Kato IC120-2 User manual

IC120-2
CB004001 ~
IC120-2 0988477EN-00
0988477EN-00

IC120-2 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 ····························································································· 2-17
LEFT LEVER UNIT ··························································································· 2-18
OPERATOR SEAT···························································································· 2-21
SEAT BELT ····································································································· 2-22
AIR CONDITIONER ·························································································· 2-23
AM RADIO (OPTION) ························································································ 2-25
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
How to Lower Body in Case of Emergency ······································································· 3-7
Engine Start/Stop Button ······························································································ 3-8

IC120-2 ENG
WARMING UP THE MACHINE ·············································································· 3-9
“BREAK-IN” OPERATION ·················································································· 3-10
TRAVEL MODES ····························································································· 3-11
Travel Mode Switching ······························································································· 3-11
Automatic Mode ········································································································ 3-12
Manual Mode ··········································································································· 3-15
STOPPING THE ENGINE ·················································································· 3-17
CAUTION OF TRAVEL ON A STEEP SLOPE ························································ 3-18
PRECAUTION ON USE OF RUBBER CRAWLER SHOE ········································· 3-20
TOWING ········································································································· 3-23
TRANSPORT··································································································· 3-24
Loading and Unloading the Machine ············································································· 3-24
Fixation at Transport ·································································································· 3-25
Lifting the Machine ···································································································· 3-26
STARTING WITH JUMPER CABLES ··································································· 3-27
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 ······························································· 4-6
GREASING ······································································································· 4-7
Vessel ······················································································································ 4-7
Oscillating Link ··········································································································· 4-7
RUBBER CRAWLER ··························································································· 4-8
Rubber Crawler Shoe Maintenance ················································································· 4-8
Track Adjustment ········································································································ 4-9
FIXED BOLT TORQUE ······················································································ 4-10
Special Torque Specifications ······················································································ 4-10
General Torque Specifications (10T bolt) ······································································· 4-12
TRAVEL REDUCTION GEAR ············································································· 4-13
Check the Travel Reduction Oil Level ············································································ 4-13
Change the Travel Reduction Oil ·················································································· 4-13
HYDRAULIC SYSTEM ······················································································ 4-14
Check the Hydraulic Oil Level ······················································································ 4-14
Drain the Hydraulic Oil Tank ························································································ 4-14
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
COOLING SYSTEM ·························································································· 4-20
Check the Coolant Level and Replenish ········································································· 4-21
Replace the Coolant Filter ··························································································· 4-22
Check Concentration of Coolant Additive········································································ 4-23
Check anti-freezing solution concentration ······································································ 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

IC120-2 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 our distributor for the latest
available information.

IC120-2 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

IC120-2 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
IC120-2 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
IC120-2 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
IC120-2 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.