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MAINTENANCE

IC50 ENG

4-22

Check the fan belt

WARNING

To help avoid being injury, check and adjust the fan
belt tension with engine stopped.
Parts are hot immediately after the engine stops.
You may get burnt.

Check

1. Push a point in the middle of the idle pulley (1) and

alternator pulley (2) at approximately 98 N (10 kgf).
The belt tension is proper if the belt slacks by
approximately 6 to 8 mm.

2. Replace the belt if the adjustment margin of the belt is

lost or the belt has flaws or cracks.

Adjustment

1.  Loosen the alternator fixing bolt (3) and lock nut (4).

2.  Adjust the belt tension with the adjust bolt (5).

3.  Tighten the fixing bolt and lock nut firmly after

adjustment.

4. Keep the engine idling for 5 minutes and check the belt

tension.

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Summary of Contents for IC50

Page 1: ...OPERATION MANUAL IC50 SERIAL NUMBER CA003001 PUB 1 1008...

Page 2: ......

Page 3: ...nel Meters Switches Control levers Operator seat Seat belt OPERATION 3 1 BEFORE STARTING OPERATION 3 1 BEFORE STARTING THE ENGINE 3 2 ENGINE STARTING 3 3 AFTER STARTING THE ENGINE 3 3 WARMING UP THE M...

Page 4: ...4 12 Check the travel reduction oil level Replace the travel reduction oil HYDRAULIC SYSTEM 4 13 Check the hydraulic oil level Drain the hydraulic oil tank Replace the hydraulic oil and clean the stra...

Page 5: ...nge the air cleaner element HYDRAULIC SYSTEM 4 30 Hydraulic system diagram ELECTRIC SYSTEM 4 31 Change the fuses Change the fusible link Check the battery Electrical wiring system diagram HANDLING IN...

Page 6: ...IC50 ENG...

Page 7: ...oughly understood at first repeat reading it until abilities as an operator are obtained and developed for proper operation Further abilities as an operator outside of descriptions in this manual can...

Page 8: ...aused We have made very 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 us...

Page 9: ...glected 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 o...

Page 10: ...IC50 ENG...

Page 11: ...medication or intoxication WEAR PROPER WORKING CLOTHES For the sake of safety during driving wear clothes that match your body The sleeves of sloppy clothes can get caught in the machine and can caus...

Page 12: ...he operator s station When any oil or other slippery substance has got adhered to hand rails or steps wipe them off clean START THE ENGINE WHILE SITTING IN THE OPERATOR SEAT If the engine is started f...

Page 13: ...engine in a well ventilated area If in an enclosed area vent the exhaust to the outside STAY SEATED WHILE OPERATING There is the danger of making wrong operations if the operating is done from a posit...

Page 14: ...functionality or life of the machine Never exceed the maximum load limits Never place a load onto the sideracks DO NOT EXCEED THE WATER DEPTH LIMIT The acceptable water limit is up to the lower rolle...

Page 15: ...NE POSITION WHILE TRAVELING ON SLOPES The machine center of gravity tends to quickly change while traveling on sloping surfaces This can create hazardous situations where the machine may tip over Obse...

Page 16: ...ped or parked on a sloping land When it is unavoidable to stop or park on a slopping land Place stopper blocks on the downhill side under both crawlers OBSERVE PRECAUTIONS WHEN PARKING THE MACHINE ON...

Page 17: ...e machine to the platform using a wire rope etc Transport safely strictly following the concerned laws PRECAUTIONS AT MAINTENANCE KEEP ROUTINE MAINTENANCE Wrong maintenance not only causes damage to t...

Page 18: ...y releasing the internal pressure SUPPORTING THE BODY If replacement or repair of couplings or hoses is made with the body in the raised condition there is the possibility that the body drops down Alw...

Page 19: ...ger of your hand being cut off Always carry out maintenance work with the engine switched off BE CAREFUL TO HOT ENGINE AFTER THE MACHINE STOPS Do not touch the engine or muffler right after the machin...

Page 20: ...g used for the battery liquid Take sufficient care while handling FIRE PREVENTION Do not leave burnable items such as oily rags dry leaves paper etc near the engine Since these can cause fire hazards...

Page 21: ...can read all safety signs Clean or replace these if you cannot read the words or see the pictures When cleaning the labels use a cloth water and soap Do not use solvent gasoline etc You must replace a...

Page 22: ...SAFETY IC50 ENG 1 12 1 Precautions on safety 4448 818 00 2 Precaution for working under the raised body 4448 816 00 3 Crawler shoe tension adjustment D405 516 00...

Page 23: ...SAFETY IC50 ENG 1 13 4 Traveling on a slope D406 188 00 5 Loading and unloading the machine 4448 820 00 6 When the body moves down D407 746 00...

Page 24: ...ouch when hot D405 361 00 10 Sign indicates an electrical hazard from handling the cable Read manual for safe and proper handling D405 363 00 11 Sign indicates an electrocution hazard if machine is br...

Page 25: ...the machine to minimize danger caused by accidents such as falling down D407 741 00 18 Sign indicates a crush hazard from falling body Read manual and follow safety instructions when holding the body...

Page 26: ...SAFETY IC50 ENG 1 16 This page is intentionally left blank...

Page 27: ...IC50 ENG CONTROLS This section describes the functions of the devices needed to operate this machine and the proper operation procedures Understand them sufficiently and operate the machine in safe...

Page 28: ...IC50 ENG...

Page 29: ...cylinder 18 Upper roller 3 Hydraulic tank 11 Safety bar 19 Oscillating link 4 Engine 12 Body 20 Travel device 5 Radiator oil cooler 13 Side gate 21 Drive sprocket 6 Muffler 14 Rear gate 22 Headlight...

Page 30: ...ing switch 2 Travel lever 9 Hour meter 16 Emergency stop switch 3 Dump lever 10 Turn signal switch 17 Travel speed select switch 4 Dump lever lock 11 Horn switch 18 Car heater switch option 5 Operator...

Page 31: ...es service dealer for repair services Engine oil pressure warning lamp This lamp goes on if the pressure of oil for lubricating the inside of the engine drops while the engine is running Stop the engi...

Page 32: ...et air system Water temperature gauge This gauge indicates the temperature of the engine coolant when the engine key switch is set to the ON position It is OK if the gauge pointer indicates a temperat...

Page 33: ...nce Switches Turn signal switch This switch works when the engine key switch is set to ON Use the lever 1 to change the direction indicator lamps B The right direction indicator lamp blinks OFF The la...

Page 34: ...o 15 seconds The glow lamp is on during preheating START position Set the key to this position to start the engine Release the hand from the key immediately after the engine starts The key returns to...

Page 35: ...out Car heater switch Use this switch to turn on the fan of the cabin heater High and Low may be selected HIGH Push down on the HIGH mark LOW Push down on the LOW mark Push down on the center to turn...

Page 36: ...dumping Raise Pull the lever up to raise the body Hold This is the neutral position Lower Push the lever down to lower the body The body stops at the current position when the lever is returned to the...

Page 37: ...cause operating errors or unforeseen accidents Shake the seat back and forth lightly and check if the seat is fixed firmly after adjusting it If the seat is not fixed it may move suddenly and cause u...

Page 38: ...CONTROLS IC50 ENG 2 10 This page is intentionally left blank...

Page 39: ...IC50 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...

Page 40: ...IC50 ENG...

Page 41: ...racks wear backlash and loose bolts of the shoes idle tumblers and sprockets Check oil leak and water leak from the engine Remove dust and foreign matters from the engine radiator and peripheral parts...

Page 42: ...g Engine preheating starts automatically Make sure that the glow lamp 4 is lit for 1 to 15 seconds and goes out then Make sure that the engine oil pressure warning lamp 5 and charge warning lamp 6 are...

Page 43: ...START position The engine starts 3 Release the hand from the key when the engine starts The key returns to the ON position automatically AFTER STARTING THE ENGINE NOTICE Never race the engine immedia...

Page 44: ...l the hydraulic oil temperature rises to approximately 20 C before starting works 1 Idle the engine for approximately 10 minutes to warm it up after starting it 2 If the hydraulic oil temperature is l...

Page 45: ...arged battery 3 Connect the clip of the black jumper cable to the negative terminal of the charged battery Connect the other clip to the upper frame of the machine with the dead battery Starting the e...

Page 46: ...hours first Pay attention to the following when breaking in a new machine Warm up the machine sufficiently Do not apply heavy loads to the machine or run it at high speed Run the machine at approximat...

Page 47: ...the parking switch 2 to deactivate the brake Make sure that the mark lamp is off 4 Use the right and left travel levers 3 and 4 as shown below Forward direction travel Push the right and left levers...

Page 48: ...er 1 backward and move the left side travel lever 2 forward at the same time This allows a quick right turn counter track rotation WARNING NEVER steer on a grade or unstable ground which causes turnov...

Page 49: ...of a slope when the body is empty This posture ensures stable driving since the center of gravity is located on the cabin side Drive the machine with the body upper side of a slope when the body is f...

Page 50: ...r down Caution of dump operation 1 If dumping is carried out on a slope uneven ground or soft ground the center of gravity may move and the machine may turn over Carry out dumping on flat and solid gr...

Page 51: ...mpletely 4 Check if the dump lever lock 2 is set to the locked position Stopping the engine 1 Keep the engine idling for approximately 5 minutes to lower the temperature of the engine 2 Set the engine...

Page 52: ...stain tension iron core to support it and covering rubber to them NOTICE If a crack reaches the steel cord it may be rusted and cut off by moisture When any crack is detected immediate repair is essen...

Page 53: ...CH ETC This wears down the lug and breaks the iron core The carrier might fall or topple over AVOID LOCATIONS WHERE THE CARRIER MIGHT FALL Do not let the carrier fall from locations like large stone s...

Page 54: ...c This causes serious abrasion or damage and breakage of the lug OTHER ITEMS FOR CAUTION DO NOT LET OIL SOLVENTS OR SALT ADHERE TO THE RUBBER CRAWLERS If fuel transmission fluid or paint should adhere...

Page 55: ...towed by another machine In such cases attach a shackle to a wire rope and attach this to the front or rear hook The carrier can now be towed 1 Start the engine 2 Select the low speed mode with the t...

Page 56: ...dirt and soil from the crawlers to prevent slippage Remove grease oil water and other adherent matters from the lading ramps Never make a turn on the loading ramps to avoid turnover To make a turn ret...

Page 57: ...ransportation Fix it firmly on the load carrying platform of the truck with wheel blocks and wire ropes Apply wheel blocks in front of and behind the rubber crawlers to fix the machine Finally make su...

Page 58: ...lifting the machine 6330 kg 1 Prepare strong enough wire ropes shackles sling frame and sling jigs 2 Fix the sling jigs at the positions of the crawler frame shown above and pass the wire rope throug...

Page 59: ...ain 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...

Page 60: ...IC50 ENG...

Page 61: ...and pull out the key from the engine key switch Put a tag which indicates that maintenance is being carried out on the engine key switch or control lever at an easy to see position Cautions for repai...

Page 62: ...r 1 Raise the body completely 2 Raise the safety bar and set it to the bracket under the body CAUTION Do not start the engine or lower the body while the safety bars are used Such an action may cause...

Page 63: ...between fuel pre filter and electromagnetic fuel pump 1 Fuel hose between electromagnetic fuel pump and fuel main filter 1 Fuel hose between fuel main filter and engine 1 Fuel hose between engine and...

Page 64: ...ecking rubber crawlers Tightening bolts Travel reduction gear Check lubricating oil q ty refill Replace lubricating oil First time Hydraulic system Check oil q ty refill Drain oil tank Replace oil cle...

Page 65: ...l Drain fuel tank Drain main filter pre filter Replace main filter pre filter element Clean electromagnetic fuel pump filter Air cleaner system Check dust indicator Clean air cleaner element Replace a...

Page 66: ...l pan Engine oil API CD H 14 L L 10 L Hydraulic oil tank Hydraulic oil Abrasion resistant Whole system 63 L Tank level 50 L Travel reduction gear Gear oil API GL 4 2 6 L Fuel tank Light oil JIS 120 L...

Page 67: ...ty bars under the body when lubricating with the body raised Body joint pins 1 2 positions Dump cylinder rod pins 2 2 positions Dump cylinder foot pins 3 2 positions Control springs of the body rear g...

Page 68: ...change it with brand new one Cutting of Steel Cords of Rubber Crawler Shoes When cutting of steel cord is detected exchange it immediately If you leave it as it is the rubber crawler shoes can be cut...

Page 69: ...er crawlers 1 Remove dirt and soil from around the idle tumblers 2 Loosen the check valve until grease is discharged by a maximum of one turn little by little Do not loosen it when grease is discharge...

Page 70: ...tite to the threads and tighten them at the specified torques Traveling rated Tightening torque No Special tightening Thread size Wrench size mm N m kgf m 1 Travel reduction gear M16 24 241 24 6 2 Dri...

Page 71: ...he torques shown in the table below Tightening torque High pressure hose union nut Metric coarse thread heat processed bolt Metric fine thread heat processed bolt Tightening torque Bolt size Wrench si...

Page 72: ...ral side 2 Remove the level plug It is OK if the oil level is near the bottom of the plug hole 3 Refill oil through the filler port 3 if oil is insufficient 4 After check and refilling clean the plugs...

Page 73: ...erature 10 to 30 C Near the H level during operation Oil temperature 50 to 80 C 3 If the oil level is below the L level open the cover 2 and refill hydraulic oil through the filler port 3 Drain the hy...

Page 74: ...discharge residual oil Tighten the drain plug after discharging oil 4 Remove the cover 4 5 Disconnect the hose from the tube 6 Remove the bolt 7 and take out the strainer 8 5 Clean the strainer to re...

Page 75: ...ng hydraulic oil Stop the engine 2 Detach the case 1 with a wrench of size 32 3 Clean the inside of the case 4 Replace the element 3 O ring 3 and backup ring 4 5 Attach the case and tighten it with th...

Page 76: ...the cover 1 and remove the filter cartridge 2 3 Clean the filter mounting position of the filter head 3 Apply hydraulic oil to the O ring 4 of a new filter cartridge 4 Attach the filter cartridge and...

Page 77: ...he L level Wait for approximately 15 minutes after refilling and check the oil level 5 If the oil level is proper close the lubrication port firmly and close the engine cover 6 Too much engine oil may...

Page 78: ...ntact IHI s sales service dealer if it contains much metallic powder foreign matters etc 5 Tighten the drain plug Replace the oil filter cartridge 1 Remove the filter cartridge 5 with the filter wrenc...

Page 79: ...xing ratio for a freezing point lower by 5 C than the expected lowest atmospheric temperature Meanwhile use city water to mix with Long Life Coolant Lowest ambient temperature C 15 or higher 25 35 Mix...

Page 80: ...in the reserve tank 1 is between the FULL and LOW levels Refill the reserve tank with coolant through the filling port up to the FULL level Close the cap firmly after refilling 2 If the reserve tank...

Page 81: ...he necessary quantity of Long Life Coolant Fill solution up to the opening of the radiator Fill solution slowly to prevent air from being mixed in solution 6 Discharge coolant from the reserve tank 6...

Page 82: ...nd alternator pulley 2 at approximately 98 N 10 kgf The belt tension is proper if the belt slacks by approximately 6 to 8 mm 2 Replace the belt if the adjustment margin of the belt is lost or the belt...

Page 83: ...t or the engine may break down if any other fuel than light oil is used Never use any other fuel than light oil Damages or troubles caused by using fuel other than light oil are not covered by the war...

Page 84: ...Close the drain plug when clean fuel is only discharged CAUTION Using fuel other than light oil may hinder the fuel injection system and or engine from demonstrating full functions and performances It...

Page 85: ...f the float rises up to the bottom of the element 2 1 Place the machine on a flat and rigid ground Bring the machine into the posture for checking the fuel filter and stop the engine 2 Loosen the air...

Page 86: ...very end 4 Be sure to check air tightness after attaching the cover Replace the main fuel filter element and the pre fuel filter element 1 Loosen the air bleeder plug 1 and drain plug 2 to discharge f...

Page 87: ...ten the air bleeder plug Move the priming pump 10 times or more until the fuel filter is filled with fuel 4 Wait for approximately 1 minute Loosen the air bleeder valve to bleed the air of fuel system...

Page 88: ...not show a red signal 2 Clean or replace the element immediately if a red signal is shown 3 Push the reset button 2 of the dust indicator to reset the red signal after cleaning or replacing the elemen...

Page 89: ...e inside of the air cleaner body 6 5 Blow dry compressed air at a pressure of 0 3 to 0 5 MPa 3 to 5 kgf cm2 onto the element from inside along the pleats Move the air flow up and down Then blow compre...

Page 90: ...t travel motor 34 0 Pump 2 A2 Backward B2 Forward Pump relief valves for left travel motor 34 0 MRV Main relief valve for dump Raise 20 6 Control Valve ORV Over load relief valve for dump Lower 6 9 Pu...

Page 91: ...aler for checks 1 Unlatch and detach the fuse cover 1 2 Replace the blown fuse with a new fuse of the same capacity Fuse capacity Circuit name c 30A Engine main relay d 10A Electromagnetic fuel pump e...

Page 92: ...the battery Check the liquid level Refill the battery with refill liquid up to UPPER LEVEL if it has lowered down to LOWER LEVEL Cleaning the battery terminals CAUTION Be sure to keep the engine stopp...

Page 93: ...MAINTENANCE IC50 ENG 4 33 This page is intentionally left blank...

Page 94: ...MAINTENANCE IC50 ENG 4 34 Electrical wiring system diagram INSTRUMENT PANEL...

Page 95: ...wire thickness is AVS 0 75 2 The connection diagram shows the layout viewed from the plane ENGINE CABIN OPTION Engine key switch contact Color symbol table Pre heat OFF ON Start Black Green Red White...

Page 96: ...Glow relay 51 Back buzzer 13 Glow plug 52 Engine Control Module 14 Water temperature sensor 15 Hour meter 16 Barometric pressure sensor 17 Air intake temperature sensor 18 Throttle potentiometer 19 M...

Page 97: ...antifreeze mixing ratio table and adjust the concentration Exchange Long Life Coolant every two years in autumn every other year Lubricant and grease Exchange engine oil and hydraulic oil with proper...

Page 98: ...Storage WARNING If you have to operate the machine indoors to prevent rust keep good ventilation and gas poisoning by window or entrance 1 During storage operate the machine once a month to maintain...

Page 99: ...lace parts Adjust both right and left tension to regular value Speed does not change even if changing selectors Discontinuity or disconnection of electric wires Defect of solenoid valve for speed sele...

Page 100: ...MAINTENANCE IC50 ENG 4 40 This page is intentionally left blank...

Page 101: ...IC50 ENG SPECIFICATIONS...

Page 102: ...IC50 ENG...

Page 103: ...6 Ground pressure Loaded kPa 35 6 Fully loaded m 3 3 0 Body capacity Flat loaded m3 1 8 A Overall length mm 4460 B Overall width mm 2290 C Overall height mm 2500 D Tumbler center distance mm 3130 E O...

Page 104: ...OPERATION MANUAL Editing Publishing Office Product Support Department 236 8611 3174 3174 Showa machi Kanazawa ku Yokohama Kanagawa 236 8611 Japan All rights reserved IC50 2010 7 First Edition July 201...

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