IHI IC75-2 Operation Manual Download Page 79 | Manualshive

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IHI IC75-2 Operation Manual Download Page 79

IC75-2 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 maintenance procedures described
below.

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Summary of Contents for IC75-2

Page 1: ...OPERATION MANUAL IC75 2 SERIAL NUMBER CA004001 09884 16EN 00...

Page 2: ...System 2 4 Explanation of Screen Displays 2 5 Trouble Code Display Screen 2 8 Regeneration Mode Selection Screen 2 10 Machine Information Display Screen 2 10 Adjustment Selection Display Screen 2 11...

Page 3: ...Hydraulic Hose 4 3 SCR Piping Hose 4 3 MAINTENANCE INTERVALS 4 4 RECOMMENDED LUBRICATION TABLE 4 7 GREASING 4 8 Vessel 4 8 Oscillating Link 4 8 RUBBER CRAWLER 4 9 Rubber Crawler Shoe Maintenance 4 9...

Page 4: ...evel 4 29 Drain the Fuel Tank 4 29 Water Separator and Fuel Filter 4 30 Replacing Water Separator and Fuel Filter 4 31 AIR INTAKE AND EXHAUST SYSTEM 4 32 Clean and Replace Air Cleaner Element 4 32 ELE...

Page 5: ...roughly 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 6: ...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 indica...

Page 7: ...eglected 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...

Page 8: ...l 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 cau...

Page 9: ...e 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 fr...

Page 10: ...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 posi...

Page 11: ...e a load onto the sideracks DO NOT EXCEED THE WATER DEPTH LIMIT The acceptable water limit is up to the lower roller Check the water depth foundation and strength of water current and other safety fac...

Page 12: ...INE 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 Obs...

Page 13: ...arked 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 THE ROAD...

Page 14: ...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 15: ...ter completely releasing the internal pressure SUPPORTING THE VESSEL If replacement or repair of couplings or hoses is made with the vessel in the raised condition there is the possibility that the ve...

Page 16: ...shed by the machine and there is the danger 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...

Page 17: ...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 18: ...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 Where the warning Signs and Labels are stuck CA...

Page 19: ...SAFETY IC75 2 ENG 1 12 1 Precautions on safety D408 704 00 2 Precaution for working under the raised vessel 4448 816 00 3 Crawler shoe tension adjustment D405 516 00...

Page 20: ...1 13 4 Gate lock lever D408 689 00 5 Traveling on a slope D406 188 00 6 Loading and unloading the machine D405 618 00 7 Under water works D406 189 00 8 Safety alarm D408 691 00 9 Dump bed operation wa...

Page 21: ...zard from touching heated parts such as engine motor or muffler during or right after operation Never touch when hot D405 477 00 14 Sign indicates an electrical hazard from handling the cable Read man...

Page 22: ...fastening the seat belt Always keep the seat belt fastened while operating the machine to minimize danger caused by accidents such as falling down D407 774 00 22 Sign indicates a crush hazard from fa...

Page 23: ...IC75 2 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 24: ...roller 2 Fuel tank 10 Dump cylinder 18 Oscillating link 3 Hydraulic tank 11 Safety bar 19 Travel device 4 Engine 12 Vessel 20 Drive sprocket 5 Radiator oil cooler 13 Rear gate 21 Headlight 6 Post proc...

Page 25: ...CONTROLS IC75 2 ENG 2 2 CONTROLS AND INSTRUMENTS No Name No Name 1 Instrument panel 4 Operator seat 2 Left lever unit 5 Seat belt 3 Accelerator pedal...

Page 26: ...Emergency engine stop switch 3 Parking switch 10 Engine service connector 4 Mode changeover switch 11 Engine key switch 5 Engine speed control dial 12 Hour meter 6 Travel speed control dial 13 Combin...

Page 27: ...the Operation screen when the key is pressed The initial screen appears when the engine key switch is turned to the ON position The initial screen changes to the Operation screen in 3 seconds Initial...

Page 28: ...Engine tachometer 2 Coolant thermometer 3 DEF gauge 4 Fuel gauge 5 Battery voltage 6 Slope warning indicator 7 Preheat indicator 8 High speed 9 Low speed 10 Parking brake indicator 11 Engine error ind...

Page 29: ...inclination angle is 9 degrees or more the buzzer sounds for 5 seconds 7 Preheat indicator The preheat indicator comes on when the engine key switch is turned on The water temperature sensor senses th...

Page 30: ...This indicator comes on when some kind of engine problem occurs When an engine error is indicated immediately contact IHI s sales service dealer 12 DEF indicator This indicator comes on when the DEF...

Page 31: ...to a safe area and stop the engine immediately Repair is required once the engine is stopped Please contact IHI or our sales service dealer 2 Engine system warning indicator This indicator comes on w...

Page 32: ...coolant s temperature rises abnormally If this indicator comes on while the engine is running stop the engine and check 8 Coolant level warning indicator This indicator comes on when the coolant leve...

Page 33: ...ion disabled indicator 1 Post processing unit regeneration indicator The post processing unit is regenerated manually 2 Post processing unit regeneration disabled indicator The automatic regeneration...

Page 34: ...ard direction Reverse Span Adjusts the zigzag travel and travel speeds when the joystick is operated to the maximum in the reverse direction Reverse Start Adjusts the diagonal travel and the sensitivi...

Page 35: ...Adjust in the left direction Slows down the maximum speed of the left travel motor Be careful with the balance between the right and left travel pressures If the travel load is small adjustment may no...

Page 36: ...liminate diagonal travel when starting to travel key Adjust in the right direction Slows down the initial speed of the right travel motor key Adjust in the left direction Slows down the initial speed...

Page 37: ...Adjust in the left direction Slows down the maximum speed of the left travel motor Be careful with the balance between the right and left travel pressures If the travel load is small adjustment may no...

Page 38: ...e initial speed of the left travel motor Start Adjusts the sensitivity of the joystick when starting to travel key The response to joystick input gets faster key The response to joystick input gets sl...

Page 39: ...l Press the mark side The mark indicator lamp goes on Low speed travel Press the side without the mark The mark indicator lamp goes off 3 Parking switch This switch activates deactivates the parking b...

Page 40: ...10 5 Engine speed control dial Automatic mode Adjust the minimum engine speed High speed Rotate the dial clockwise Low speed Rotate the dial counterclockwise Manual mode This mode adjusts the number...

Page 41: ...switch is automatically turns ON when this knob is pushed down It pushes up after several seconds use the cigarette lighter by pulling it out 9 Emergency engine stop switch Use this switch to activate...

Page 42: ...to the electrical system turns ON START This is the engine start position When the engine starts immediately release your hand from the key The key returns to the ON position automatically 12 Hour me...

Page 43: ...d when the engine key switch is at the ON position Use the lever 2 to operate the head lights Turn the lever to point the mark to a head light symbol OFF ON The head light goes on downward ON The head...

Page 44: ...CONTROLS IC75 2 ENG 2 21 LEFT LEVER UNIT No Name No Name 1 Joystick lever 4 Engine start stop button 2 Lever lock switch 5 Horn button 3 Dump operation switch 6 Spin turn button...

Page 45: ...n be operated by pulling up and down the left lever unit Lock Pull up the left lever unit The joystick is disabled at the lock position Release Pull down the left lever unit to the operation position...

Page 46: ...ng down the switch button 6 For more information about spin turn operation see the article on Steering control in the OPERATION section Turning ON the engine key switch while holding down the spin tur...

Page 47: ...pension The appropriate body weight is displayed on the display 4 Adjusting the seat height When the seat is lifted from the bottom of the seat 5 the seat height is raised by 30 mm a maximum of 60 mm...

Page 48: ...he buckle 2 securely 3 Slightly pull the belt and confirm the belt is locked 4 Press the button 3 of the buckle to unfasten seat belt ALWAYS fasten the seat belt while operating the machine ALWAYS che...

Page 49: ...ture setting spurting temperature Pressing decreases the temperature setting spurting temperature The newly set temperature state is displayed on the LCD screen R F switch REC FRESH switch Each time t...

Page 50: ...the airflow switches select the desired airflow Using the MODE switch select Foot as the air outlet It is the recommended position but you can change the foot position as desired Using the R F switch...

Page 51: ...ion using the preset buttons or the tuning buttons 3 Adjust the volume and sound quality as desired Be sure to listen to the radio at an appropriate volume level in order to secure safe operation 4 To...

Page 52: ...C75 2 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 53: ...tumblers and sprockets Check oil leak and water leak from the engine Remove dust and foreign matters from the engine radiator and peripheral parts Check for leaks from and damages to the intake and ex...

Page 54: ...preheat lamp 4 is lit and goes out then The lighting time of the preheat lamp varies with the water temperature Make sure that the battery voltage display is normal approximately 24 V Make sure that t...

Page 55: ...The engine starts 3 Release the hand from the key when the engine starts The key returns to the ON position automatically 4 Set the left lever unit to the operation position when starting operation A...

Page 56: ...g switch 2 to deactivate the brake Make sure that the mark lamp is off The parking switch 2 is equipped with the parking brake safety function for preventing erroneous travel after turning ON the engi...

Page 57: ...in the right forward direction Left turn and backward Pull the joystick lever in the right backward direction Right turn and backward Pull the joystick lever in the left backward direction Spin Turn O...

Page 58: ...may turn over Carry out dumping on flat and solid grounds where the machine may be maintained as horizontally as possible 2 Avoid dumping on cliffs or near ditches in danger of falling as far as poss...

Page 59: ...e key switch is turned ON 2 Pressing the engine start stop button while the engine key switch is ON starts the engine The use of the engine start stop button on the joystick lever is for temporary ope...

Page 60: ...gine cooling water is low the warm up mode is activated While in the warm up mode the idling engine speed increases however when the water temperature rises the warm up mode is automatically deactivat...

Page 61: ...hours first Pay attention to the following when breaking in a new machine Warm up the machine sufficiently Do not start or accelerate quickly or stop unnecessarily Do not change the direction quickly...

Page 62: ...lic pump with the joystick lever to adjust the travel speed The engine revolutions can also be set with the accelerator pedal This mode allows the operator to feel as if the operator operates the mach...

Page 63: ...ic mode the engine revolutions are automatically linked according to the amount of each operation 2 Accelerator pedal Combined with the joystick the accelerator pedal adjusts the travel speed of the m...

Page 64: ...ick Low speed End 0 Very slow speed High speed End 0 Maximum Speed When you want to travel a narrow course for instance setting the dial at the low speed side makes it easier to travel 4 Engine speed...

Page 65: ...l dial is at the lowest speed position Operating the joystick travels the machine at a speed range from stop to very slow Operating the accelerator pedal can adjust the speed of travel from very slow...

Page 66: ...erator needs to adjust the engine revolutions 2 Accelerator pedal In the manual mode the accelerator pedal adjusts the engine revolutions With the amount of step on the accelerator pedal the engine re...

Page 67: ...PERATION IC75 2 ENG 3 15 3 Travel speed control dial This is not used in the manual mode 4 Engine speed control dial In the manual mode this sets the engine revolutions Low speed High speed CA C201040...

Page 68: ...nit 2 is set to the lock position Stopping the engine 1 Keep the engine idling for approximately 5 minutes to lower the temperature of the engine 2 Set the engine key switch 3 to the OFF position to s...

Page 69: ...l in the proper postures shown below Drive the machine with the cabin upper side of a slope when the vessel is empty This posture ensures stable driving since the center of gravity is located on the c...

Page 70: ...educe the speed 1 Return the joystick lever to the neutral position 2 Reduce the engine speed control dial 3 down to the low speed The cause of overrun is over loading Never over load the machine Emer...

Page 71: ...of steel cord to sustain tension iron core to support it and covering rubber to cover them NOTICE If a crack reaches the steel cord it may be rusted and cut off by moisture When any crack is detected...

Page 72: ...TCH 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...

Page 73: ...ses 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 urea aqueous solution or paint s...

Page 74: ...ed 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 trave...

Page 75: ...t and solid ground Remove dirt and soil from the crawlers to prevent slippage Remove grease oil water and other adherent matters from the loading ramps Never make a turn on the loading ramps to avoid...

Page 76: ...portation Fix it firmly on the load carrying platform of the trailer with wheel blocks and wire ropes Apply wheel blocks in front of and behind the rubber crawlers to fix the machine Finally make sure...

Page 77: ...eight on lifting the machine 10500 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 ro...

Page 78: ...ed 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 engi...

Page 79: ...tain 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 80: ...hen remove the key from the engine key switch Hang a tag indicating that inspection and maintenance are in progress at an easily visible location on the engine key switch or the left lever unit Cautio...

Page 81: ...vessel completely 2 Raise the safety bar and set it to the bracket under the vessel Do not start the engine or lower the vessel while the safety bars are used Such an action may cause breakage of the...

Page 82: ...c fuel pump and fuel main filter 1 Fuel hose between fuel main filter and engine 1 Fuel hose between engine and fuel cooler 1 Fuel hose between fuel cooler and fuel tank 1 Hydraulic Hose Parts to be r...

Page 83: ...el reduction gear Inspect lubricant level and replenish Change lubricant First time Hydraulic system Hydraulic oil tank Inspect hydraulic oil level and replenish Drain Change hydraulic oil Suction str...

Page 84: ...ect for fuel leaks and damages Air intake and exhaust system Air cleaner Inspect clogging warning lamp Clean and change element Air intake and exhaust SCR pipes Inspect for leaks and damages Electrica...

Page 85: ...stem 96 L Tank level 70 L Travel reduction gear Gear oil API GL 4 4 0 L Fuel tank Diesel fuel JIS 255 L Cooling system Coolant LLC Make a 50 addition of long life coolant LLC Total q ty 33 8 L DEF sys...

Page 86: ...ised Hinge pins of the vessel rear gate 1 2 positions Lock pins of the vessel rear gate 2 2 positions Control springs of the vessel rear gate 3 2 positions Vessel joint pins 4 2 positions Dump cylinde...

Page 87: ...xchange 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 88: ...ealer for repair services Loosening the rubber 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 litt...

Page 89: ...the locktite to the threads and tighten them at the specified torques Traveling rated No Special tightening Thread size Wrench size mm Tightening torque N m kgf m 1 Travel reduction gear M16 24 241 24...

Page 90: ...et rear M12 19 97 9 9 2 Bracket and frame rear M16 24 241 24 6 3 Engine and bracket front M10 17 55 5 6 4 Bracket and frame front M16 24 241 24 6 Hydraulic pump No Tightening position Bolt size Wrench...

Page 91: ...hose union nut Metric coarse thread heat processed bolt Metric fine thread heat processed bolt Hose size inch Tightening torque N m kgf m N m kgf m N m kgf m M8 13 23 2 3 25 2 5 1 4 25 2 5 M10 17 47...

Page 92: ...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 an...

Page 93: ...emperature 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 refill hydraulic oil through the filler port 2 Drain the Hydraulic Oil Tank O...

Page 94: ...discharge residual oil Tighten the drain plug after discharging oil 4 Disconnect the hose from the tube 3 Remove the bolt 4 and take out the strainer 5 5 Clean the strainer 5 to remove dust and forei...

Page 95: ...the filter head 2 Apply hydraulic oil to the O ring 3 of a new filter cartridge 3 Attach the filter cartridge and tighten it with the filter wrench Tighten it until the O ring is crushed and the top...

Page 96: ...s below the 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 engin...

Page 97: ...cap 3 Remove the drain plug slowly so that oil will not splash on you Discharge oil then 4 Check drain oil Contact IHI s sales service dealer if it contains much metallic powder foreign matters etc 5...

Page 98: ...ler port 2 up to a point between the H and L levels of the level gauge 4 2 Run the engine idle for a mean while and check if no oil leaks 3 Check the oil level again after 15 minutes or more have pass...

Page 99: ...line 12 Turbo 13 Outside discharge line Anti freezing solution A new machine is filled with coolant containing 50 ethylene glycol long life coolant LLC This coolant has anti freezing effect and corro...

Page 100: ...ot remove the radiator cap 3 Remove the pressure cap 3 on the coolant tank and then replenish coolant to the center line of the sight glass 4 After replenishment secure the pressure cap tightly in pla...

Page 101: ...container 3 Slowly turn the radiator cap 1 to remove it 4 Wash the coolant tank 5 After discharging the water close the drain cock 2 6 Replenish the radiator with a new LLC mixture from the radiator i...

Page 102: ...Wait until each part cools down 1 Inspect belt tension When slackness is measured by applying a force of 110 N 11 kgf to the pulley s intermediate position it is necessary to adjust the belt tension i...

Page 103: ...sh other fluids than the specified DEF Also never replenish DEF diluted with water The new machine is shipped with about 10 liters of AdBlue in its tank DEF must be stored in an airtight container in...

Page 104: ...ect If DEF is not wiped off it will crystallize and whiten When replenishing be careful not to introduce dust and other foreign objects into the DEF tank They will cause clogging in the DEF pump DEF p...

Page 105: ...Must have little residual carbon Use light oil for normal diesel cars that meets the above requirements The functions or performance of parts of the fuel injection system or the engine may be lost or...

Page 106: ...d or spilt fuel may cause a fire Wipe it off completely if it overflows or spills Do not replenish from a drum and plastic container Replenish from a tank track to prevent water and impurities from be...

Page 107: ...letely if it spills Draining water separator Discharge water and sediment contained in fuel from the water separator 1 everyday 1 Place the machine on a flat and firm location and then stop the engine...

Page 108: ...e of the filter head Tighten it with the filter wrench 7 Connect the wire harness of the water separator The Cummins fuel system checks if a proper in fuel water sensor is used or not If the in fuel w...

Page 109: ...lements by blowing with strong air Doing so may degrade filter performance 4 Replace the elements with new ones if they are contaminated excessively or damaged 5 Clean the inside of the pre cleaner an...

Page 110: ...the fuse box Code Capacity A Circuit name F1 15 A Engine start F2 10 A SCR relay F3 10 A Engine service tool F4 15 A DEF S M relay DEF heater relay F5 10 A Back monitor radio F6 20 A Solenoids display...

Page 111: ...when handing 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 Be sure to keep the engine...

Page 112: ...ons Replace the long life coolant every 2000 hours or two years Lubricant and grease Exchange engine oil and hydraulic oil with proper oil having viscosity appropriate for the outer temperature Refer...

Page 113: ...om the machine During Storage 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...

Page 114: ...not change even if changing selectors Discontinuity or disconnection of electric wires Defect of solenoid valve for speed selection Repair or replace parts Repair or replace parts Machine curves durin...

Page 115: ...ntity Unit Remarks Fuel filter cartridge FF63009 1 Cummins Water separator cartridge FS1098 1 Cummins Engine oil filter cartridge LF3970 1 Cummins Air cleaner element primary AF55005 1 Cummins Air cle...

Page 116: ...Ground pressure Empty kPa 24 5 Loaded kPa 39 8 Vessel capacity Fully loaded m 3 4 4 Flat loaded m 3 2 5 A Overall length mm 5460 B Overall width mm 2640 C Overall height mm 2860 D Tumbler center dista...

Page 117: ...OPERATION MANUAL Editing Publishing Office Product Support Group 236 8611 3174 3174 Showa machi Kanazawa ku Yokohama Kanagawa 236 8611 Japan All rights reserved IC75 2 2015 4 First Edition April 2015...

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