

Arm and arm

link

Bucket and

bucket link

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-8

Boom Swing

No. Name Qty

Boom swing vertical shaft (upper)

Boom swing vertical shaft (lower)

3 Swing cylinder foot pin 1

4 Swing cylinder rod pin 1

Blade

No. Name Qty

1 Blade foot pin 2

2 Blade cylinder rod pin 1

3 Blade cylinder foot pin 1

x Carry out greasing, regardless of the greasing interval, if abnormal noises are

generated from a greasing point.

x Be sure to grease the pins around the bucket before starting in-water digging.

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-9

Swing Bearing

1. Lower the bucket onto the ground and stop the engine.

2. Fill three to five strokes of grease using a grease gun

into the grease nipple (1).

3. Fill grease every time the upper structure is swung by approximately 90 degrees until it swings by 360

degrees.

Ring Gear

1. Lower the bucket onto the ground and stop the engine.

2. Remove the greasing cover (2) from the upper structure. Make sure that grease is sufficiently provided for the swing gear. If grease on the gear surface is insufficient, add grease (approximately 0.5 kg).

3. Change old grease with fresh grease completely if water or mud is mixed in grease and grease looks cloudy. Remove the cover (3) of the carbody and the discharge port cover (4) and discharge old grease when changing it.

4. Attach the discharge port cover and fill fresh grease through the greasing cover. (Total grease qty: 11 kg)

5. Swing two or three times, make sure that grease is spread over the ring gear, and attach the cover of the carbody and greasing cover.

No. Name Qty

1 Swing bearing 1 2 Ring gear 1

If you carry out greasing while the machine is swinging, you may be caught by it. Do not swing the machine when greasing.

If greasing is carried out in the same position, grease is not spread all over the swing bearing. Be sure to swing the machine by approximately 90 degrees and grease the bearing at different points.

Front

Upper structure

Carbody

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-10

MAINTENANCE OF BUCKET

Replace the Tooth

x It is dangerous if the bucket moves when

replacing the bucket tooth. Fix the bucket firmly, stop the engine, and set the gate lock lever to the lock position.

x Fragment may scatter, resulting in injury. Put

on protective goggles, protective cap and protective gloves.

x Replace the tooth when the wear hole appears. x Replace the tooth before it wears up to the

adapter.

1. Remove the lock pin.

Remove the tooth.

2. Clean the adapter.

It is recommended that the rubber lock pin should

be replaced every time the tooth is replaced.

4. Attach the rubber lock pin to the nose.

5. Insert the tooth into the nose.

6. Drive the lock pin until it becomes flush with the tooth

surface with a hammer. If the lock pin is not driven sufficiently, the tooth may

be dislocated.

7. Make sure that the tooth is fixed firmly.

WC-C300090

WC-C300100

WC-C300110

WC-C300120

Wear hole

Tooth

Rubber lock pin

dapte

Tooth

Lock pin

Nose

Lock pin

Wrong

Lock pin is too short.

Wrong

Rubber lock pin

Balls sink.

WC-C300130

Lock pin is not driven enough.

Wrong

Lock pin

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-11

Change the Bucket

x When the pin is driven with a hammer,

fragments may scatter, resulting in injury. Put on protective goggles, protective cap and protective gloves in work.

x Never insert your finger into the pin holes when

adjusting the pin holes.

Remove the bucket

1. Place the back of the bucket completely on the

ground.

2. Remove the lock bolt from the portion (A).

Remove the arm point pin.

3. Remove the lock bolt from the portion (B).

Remove the bucket link pin.

4. Raise the arm slowly.

Then remove the arm and the bucket.

Install the bucket

1. Clean the pin holes in the arm and bucket link and

the removed pins. Apply grease to the holes and

pins.

2. Replace the O-rings if they are damaged or worn.

Attach new O-rings to the bosses of the bucket

temporarily.

3. Lower the arm slowly, fit the pin holes in the arm and

bucket, and drive the arm point pin. Adjust the

positions of the lock bolt and lock hole at this time.

4. Raise the boom to move the bucket apart from the

ground and make it free.

5. Extend or contract the bucket cylinder to adjust the

pin hole in the bucket link and bucket. Drive the bucket link pin into the holes.

6. Attach the lock bolt.

Leave the clearance shown on the right when tightening the nut.

7. Move the O-rings to the proper grooves.

8. Grease the arm point pin and bucket link pin.

WC-C300140

Bucket link

Lock bolt

rm point

Clearance Clearance

O-rings

Bucket link

Lock bolt

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-12

Adjust the Bucket Clearance

The standard bucket has a bucket clearance adjusting mechanism to prevent backlash.

1. Bring the back of the bucket into slight contact with

the ground, and swing the machine a little to the right to make the condition where the top of the arm is

pressed against the inside of the clearance adjusting

mechanism.

2. Stop the engine.

3. Move the O-ring to above the boss and measure the

clearance of the bucket and arm.

4. Remove the shim to adjust the clearance if the

clearance is 1 mm or more.

The thickness of the shim is 0.8 mm. Do not remove the shim if the clearance is 0.8 mm or less.

5. Remove the four bolts. Remove as much shims as

the amount of backlash (wear amount) from inside

the flange.

6. Attach the flange. Tighten the four bolts.

7. Measure the clearance.

The standard clearance is 0.1 to 1.3 mm.

WC-C300160

WC-C300170

Clearance adjusting mechanism

rm Shim

Bolt

Bucket

O-ring

Flange

Standard clearance: 0.1 to 1.3 mm

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-13

CRAWLER TRACK

Rubber Track Maintenance

Rubber track should be repaired or exchanged if goes into any of the conditions described below.

If it is necessary to repair or replace it, contact your IHI

dealer.

Height of Lug

The rubber track can be used even if it is worn, however,

if it is excessively worn, the rubber track is likely to be

slippery and more travel force is required. If the remaining lug is less than 5 mm high, exchange it with

brand-new one.

Exposure of Steel Cord

If steel cord is exposed because of weary rubber or damage, exchange it with brand-new one.

Cutting of Steel Cord

Replace immediately if more than half of the steel cord

layer on one side has been cut. If this is left as it is, the rubber tracks breaks suddenly

during operation, thereby leading to a serious accident.

Crack of Covering Rubber

If a crack is 30 mm or more long and 8 mm or more deep, repair the covering rubber immediately. If steel cord

appears even if a crack is small, repair it immediately.

Otherwise, water may come into a crack, which rusts steel cords and cuts off the rubber track.

Dislocation of the iron core

Exchange the rubber track with a new one if one or more

iron cores are dislocated from it.

WC-C300630

Height of lug

Crack of covering rubbe

Iron core

Exposure of steel cord

Steel cord cut by 1/2 or more need to be replaced.

Damages of rubber track

MAINTENANCE

45V4 • 55V4 • 60V4 ENG 3-14

Inspection of Crawler Track

The machine needs to be raised to inspect the track tension. If the machine drops by mistake during inspection, a serious injury may result. Be very careful when the machine is raised.

The conditions of wear and sag of the crawler tracks differ with the conditions of the work sites. If the slack crawler

tracks are used, they may be slipped off. Inspect and

adjust their tension as the necessity requires.

Inspection

1. Raise the machine using the attachment and blade

until the crawler tracks become apart from the ground.

Support the crawler frame securely with blocks, etc.

2. Measure the clearance between the tread of the

lower roller near the center and the tread of the crawler track.

The tension is proper if the clearance is as shown

below.

10 to 20 mm (Rubber track)

30 to 50 mm (Steel track)

Raise the machine until the tracks are apart from the ground.

Lower rolle

Trac

mount of sag

Menzi Muck Menzi IHI 45v4, Menzi IHI 55v4, Menzi IHI 60v4 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual