IHI IC50 Operation Manual

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OPERATION MANUAL

IC50

SERIAL NUMBER

CA003001 ~

PUB.1

1008

Table of Contents

Summary of Contents for IHI IC50

Page 1 OPERATION MANUAL IC50 SERIAL NUMBER CA003001 ~ PUB.1 1008...
Page 3: Table Of Contents
Steering control Caution of travel on a steep grade DUMP OPERATION ··········································································································· 3-10 Procedure of dump operation Caution of dump operation STOPPING THE ENGINE ·································································································· 3-11 PRECAUTION ON USE OF RUBBER CRAWLER SHOE ················································· 3-12 TOWING ····························································································································· 3-15 IC50 ENG...
Page 4 Check the fuel level Drain the fuel tank Drain the fuel main filter and the fuel pre-filter Clean the electromagnetic fuel pump Replace the main fuel filter element and the pre fuel filter element Fuel system air bleeding IC50 ENG...
Page 5 ELECTRIC SYSTEM ·········································································································· 4-31 Change the fuses Change the fusible link Check the battery Electrical wiring system diagram HANDLING IN COLD REGIONS ························································································ 4-37 LONG TERM STORAGE···································································································· 4-38 TROUBLE SHOOTING ······································································································ 4-39 SPECIFICATIONS SPECIFICATIONS AND DIMENSIONS ··············································································· 5-1 IC50 ENG...
Page 6 IC50 ENG...
Page 7: Foreword
Please understand it. Whenever a question arises regarding your machine, or this publication, please consult your local IHI distributor for the latest available information.
Page 8: Safety Information
• Keep this manual on hand during operation so that you can immediately consult it when necessary. If it should be missing or damaged, place an order from IHI distributor for a replacement. • There are various kinds of federal, state, and local regulations that effect construction and industrial machinery.
Page 9: Safety
This manual describes the basic safety instructions to be observed in daily operation, inspection and maintenance of the machine. Observe these instructions carefully for safety. Check the safety with great care for any other matters not described in this manual. IC50 ENG...
Page 10 IC50 ENG...
Page 11: Precautions Before Operation
• Start the work only after discussing with the person in charge at the site the rules and precautions inside the work place as well as the work procedure. • When working together with other persons, determine the signals and who is to give those signals. IC50 ENG...
Page 12 CONDUCT WARM-UP BEFORE OPERATION. If the machine is operated without carrying out sufficient warming up operation, it can lead to movements not intended by the operator, and can lead to accidents. Always carry out sufficient warming up operation. IC50 ENG...
Page 13: Precautions During Operation
Check that no one is within the working area of the machine before attempting to move it. • Position a guiding person to guide and check when necessary or when the field of view is bad. IC50 ENG...
Page 14 Allowable water depth DO NOT TRY TO TRAVEL OVER OBSTRUCTIONS Trying to travel over obstacles could cause the machine to lose its balance and topple over. Avoid potential obstacles in your path. IC50 ENG...
Page 15 Any person riding as a passenger can fall off and suffer injury. In addition, such a passenger also obstructs the driving by the Operator. Only operator is authorized to be on the machine during operation. Never let unauthorized personnel ride on the machine. IC50 ENG...
Page 16: Precautions After Operation
• Apply the parking brake. • Put the dump lock lever in their locked positions. • Stop the engine and take out the ignition key. • Lock all lockable locations such as the cover, etc., and only then leave the crane. IC50 ENG...
Page 17: Precautions At Transporting
INDICATIONS DURING INSPECTION AND MAINTENANCE Hang a warning board saying “Under Inspection / Maintenance” at an easy to see location of the operation lever so that nobody other than the concerned persons touches it. IC50 ENG...
Page 18 • Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the check valve one turn only. • Do not put your face, hand, foot, or body in front of the check valve. IC50 ENG...
Page 19 Never open the radiator cap when the temperature is till high. After the water temperature has gone down, gradually open the radiator cap thereby releasing the pressure. IC50 ENG...
Page 20 • Inspect for leakage of fuel, oil, and working oil and repair if there is any defect, and wipe off all oil that has leaked. • Make sure where a fire extinguisher is placed and know how to use it. IC50 ENG 1-10...
Page 21: Warning Signs And Labels
You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part. See your IHI dealer for new labels. Where the warning Signs and Labels are stuck...
Page 22 SAFETY 1. Precautions on safety 2. Precaution for working under the (4448 818 00) raised body (4448 816 00) 3. Crawler shoe tension adjustment (D405 516 00) IC50 ENG 1-12...
Page 23 SAFETY 4. Traveling on a slope 5. Loading and unloading the machine (D406 188 00) (4448 820 00) 6. When the body moves down (D407 746 00) IC50 ENG 1-13...
Page 24 Turn off before over an obstacle. inspection and Read manual and maintenance. follow instructions for (D405 366 00) safe and proper operation. (D405 368 00) IC50 ENG 1-14...
Page 25 Do not start the engine or move any of the controls if there is DO NOT OPERATE or similar warning tag attached to the start switch or controls. (D405 323 00) IC50 ENG 1-15...
Page 26 SAFETY This page is intentionally left blank IC50 ENG 1-16...
Page 27: Controls
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. IC50 ENG...
Page 28 IC50 ENG...
Page 29: Nomenclature
Fuel tank Dump cylinder Upper roller Hydraulic tank Safety bar Oscillating link Engine Body Travel device Radiator, oil cooler Side gate Drive sprocket Muffler Rear gate Headlight Air cleaner Rubber crawler Direction indicator lamp Hydraulic pump Idle tumbler IC50 ENG...
Page 30: Controls And Instruments
Hour meter Emergency stop switch Dump lever Turn signal switch Travel speed select switch Dump lever lock Horn switch Car heater switch (option) Operator seat Light switch Inclinometer Seat belt Engine throttle dial Monitor panel Engine key switch IC50 ENG...
Page 31 Fuel level gauge Engine system warning lamp This lamp goes on if the engine system is defective. Ask IHI’s sales 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.
Page 32 Green Fuel level gauge This gauge indicates the fuel level in the fuel tank. F: The fuel tank is full. Fuel tank capacity: 200 liters E: The fuel level is below 25 liters. Refill the tank with fuel. IC50 ENG...
Page 33: Meters
Turn the lever to point the mark (►) to a symbol. : (OFF) : (ON) Two outside lights emit light downward. : (ON) Four lights emit light upward. Horn switch Press the button (3) of this switch to turn on the horn. IC50 ENG...
Page 34 STOP: Push down on the STOP mark position. The mark lamp goes on. The engine stops in emergency and the machine stops traveling. Reset: Push down on the no-mark position. The mark lamp goes out. IC50 ENG...
Page 35 • Push down on the center to turn off the heater. Inclinometer This meter indicates inclination of the machine in the travel direction. The pointer shakes forward when the machine tilts forward. The pointer shakes backward when the machine tilts backward. IC50 ENG...
Page 36: Control Levers
The body stops at the current position when the lever is Dump lever returned to the neutral position. Dump lever lock This lock prevents the body from moving if you touch the dump lever by mistake. Free Locked position: Dumping is disabled. Free position: Dumping is enabled. Locked IC50 ENG...
Page 37: Operator Seat
ALWAYS fasten the seat belt while operating the machine. • ALWAYS check the condition of the seat belt and mounting hardware before operating the machine. Replace the seat belt at least once every three years, regardless of appearance. IC50 ENG...
Page 38 CONTROLS This page is intentionally left blank IC50 ENG 2-10...
Page 39: 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. IC50 ENG...
Page 40 IC50 ENG...
Page 41: Before Starting Operation
• Check the coolant quantity. Refill if necessary. • Check the engine oil quantity. Refill if necessary. • Check the fuel quantity. Refill if necessary. • Check the hydraulic oil quantity. Refill if necessary. • Check the dust indicator. IC50 ENG...
Page 42: Before Starting The Engine
• Turn the turn signal switch (9) and make sure that the direction indicator lamps go on. • Push down the horn switch (10) and make sure that the horn sounds. Ask IHI’s sales service dealer for repair services, if some abnormality is found in the above check. IC50 ENG...
Page 43: Engine Starting
If some abnormality is found, stop the engine immediately, find the cause and repair the defective part. 1. Checking monitor functioning Make sure that all lamps (2) on the monitor are off. 2. Check if engine exhaust color, sound and vibrations are not abnormal. IC50 ENG...
Page 44: Warming Up The Machine
3 to 5 minutes with the dump lever to the “Lower” position to increase the hydraulic oil temperature, when it is low. 3. Move the machine forward and backward and raise and lower the body several times to warm up the mechanisms. IC50 ENG...
Page 45: Starting With Jumper Cables
Disconnect the clip from the negative terminal of the charged battery then. 2. Disconnect the clip of the red cable from the positive terminal of the charged battery first. Disconnect the clip from the positive terminal of the dead battery then. IC50 ENG...
Page 46: Break-In" Operation
Run the machine at approximately 80% of the maximum engine speed. Place loads of approximately 80% of the maximum loading capacity. • Do not start or accelerate quickly or stop unnecessarily. Do not change the direction quickly. IC50 ENG...
Page 47: Traveling The Machine
Increase the travel lever stroke to raise the speed. Decrease the stroke to reduce the speed. 5. Stopping Set the right and left levers (3) and (4) to the neutral position. The machine stops and the travel brake is applied automatically. IC50 ENG...
Page 48: Steering Control
Never change the travel direction quickly on a slope. Quick direction change may cause turnover or slip. Spot turn If it is necessary to change the travel direction quickly, move to a solid ground with a gentle slope and change the direction. IC50 ENG...
Page 49: Caution Of Travel On A Steep Grade
• Do not accelerate or decelerate the speed or stop Downhill suddenly. • The engine may stop if the travel lever is pulled fully while climbing a slope. When the engine speed lowers, return the travel lever slightly to reduce the engine load. IC50 ENG...
Page 50: Dump Operation
If there is a too big object to be dumped through the rear gate, remove the gate in advance. 4. Make sure that the body has lowered completely before starting the machine. 5. Do not travel while the body is raised. ALWAYS travel keeping the body lowered. IC50 ENG 3-10...
Page 51: Stopping The Engine
Repair defective parts if oil leak or damages are found. 2. Fill the fuel tank with fuel. 3. Remove soil and sand from the body and traveling mechanisms, in particular. 4. Lock the fuel filling port, engine hood and all other lockable parts. IC50 ENG 3-11...
Page 52: Precaution On Use Of Rubber Crawler Shoe
When any crack is Steel cord Covering rubber detected, immediate repair is essential. Please contact your local IHI distributor. Cautions while working and traveling Avoid the following while traveling. DO NOT TRAVEL OR WORK ON STONE...
Page 53 • Travel slowly and take care not to let the crawlers come off the rollers. • Do not change directions when the crawlers may have lost tension at the high and low parts of ruts and protrusions. This may cause the crawlers to come off. IC50 ENG 3-13...
Page 54 ALWAYS USE CORRECT TENSION ON THE SHOE Upper roller Idler Attempting to change directions on terrain with different levels or steps while the rubber crawler is still slack may damage the rubber crawlers or cause them to come off the rollers. IC50 ENG 3-14...
Page 55: Towing
4. Move the travel lever in the travel direction slowly when towing starts. NOTICE When the engine is broken and will not start, the parking brake will not release. The parking brake will prevent the crawler belt from rotating so the carrier cannot be towed. IC50 ENG 3-15...
Page 56: Transport
3. Maintain the slope of loading ramps within 15 degrees. 4. Drive the machine slowly at low speed. 5. Maintain the machine balance point while traveling over the loading ramp joint areas. 6. Load the machine properly at the specified position on the truck. IC50 ENG 3-16...
Page 57: Fixation At Transport
Wire rope Wire rope Apply wheel blocks in front of and behind the rubber crawlers to fix the machine. Finally, make sure that the machine is loaded properly and fixed completely. Wheel block Wheel block IC50 ENG 3-17...
Page 58: Lifting The Machine
Install the wire rope to the sling frame with the shackle. Install the wire rope to the crane hooks and lift upward so the crawler is a little bit above the ground, then stop lifting. If the balance is good continue slowing lifting the machine. IC50 ENG 3-18...
Page 59 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. IC50 ENG...
Page 60 IC50 ENG...
Page 61: Precaution On Maintenance
Use oil and grease of viscosity appropriate to the temperature. Ask IHI’s sales service dealer for important maintenance. Ask IHI’s sales service dealer for important maintenance works such as replacement of electronic parts, adjustment of the hydraulic pressure and so forth that require professional knowledge and technique.
Page 62: Use The Safety Bar
Such an action may cause breakage of the safety bar or body. When the safety bar is set. Frame Removing the safety bar 1. Raise the body completely. 2. Remove the safety bar from the bracket and store the bar onto the frame. IC50 ENG...
Page 63: Periodical Exchange Of The Important Parts
Hydraulic hose (between pump, CV and dump cylinder) Repair or replace these parts immediately if some abnormalities or defects are found in them even before the replacement periods. Also check the fuel hoses and hydraulic hoses in daily check, monthly check and yearly check. IC50 ENG...
Page 64: Maintenance Intervals
Engine oil system Check oil q’ty & refill Replace oil & oil filter First cartridge time Engine cooling system Check coolant q’ty & refill Replace coolant (use LLC) Check & adjust fan First belt tension time IC50 ENG...
Page 65 Clean air cleaner element Replace air cleaner element Electric system Replace fuse Replace fusible link Check battery Engine, etc. Measure engine compression pressure Check valve clearance • Inquire of IHI’s sales service dealer about the maintenance items with marks. IC50 ENG...
Page 66: Recommended Lubrication Table
Tank level: 50 L Travel Gear oil API GL-4 2.6 L SAE90 reduction gear JIS No. 2 Fuel tank Light oil 120 L JIS No. 3 JIS special No. 3 Total q’ty: Cooling system Coolant Long-life coolant (LLC) added 16.4 L IC50 ENG...
Page 67: Lubricate The Grease
• Control springs of the body rear gate (4) 2 positions Oscillating link • Oscillating link pins (5) 8 positions NOTICE Grease the link pins everyday before starting works if the machine is used on damp grounds or in mud. IC50 ENG...
Page 68: Rubber Crawler
RUBBER CRAWLER Rubber crawler shoe maintenance Rubber crawler shoe should be repaired or exchanged under the next conditions. If it is necessary to repair or replace it, contact your IHI dealer. Crack of covering rubber • Height of Lugs Height of lugs...
Page 69: Track Adjustment
Adjust the right and left rubber crawlers evenly. • If the rubber crawlers are not tensioned properly, the cylinders may be defective. Ask IHI’s sales service dealer for repair services. Loosening the rubber crawlers 1. Remove dirt and soil from around the idle tumblers.
Page 70: Check The Fixed Bolt Torque
(1) Tighten all of five bolts with the locktite applied at a torque of 98 to 156.9 N⋅m first. (2) Then, tighten the five bolts in the order shown on the right at the specified torque of 241 N⋅m. Tighten the bolts quickly since screw locking agent is applied to them. IC50 ENG 4-10...
Page 71: General Torque Specifications
Tightening size thread heat- Hose size size heat-processed bolt torque (mm) processed bolt (inch) (N·m) (kgf·m) (N·m) (kgf·m) (N·m) (kgf·m) 1/4" 3/8" 1/2" 13.7 13.8 3/4" 12.0 21.2 22.5 1" 14.0 41.9 46.1 1-1/4" 17.0 72.9 82.7 IC50 ENG 4-11...
Page 72: Travel Reduction Gear
3. Remove the 3 plugs to discharge oil. 4. Attach the drain plug. 5. Fill the specified quantity of gear oil through the filler port. 6. Attach the level plug when oil is discharged through the level port. IC50 ENG 4-12...
Page 73: Hydraulic System
1. Loosen the drain plug (4) under the hydraulic oil tank to discharge water and sediment into the container. 2. Close the drain plug when clean hydraulic oil is only discharged. 3. Check the hydraulic oil level. Refill oil if insufficient. IC50 ENG 4-13...
Page 74: Replace The Hydraulic Oil And Clean The Strainer
Bring the machine into the posture for checking the hydraulic oil level. Stop the engine. 9. Make sure that the hydraulic oil level is within the proper range. Refill hydraulic oil if insufficient. IC50 ENG 4-14...
Page 75: Replace The Line Filter Element
7. Store the safety bar, move down the load carrying platform, and check the level of hydraulic oil. The level is proper if it is between the H and L levels of Line filter the level gauge. Refill hydraulic oil if the level is too low. IC50 ENG 4-15...
Page 76: Replace The Return Filter Cartridge
6. Store the safety bars, lower the body and check the oil level in the hydraulic oil tank. It is OK if the oil level is between the H and L positions of the level gauge. Refill hydraulic oil if insufficient. IC50 ENG 4-16...
Page 77: Engine Oil System
Further, it may increase oil consumption, reduce the engine output and cause engine breakage or other serious accidents. We will not warrant any breakdown or accidents caused by using improper engine oil. IC50 ENG 4-17...
Page 78: Replace The Engine Oil And Engine Oil Filter Cartridge
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. Tighten the drain plug.
Page 79: Cooling System
If it is put into eyes, wash the eyes with water sufficiently immediately and consult a doctor. • If it is necessary to store it, use a container with an antifreeze mark, cap it and store it in a place inaccessible by children. IC50 ENG 4-19...
Page 80: Check The Coolant Level
2. If the reserve tank is empty, check water leak, remove the radiator cap (2), and check the radiator coolant level. If radiator coolant is insufficient, refill radiator with coolant. Then, refill the reserve tank with coolant. IC50 ENG 4-20...
Page 81: Change The Coolant
9. Keep the engine idling for 5 minutes or less with the radiator cap removed to discharge air from the cooling system. 10. Stop the engine. Check the coolant level after the engine cools down. Refill coolant if insufficient. Tighten the radiator cap then. IC50 ENG 4-21...
Page 82: Check The Fan Belt
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. IC50 ENG 4-22...
Page 83: Fuel System
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 insufficient. 2. Close the cap of the filler port firmly after refilling. IC50 ENG 4-23...
Page 84: Drain The Fuel Tank
It may also cause engine troubles and accidents. Never use fuel other than light oil. We will not warrant any troubles caused by using fuel other than light oil. IC50 ENG 4-24...
Page 85: Drain The Fuel Main Filter And The Fuel Pre-Filter
Then, loosen the drain plug (4) at the bottom of the case to discharge water collected inside. 3. Be sure to tighten the plugs after discharging water. Discharge air from the fuel system. Be careful not to over-tighten the air bleeder plug (4). IC50 ENG 4-25...
Page 86: Clean The Electromagnetic Fuel Pump
O ring and screw the case. Tighten the case using the filter wrench firmly when the O ring contacts with the seal surface. 4. Discharge air from the fuel system. See page 4-27 “Fuel system air bleeding”. IC50 ENG 4-26...
Page 87 9. Increase the engine speed gradually and keep the maximum speed for 3 minutes. 10. Repeat steps 8 and 9 several times. WARNING Check if no fuel leaks from the fuel system. Leaked fuel may cause a fire. IC50 ENG 4-27...
Page 88: Air Cleaner System
3. Push the reset button (2) of the dust indicator to reset the red signal after cleaning or replacing the element. NOTICE Clean the air cleaner element if the dust indicator shows a red signal in daily check, regardless of the maintenance time. Red signal Reset IC50 ENG 4-28...
Page 89: Clean And Change The Air Cleaner Element
Insert the O ring (7) and fix it with the clamp. 9. Push the button of the dust indicator to reset the red signal. Replacing the element Replace the element with a new element in the same procedures as shown above. IC50 ENG 4-29...
Page 90: Hydraulic System
B1: Forward A2: Backward Pump 2 Pump relief valves for left travel motor 34.0 B2: Forward Control Main relief valve for dump (Raise) 20.6 Valve Over load relief valve for dump (Lower) Pump1•2 C1•C2 Charge relief valve IC50 ENG 4-30...
Page 91: Electric System
• If a new fuse still blows out after replacement, ask IHI’s sales service dealer for checks. 1. Unlatch and detach the fuse cover (1). 2. Replace the blown fuse with a new fuse of the same capacity.
Page 92: Check The Battery
2. Detach the terminals and polish them with a wire brush or sandpaper if they are corroded remarkably. 3. Apply grease, etc. thinly to the terminals after cleaning and tightening. IC50 ENG 4-32...
Page 93 MAINTENANCE This page is intentionally left blank IC50 ENG 4-33...
Page 94: Electrical Wiring System Diagram
MAINTENANCE Electrical wiring system diagram INSTRUMENT PANEL IC50 ENG 4-34...
Page 95 2. The connection diagram shows the layout viewed from the plane. ENGINE Color symbol table Black Gray Engine key switch contact Green Brown Violet White Sky blue Pre-heat Yellow Pink Blue Light green CABIN (OPTION) Orange Start IC50 ENG 4-35...
Page 96 Fuel level sensor Monitor panel Diode Car heater switch (opt.) Car heater Engine tachometer Travel speed select switch Travel speed select solenoid Parking switch Parking brake solenoid Combination switch Turn signal(right) Turn signal(left) Flasher relay Horn relay Horn IC50 ENG 4-36...
Page 97: Handling In Cold Regions
• Put plates on dry and solid ground and park the machine on them in order to prevent the crawlers and around them from freezing. • Discharge water from the fuel tank to prevent fuel from freezing. IC50 ENG 4-37...
Page 98: Long Term Storage
3. Warm up the engine at low speed. Increase the engine speed after the water temperature reaches the proper temperature. After Storage Lubricate or grease every necessary part, check the coolant level and refill coolant if necessary, before using the machine after long-term storage. IC50 ENG 4-38...
Page 99: Trouble Shooting
Machine does not • Short of hydraulic oil • Supply oil to specified level. travel smoothly. • Defect of motor or reduction gear • Repair or replace parts.* • Defect of pump • Repair or replace parts.* IC50 ENG 4-39...
Page 100 MAINTENANCE This page is intentionally left blank IC50 ENG 4-40...
Page 101: Specifications
SPECIFICATIONS IC50 ENG...
Page 102 IC50 ENG...
Page 103: Specifications And Dimensions
Tumbler center distance 3130 Overall crawler width 2200 Crawler width Minimum height from ground Body length 2600 Inner body width 1950 Body height Body floor height from ground 1160 Maximum dumping angle ºC Maximum height in dumping 3540 IC50 ENG...

IHI IC50 Operation Manual

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