Menzi Muck Menzi IHI 45v4 Operator's Manual
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Menzi Muck Menzi IHI 45v4 Operator's Manual

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Menzi IHI 45v4
Menzi IHI 55v4
Menzi IHI 60v4
Operator's manual
Menzi Muck AG
9451 Kriessern/Switzerland
Telefon +41 (0)71 727 12 12
Fax +41 (0)71 727 12 13
www.menzimuck.com
info@menzimuck.com

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  • Page 1 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...
  • Page 2 45V4 55V4 60V4 WG010001~ WY010001~ WZ010001~ 0988405EN-02...

  • Page 3: Table Of Contents

    CONTENTS FOREWARD ..........0-1 EMERGENCY ACTIONS IF ENGINE INTRODUCTION ........0-1 STOPS ..........2-23 MACHINE NUMBER ....... 0-2 RUNNING IN NEW MACHINE....2-24 MACHINE DIRECTION ......0-3 LEVER OPERATIONS ......2-25 Operation Mode ......... 2-25 SAFETY ............ 1-1 SAFETY INFORMATION ......1-1 Operation Mode Plate ......
  • Page 4 No. 3 AUX .......... 2-47 Replace the Engine Oil and Engine TOWING ..........2-48 Oil Filter ..........3-22 TRANSPORT ........2-49 FUEL SYSTEM ........3-23 Loading and Unloading the Machine . 2-49 Check Fuel Quantity and Refilling ..3-23 Fixation at Transport ......2-50 Check and Clean Water Separator LIFTING THE MACHINE ......
  • Page 5 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...
  • Page 6 45V4 • 55V4 • 60V4 ENG...

  • Page 7: Foreward

    FOREWORD 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.

  • Page 8: Machine Number

    FOREWORD MACHINE NUMBER The machine No. and engine No. are marked at the positions shown below. 45V4 • 55V4 • 60V4 ENG...

  • Page 9: Machine Direction

    FOREWORD 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. Front Blade Right Left Rear 45V4 •...
  • Page 10 FOREWORD This page is intentionally left blank 45V4 • 55V4 • 60V4 ENG...

  • Page 11: Safety

    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.
  • Page 12 45V4 • 55V4 • 60V4 ENG...

  • Page 13: Safety Information

    SAFETY 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.

  • Page 14: Safety Precautions

    SAFETY SAFETY PRECAUTIONS PRECAUTIONS BEFORE OPERATION Read and understand the safety signs and labels There are several specific safety signs on your machine. Please read and understand the safety signs and labels. You must replace a label if it is damaged, missing or cannot be read.
  • Page 15 SAFETY 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 Do not leave oiled waste cloth, dead leaves, paper trash or other flammable objects around the engine. Such matters may cause a fire.

  • Page 16: Precautions During Operation

    SAFETY 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.

  • Page 17: Bucket

    SAFETY 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...
  • Page 18 SAFETY 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.
  • Page 19 SAFETY 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...

  • Page 20: Precautions For Traveling

    SAFETY 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.

  • Page 21: Precautions For Transporting

    SAFETY PRECAUTIONS FOR TRANSPORTING Load and unload the machine Always load and unload the machine on the level ground. Use a ramp board that has sufficient strength, width, length, and thickness. Remove ice, snow, or slippery material from the ramp board and truck deck before loading.

  • Page 22: Precautions For Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE Keep routine maintenance You must read and understand the warnings and Operation Manual 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.
  • Page 23 SAFETY When working under tracks If the machine is merely jacked up with the attachment, you may be caught by the machine when it lowers. Danger Place the supporting blocks under the crawler and make Do Not Operate 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...
  • Page 24 SAFETY 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.
  • Page 25 SAFETY This page is intentionally left blank 45V4 • 55V4 • 60V4 ENG 1-13...

  • Page 26: Safety Signs And Labels

    SAFETY 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.
  • Page 27 SAFETY 14 (Put in storage box when not used.) (Side view of hydraulic oil tank) View C (Detail of operator's seat) (Detail of counterweight section) (Operator's cab inside left) (Operator's cab inside right) Cabin specification 45V4 • 55V4 • 60V4 ENG 1-15...
  • Page 28 SAFETY 1. Safety operation (440645800) 2. Read manual! 3. Crush hazard (D405 359 00) (D405 508 00) Read manual Sign indicates a before operation, hazard of being maintenance, crushed or run over disassembly, by unexpected assembly and moving of stopped transportation.
  • Page 29 SAFETY 6. Hazard of rotating parts 7. Hazard of rotating parts (D405 509 00) (D405 366 00) Sign indicates a hazard of rotating parts, Sign indicates a hazard of rotating parts, such as fan. such as belt. Turn off before inspection and maintenance. Turn off before inspection and maintenance.
  • Page 30 SAFETY 12. Warning for track adjuster 13. Hazard from falling window (D405 505 00) (D405 510 00) Sign indicates a hazard of flying plug from Sign indicates a hazard from falling track adjuster that could cause injury. window. Read manual before adjusting track for safe After raising window, be sure to lock it in and proper handling.

  • Page 31: Operation

    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...
  • Page 32 45V4 • 55V4 • 60V4 ENG...

  • Page 33: Names Of Components

    OPERATION OPERATION NAMES OF COMPONENTS Right Rear Left Front Name Name Name Bucket Battery Travel unit Bucket link Return filter Upper roller Arm link Radiator and oil cooler Lower roller Bucket cylinder Canopy Track adjusting device Air cleaner Swing bearing Arm cylinder Engine Front idler...

  • Page 34: Controls And Instruments

    OPERATION CONTROLS AND INSTRUMENTS Name Name Right control box Boom swing pedal Left control box Operator's seat Travel lever No. 1 AUX. pedal (Option) 45V4 • 55V4 • 60V4 ENG...

  • Page 35: Right Control Box

    OPERATION Right Control Box Right operation lever (Option) Front of machine Name Name OK monitor Mode select switch Right operation lever Horn switch Blade lever Auto idle selector Travel speed select switch No. 1 AUX. proportional lever (E Grip) Throttle dial No.
  • Page 36 OPERATION 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. Name No use Travel speed indicator...
  • Page 37 OPERATION 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 WC-C200050 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.
  • Page 38 OPERATION 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 WC-C200100 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.
  • Page 39 OPERATION 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. Boom raise: Pull the lever backward. Front of Boom lower: Push the lever forward. machine Bucket dig: Turn the lever to the left.
  • Page 40 OPERATION 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.
  • Page 41 OPERATION 10. Horn switch Press this switch to turn on the horn. S grip specification E grip specification (Option) 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.

  • Page 42: Left Control Box

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

  • Page 43: Travel Levers

    OPERATION Travel Levers Forward Use these levers to control traveling. Forward: Push the right and left travel levers forward. Backward 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.

  • Page 44: Operator's Seat

    OPERATION 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.

  • Page 45: Operator's Cabin

    OPERATION Operator’s Cabin Door lock The door may be locked at the fully opened or closed position. Push the door until it is locked completely. 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 Move down the front window slowly, when closing it, with care not to pinch your hand, etc.
  • Page 46 OPERATION Opening and Closing the Bottom Window of the Cabin Move down the bottom window slowly, when closing it, with care not to pinch your hand, etc. 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.
  • Page 47 OPERATION Wiper switch Press the mark side to activate the wiper. Window washer tank Do not start the wiper in the condition where the window is dry, muddy or snowy. Never turn on the wiper switch when the cabin front window (upper) is stored on the ceiling. Wiper switch Window washer switch Window washer switch...

  • Page 48: Air Conditioner (Option)

    OPERATION 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.

  • Page 49: Heater (Option)

    OPERATION 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.

  • Page 50: Starting Engine

    OPERATION STARTING ENGINE Unlock Lock 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 Front of machine locked position.

  • Page 51: Normal Starting

    OPERATION Normal Starting 1. Set the throttle dial to the middle speed. 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.

  • Page 52: Starting Engine With Booster Cables

    OPERATION Starting Engine with Booster Cables Follow the instructions shown below to start the engine using the booster cables. If the booster cables are connected improperly, the battery will be shorted, resulting in a dangerous accident. Never connect the + and - terminals. The battery produces flammable hydrogen gas, which is explosive.

  • Page 53: Check After Starting Engine

    OPERATION 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. Do not accelerate the engine or apply loads to it quickly when the cooling water temperature is low.

  • Page 54: Stopping Engine

    OPERATION 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.

  • Page 55: Emergency Actions If Engine Stops

    OPERATION 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.

  • Page 56: Running In New Machine

    OPERATION 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. Warming up 1.

  • Page 57: Lever Operations

    OPERATION 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.

  • Page 58: Operation Mode Plate

    OPERATION 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 45V4 •...

  • Page 59: Af Multi-Selection Method (For Machine With Af Multi-Selector Valve)

    OPERATION 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. Wing bolt Position A Position F Selector valve...

  • Page 60: Abg Multi-Selection Method (For Machine With Abg Selector Valve)

    OPERATION 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. Lever fixing bolt Selector valve 1.

  • Page 61: Abcd Multi-Selection Method (For Machine With Abcd Selector Valve)

    OPERATION 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. Lever fixing bolt ABCD multi-selection 1.

  • Page 62: Blade Operation

    OPERATION BLADE OPERATION Move the blade lever forward or backward. Raising blade Lowering blade Raising Lowering Blade 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. Pedal cover Left boom Right boom...

  • Page 63: Swing Operation

    OPERATION SWING OPERATION Right swing Use the left operation lever to swing. Turn the lever to the right to swing to the right. Left swing Turn the lever to the left to swing to the left. Return the lever to the neutral position to stop swinging. Left operation lever Right swing Left swing...

  • Page 64: Traveling

    OPERATION TRAVELING Travel levers Starting, Traveling and Stopping Throttle dial Control lock lever 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.

  • Page 65: Changing Direction

    OPERATION 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. Forward Pivot turning (when blade is in front of machine) turning to left...

  • Page 66: High Speed Traveling

    OPERATION 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.

  • Page 67: Work Instructions

    OPERATION WORK INSTRUCTIONS Digging The digging force of the arm cylinder is maximized when the angle between the arm cylinder and arm is 90 When being the same angle degrees. The digging force of the bucket cylinder is maximized when the angle between the bucket cylinder and the arm WC-C200700 link is the same as the angle between the arm link and bucket link.

  • Page 68: Precautions For Works

    OPERATION 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. WC-C200770 Never sweep with the bucket Avoid sweeping the bucket like a broom in order to level off ahead of machine.
  • Page 69 OPERATION 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. WC-C200820 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.
  • Page 70 OPERATION 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. WC-C200860 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...

  • Page 71: Precaution On Use Of Rubber Track

    OPERATION 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.
  • Page 72 OPERATION Do not travel or work on steel or scrap material This causes damage of the lug and breakage of the steel cord. WC-C200930 Do not travel on large step While traveling up the large step, do not change the course.
  • Page 73 OPERATION 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. WC-C201030 Do not let oil, solvents and salt adhere to the rubber tracks Solvent If fuel, hydraulic oil and paint should adhere to the...

  • Page 74: Aux When Using Special Attachment

    OPERATION 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. Select the proper special attachments such as hydraulic breakers, iron forks, special hydraulic devices and so forth that fit the capability of this machine. Some special attachments require reinforcement of the arm.

  • Page 75: No. 1 Aux

    OPERATION No. 1 AUX Names of Switches and Applicable Works Work Operating lever Name Specifications Breaker Iron fork S Grip No. 1 AUX. pedal No. 1 AUX. proportional lever 3 No. 1 AUX. button E Grip No. 1 AUX. flow (Option) limit switch No.

  • Page 76: When Using Breaker

    OPERATION 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.

  • Page 77: When Using Iron Fork

    OPERATION 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.

  • Page 78: No. 2 Aux

    OPERATION 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).

  • Page 79: No. 3 Aux

    OPERATION 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.

  • Page 80: Towing

    OPERATION TOWING It is very dangerous if the wire rope is disentangled during towing. Do not stand between the towing machine and the towed machine. Use wire ropes and shackles for towing that are strong enough for the towing weight. The machine is provided with a pulling hook at the back of the lower frame to pull light objects.

  • Page 81: Transport

    OPERATION 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 Carry out operation on a flat and firm ground. Set the travel speed select switch to the low speed mode and load or unloading the machine at low engine speed.

  • Page 82: Fixation At Transport

    OPERATION 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.

  • Page 83: Lifting The Machine

    OPERATION LIFTING THE MACHINE Always lift the machine on a flat and firm ground. Never lift the machine loaded with any personnel. Make sure the lifting cables and other lifting devices are strong enough to support the machine. Do not perform crane operation including slinging work unless you are not qualified. 1.
  • Page 84 OPERATION This page is intentionally left blank 45V4 • 55V4 • 60V4 ENG 2-52...

  • Page 85: Maintenance

    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 •...
  • Page 86 45V4 • 55V4 • 60V4 ENG...

  • Page 87: Periodic Replacement Of The Important Parts

    MAINTENANCE 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.

  • Page 88: Maintenance Intervals

    MAINTENANCE 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. : Check. : Replace. Maintenance interval Maintenance Maintenance point work Daily 100h 250h 500h 1000h 1500h 2000h Irregular...
  • Page 89 MAINTENANCE Maintenance interval Maintenance Maintenance point work Daily 100h 250h 500h 1000h 1500h 2000h Irregular Check oil qty & refill Drain water Hydraulic oil tank Change hydraulic (Breaker specification 600h) Clean the tank Suction Clean strainer (Breaker specification First Return filter Replace cartridge 100h) time...
  • Page 90 MAINTENANCE Maintenance interval Maintenance Maintenance point work Daily 100h 250h 500h 1000h 1500h 2000h Irregular Check coolant Sub tank qty & refill Clean Radiator Change coolant 1 year Radiator fins Check & clean Oil cooler fins Check tension First & adjust time Fan belt Check cracks...
  • Page 91 MAINTENANCE Maintenance interval Maintenance Maintenance point work Daily 100h 250h 500h 1000h 1500h 2000h Irregular Fuse Replace Fusible link Replace Check battery liquid qty & refill Battery Clean terminals Bolt tightening Retightening First time 45V4 • 55V4 • 60V4 ENG...

  • Page 92: Recommended Lubrication Table

    MAINTENANCE RECOMMENDED LUBRICATION TABLE Temp. & application (ºC) Lubrication Oil type Grade Qty required points -20 -10 * SAE10W-30 Engine oil H: 9.7 L Engine oil API-CF L: 6.7 L * SAE15W-40 * ISO-VG46 Hydraulic oil Hydraulic Abrasion- System: 75 L tank resistant Tank level: 56 L...

  • Page 93: Lubricate The Grease

    MAINTENANCE 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. Boom and swing Boom and Bucket and...

  • Page 94: Boom Swing

    MAINTENANCE Boom Swing Name Boom swing vertical shaft (upper) Boom swing vertical shaft (lower) Swing cylinder foot pin Swing cylinder rod pin Blade Name Blade foot pin Blade cylinder rod pin Blade cylinder foot pin Carry out greasing, regardless of the greasing interval, if abnormal noises are generated from a greasing point.

  • Page 95: Swing Bearing

    MAINTENANCE 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.

  • Page 96: Maintenance Of Bucket

    MAINTENANCE MAINTENANCE OF BUCKET Tooth Wear hole Replace the Tooth It is dangerous if the bucket moves when replacing the bucket tooth. Fix the bucket firmly, stop the engine, and set WC-C300090 Adapter the gate lock lever to the lock position. Rubber lock pin Fragment may scatter, resulting in injury.

  • Page 97: Change The Bucket

    MAINTENANCE Change the Bucket 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. Never insert your finger into the pin holes when adjusting the pin holes. Remove the bucket Place the back of the bucket completely on the ground.

  • Page 98: Adjust The Bucket Clearance

    MAINTENANCE Adjust the Bucket Clearance Clearance The standard bucket has a bucket clearance adjusting adjusting mechanism to prevent backlash. mechanism 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.

  • Page 99: Crawler Track

    MAINTENANCE 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, Crack of covering rubber if it is excessively worn, the rubber track is likely to be Height of lug...

  • Page 100: Inspection Of Crawler Track

    MAINTENANCE 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.

  • Page 101: Adjustment Of Crawler Track

    MAINTENANCE Adjustment of Crawler Track Tension the crawler track 1. Fill grease through the grease nipple (2) of the check valve (1) until the crawler track is tensioned properly. 2. Rotate the crawler forward and backward and check tension. Re-adjust it if necessary. Adjust the right and left crawler tracks evenly.

  • Page 102: Travel Reduction Gear

    MAINTENANCE TRAVEL REDUCTION GEAR Check Oil Level and Refilling 1. Stop the engine so that the filler port is located at the upper position. 2. Place the container under the drain port. 3. Remove the level plug (1). If the oil surface reaches the level part, the oil level is proper.

  • Page 103: Hydraulic System

    MAINTENANCE HYDRAULIC SYSTEM Place the machine in a horizontal place, bring the blade in contact with the ground, retract the arm cylinder and bucket cylinder fully, and move down the boom to lower the bucket onto the ground when executing inspection and/or maintenance of the hydraulic system. Oil is hot immediately after stopping the engine.

  • Page 104: Replace Return Filter Cartridge

    MAINTENANCE Replace Return Filter Cartridge Return filter 1. Release the pressure inside the tank by pressing the air breather button (1). 2. Turn the filter cartridge (2) counterclockwise with the filter wrench. 3. Apply hydraulic oil thinly to the gasket (3) of a new cartridge and tighten it with the filter wrench.

  • Page 105: Change The Hydraulic Oil And Clean The Strainer

    MAINTENANCE Change the Hydraulic Oil and Clean the Strainer 1. Swing the upper structure until the drain plug (1) of the hydraulic oil tank is in the center of the right and left crawlers. 2. Lower the boom to lower the bucket onto the ground. Posture of discharging hydraulic oil 3.

  • Page 106: Air Breather Element Replacement

    MAINTENANCE 10. Discharge air from the hydraulic pump. Remove the air vent plug (8) and make sure that air Hydraulic pump is discharged and oil flows out through the plug hole. The hydraulic pump may be broken unless air is discharged.

  • Page 107: Engine Oil

    MAINTENANCE ENGINE OIL Place the machine in a horizontal place, bring the blade in contact with the ground, retract the arm cylinder and bucket cylinder fully, and move down the boom to lower the bucket onto the ground when executing inspection and/or maintenance of the lubrication system.

  • Page 108: Replace The Engine Oil And Engine Oil Filter

    MAINTENANCE Replace the Engine Oil and Engine Oil Filter Place the container just under the drain port of the engine. Clean the oil filler cap (2) and around it in order not to let in foreign matters. Remove the oil filler cap. Remove the drain plug (3) slowly so that oil will not splash on you.

  • Page 109: Fuel System

    MAINTENANCE FUEL SYSTEM Check Fuel Quantity and Refilling 1. Turn the engine key switch key to the ON position and White check the quantity of remaining fuel on the fuel gauge. Fuel tank capacity: 65 L 2. Refill the tank with fuel through the filler port (1) if remaining fuel is insufficient.

  • Page 110: Check And Clean Water Separator And Replace Element

    MAINTENANCE Check and Clean Water Separator and Replace Element Check and Discharging Water Water separator If the float (1) of the water separator is floating, water reaches the bottom of the float. When the water separator warning indicator on the OK monitor turns on, the water separator contains the specified amount of water.

  • Page 111: Replace Fuel Filter

    MAINTENANCE Replace Fuel Filter Fuel filter 1. Turn the filter (1) counterclockwise with the filter wrench to detach it. 2. Thinly coat fuel oil on the gasket (2) of the new filter, and tighten sufficiently by hand without using a filter wrench. 3.

  • Page 112: Cooling System

    MAINTENANCE COOLING SYSTEM Subtank Filler port Check the Coolant Level and Refill Do not open the radiator cap normally. Check coolant in the subtank when the engine is cool. 1. Open the right cover and check if the coolant level in the subtank is between the LOW and FULL levels.
  • Page 113 MAINTENANCE 2. Mixing ratio of coolant The freezing temperature of the long life coolant varied depending on the ratio of mixing it with water. In this machine, irrespective of the outdoor temperature, the long life coolant is mixed with water with a mixing ratio of 49% at the time of shipment in order to maintain the rust prevention effect of the cooling system.

  • Page 114: Check The Fan Belt

    MAINTENANCE Check the Fan Belt The engine is hot immediately after stopping it. You may get burnt if you touch the engine. Wait until each part cools down. Stop the engine and keep the key of the starter switch in safe. If belt tension is excessive, the bearings and belt will be damaged earlier.

  • Page 115: Inspect And Clean Radiator Fins And Oil Cooler Fins

    MAINTENANCE Inspect and Clean Radiator Fins and Oil Cooler Fins Be sure to put on protective goggles when handling compressed air or high-pressure water in inspection of the engine. Otherwise, your eyes may be hurt by dust, scattered matters, compressed air, high-pressure water or steam. 1.

  • Page 116: Intake Air System

    MAINTENANCE INTAKE AIR SYSTEM Inspect Dust Indicator Dust indicator 1. Check if the red signal is indicated on the dust indicator of the air cleaner. 2. Clean or replace the element immediately if the red signal is indicated. 3. Push the reset button of the dust indicator to reset the red signal after cleaning or replacing the element.

  • Page 117: Inspect And Clean Air Cleaner Element

    MAINTENANCE Inspect and Clean Air Cleaner Element 1. Stop the engine. 5. Emit light (white light) from the inside of the 2. Remove the cover (1), and take out the element and inspect for damage to the filter. outer element (2). Do not use the filter if the filter is damaged, Do not remove the inner element (4).

  • Page 118: Engine

    MAINTENANCE ENGINE Adjust Intake Valve and Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. Check of Fuel Injection System Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance.

  • Page 119: Electric System

    MAINTENANCE ELECTRIC SYSTEM Replace the Fuses Be sure to set the engine key switch to the OFF position before replacing the fuses. Do not use wires, silver foils, etc. instead of Fuse box fuses. If such materials are used, the wires may overheat and burn, resulting in a fire.

  • Page 120: Check The Battery

    MAINTENANCE Check the Battery The battery produces inflammable hydrogen gas. It ignites or explodes if fire is nearby. Never bring fire close to the battery or strike a spark near it. Never place any tool, metallic object or inflammable matter on or near the battery. The battery may possibly ignite and explode if it short-circuits.

  • Page 121: Tighten Bolts

    MAINTENANCE TIGHTEN BOLTS Retighten loose bolts in daily inspection. Be sure to make up for lacking bolts. Check and retighten the bolts after the first 50 hours if a new machine is used. Special Tightening Positions The bolts shown below bear large forces. Tighten them at the torque shown in the table below. When replacing the bolts in these positions, apply molybdenum disulfide grease to the threads and the bearing surfaces of the nuts and tighten at the specified torque.
  • Page 122 MAINTENANCE 3. Engine Tightening torque Wrench size Tightening position Bolt size (mm) (N·m) (kgf·m) Engine bracket 10.8 Vibration-proof bracket 10.8 4. Counterweight View A View B Apply Apply 45V4 45V4 (Option) 55V4 55V4 60V4 Tightening torque Wrench size Tightening position Bolt size (mm) (N·m)

  • Page 123: Standard Tightening Torques

    MAINTENANCE Standard Tightening Torques Tighten bolts and nuts not shown above at the torques shown in the tables below. 10T Heat-treatment bolts High-pressure hose union nut Coarse thread Fine thread Bolt Wrench size Hose size (N·m) (kgf·m) size (mm) (inch) (N·m) (kgf·m) (N·m)

  • Page 124: Handling In Cold Weather

    MAINTENANCE HANDLING IN COLD WEATHER At low temperature, the engine hardly starts and coolant is subject to freezing. Make preparation for cold weather as shown below. Fuel In cold weather, fuel may be frozen and it may be difficult to start the engine.

  • Page 125: Long Term Storage

    MAINTENANCE LONG TERM STORAGE To protect the cylinder rod from rust, set the machine to the posture for long term storage. Before storage Clean the machine. Carry out lubrication, greasing and oil changing of each part. Apply grease to the exposed piston rods of the Posture for long term storage hydraulic cylinders.

  • Page 126: Hydraulic System Diagram

    MAINTENANCE HYDRAULIC SYSTEM DIAGRAM Boom swing Travel right Travel left Swing Bucket Boom Blade Brake Brake valve valve Rotary Joint Return filter Main pump Travel speed select solenoid Variable capacity plunger Engine Hydraulic oil tank KUBOTA To remote control valve Suction strainer Oil cooler Pilot pump...
  • Page 127 MAINTENANCE This page is intentionally left blank 45V4 • 55V4 • 60V4 ENG 3-41...

  • Page 128: Electric System Diagram

    MAINTENANCE ELECTRIC SYSTEM DIAGRAM HORN 45V4 • 55V4 • 60V4 ENG 3-42...
  • Page 129 MAINTENANCE 21 20 3RD CHG SOL. QUICK HITCH 45V4 • 55V4 • 60V4 ENG 3-43...
  • Page 130 MAINTENANCE Name Name Battery Glow indicator Fusible link (65A) Battery charge warning indicator Starting motor Engine oil pressure warning indicator Alternator Coolant temperature warning indicator Engine stop solenoid Water separator warning indicator Engine oil pressure switch Control lock indicator Water temperature sensor (gauge) Auto idol indicator Water temperature switch Fuel gauge...

  • Page 131: Specifications

    SPECIFICATIONS 45V4 • 55V4 • 60V4 ENG...
  • Page 132 45V4 • 55V4 • 60V4 ENG...

  • Page 133: Speed And Gradeability

    SPECIFICATIONS SPECIFICATIONS SPEED AND GRADEABILITY Swing speed 9.3 min Travel speed (low/high) 2.9/4.6 km/h Gradeability 58% (30 degrees) ENGINE Engine model Kubota V2403-DI-EDM Vertical in-line, water cooled, 4-cycle Type diesel engine (Direct injection) No. of cyl. - bore x stroke 4-87 mm 102.4 mm Displacement...

  • Page 134: Capacity

    SPECIFICATIONS CAPACITY Fuel 66 L Tank level 56 L Hydraulic oil Total quantity 75 L Maximum 9.7 L Engine oil Minimum 6.7 L Engine only 3.7 L Coolant Total quantity 10.1 L BUCKET 45V4 : Standard, : compatible, : not compatible Bucket Bucket width capacity...
  • Page 135 SPECIFICATIONS 60V4 : Standard, : compatible, : not compatible Bucket Bucket width capacity Compatibility (mm) No. of Mass Applied Specification teeth (kg) With Without Standard Long Heaped side side cutter cutter 0.18 Standard General digging 0.08 Ditching 0.11 Ditching 0.14 (Long arm) 0.16 (Reinforced)

  • Page 136: Dimensions

    SPECIFICATIONS DIMENSIONS Unit: mm Symbol Name 4-post ROPS Cabin Crawler track width Crawler overall length 2490 2490 Crawler overall width 1990 1990 Upper structure overall width 1780 1790 Overall height of base machine 2570 2570 Swing radius Clearance height under upper structure Ground clearance of undercarriage Undercarriage overall length 3090...
  • Page 137 SPECIFICATIONS Unit: mm Symbol Name 4-post ROPS Cabin Crawler track width Crawler overall length 2490 2490 Crawler overall width 1990 1990 Upper structure overall width 1780 1790 Overall height of base machine 2570 2570 Swing radius 1090 1090 Clearance height under upper structure Ground clearance of undercarriage Undercarriage overall length 3090...
  • Page 138 SPECIFICATIONS Unit: mm Symbol Name 4-post ROPS Cabin Crawler track width Crawler overall length 2490 2490 Crawler overall width 1990 1990 Upper structure overall width 1780 1790 Overall height of base machine 2570 2570 Swing radius 1120 1120 Clearance height under upper structure Ground clearance of undercarriage Undercarriage overall length 3090...

  • Page 139: Working Range

    SPECIFICATIONS WORKING RANGE The operating range is common to 4-post canopy, 2-post canopy, and cabin models. Standard arm Long arm Unit: mm Standard Symbol Name Long arm Maximum reach 5760 5970 Maximum reach at ground reference plane 5600 5810 Maximum digging depth 3340 3590 Reach at maximum digging depth...
  • Page 140 SPECIFICATIONS Standard arm Long arm Unit: mm Standard Symbol Name Long arm Maximum reach 5970 6200 Maximum reach at ground reference plane 5810 6050 Maximum digging depth 3590 3830 Reach at maximum digging depth 2140 2120 Maximum height of cutting edge 5470 5610 Reach at maximum height...
  • Page 141 SPECIFICATIONS Standard arm Long arm Unit: mm Standard Symbol Name Long arm Maximum reach 6200 6440 Maximum reach at ground reference plane 6060 6300 Maximum digging depth 3800 4040 Reach at maximum digging depth 1960 2250 Maximum height of cutting edge 5710 5860 Reach at maximum height...

  • Page 142: Working Range For Offset Digging

    SPECIFICATIONS WORKING RANGE FOR OFFSET DIGGING Unit: mm 45V4 Standard arm Long arm 2100 2190 Minimum radius of equipment at maximum front offset 2010 2100 Unit: mm 55V4 Standard arm Long arm 2190 2230 Minimum radius of equipment at maximum front offset 2100 2130 45V4 •...
  • Page 143 SPECIFICATIONS Unit: mm 60V4 Standard arm Long arm 2220 2240 Minimum radius of equipment at maximum front offset 2120 2130 45V4 • 55V4 • 60V4 ENG 4-11...

  • Page 144: Rated Object Handling Capacities Table

    SPECIFICATIONS RATED OBJECT HANDLING CAPACITIES TABLE 45V4 45V4 • 55V4 • 60V4 ENG 4-12...
  • Page 145 SPECIFICATIONS 55V4 45V4 • 55V4 • 60V4 ENG 4-13...
  • Page 146 SPECIFICATIONS 60V4 45V4 • 55V4 • 60V4 ENG 4-14...
  • Page 147 Original Instructions 2014 All rights reserved. First Edition, February 2014 45V4 55V4 OPERATION MANUAL 60V4 Editing & Publishing Office. Product Support Department 236-8611 3 1 7 4 3174 Showa-machi, Kanazawa-ku, Yokohama, Kanagawa 236-8611 Japan...

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