WARMING UP THE MACHINE ···························································································· 3-4 STARTING WITH JUMPER CABLES ·················································································· 3-5 “BREAK-IN” OPERATION ···································································································· 3-6 TRAVELING THE MACHINE································································································ 3-7 Start-travel-stop Steering control Caution of travel on a steep grade DUMP OPERATION ··········································································································· 3-11 Procedure of dump operation Caution of dump operation IC75 ENG...
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Change the line filter cartridge and return filter cartridge ENGINE OIL SYSTEM ······································································································· 4-17 Check the engine oil level Replacing engine oil and engine oil filter cartridge COOLING SYSTEM ··········································································································· 4-19 Selection of coolant Check the coolant level Change the coolant Check the fan belt IC75 ENG...
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ELECTRIC SYSTEM ·········································································································· 4-30 Change the fuses Change the fusible link Check the battery Electrical wiring system diagram HANDLING IN COLD REGIONS ························································································ 4-35 LONG TERM STORAGE···································································································· 4-36 TROUBLE SHOOTING ······································································································ 4-37 SPECIFICATIONS SPECIFICATIONS AND DIMENSIONS ··············································································· 5-1 IC75 ENG...
Please understand it. Whenever a question arises regarding your machine, or this publication, please consult your local IHI distributor for the latest available 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.
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. IC75 ENG...
• 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. IC75 ENG...
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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. IC75 ENG...
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. IC75 ENG...
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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. IC75 ENG...
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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. IC75 ENG...
• Put the gate lock lever and 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. IC75 ENG...
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. IC75 ENG...
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• 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. IC75 ENG...
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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. IC75 ENG...
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• 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. IC75 ENG 1-10...
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...
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SAFETY 1. Precautions on safety 2. Precaution for working under the (D405 624 00) raised body (4448 816 00) 3. Crawler shoe tension adjustment 4. Gate lock lever (D405 516 00) (D405 620 00) IC75 ENG 1-12...
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5. Traveling on a slope 6. Loading and unloading the machine (D406 188 00) (D406 618 00) 7. Under-water works 8. When the body moves down (D406 189 00) (D407 746 00) 9. Safety alarm (D407 716 00) IC75 ENG 1-13...
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Turn off before over an obstacle. inspection and Read manual and maintenance. follow instructions for (D405 482 00) safe and proper operation. (D405 368 00) IC75 ENG 1-14...
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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) IC75 ENG 1-15...
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SAFETY This page is intentionally left blank IC75 ENG 1-16...
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. IC75 ENG...
Dump lever lock Horn switch Emergency stop switch Gate lock lever Light switch Engine key switch Operator seat Travel speed select switch Slope warning lamp Seat belt Parking switch Overrun warning lamp Monitor panel Car heater switch (option) IC75 ENG...
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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.
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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. IC75 ENG...
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. IC75 ENG...
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• Push down on the center to turn off the heater. Engine throttle dial Use this dial to adjust the engine speed and output. High: Turn the dial to the mark position. Low: Turn the dial to the mark position. IC75 ENG...
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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. IC75 ENG...
Overrun warning lamp The warning lamp (2) on the ceiling goes on and the alarm buzzer keeps sounding, if the engine speed exceeds 2300 min while moving down a slope. Posture that activates the safety warning devices IC75 ENG...
The body stops at the current position when the lever is returned to the neutral position. Dump lever lock Free This lock prevents the body from moving if you touch the dump lever by mistake. Locked position: Dumping is disabled. Locked Free position: Dumping is enabled. IC75 ENG...
Push down the lever (1) inside the door to unlock the door when the door is closed. Push down the lever (2) inside the door to unlock the door when the door is open. Left position inside the cabin IC75 ENG 2-10...
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. IC75 ENG 2-11...
Adjust the temperature of air blow out of the air port between heating (red) and cooling (blue) with this lever. 4. Inner/outer air select switch Select inner air or outer air with this switch. The inner air mode and outer air mode are selectable. IC75 ENG 2-12...
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. IC75 ENG...
• 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. IC75 ENG...
• Turn the turn signal switch (10) and make sure that the direction indicator lamps go on. • Push down the horn switch (11) 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. IC75 ENG...
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. IC75 ENG...
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. IC75 ENG...
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. IC75 ENG...
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. IC75 ENG...
Increase the travel lever stroke to raise the speed. Decrease the stroke to reduce the speed. 5. Stopping Set the right and left levers to the neutral position. The machine stops and the travel brake is applied automatically. IC75 ENG...
Never change the travel direction quickly on a slope. Quick direction change may cause turnover or slip. If it is necessary to change the travel direction quickly, move to a solid ground with a gentle slope and change the direction. Spot right turn IC75 ENG...
• Do not accelerate or decelerate the speed or stop 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. IC75 ENG...
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2. Reduce the engine speed down to the low idling speed. 3. If the speed is not reduced, push down on the STOP mark position of the emergency stop switch (4). The engine stops in emergency and the machine stops traveling. IC75 ENG 3-10...
Dump at a level and stable place. 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. IC75 ENG 3-11...
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. IC75 ENG 3-12...
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...
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• 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. IC75 ENG 3-14...
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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. IC75 ENG 3-15...
4. Move the travel lever in the travel direction slowly when towing starts. IMPORTANT When the engine is broken and will not start, the parking brake will not release. The parking brake will prevent the crawler shoe from rotating so the carrier cannot be towed. IC75 ENG 3-16...
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 trailer. IC75 ENG 3-17...
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 IC75 ENG 3-18...
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. IC75 ENG 3-19...
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OPERATION This page is intentionally left blank IC75 ENG 3-20...
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. IC75 ENG...
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.
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. IC75 ENG...
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. IC75 ENG...
Engine oil system Checking oil q’ty & refilling Replacing oil & oil filter First cartridge time Engine cooling system Checking coolant q’ty & refilling Replacing coolant (using LLC) Checking & adjusting First fan belt tension time IC75 ENG...
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Checking battery Engine, etc. Checking turbo charger Checking & cleaning EGR valve Cleaning EGR lead valve Cleaning EGR cooler Measuring engine compression pressure Checking valve clearance • Inquire of IHI’s sales service dealer about the maintenance items with marks. IC75 ENG...
Tank level: 70 L Travel Gear oil API GL-4 4.0 L SAE90 reduction gear JIS No. 2 Fuel tank Light oil 200 L JIS No. 3 JIS special No. 3 Total q’ty: Cooling system Coolant Long-life coolant (LLC) added 28.8 L IC75 ENG...
Control lever • Foot pin of the travel lever (8) 1 position • Foot pin of the dump lever (9) 1 position • Link pin of dump lever linkage (10) 1 position IC75 ENG...
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. • Height of Lugs Crack of covering rubber The rubber crawler can be used even if it is worn,...
• 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. 2. Loosen the check valve until grease is discharged (by a maximum of one turn) little by little.
(2) Tighten all of six bolts with screw locking agent applied at a torque of 98 to 156.9 N⋅m first. (3) Then, tighten the 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. IC75 ENG 4-10...
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Bracket and turntable (rear) 24.6 Engine and bracket (front) Bracket and turntable (front) 24.6 Hydraulic pump Tightening torque Wrench required Tightening position Bolt size (mm) (N·m) (kgf·m) Engine and pump housing Pump housing and hydraulic pump 15.9 IC75 ENG 4-11...
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. IC75 ENG 4-13...
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. IC75 ENG 4-14...
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. IC75 ENG 4-15...
5. 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. Return filter Line filter IC75 ENG 4-16...
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 cause engine troubles. Be careful. IC75 ENG 4-17...
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.
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. IC75 ENG 4-19...
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. FULL level LOW level Reserve tank IC75 ENG 4-20...
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. IC75 ENG 4-21...
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. IC75 ENG 4-22...
2. Close the cap of the filler port firmly after refilling. Drain the fuel tank 1. Loosen the drain plug (3) at the bottom of the fuel tank to discharge water and sediment into the container. 2. Close the drain plug when clean fuel is only discharged. IC75 ENG 4-23...
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. IC75 ENG 4-24...
Put a new element (6) into the case. Apply fuel thinly to the 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. IC75 ENG 4-25...
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. IC75 ENG 4-26...
3. Push the reset button (2) of the dust indicator to reset the red signal after cleaning or replacing the element. IMPORTANT Clean the air cleaner element if the dust indicator shows a red signal in daily check, regardless of the maintenance time. Re signal Reset IC75 ENG 4-27...
Insert the O ring (7) and fix it with the clamp. 9. Push the button of the dust indicator (8) to reset the red signal. Replacing the element Replace the element with a new element in the same procedures as shown above. IC75 ENG 4-28...
B1: Forward A2: Backward Pump 2 Pump relief valves for left travel motor 37.0 B2: Forward Control Main relief valve for dump (Raise) 17.7 Valve Over load relief valve for dump (Lower) Pump1•2 C1•C2 Charge relief valve IC75 ENG 4-29...
• 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.
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. IC75 ENG 4-31...
MAINTENANCE Electrical wiring system diagram INSTRUMENT PANEL IC75 ENG 4-32...
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1. Unless otherwise specified, the wire thickness is AVS-0.75. 2. The connection diagram shows the layout viewed from the plane. Color symbol table Black Gray Engine key switch contact Green Brown Violet Pre- White Sky blue heat Yellow Pink Blue Light green CABIN Orange Start IC75 ENG 4-33...
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Car heater switch (opt.) Engine Control Module Car heater Air conditioner Condenser pressure switch Compressor Engine tachometer Overrun warning controller Clinometer Incline warning lamp Warning buzzer Travel speed select switch Travel speed select solenoid Parking brake solenoid IC75 ENG 4-34...
• 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. IC75 ENG 4-35...
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. IC75 ENG 4-36...
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.* IC75 ENG 4-37...
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MAINTENANCE This page is intentionally left blank IC75 ENG 4-38...
Tumbler center distance 3870 Overall crawler width 2500 Crawler width Minimum height from ground Body length 3100 Inner body width 2200 Body height Body floor height from ground 1280 Maximum dumping angle ºC Maximum height in dumping 4487 IC75 ENG...
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All rights reserved. First Edition, July 2010 取 扱 説 明 書 IC75 OPERATION MANUAL 編集及び発行所 プロダクトサポート部 Editing & Publishing Office. Product Support Department 〒236-8611 神 奈 川 県 横 浜 市 金 沢 区 昭 和 町 3 1 7 4...