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IHI IC75 Operation Manual Download Page 63

IC75 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

Page 1: ...OPERATION MANUAL IC75 SERIAL NUMBER CA003001 PUB 1 1007...

Page 2: ......

Page 3: ...S 2 2 Monitor panel Meters Switches Safety warning devices Control levers CABIN 2 10 Cabin Operator seat Seat belt Air conditioner OPERATION BEFORE STARTING OPERATION 3 1 BEFORE STARTING THE ENGINE 3...

Page 4: ...ER CRAWLER 4 8 Rubber crawler shoe maintenance TRACK ADJUSTMENT 4 9 CHECK THE FIXED BOLT TORQUE 4 10 Special torque specifications General torque specifications TRAVEL REDUCTION GEAR 4 13 Check the tr...

Page 5: ...lter element Fuel system air bleeding AIR CLEANER SYSTEM 4 27 Check the dust indicator Clean and change the air cleaner element HYDRAULIC SYSTEM 4 29 Hydraulic system diagram ELECTRIC SYSTEM 4 30 Chan...

Page 6: ...IC75 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: ...caused 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...

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: ...IC75 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: ...d 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 If...

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: ...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 label if it is damaged missing or...

Page 22: ...SAFETY IC75 ENG 1 12 1 Precautions on safety D405 624 00 2 Precaution for working under the raised body 4448 816 00 3 Crawler shoe tension adjustment D405 516 00 4 Gate lock lever D405 620 00...

Page 23: ...AFETY IC75 ENG 1 13 5 Traveling on a slope D406 188 00 6 Loading and unloading the machine D406 618 00 7 Under water works D406 189 00 8 When the body moves down D407 746 00 9 Safety alarm D407 716 00...

Page 24: ...touch when hot D405 477 00 13 Sign indicates an electrical hazard from handling the cable Read manual for safe and proper handling D405 363 00 14 Sign indicates an electrocution hazard if machine is...

Page 25: ...he machine to minimize danger caused by accidents such as falling down D407 741 00 21 Sign indicates a crush hazard from falling body Read manual and follow safety instructions when holding the body i...

Page 26: ...SAFETY IC75 ENG 1 16 This page is intentionally left blank...

Page 27: ...IC75 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: ...IC75 ENG...

Page 29: ...0 Dump cylinder 18 Oscillating link 3 Hydraulic tank 11 Safety bar 19 Travel device 4 Engine 12 Body 20 Drive sprocket 5 Radiator oil cooler 13 Rear gate 21 Headlight 6 Muffler 14 Rubber crawler 22 Di...

Page 30: ...witch Cabin 3 Dump lever 11 Turn signal switch 19 Cigarette lighter Cabin 4 Dump lever lock 12 Horn switch 20 Emergency stop switch 5 Gate lock lever 13 Light switch 21 Engine key switch 6 Operator se...

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: ...e ON Push down on the P mark position The mark lamp goes on OFF Push down the no mark position The mark lamp goes out Car heater switch Use this switch to turn on the fan of the cabin heater High and...

Page 35: ...urned on automatically when the knob is pushed down It is pushed out several seconds later Pull it out and use it Emergency stop switch Use this switch if the brake does not work and the machine does...

Page 36: ...to this position to start the engine Release the hand from the key immediately after the engine starts The key returns to the ON position automatically Safety warning devices Slope warning lamp The w...

Page 37: ...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 38: ...hen the travel lever is operated Move the gate lock lever to the free position when starting the engine The engine does not start if the gate lock lever is at the locked position CABIN Cabin Door lock...

Page 39: ...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 40: ...cator lamp is lit while this switch is on 2 Fan speed select dial Turn on or off the fan and adjust the air quantity with this dial Select the low middle or high fan speed to control the air quantity...

Page 41: ...IC75 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 42: ...IC75 ENG...

Page 43: ...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 44: ...ition and check the following Engine preheating starts automatically Make sure that the glow lamp 5 is lit for 1 to 15 seconds and goes out then Make sure that the engine oil pressure warning lamp 6 a...

Page 45: ...urn the key to the START position The engine starts 4 Release the hand from the key when the engine starts The key returns to the ON position automatically AFTER STARTING THE ENGINE IMPORTANT Never ra...

Page 46: ...until 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...

Page 47: ...harged 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...

Page 48: ...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 approxima...

Page 49: ...of 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 leve...

Page 50: ...right side travel lever backward and move the left side travel lever forward at the same time This allows a quick right turn counter track rotation WARNING NEVER steer on a grade or unstable ground w...

Page 51: ...pper side 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...

Page 52: ...ng if the engine speed exceeds 2300 min 1 while moving down a slope Carry out the following operation to reduce the speed immediately 1 Return the travel lever to the neutral position 2 Reduce the eng...

Page 53: ...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 grounds where the ma...

Page 54: ...ver lock 2 is set to the locked position 5 Set the gate lock lever 3 to the locked position Stopping the engine 1 Keep the engine idling for approximately 5 minutes to lower the temperature of the eng...

Page 55: ...tain tension iron core to support it and covering rubber to them IMPORTANT If a crack reaches the steel cord it may be rusted and cut off by moisture When any crack is detected immediate repair is ess...

Page 56: ...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 57: ...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 58: ...owed 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 tra...

Page 59: ...olid ground Remove 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...

Page 60: ...ansportation 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 s...

Page 61: ...ight on lifting the machine 10300 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 rop...

Page 62: ...OPERATION IC75 ENG 3 20 This page is intentionally left blank...

Page 63: ...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 64: ...IC75 ENG...

Page 65: ...the engine 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...

Page 66: ...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 breakage o...

Page 67: ...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 68: ...htening bolts Travel reduction gear Checking lubricating oil q ty refilling Replacing lubricating oil First time Hydraulic system Checking oil q ty refilling Draining oil tank Replacing oil cleaning s...

Page 69: ...ain filter pre filter element Cleaning electromagnetic fuel pump filter Air cleaner system Checking dust indicator Cleaning air cleaner element Replacing air cleaner element Electric system Replacing...

Page 70: ...l pan Engine oil API CD H 22 L L 17 L Hydraulic oil tank Hydraulic oil Abrasion resistant Whole system 100 L Tank level 70 L Travel reduction gear Gear oil API GL 4 4 0 L Fuel tank Light oil JIS 200 L...

Page 71: ...of the body rear gate 2 2 positions Control springs of the body rear gate 3 2 positions Body joint pins 4 2 positions Dump cylinder rod pins 5 2 positions Dump cylinder foot pins 6 2 positions Oscilla...

Page 72: ...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 73: ...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 74: ...m 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 Drive sprocket M16 24 241 24 6 3 Oscil...

Page 75: ...ar M12 19 97 9 9 2 Bracket and turntable rear M16 24 241 24 6 3 Engine and bracket front M10 17 55 5 6 4 Bracket and turntable front M16 24 241 24 6 Hydraulic pump Tightening torque No Tightening posi...

Page 76: ...rse thread heat processed bolt Metric fine thread heat processed bolt Tightening torque Bolt size Wrench size mm N m kgf m N m kgf m Hose size inch N m kgf m M8 13 23 2 3 25 2 5 1 4 25 2 5 M10 17 47 4...

Page 77: ...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 78: ...e 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 hydrauli...

Page 79: ...o discharge residual oil Tighten the drain plug after discharging oil 4 Remove the cover 4 Disconnect the hose from the tube 5 Remove the bolt 6 and take out the strainer 7 5 Clean the strainer to rem...

Page 80: ...f 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 3 is crushed and the t...

Page 81: ...ll it out 3 The oil level is proper if oil on the oil level gauge reaches between the H and L positions 4 Refill engine oil through the filler port 2 if the oil level is below the L level Wait for app...

Page 82: ...ain oil Contact IHI s sales service dealer if it contains much metallic powder foreign matters etc 5 Tighten the drain plug Replacing the filter cartridge 1 Remove the filter cartridge 5 with the filt...

Page 83: ...g 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 Mixing...

Page 84: ...ank 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 is empty check wa...

Page 85: ...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 86: ...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 87: ...ank with fuel up to the top 1 Turn the engine key switch to the ON position and check the quantity of remaining fuel with the fuel gauge Refill the tank with fuel through the filler port 1 if fuel is...

Page 88: ...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 bleeder plug 3 on...

Page 89: ...cover Use the wrench to attach it and tighten firmly to the very end 4 Be sure to check air tightness after attaching the cover Change the main fuel filter element and the pre fuel filter element 1 Lo...

Page 90: ...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 91: ...ot 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 element...

Page 92: ...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 compress...

Page 93: ...t travel motor 37 0 Pump 2 A2 Backward B2 Forward Pump relief valves for left travel motor 37 0 MRV Main relief valve for dump Raise 17 7 Control Valve ORV Over load relief valve for dump Lower 5 9 Pu...

Page 94: ...r 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 15A Em...

Page 95: ...hen 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 CAUTION Be sure to keep the...

Page 96: ...MAINTENANCE IC75 ENG 4 32 Electrical wiring system diagram INSTRUMENT PANEL...

Page 97: ...the wire thickness is AVS 0 75 2 The connection diagram shows the layout viewed from the plane ENGINE CABIN Engine key switch contact Color symbol table Pre heat OFF ON Start Black Green Red White Yel...

Page 98: ...54 Cigarette lighter 16 Air intake temperature sensor 55 Gate lock solenoid 17 Throttle potentiometer 56 Gate lock limit switch 18 Memory clear switch 57 Radio 19 Emergency stop switch 58 Wiper switch...

Page 99: ...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 100: ...g 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 101: ...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 102: ...MAINTENANCE IC75 ENG 4 38 This page is intentionally left blank...

Page 103: ...IC75 ENG SPECIFICATIONS...

Page 104: ...IC75 ENG...

Page 105: ...0 Ground pressure Loaded kPa 39 1 Fully loaded m 3 4 0 Body capacity Flat loaded m 3 2 4 A Overall length mm 5420 B Overall width mm 2590 C Overall height mm 2860 D Tumbler center distance mm 3870 E O...

Page 106: ...OPERATION MANUAL Editing Publishing Office Product Support Department 236 8611 3174 3174 Showa machi Kanazawa ku Yokohama Kanagawa 236 8611 Japan All rights reserved IC75 2010 7 First Edition July 201...

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