1. Manuals
  2. Brands
  3. Kato Manuals
  4. Construction Equipment
  5. IC120-2
  6. Operation manual

Kato IC120-2 Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

IC120-2
CB004001 ~
0988477EN-00

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IC120-2 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Kato IC120-2

Summary of Contents for Kato IC120-2

  • Page 1 IC120-2 CB004001 ~ 0988477EN-00...

  • Page 2: Table Of Contents

    ENGINE STARTING ··························································································· 3-3 AFTER STARTING THE ENGINE ·········································································· 3-3 BASIC OPERATION ··························································································· 3-4 Start-Travel-Stop ········································································································ 3-4 Steering Control ·········································································································· 3-5 Dump Operation ········································································································· 3-6 How to Lower Body in Case of Emergency ······································································· 3-7 Engine Start/Stop Button ······························································································ 3-8 IC120-2 ENG...
  • Page 3 Change the Hydraulic Oil and Clean the Strainer ····························································· 4-15 Replace the Return Filter and Line Filter ········································································ 4-16 ENGINE OIL SYSTEM ······················································································· 4-17 Check the Engine Oil Level ························································································· 4-17 Replace the Engine Oil and Engine Oil Filter ··································································· 4-18 IC120-2 ENG...
  • Page 4 Change the Fuses ····································································································· 4-33 Change the Fusible Link ····························································································· 4-33 Check the Battery ····································································································· 4-34 HANDLING IN COLD REGIONS ·········································································· 4-35 LONG TERM STORAGE ···················································································· 4-36 TROUBLESHOOTING ······················································································· 4-37 PARTS LIST ···································································································· 4-38 SPECIFICATIONS ···································································································· 5-1 SPECIFICATIONS AND DIMENSIONS ··································································· 5-1 IC120-2 ENG...

  • Page 5: Foreword

    Please understand it. Whenever a question arises regarding your machine, or this publication, please consult our distributor for the latest available information. IC120-2 ENG...

  • Page 6: Safety Information

    It is the owner or user of the machine who is responsible for always paying attention to operate the machine, as well as reading and understanding this manual enough to obtain the essential knowledge and skills fundamental to correct machine operation. IC120-2 ENG...

  • Page 7: 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. IC120-2 ENG...

  • Page 8: 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. IC120-2 ENG...
  • Page 9 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. IC120-2 ENG...

  • Page 10: 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. IC120-2 ENG...
  • Page 11 Be careful. 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. IC120-2 ENG...
  • Page 12 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. IC120-2 ENG...

  • Page 13: Precautions After Operation

     Set the left lever unit to the lock position.  Stop the engine and take out the ignition key.  Lock the cover and all other lockable parts. Leave the operator’s seat after taking the above measures. IC120-2 ENG...

  • Page 14: 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 novessel other than the concerned persons touches it. IC120-2 ENG...
  • Page 15  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. IC120-2 ENG...
  • Page 16 Removing the radiator cap or coolant tank cap when the temperature of the coolant is high can cause high temperature steam to spurt out, resulting in burns. After the coolant temperature has gone down, gradually loosen the cap to release the pressure. IC120-2 ENG...
  • Page 17  Inspect for leakage of fuel, oil, and hydraulic 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. IC120-2 ENG 1-10...

  • Page 18: Warning Signs And Labels

    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 Left side of the instrument panel Viewed from direction of A Viewed from direction of B Viewed from direction of C IC120-2-C101000 IC120-2 ENG 1-11...
  • Page 19 1. Precautions on safety 2. Precaution for working under the (D408 704 00) raised vessel (4448 816 00) 3. Crawler shoe tension adjustment (D405 516 00) 4. How to lower body in case of emergency (D408 034 00) IC120-2 ENG 1-12...
  • Page 20 6. Traveling on a slope (D408 689 00) (D406 188 00) 7. Loading and unloading the machine 8. Under-water works (D405 618 00) (D406 189 00) 9. Safety alarm 10. Dump bed operation warning (D408 691 00) (D408 686 00) IC120-2 ENG 1-13...
  • Page 21 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) IC120-2 ENG 1-14...
  • Page 22 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) IC120-2 ENG 1-15...
  • Page 23 SAFETY 25. Contains Fluorinated Greenhouse Gases (Only for air conditioner equipped machine) (D409 001 00) IC120-2 ENG 1-16...

  • Page 24: 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. IC120-2 ENG...

  • Page 25: Names Of Components

    Dump cylinder Oscillating link Hydraulic tank Safety bar Travel device Engine Vessel Drive sprocket Radiator, oil cooler Rear gate Headlight Post-processing unit Rubber crawler Direction indicator lamp Air cleaner Idle tumbler Coolant tank Hydraulic pump Lower roller DEF tank IC120-2 ENG...

  • Page 26: Controls And Instruments

    CONTROLS CONTROLS AND INSTRUMENTS Name Name Instrument panel Operator seat Left lever unit Seat belt Accelerator pedal IC120-2 ENG...

  • Page 27: Instrument Panel

    Cigarette lighter (24 V) Travel speed select switch Emergency engine stop switch Parking switch Engine service connector Mode changeover switch Engine key switch Engine speed control dial Hour meter Travel speed control dial Combination switches Wiper switch Fuse box IC120-2 ENG...

  • Page 28: Display Screen System

    The “Fault code display screen” and “Machine information display screen” are used by our serviceman when a trouble occurs in the machine or engine. The screen returns to the “Operation screen” when the key is pressed. IC120-2 ENG...

  • Page 29: Explanation Of Screen Displays

    Slope warning indicator Preheat indicator High speed Low speed Parking brake indicator Engine error indicator DEF indicator HEST indicator Regeneration indicator Regeneration stop indicator Engine tachometer This meter indicates the number of engine revolutions. Coolant thermometer Indicates the coolant temperature. IC120-2 ENG...
  • Page 30 The water temperature sensor senses the water temperature, the engine is preheated automatically, and FM-C300850 the indicator lamp goes off when preheating is completed. Do not start the engine while the preheat indicator lamp is IC120-2 ENG...
  • Page 31 When the engine is started, the post-processing unit is in the regeneration state. 15. Regeneration stop indicator This indicator comes on when regeneration of the post- processing unit has stopped. Stop regeneration when you do not want to regenerate the post-processing unit for some reason. IC120-2 ENG...

  • Page 32: Trouble Code Display Screen

    Stop the engine and check the fan belt tension. Water separator warning indicator This indicator comes on when water accumulates up to the designated level of the water separator. When this comes on, stop the engine and drain the water from the water separator. IC120-2 ENG...
  • Page 33 30 seconds. When the engine stop indicator starts flashing, the engine stops 30 seconds later. When this key is pressed while the engine stop indicator is flashing, you can extend the time until the stop of the engine for 30 seconds. IC120-2 ENG...

  • Page 34: Regeneration Mode Selection Screen

    The automatic regeneration function is enabled by pressing this indicator again. (Please refer to CUMMINS MANUAL QSL9CM2350L102) Machine Information Display Screen This screen is used by our serviceman to check the status of the machine. IC120-2 ENG 2-10...

  • Page 35: Adjustment Selection Display Screen

    "Forward Span" through "Reverse Start" whenever changes occur to the devices related to foot including the replacements of the hydraulic pump, travel motor and rubber crawler. For details of the setting procedure, contact our service dealer. IC120-2 ENG 2-11...
  • Page 36 CONTROLS Tilt zero adjust (Tilt Zero Adjust Screen) Install the IC120-2 on a level place and then press the [ZERO] button to adjust. Bright/Contrast (Brightness and Contrast Adjustment Screen) Bright (Brightness) Pressing the [+] key makes the screen display brighter and pressing the [-] key makes it darker.
  • Page 37 The parking brake safety function is provided to prevent erroneous travel after the engine key switch is turned ON. After the engine key switch is turned ON, the machine cannot travel unless the parking brake is turned ON once and then released. IC120-2 ENG 2-13...
  • Page 38 Travel speed control dial High speed Low speed • Automatic mode: This mode adjusts the travel speed of the machine. High speed: Rotate the dial clockwise. Low speed: Rotate the dial counterclockwise. • Manual mode: This mode is not used. IC120-2 ENG 2-14...
  • Page 39 When this switch is pressed, the engine stops. Release: When this switch is turned clockwise, the lock is released and the engine can be started. 10. Engine service connector Connect the engine service tool to this connector when diagnosing engine troubles. IC120-2 ENG 2-15...
  • Page 40 The smallest digit shows 1/10 of an hour (6 minutes). • The meter advances as long as the engine is running even if the machine does not move. • The total operating hours are used as the guideline for inspection and maintenance time. IC120-2 ENG 2-16...

  • Page 41: Safety Warning Devices

    The slope angle of the machine is indicated on the display. When the machine travels on a slope of 9° or more, the alarm buzzer sounds for 5 seconds. 9° The posture at which the safety warning devices are activated IC120-2-C301160 IC120-2 ENG 2-17...

  • Page 42: Left Lever Unit

    CONTROLS LEFT LEVER UNIT Name Name Joystick lever Engine start/stop button Lever lock switch Horn button Dump operation switch Spin turn button IC120-2 ENG 2-18...
  • Page 43 Release the switch to stop the vessel. Raise Lower: Push the upper part of the switch to lower the vessel. For more information about dump operation, see the article on "Dump Operation" (page 3-6) in the OPERATION section. IC120-2 ENG 2-19...
  • Page 44 This mode adjusts the travel speed of the machine. • Manual mode: This mode adjusts the number of engine revolutions. For more information about accelerator pedal operation, see the article on "TRAVEL MODES" (page 3-11) in the OPERATION section. IC120-2 ENG 2-20...

  • Page 45: Operator Seat

     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 unforeseen accidents. IC120-2 ENG 2-21...

  • Page 46: Seat Belt

    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. IC120-2 ENG 2-22...

  • Page 47: Air Conditioner

    LCD screen. foot (gentle breeze) Air outlet Front glass Use this switch to clear condensation on the inside of direction Underfoot the front glass and thaw frost from the outside of the front glass. IC120-2 ENG 2-23...
  • Page 48 ③ Using the MODE switch, select Foot switch. as the air outlet. (It is the recommended  By pressing the MODE switch, the setting position, but you can change the foot before the DEF switch was pressed is restored. position as desired.) IC120-2 ENG 2-24...

  • Page 49: Am Radio (Option)

    (4) To turn OFF the radio, rotate the VOL know counterclockwise until you hear a clicking sound. Hour Regarding seek (automatic) station selection adjustment When the SEEK switch is pressed, station selection starts toward higher frequency broadcasting stations. IC120-2 ENG 2-25...

  • Page 50: 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. IC120-2 ENG...

  • Page 51: Before Starting Operation

     Check the coolant level. Refill if necessary.  Check the engine oil level. Refill if necessary.  Check the fuel level. Refill if necessary.  Check the hydraulic oil level. Refill if necessary.  Check the DEF level. Refill if necessary. IC120-2 ENG...

  • Page 52: Before Starting The Engine

     Push down the combination switch (7) and the horn button (8) of the joystick and make sure that the horn sounds. Ask our service dealer for repair services, if some abnormality is found in the above check. IC120-2 ENG...

  • Page 53: Engine Starting

    1. Make sure that all alarm lamps on the display are off. 2. Check if engine exhaust color, sound and vibrations are not abnormal. 3. After the engine has started, perform a warm-up operation (described later). IC120-2 ENG...

  • Page 54: Basic Operation

    (2) is turned ON once and then OFF. Joystick Lever Operation Procedure Use the joystick lever as shown below. Forward: Push the joystick forward. Stop: Set the travel joystick lever to the neutral position. Backward: Pull the joystick lever backward. IC120-2 ENG...

  • Page 55: Steering Control

    Turning ON the engine key switch while holding down the spin turn button switches the mode to the "spin turn mode." Once the "spin turn mode" is activated, spin turn operation is enabled without pressing the spin turn button. IC120-2 ENG...

  • Page 56: Dump Operation

    6. The vessel cannot be raised while traveling. The travel speed is restricted during travel operation while the vessel is being raised or lowered. As a rule, raise or lower the vessel only when the machine is stopped. IC120-2 ENG...

  • Page 57: How To Lower Body In Case Of Emergency

    1. Make sure that there are no persons under or around the body. 2. Open the cover. 3. Loosen the plug slowly until the body begins to lower. 4. Tighten the plug firmly after body has lowered completely. Control valve IC120-2-C301220 IC120-2 ENG...

  • Page 58: Engine Start/Stop Button

    When the engine is stopped by this method, the engine key switch is in ON position and the battery is consumed. Therefore, when away from the machine for an extended period of time, be sure to stop the engine using the engine key switch (described later). IC120-2 ENG...

  • Page 59: 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. 4. Move the machine forward and backward and raise and lower the vessel several times to warm up the mechanisms. IC120-2 ENG...

  • Page 60: Break-In" Operation

    Do not change the direction quickly.  Do not apply heavy loads to the machine or run it at high speed. Run the machine at approximately 80% of the maximum engine speed. Place loads of approximately 80% of the maximum loading capacity. IC120-2 ENG 3-10...

  • Page 61: Travel Modes

    (3) full counterclockwise to the lowest setting and turn ON the parking switch (4). When in manual mode When in automatic mode (The indicator lamp is lit.) Mode selector switch Low speed Low speed Engine speed control dial Travel speed control dial IC120-2 ENG 3-11...

  • Page 62: Automatic Mode

    When using the accelerator pedal, tilt the joystick lever all the way toward the direction of travel and adjust the travel speed with the amount of step on the accelerator pedal; thereby the operator can operate the machine with the feeling of driving an automobile. IC120-2 ENG 3-12...
  • Page 63 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 control dial Low speed High speed This adjusts the idling speed of the engine. CA-C201040 IC120-2 ENG 3-13...
  • Page 64 When the travel speed control dial is at the highest speed position High • Operating the joystick adjusts the travel speed in a speed range from stop to the maximum. • The operation of the accelerator pedal is disabled. IC120-2 ENG 3-14...

  • Page 65: Manual Mode

    (4) to the maximum revolutions. When the accelerator pedal is released, the engine revolutions return to the original setting of dial (4). IC120-2 ENG 3-15...
  • Page 66 OPERATION 3. Travel speed control dial This is not used in the manual mode. Low speed High speed 4. Engine speed control dial In the manual mode, this sets the engine revolutions. CA-C201040 IC120-2 ENG 3-16...

  • Page 67: Stopping The Engine

    2. Fill the fuel tank with fuel and urea aqueous solution. 3. Remove soil and sand from the vessel and traveling mechanisms, in particular. 4. Lock the fuel filling port, engine hood and all other lockable parts. IC120-2 ENG 3-17...

  • Page 68: Caution Of Travel On A Steep Slope

    Traveling on slope with a loaded machine.  When driving over an obstacle, reduce the speed and Uphill drive safely with care not to turn over. Vessel  Do not accelerate or decelerate the speed or stop Downhill suddenly. IC120-2-C301150 IC120-2 ENG 3-18...
  • Page 69  Avoid using the emergency engine stop switch while traveling at high speed. Otherwise, it will not only cause the machine to turn over and/or malfunction, but also become dangerous to the operator. IC120-2 ENG 3-19...

  • Page 70: Precaution On Use Of Rubber Crawler Shoe

    This wears down the lug and causes the steel cord to break. DO NOT TRAVEL OR WORK ON SURFACES WITH MANY STONES SUCH AS RIVER BEDS This causes damage or wear on the rubber crawler and they may slip off. IC120-2 ENG 3-20...
  • Page 71  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. IC120-2 ENG 3-21...
  • Page 72 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. IC120-2 ENG 3-22...

  • Page 73: Towing

    4. Move the joystick 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 shoe from rotating so the carrier cannot be towed. IC120-2 ENG 3-23...

  • Page 74: Transport

    3. Maintain the slope of loading ramps within 15. 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. IC120-2 ENG 3-24...

  • Page 75: 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 IC120-2-C301270 IC120-2 ENG 3-25...

  • Page 76: 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. IC120-2 ENG 3-26...

  • Page 77: 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. IC120-2 ENG 3-27...

  • Page 78: 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. IC120-2 ENG...

  • Page 79: Precaution On Maintenance

    Use oil and grease of viscosity appropriate to the temperature. Ask our service dealer for important maintenance. Ask our 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. IC120-2 ENG...

  • Page 80: Use Of Safety Bar

    Such an action may cause breakage of the safety bar or vessel. When the safety bar is set. Frame Removing the safety bar 1. Raise the vessel completely. 2. Remove the safety bar from the bracket and store the bar onto the frame. IC120-2 ENG...

  • Page 81: Periodical Replacement Of The Important Parts

    DEF hose (supply module OUT to DRT) 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. IC120-2 ENG...

  • Page 82: Maintenance Intervals

     concentration Coolant Inspect antifreeze  solution density. Change coolant.  Coolant filter Change cartridge  Inspect tension Fan belt  and for scratches. Inspect for cracks  and deformation. Radiator Inspect for leaks  hose and damages. IC120-2 ENG...
  • Page 83 DEF pump Clean and  filter change. DEF dosing Change.  filter  For more information about the engine, also refer to the Engine Operation Manual.  Inquire of our service dealer about the maintenance items with  marks. IC120-2 ENG...

  • Page 84: Recommended Lubrication Table

    1.9 L DEF (Diesel Use the product conforming to the DEF system Exhaust 38 L AdBlue ISO standard. Fluid) The oils and fluids marked with an asterisk (*) are used at the time of shipment from the factory. IC120-2 ENG...

  • Page 85: Greasing

    IC120-2-C401020  Dump cylinder foot pins (6) 2 positions Oscillating Link  Oscillating link pins (7) 8 positions NOTICE Grease the link pins everyday before starting works if the machine is used on damp grounds or in mud. IC120-2 ENG...

  • Page 86: Rubber Crawler

     Dislocation of the rubber crawler cores Exchange the rubber crawler with a new crawler if one or more cores are dislocated from it. IC120-2 ENG...

  • Page 87: Track Adjustment

    (It should be loosened by a maximum of one turn.)  Grease may spout out at high pressure. Never loosen the grease nipple.  Do not bring your face or hand close to the check valve during adjustment. IC120-2 ENG...

  • Page 88: Fixed Bolt Torque

    (2) Tighten all of six bolts with the locktite applied at a torque of 245 to 295 Nm first. (3) Then, tighten the bolts in the order shown on the right at the specified torque of 476 Nm. Tighten the bolts quickly since screw locking agent is applied to them. IC120-2-C400530 IC120-2 ENG 4-10...
  • Page 89 Bracket and frame (rear) 48.5 Engine and bracket (front) Bracket and frame (front) 24.6 Hydraulic pump IC120-2-C401050 Tightening torque Wrench required Tightening position Bolt size (mm) (N·m) (kgf·m) Engine and pump housing Pump housing and hydraulic pump 48.5 IC120-2 ENG 4-11...

  • Page 90: General Torque Specifications (10T Bolt)

    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 IC120-2 ENG 4-12...

  • Page 91: 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. IC120-2 ENG 4-13...

  • Page 92: Hydraulic System

    1. Loosen the drain plug (3) under the hydraulic oil tank to discharge water and sediment into the container. 2. Close the drain plug (3) when clean hydraulic oil is only discharged. 3. Check the hydraulic oil level. Refill oil if insufficient. IC120-2 ENG 4-14...

  • Page 93: Change The Hydraulic Oil And Clean The Strainer

    Bring the machine into the posture for checking the hydraulic oil level. Stop the engine. 10. Make sure that the hydraulic oil level is within the proper range. Refill hydraulic oil if insufficient. IC120-2 ENG 4-15...

  • Page 94: Replace The Return Filter And Line Filter

    2. Put in the safety bar, lower the body, and check the level of the hydraulic oil tank. If the oil surface is between H and L of the level gauge, the oil quantity is proper. Refill the tank with hydraulic oil if the oil level is low. IC120-2 ENG 4-16...

  • Page 95: Engine Oil System

    Furthermore, it may cause increase of oil consumption, reduction of the engine output, and damage to the engine. Troubles and accidents caused by using improper engine oil are exempted from the warranty. IC120-2 ENG 4-17...

  • Page 96: Replace The Engine Oil And Engine Oil Filter

    4. Screw the filter cartridge by hand until the gasket is brought into contact with the seal surface of the filter head. 5. Tighten the filter cartridge by one turn from this condition with the filter wrench. IC120-2 ENG 4-18...
  • Page 97 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 passed since the engine stops. Refill the engine with engine oil if it is insufficient. IC120-2 ENG 4-19...

  • Page 98: 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. IC120-2 ENG 4-20...

  • Page 99: Check The Coolant Level And Replenish

    After inspecting for water leak, remove the radiator cap and check the fluid level in the radiator. If the coolant level is too low, replenish the radiator with coolant and then fill up the coolant tank with coolant. IC120-2 ENG 4-21...

  • Page 100: Replace The Coolant Filter

    If the coolant filter is tightened excessively with a tool, its threads may be deformed or the filter head may be damaged.  Set the shut-off valve to the “Open” position to avoid damages to the engine. IC120-2 ENG 4-22...

  • Page 101: Check Concentration Of Coolant Additive

    It is needed in all seasons throughout the year. * Use the FleetGuard Refractometer (part No. C2800) to check the freezing point of coolant and the concentration of anti-freezing solution. IC120-2 ENG 4-23...

  • Page 102: Change The Coolant

    10. Run the engine five minutes and stop it then. Wait until the temperature of coolant lowers, and check the coolant level. Refill the tank with coolant if coolant is insufficient. IC120-2 ENG 4-24...

  • Page 103: Check The Fan Belt

    There is a mechanism to automatically adjust the fan belt tension by the spring-loaded belt tensioner pulley. If it is necessary to adjust the belt tension or change the belt, please contact our service dealer. IC120-2 ENG 4-25...

  • Page 104: Inspection Of Def Level And Replenishment

    Never disconnect the battery immediately after the engine has stopped or remove the connectors including the harnesses. Similarly, never remove the DEF pipe immediately after the machine has stopped. When conducting maintenance and other related work, be sure to allocate ample time before starting such work. IC120-2 ENG 4-26...

  • Page 105: Replenishment Of Def

    DEF dosing filter). Regarding the above filter change, please refer to the Engine Operation Manual that comes with this machine and implement it as an inspection and maintenance item of specified period. (Please refer to CUMMINS MANUAL QSL9CM2350L102.) IC120-2 ENG 4-27...

  • Page 106: Fuel System

    Never use any other fuel than light oil. Damages or troubles caused by using fuel other than light oil are not covered by the warranty. Name Fuel tank Water separator Fuel filter Fuel cooler Fuel piping system diagram IC120-2-C401190 IC120-2 ENG 4-28...

  • Page 107: Check The Fuel Level

    Do not fill the tank with fuel up to the top. 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. IC120-2 ENG 4-29...

  • Page 108: Water Separator And Fuel Filter

    When the valve is rotated by about 3.5 turns, the valve lowers by 25.4 mm and draining starts. 3. Discharge water and sediments until clear fuel comes out. 4. Once clear fuel comes out, close the valve. IC120-2-C401220 Open Close IC120-2 ENG 4-30...

  • Page 109: Replacing Water Separator And Fuel Filter

    4. Start the engine at low revolution. 5. Increase the engine revolution slowly. Do not open the high-pressure engine fuel system while the engine is running. Otherwise, high-pressure fuel spouts out, resulting in serious injury or death. IC120-2 ENG 4-31...

  • Page 110: Air Intake And Exhaust System

    When removing the secondary element, be careful not to introduce particles and foreign objects into the air cleaner pipe. • Primary and secondary elements are disposable. You cannot reuse them by blowing air to them and cleaning them. IC120-2 ENG 4-32...

  • Page 111: Electric System

    Detach and check the fusible link. Replace it with a new fusible link, if it has blown out. The fusible link is mounted in the battery cover. Fusible link 2P (60 A + 140 A) IC120-2-C401270 IC120-2 ENG 4-33...

  • Page 112: 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. IC120-2 ENG 4-34...

  • Page 113: 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. IC120-2 ENG 4-35...

  • Page 114: Long Term Storage

    3. After starting the engine, let it idle for about 5 minutes. After Storage Before using the machine after long-term storage, lubricate or grease every necessary parts, check the coolant and DEF levels, and replenish them if necessary, IC120-2 ENG 4-36...

  • Page 115: Troubleshooting

    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.* IC120-2 ENG 4-37...

  • Page 116: Parts List

    0830 243 01 Fuse 20A 0830 243 02 Fuse 30A 0830 243 05 Fusible link 60A 0830 106 00 Fusible link 140A 0830 106 03 Headlight bulb 0854 527 06 Direction indicator lamp bulb 0854 528 02 IC120-2 ENG 4-38...

  • Page 117: Specifications

    SPECIFICATIONS IC120-2 ENG...

  • Page 118: Specifications And Dimensions

    Tumbler center distance 3790 Overall crawler width 2750 Crawler width Minimum height from ground Vessel length 3545 Inner vessel width 2450 Vessel height Vessel floor height from ground 1390 Maximum dumping angle degree Maximum height in dumping 5170 IC120-2 ENG...
  • Page 119 First Edition, January 2017 取 扱 説 明 書 IC120-2 OPERATION MANUAL 編集及び発行所 プロダクトサポート G Editing & Publishing Office. Product Support Group 〒236-8611 神 奈 川 県 横 浜 市 金 沢 区 昭 和 町 3 1 7 4...

Table of Contents