IHI IC50 User manual

OPERATION MANUAL
IC50
SERIAL NUMBER
CA003001 ~
PUB.1
1008

IC50 ENG
0
CONTENTS
FOREWORD ······························································································································· 0-1
SAFETY INFORMATION ············································································································ 0-2
SAFETY
PRECAUTIONS BEFORE OPERATION·············································································· 1-1
PRECAUTIONS DURING OPERATION ·············································································· 1-3
PRECAUTIONS AFTER OPERATION················································································· 1-6
PRECAUTIONS AT TRANSPORTING················································································· 1-7
PRECAUTIONS AT MAINTENANCE ··················································································· 1-7
WARNING SIGNS AND LABELS ······················································································· 1-11
CONTROLS
NOMENCLATURE ··············································································································· 2-1
CONTROLS AND INSTRUMENTS ······················································································ 2-2
Monitor panel
Meters
Switches
Control levers
Operator seat
Seat belt
OPERATION ······························································································································· 3-1
BEFORE STARTING OPERATION······················································································ 3-1
BEFORE STARTING THE ENGINE····················································································· 3-2
ENGINE STARTING············································································································· 3-3
AFTER STARTING THE ENGINE························································································ 3-3
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 ··········································································································· 3-10
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
TRANSPORT ····················································································································· 3-16
Loading and unloading the machine
Fixation at transport
Lifting the machine
MAINTENANCE
PRECAUTION ON MAINTENANCE····················································································· 4-1
USE THE SAFETY BAR······································································································· 4-2
PERIODICAL EXCHANGE OF THE IMPORTANT PARTS ················································· 4-3
Fuel relation
Hydraulic relation
MAINTENANCE INTERVALS······························································································· 4-4
RECOMMENDED LUBRICATION TABLE ··········································································· 4-6
LUBRICATE THE GREASE ································································································· 4-7
Body
Oscillating link
RUBBER CRAWLER············································································································ 4-8
Rubber crawler shoe maintenance
TRACK ADJUSTMENT
CHECK THE FIXED BOLT TORQUE················································································· 4-10
Special torque specifications
General torque specifications
TRAVEL REDUCTION GEAR ···························································································· 4-12
Check the travel reduction oil level
Replace the travel reduction oil
HYDRAULIC SYSTEM ······································································································· 4-13
Check the hydraulic oil level
Drain the hydraulic oil tank
Replace the hydraulic oil and clean the strainer
Replace the line filter element
Replace the return filter cartridge
ENGINE OIL SYSTEM ······································································································· 4-17
Check the engine oil level
Replace the 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
FUEL SYSTEM··················································································································· 4-23
Applicable Fuel
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
AIR CLEANER SYSTEM···································································································· 4-28
Check the dust indicator
Clean and change the air cleaner element
Clean and change the air cleaner element
HYDRAULIC SYSTEM ······································································································· 4-30
Hydraulic system diagram
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

IC50 ENG 0-1
FOREWORD
This manual contains safety, operation, maintenance, and adjustment information.
The procedures are designed to provide the best performance of the machine in an effective and
economical way. In order to obtain it, remember the next basic rules.
• This manual should be stored in the operator’s compartment in the literature holder or
seat back literature storage area.
• Before inspection, maintenance or operating the machine, read and understand this
manual completely.
• Since all of the explanations in this manual may not be thoroughly 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 be obtained
from the experience during normal operations and under proper supervision.
• The illustrations in this manual are used first of all to let you pay attention. They do not
show all of illustrations in this manual. Because of continuing improvement and
advancement of product design, the shape of machine in the illustrations may be partly
different from your machine. Please understand it. Whenever a question arises
regarding your machine, or this publication, please consult your local IHI distributor for the
latest available information.

IC50 ENG 0-2
SAFETY INFORMATION
We offer you basic and important rules and precautions for safe operations.
Read, understand, and observe them before starting operation. This is the most essential way to
prevent accidents.
Wrong operation, inspection, or maintenance can cause personal injury or death.
Throughout this manual and on the machine, precautions are provided with marks and
classified by the words “DANGER”, “WARNING”, and “CAUTION” according to their extent of
danger.
The classification is as follows:
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury. It may also be used to alert against
possible damage to the machine and its components.
NOTICE indicates a potentially hazardous situation which, if not avoided, could
result in the damage of the machine or the performance and the
decrease in longevity are 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 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.
WARNING
•BEFORE inspection, operation, or maintenance of the machine, be sure to read and
understand this manual.
•Incorrect operation or maintenance of the machine can cause the accident and serious
injury or death.
•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. Since the regulations are subject to change, and differ from one
locale to another, it is impossible for us to provide such information in this manual.
It is the responsibility of the owner or user to be familiar with the regulations.
•Specifications and materials of the machine are subject to change without any obligation
on the part of the manufacturer.

IC50 ENG
SAFETY
Read the SAFETY section without fail. It
describes the basic instructions about safety.
Most accidents occur during works when preventive measures
against danger are neglected 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 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

SAFETY
IC50 ENG 1-1
1
PRECAUTIONS BEFORE OPERATION
READ AND UNDERSTAND THE WARNINGS SIGNS
AND LABELS
•There are several specific safety signs on your
machine. Please take the time to familiarize yourself
with these safety signs.
Make sure that you can read all safety signs.
•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.
OPERATION SHOULD BE IN GOOD HEALTH.
Operator should be physically and mentally alert, which is
one of the best insurance against an accident.
NEVER operate the machine under the influence of
alcohol, 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 cause unforeseen
accidents.
•Always wear protective cap and safety boots.
Wear a hard hat, protective glasses and other
protective equipment as required by job conditions.
PERFORM “WALK-AROUND” INSPECTION.
Walk around the machine to check safety guards, plates,
and other related parts are set in place. Do not attempt to
operate the machine when any unsafe condition is
detected.
MAKE A WORK PLAN.
•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.

SAFETY
IC50 ENG 1-2
CHECK THE JOB SITE.
•Confirm in advance if there are any dangerous
locations where the land collapses or where machine
can fall off a cliff, etc.
•Take measures necessary for safety in dangerous
locations.
CAREFULLY MOUNT AND DISMOUNT THE MACHINE.
•Maintain a three point contact (Two feet and one hand
or one foot and two hands contact) with the steps and
handholds.
•Do not use any controls as handholds when entering or
leaving the 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 from a position other than sitting in
the operator seat, there is the danger that the machine
starts moving suddenly.
Start the engine only after carrying out checks while
sitting in the operator seat.
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.

SAFETY
IC50 ENG 1-3
PRECAUTIONS DURING OPERATION
CLEAR ALL PERSONNEL FROM THE MACHINE AND
AREA.
Be sure to barricade the job site to prevent entry of the
unauthorized. Confirm that there is no one around the
machine before starting the engine or operating the
machine.
MAINTAIN GOOD VENTILATION.
Diesel engine exhaust contains products of combustion
which may be harmful to your health. Always start and
operate the 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 position other than the operator
seat or while standing.
Operate the machine only while seated and with the seat
belt fastened.
PREVENT ACCIDENTS WHILE MOVING
•Always sound the horn to signal others nearby that you
are moving the machine. 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.

SAFETY
IC50 ENG 1-4
DO NOT TRAVEL WITH THE BODY IN DUMP
POSITION
Traveling with the body in dump position not only makes
the machine unstable but limits operator visibility causing
hazardous situations.
Never attempt to travel with the body in dump position.
DO NOT OVERLOAD
•Working with loads exceeding the performance of the
machine can cause loss of safety or reduction in the
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 roller.
Check the water depth, foundation and strength of water
current and other safety factors before operating. Do not
place the machine in locations exceeding the lower frame
of the machine.
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.
A
llowable water depth

SAFETY
IC50 ENG 1-5
DO NOT CHANGE DIRECTIONS WHILE ON A SLOPE
Avoid changing the direction of travel on a slope, which
could result in tipping or side slipping of the machine.
When it is inevitable to change the direction, carry it out in
a hard ground where the slope is gradual.
MOVE UP AND DOWN SLOPES DIRECTLY NOT
SIDEWAYS
Moving sideways or parallel to the slope while on it may
cause the machine to slide and fall over.
To prevent such accidents, only move up and down
slopes at a direct angle.
WATCH THE MACHINE 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.
Observe the following points regarding machine position:
•Go forward up the hill and back down the hill WHEN
NO CARRYING A LOAD.
•Reverse up the hill and go forward down the hill WHEN
CARRYING A LOAD.
NEVER ALLOW PERSONNEL RIDE ON THE MACHINE
OTHER THAN OPERATOR.
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.

SAFETY
IC50 ENG 1-6
PRECAUTIONS AFTER OPERATION
PARK IN A SAFE PLACE
For parking, select a flat ground with good foothold and
where there is no danger of land or mud slides, and also,
near a river, select a place which is safe even if the river
water level becomes high.
DO NOT PARK THE MACHINE ON A GRADE
There is the danger of the machine running off wild when
stopped or parked 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 you have to park the machine on the road, use
appropriate flags, barriers, flares, and warning signals.
OPERATOR LEAVING MACHINE
•Lower the body completely.
•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.

SAFETY
IC50 ENG 1-7
PRECAUTIONS AT TRANSPORTING
CAREFULLY LOAD AND UNLOAD THE MACHINE
•ALWAYS load and unload the machine on the level
ground.
•Use a ramp that has sufficient strength, width, length,
and thickness.
•Remove ice, snow, or slippery material from the ramp
and truck deck before loading.
•NEVER make a turn on a ramp.
OBSERVE PRECAUTIONS ON TRANSPORTATION.
•Blocks tracks and secure the machine to the truck
before transporting.
•Securely fix the 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 the
machine but also has the danger of causing accidents
that involve injury to humans.
•You must read and understand the warnings and
instructions contained in this manual, before
performing any operation or maintenance procedures.
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.

SAFETY
IC50 ENG 1-8
WHEN WORKING UNDER TRACKS
There is the danger of an accident of being caught under
the machine if the machine comes down.
Place supporting pillars or blocks under the crawler and
make sure that it is supported firmly.
ALWAYS RELEASE PRESSURE BEFORE
DISCONNECTING HYDRAULIC LINES.
There is the danger of high pressure oil jetting out if a
piping or a hose is removed without releasing the internal
pressure of the hydraulic system. Start the work only
after completely 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.
Always support the body using the safety bar, and also
lock it using the dump lever.
DO NOT WATCH THE RELIEF VALVE WHEN
ADJUSTING TRACKS.
•Track adjusting grease is under high pressure. Grease
coming out of the check valve under pressure can
penetrate the body causing injury or death.
•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.
Supported
the body

SAFETY
IC50 ENG 1-9
PRECAUTIONS AGAINST HIGH PRESSURE OIL
•It is very dangerous if the high pressure oil enters your
skin or eyes.
•Use a thick sheet of paper or a wooden piece to test
for the leakage of high pressure oil, and never test with
your hands.
Wear protective goggles for protecting your eyes.
•If oil enters your skin, immediately go to a doctor and
get medical attention.
NEVER CARRY OUT MAINTENANCE WITH THE
ENGINE RUNNING
Touching a rotating or moving part such as the fan belt,
etc., can get your hand crushed by the machine and there
is the danger of your hand being cut off.
Always carry out maintenance work with the engine
switched off.
BE CAREFUL TO HOT ENGINE AFTER THE MACHINE
STOPS.
Do not touch the engine or muffler right after the machine
is stopped. It is very hot and causes burns.
Start inspection and maintenance only after the
temperatures of the different parts have gone down
sufficiently,
NEVER OPEN A RADIATOR CAP WHEN IT IS HOT
Removing the radiator cap when the temperature of the
water inside the radiator is still high can cause high
temperature steam to jet out, and can cause scalding of
your hands and body. 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.

SAFETY
IC50 ENG 1-10
HANDLING BATTERY
•When maintaining the electrical system or when
carrying out welding, remove the lead connected to the
negative terminal (-) of the battery.
•A battery can generate flammable gases and there is
the danger of the gases catching fire and exploding.
Also, dilute sulfuric acid is being 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, constantly check and remove them.
•Stop the engine during refueling, and take care not to
bring sparks or fire near the fuel.
•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.