IHI IC75-2 User manual

OPERATION MANUAL
IC75-2
SERIAL NUMBER
CA004001~
09884 16EN-00

IC75-2 ENG
0
CONTENTS
FOREWORD········································································································· 0-1
SAFETY INFORMATION························································································· 0-2
SAFETY ·············································································································· 1-1
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·········································································································· 2-1
NAMES OF COMPONENTS ··············································································· 2-1
CONTROLS AND INSTRUMENTS······································································· 2-2
INSTRUMENT PANEL······················································································· 2-3
Display Screen System ································································································2-4
Explanation of Screen Displays ······················································································2-5
Trouble Code Display Screen ························································································2-8
Regeneration Mode Selection Screen············································································ 2-10
Machine Information Display Screen ············································································· 2-10
Adjustment Selection Display Screen ············································································ 2-11
Safety Warning Devices ····························································································· 2-20
LEFT LEVER UNIT ··························································································2-21
OPERATOR SEAT ··························································································2-24
SEAT BELT ···································································································2-25
AIR CONDITIONER ·························································································2-26
AM RADIO (OPTION)·······················································································2-28
OPERATION········································································································· 3-1
BEFORE STARTING OPERATION ······································································ 3-1
BEFORE STARTING THE ENGINE······································································ 3-2
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
Engine Start/Stop Button ······························································································3-7

IC75-2 ENG
WARMING UP THE MACHINE············································································ 3-8
“BREAK-IN” OPERATION ·················································································· 3-9
TRAVEL MODES ····························································································3-10
Travel Mode Switching ······························································································· 3-10
Automatic Mode········································································································ 3-11
Manual Mode ··········································································································· 3-14
STOPPING THE ENGINE ·················································································3-16
CAUTION OF TRAVEL ON A STEEP SLOPE························································3-17
PRECAUTION ON USE OF RUBBER CRAWLER SHOE ·········································3-19
TOWING ·······································································································3-22
TRANSPORT ·································································································3-23
Loading and Unloading the Machine ············································································· 3-23
Fixation at Transport·································································································· 3-24
Lifting the Machine ···································································································· 3-25
STARTING WITH JUMPER CABLES···································································3-26
MAINTENANCE ···································································································· 4-1
PRECAUTION ON MAINTENANCE ····································································· 4-1
USE OF SAFETY BAR ······················································································ 4-2
PERIODICAL REPLACEMENT OF THE IMPORTANT PARTS ··································· 4-3
Fuel Hose··················································································································4-3
Hydraulic Hose ···········································································································4-3
SCR Piping Hose ········································································································4-3
MAINTENANCE INTERVALS·············································································· 4-4
RECOMMENDED LUBRICATION TABLE······························································ 4-7
GREASING····································································································· 4-8
Vessel ······················································································································4-8
Oscillating Link ···········································································································4-8
RUBBER CRAWLER ························································································ 4-9
Rubber Crawler Shoe Maintenance·················································································4-9
Track Adjustment ······································································································ 4-10
FIXED BOLT TORQUE·····················································································4-11
Special Torque Specifications ······················································································ 4-11
General Torque Specifications ····················································································· 4-13
TRAVEL REDUCTION GEAR ············································································4-14
Check the Travel Reduction Oil Level ············································································ 4-14
Change the Travel Reduction Oil ·················································································· 4-14
HYDRAULIC SYSTEM ·····················································································4-15
Check the Hydraulic Oil Level ······················································································ 4-15
Drain the Hydraulic Oil Tank ························································································ 4-15
Change the Hydraulic Oil and Clean the Strainer ····························································· 4-16
Replace the Line Filter Cartridge and Return Filter Cartridge ·············································· 4-17
ENGINE OIL SYSTEM······················································································4-19
Check the Engine Oil Level ························································································· 4-19
Replace the Engine Oil and Engine Oil Filter ··································································· 4-20

IC75-2 ENG
COOLING SYSTEM·························································································4-22
Check the Coolant Level····························································································· 4-23
Change the Coolant··································································································· 4-24
Check the Fan Belt···································································································· 4-25
INSPECTION OF DEF LEVEL AND REPLENISHMENT···········································4-26
Replenishment of DEF ······························································································· 4-27
FUEL SYSTEM ·······························································································4-28
Applicable Fuel········································································································· 4-28
Check the Fuel Level ································································································· 4-29
Drain the Fuel Tank ··································································································· 4-29
Water Separator and Fuel Filter ··················································································· 4-30
Replacing Water Separator and Fuel Filter ····································································· 4-31
AIR INTAKE AND EXHAUST SYSTEM ································································4-32
Clean and Replace Air Cleaner Element ········································································ 4-32
ELECTRIC SYSTEM························································································4-33
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

IC75-2 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.

IC75-2 ENG 0-2
SAFETY INFORMATION
Read and understand the operation manual, safety signs and labels before using or maintaining
this machine.
The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
The signal words used with the safety alert symbol indicate a specific level of severity of the
potential hazard. All are used as attention-getting devices throughout this manual as well as on
labels fixed to the machine to assist in potential hazard recognition and prevention.
This safety alert symbol and signal word indicates an imminently
hazardous situation which, if not avoided, will result in death or serious
injury.
This safety alert symbol and signal word indicates a potentially
hazardous situation which, if not avoided, could result in death or serious
injury.
This safety alert symbol and signal word indicates a potentially
hazardous situation which, if not avoided, could result in minor or
moderate injury or serious damages of the machine.
This signal word indicates a potentially hazardous situation which, if not
avoided, could result in damages of the machine or reduction of the
service life.
We have made every 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.
NOTICE

IC75-2 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.

SAFETY
IC75-2 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
IC75-2 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 GET ON AND OFF. 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
IC75-2 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
IC75-2 ENG 1-4
DO NOT TRAVEL WITH THE VESSEL IN DUMP
POSITION
Traveling with the vessel in dump position not only makes
the machine unstable but limits operator visibility causing
hazardous situations.
Never attempt to travel with the vessel 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.
•If the machine goes into water in a descending posture
on a steep slope, water may splash on the radiator and
peripheral parts, resulting in damages of the radiator
fan. 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.
Allowable water depth

SAFETY
IC75-2 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
IC75-2 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 SLOPE
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 vessel completely.
•Apply the parking brake.
•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.

SAFETY
IC75-2 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 novessel other than the concerned persons
touches it.

SAFETY
IC75-2 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 VESSEL
If replacement or repair of couplings or hoses is made
with the vessel in the raised condition, there is the
possibility that the vessel drops down.
Be sure to support the vessel using the safety bar.
DO NOT WATCH THE CHECK 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 vessel

SAFETY
IC75-2 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 THE RADIATOR CAP OR COOLANT
TANK CAP WHEN THEY ARE HOT
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.

SAFETY
IC75-2 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 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.

SAFETY
IC75-2 ENG 1-11
WARNING SIGNS AND LABELS
There are several specific safety signs on your machine.
Make sure that you can read all safety signs. Clean or replace these if you cannot read the
words.
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
CA-C101000
11
10
18
15
21
12
13
24
2 478
65
23
22 23
319
13
12
17
1
13
23
19 3
22
14
20
16
Viewed from
direction of A
Left side of the
instrument panel
A

SAFETY
IC75-2 ENG 1-12
1. Precautions on safety
(D408 704 00)
2. Precaution for working under the
raised vessel
(4448 816 00)
3. Crawler shoe tension adjustment
(D405 516 00)

SAFETY
IC75-2 ENG 1-13
4. Gate lock lever
(D408 689 00)
5. Traveling on a slope
(D406 188 00)
6. Loading and unloading the machine
(D405 618 00)
7. Under-water works
(D406 189 00)
8. Safety alarm
(D408 691 00)
9. Dump bed operation warning
(D408 686 00)