This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
COVER......................................................................................... 1
FOREWARD...................................................................................... 2
FOREWARD.................................................................................. 3
SAFETY INFORMATION........................................................................ 6
INTRODUCTION.............................................................................. 8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.......................................... 8
NECESSARY INFORMATION..................................................................... 9
MACHINE SERIAL NO. PLATE AND POSITION................................................. 9
ENGINE SERIAL NO. PLATE AND POSITION.................................................. 9
POSITION OF SERVICE METER............................................................. 10
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................. 10
CONTENTS...................................................................................... 11
SAFETY........................................................................................ 14
SAFETY.................................................................................... 15
SAFETY LABELS............................................................................. 17
LOCATION OF SAFETY LABELS............................................................. 18
GENERAL PRECAUTIONS....................................................................... 24
SAFETY RULES.......................................................................... 24
IF ABNORMALITIES ARE FOUND............................................................ 24
CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................ 24
FIRE EXTINGUISHER AND FIRST AID KIT................................................... 24
SAFETY FEATURES....................................................................... 24
KEEP MACHINE CLEAN.................................................................... 25
INSIDE OPERATOR'S COMPARTMENT......................................................... 25
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT........................................ 25
HANDRAILS AND STEPS................................................................... 26
MOUNTING AND DISMOUNTING.............................................................. 26
NO PEOPLE ON ATTACHMENTS.............................................................. 26
DO NOT GET CAUGHT IN ARTICULATED PORTION.............................................. 27
PREVENTION OF BURNS................................................................... 27
FIRE PREVENTION....................................................................... 28
ACTION IF FIRE OCCURS................................................................. 28
WINDOW WASHER LIQUID.................................................................. 29
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).......................... 29
PRECAUTIONS FOR ATTACHMENTS........................................................... 29
UNAUTHORIZED MODIFICATION............................................................. 29
SAFETY AT WORKSITE.................................................................... 29
WORKING ON LOOSE GROUND............................................................... 30
DO NO GO CLOSE TO HIGH VOLTAGE CABLES................................................. 30
ENSURE GOOD VISIBILITY................................................................ 31
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS........................................ 31
CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................ 31
VENTILATION FOR ENCLOSED AREAS........................................................ 31
PRECAUTIONS FOR OPERATION................................................................. 32
BEFORE STARTING ENGINE................................................................ 32
CHECKS BEFORE STARTING ENGINE..................................................... 32
PRECAUTIONS WHEN STARTING ENGINE.................................................. 32
PRECAUTIONS ON COLD AREAS......................................................... 33
OPERATION............................................................................. 34
CHECKS BEFORE OPERATION........................................................... 34
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE.................................. 34
PRECAUTIONS WHEN TRAVELING........................................................ 35
TRAVELING ON SLOPES............................................................... 36
PROHIBITED OPERATIONS............................................................. 36
PRECAUTIONS WHEN OPERATING........................................................ 37
METHODS OF USING BRAKE............................................................ 37
OPERATE CAREFULLY ON SNOW......................................................... 37
PARKING MACHINE................................................................... 38
TRANSPORTATION........................................................................ 39
LOADING AND UNLOADING............................................................. 39
SHIPPING.......................................................................... 39
BATTERY............................................................................... 40
BATTERY HAZARD PREVENTION......................................................... 40
STARTING WITH BOOSTER CABLES...................................................... 41
TOWING................................................................................ 42
PRECAUTIONS FOR MAINTENANCE............................................................... 43
WARNING TAG........................................................................... 43
KEEP WORK PLACE CLEAN AND TIDY........................................................ 43
APPOINT LEADER WHEN WORKING WITH OTHERS............................................... 43
MAINTENANCE WITH ENGINE RUNNING....................................................... 43
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.................................... 45
PROPER TOOLS.......................................................................... 45
WORK EQUIPMENT SUPPORT................................................................ 46
ACCUMULATOR........................................................................... 46
PERSONNEL............................................................................. 46
ATTACHMENTS........................................................................... 46
NOISE................................................................................. 46
PRECAUTIONS WHEN USING HAMMER......................................................... 47
REPAIR WELDING........................................................................ 47
REMOVING BATTERY TERMINAL............................................................. 47
PRECAUTIONS WITH HIGH PRESSURE OIL.................................................... 47
HANDLING HIGH PRESSURE HOSES.......................................................... 48
WASTE MATERIALS....................................................................... 48
MAINTENANCE OF AIR CONDITIONER........................................................ 48
COMPRESSED AIR........................................................................ 48
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......................................... 48
PRECAUTIONS WITH TIRES.................................................................... 49
HANDLING TIRES........................................................................ 49
PRECAUTIONS WHEN STORING TIRES........................................................ 49
OPERATION..................................................................................... 50
GENERAL VIEW.............................................................................. 51
GENERAL VIEW OF MACHINE............................................................... 51
GENERAL VIEW OF CONTROLS AND GAUGES................................................... 52
EXPLANATION OF COMPONENTS................................................................. 54
MACHINE MONITOR....................................................................... 54
SWITCHES.............................................................................. 67
CONTROL LEVERS, PEDALS................................................................ 76
STEERING COLUMN TILT LEVER............................................................ 81
CAP WITH LOCK......................................................................... 82
SAFETY BAR............................................................................ 83
TOWING PIN............................................................................ 83
GREASE PUMP........................................................................... 84
BACKUP ALARM.......................................................................... 84
DUST INDICATOR........................................................................ 84
CAB DOOR OPEN LOCK.................................................................... 85
TOOL BOX.............................................................................. 85
OIL FILLER LOCATION................................................................... 85
FUSE.................................................................................. 85
SLOW BLOW FUSE........................................................................ 87
LUNCH BOX TRAY........................................................................ 87
TAKING OFF POWER...................................................................... 87
OPERATION................................................................................. 88
CHECK BEFORE STARTING ENGINE, ADJUST.................................................. 88
STARTING ENGINE.......................................................................102
OPERATIONS AND CHECKS AFTER STARTING ENGINE...........................................104
STOPPING ENGINE.......................................................................106
CHECK AFTER STOPPING ENGINE...........................................................106
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING.....................................107
TURNING...............................................................................112
OPERATION OF WORK EQUIPMENT...........................................................112
WORK POSSIBLE USING WHEEL DOZER.......................................................115
PRECAUTIONS FOR OPERATION.............................................................115
PARKING MACHINE.......................................................................117
CHECKS AFTER COMPLETION OF OPERATION..................................................118
LOCKING...............................................................................118
HANDLING THE TIRES....................................................................119
TRANSPORTATION............................................................................121
LOADING, UNLOADING WORK...............................................................121
PRECAUTIONS FOR LOADING...............................................................121
LIFTING MACHINE.......................................................................122
COLD WEATHER OPERATION....................................................................123
PRECAUTIONS FOR LOW TEMPERATURE.......................................................123
PRECAUTIONS AFTER COMPLETION OF WORK..................................................124
AFTER COLD WEATHER....................................................................125
WARMING UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...................125
LONG TERM STORAGE.........................................................................126
BEFORE STORAGE........................................................................126
DURING STORAGE........................................................................126
AFTER STORAGE.........................................................................126
TROUBLESHOOTING...........................................................................127
WHEN MACHINE RUNS OUT OF FUEL.........................................................127
TOWING THE MACHINE....................................................................128
IF THE BATTERY IS DISCHARGED..........................................................131
OTHER TROUBLE.........................................................................134
MAINTENANCE...................................................................................138
GUIDES TO MAINTENANCE.....................................................................139
OUTLINES OF SERVICE.......................................................................141
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC................................141
OUTLINE OF ELECTRIC SYSTEM............................................................143
WEAR PARTS................................................................................144
WEAR PARTS LIST.......................................................................144
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE......................145
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS......................................145
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS............................................149
TORQUE LIST...........................................................................149
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................150
SAFETY CRITICAL PARTS.................................................................150
MAINTENANCE SCHEDULE CHART................................................................151
MAINTENANCE SCHEDULE CHART............................................................151
SERVICE PROCEDURE.........................................................................153
INTITIAL 250 HOURS SERVICE............................................................153
REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................184
REPLACE HYDRAULIC FILTER ELEMENT..................................................190
INITIAL 2000 HOURS SERVICE............................................................153
CHECK INJECTOR SETTING LOAD, ADJUST...............................................153
WHEN REQUIRED.........................................................................154
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......................................154
CLEAN INSIDE OF COOLING SYSTEM....................................................156
CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................159
CHECK AXLE OIL LEVEL, ADD OIL.....................................................160
CLEAN AXLE CASE BREATHER..........................................................161
CLEAN CONDENSER OF AIR CONDITIONER................................................161
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.......................................162
CLEAN RADIATOR FINS...............................................................162
REVERSE, REPLACE CUTTING EDGE, END BIT............................................163
CHECK AIR CONDITIONER.............................................................164
REPLACE SLOW BLOW FUSE............................................................165
BLEEDING AIR FROM HYDRAULIC TANK..................................................166
REPLACE FAN BELT, ADJUST AUTO TENSIONER...........................................166
SELECTION AND INPECTION OF TIRES..................................................168
DRAIN WATER FROM WATER SEPARATOR..................................................169
CHECK BEFORE STARTING.................................................................170
EVERY 50 HOURS SERVICE................................................................171
DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................171
EVERY 100 HOURS SERVICE..............................................................172
LUBRICATE REAR AXLE PIVOT PIN.....................................................172
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................172
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................173
EVERY 250 HOURS SERVICE...............................................................174
CHECK BATTERY ELECTROLYTE LEVEL...................................................174
CHECK PARKING BRAKE...............................................................175
CHECK ALTERNATOR BELT TENSION, ADJUST.............................................176
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................177
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...........................................177
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................178
LUBRICATING.......................................................................178
EVERY 500 HOURS SERVICE...............................................................181
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................181
REPLACE FUEL FILTER CARTRIDGE.....................................................183
REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................184
LUBRICATE CENTER DRIVE SHAFT SPLINE...............................................185
CHECK FAN BELT FOR WEAR...........................................................185
EVERY 1000 HOURS SERVICE..............................................................186
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...................................186
CLEAN TRANSMISSION CASE BREATHER..................................................187
CLEAN RADIATOR SUB TANK BREATHER..................................................187
LUBRICATING.......................................................................187
CHECK TIGHTENING PARTS OF TURBOCHARGER............................................189
CLEAN FUEL STRAINER...............................................................189
REPLACE CORROSION RESISTOR CARTRIDGE..............................................189
EVERY 2000 HOURS SERVICE..............................................................190
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....................190
REPLACE HYDRAULIC TANK BREATHER ELEMENT...........................................192
CHANGE AXLE OIL...................................................................192
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESHE AIR FILTER....193
CLEAN PPC CIRCUIT STRAINER........................................................194
CLEAN ENGINE BREATHER ELEMENT.....................................................195
CHECK ALTERNATOR, STARTING MOTOR..................................................195
CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................195
CHECK BRAKE DISC WEAR.............................................................195
CLEAN AND CHECK TURBOCHARGER......................................................195
CHECK ACCUMULATOR FUNCTION........................................................196
CHECK ACCUMULATOR GAS PRESSURE....................................................196
EVERY 4000 HOURS SERVICE..............................................................197
CHECK WATER PUMP..................................................................197
CHECK VIBRATION DAMPER............................................................197
CHECK FAN PULLEY AND TENSION PULLEY...............................................197
CHECK AIR CONDITIONER COMPRESSOR, ADJUST..........................................197
SPECIFICATIONS................................................................................198
SPECIFICATIONS............................................................................199
ATTACHMENTS, OPTIONS..........................................................................202
HANDLING AUTOMATIC SHIFT SYSTEM...........................................................203
METHOD OF OPERATION...................................................................203
PRECAUTION WHEN CHANGING DIRECTION....................................................204
HANDLING JOYSTICK STEERING SYSTEM.........................................................205
STRUCTURE AND FUNCTION OF JOYSTICK STEERING...........................................205
OPERATION METHOD OF JOYSTICK STEERING SYSTEM..........................................209
PRECAUTIONS FOR STEERING WITH JOYSTICK................................................211
ADJUSTMENT OF JOYSTICK CONSOLE........................................................212
HANDLING AIR SUSPENSION SEAT..............................................................213
SEAT ADJUSTMENT.......................................................................213
FAILURE DISPLAY ON MAIN MONITOR...........................................................215
FAILURE CODE ON MAIN MONITOR..........................................................215
FAILURE CODE ON AUTOMATIC SHIFT AND JOYSTICK STEERING SYSTEM..........................215
CAR RADIO.................................................................................216
EXPLANATION OF COMPONENTS.............................................................216
METHOD OF USE.........................................................................219
PRECAUTIONS WHEN USING................................................................221
AM/FM RADIO CASSETTE STEREO...............................................................222
EXPLANATION OF COMPONENTS.............................................................222
METHOD OF OPERATION...................................................................227
PRECAUTIONS FOR USE...................................................................229
AIR CONDITIONER...........................................................................230
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.......................................230
METHOD OF OPERATION...................................................................232
HANDLING TORQUE CONVERTER LOCK UP.........................................................234
GENERAL LOCATIONS.....................................................................234
METHOD OF OPERATION...................................................................235
TRAVEL SPEED LIMIT FUNCTION...........................................................235
INDEX.........................................................................................236
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