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Operation & Maintenance SEAMU424KD10
Manual
WA420-ILC
WHEEL LOADER
SERIAL NUMBERS wA420-1 :~5001 and UP

QUICK REFERENCE INFORMATION
MACHINE MODEL NAME 8 MACHINE SERIAL NO. ENGINE MODEL NAME 8 ENGINE SERIAL-NO.
DISTRIBUTOR’S NAME 8 TELEPHONi NO.
PERIODIC SERVICE ITEM DATE SERVICE METER
DELIVERY
. PERIODIC
PERIODIC
PERIODIC
PERIODIC
CONSUMABLE PARTS PARTS NO. PARTS NAME QTY.

Page 1
FORWARD
This manual describes procedures for operation, handling, lubrication, maintenance,
checking, and adjustment. It will help the operator or anyone realize peak performance
through effective, economical and safe machine operation and maintenance.
Please read this manual carefully BEFORE operating the machine.
Please ,continue studying this manual until proper operation is completely reinforced
into personal habit.
This manual describes the basic techniques. Skill is performed as the operator or
anyone get the correct knowledge and performance of the machine.
Operation, inspection, and maintenance should be carefully carried out, and the
safety must be given the first priority. Safety precautions are indicated with A marks
and technical precautions with + marks in this manual. The safety information
contained in this manual is intended only to supplement safety codes, insurance
requirements, local laws, rules and regulations.
Some photographs and illustration pictures are different from your machine as
technical improvement is continuously reflected on it. Revision to up-to-date manual’s
content is performed in later editions.
This operation & maintenance manual may contain attachments and optional
equipment that are not available in your area. Please consult your local distributor
for those items you may require.
Materials and specifications are subject to change without notice.

Page 2
BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a new
machine requires careful operation during the first 100 hours to break in the various
parts.
If a machine is subjected to unreasonably hard use at the initial operation stage, the
potential of performance will prematurely deteriorate and the service life will be reduced.
A new machine must be operated with care, particularly with regard to the following
items.
. After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior
to actual operation.
0 Avoid operation with heavy loads or at high speeds.
l Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning’

should be avoided.
l At the first 250 hours of operation, the machine should be maintained in the
following manner in addition to usual 250 hours service:
1) Replacement of transmission oil filter element.

For replacement procedure and details, see maintenance table in the maintenance
section.
* When replacing oil filter elements (cartridges), check their interiors for dirt and dust.
If heavily collected, check for possible cause before starting operation.
* Hours of operation are indicated by the service meter.

Page 3
CONTENTS
DESCRIPTION PAGE
OPERATION
GENERAL LOCATIONS AND $PEClFlCATlONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL LOCATIONS . . . . . . .................................. 2
PERFORMANCE . . . . . . . . . . . .................................. 2
ENGINE,................ .................................. 2
INSTRUMENTS AND COtiROLS . . ..................................

MONITOR PANEL . . . . . . . . . . .................................. :
CHECK MONlTOR GROUP . .................................. 5
Engine Oil Level Monitor . ..................................
Coolant Level Monitor . . . .................................. :
CAlJION MONITOR GROUP ..................................
Charge Monitor . . . . . . . .................................. :
Fuel Level Monitor . . . . . ..-......i ........................ 6
CALJTION MONITOR GROUP .................................. 7
Brake tine Failure Monitor .................................. 7
Engine Oil Pressure Monitor ................................. 7
Coolant Level Monitor .....................................
Air Pressure Monitor ...................................... 8’
Coolant Temperature Monitor ................................ 8
Torque Converter Oil Temperature Monitor .......................
METER GROUP PILOT DISPLAY ................................ :
Parking Brake Pilot Lamp .................................. 9
PilotLampforWorkingLamp.. .............................. 10
Transmission Cut-Off Selector Pilot Lamp ........................ 10
Air Pressure Gauge ...................................... 10
Engine Cooling Water Temperature Gauge ....................... 11
Torque Converter Oil Temperature Gauge ....................... 11
Fuel Gauge ............................................ 11
Turn Signal Pilot Lamp .................................... 11
High Beam Pilot Lamp .................................... 12
Speedometer ........................................... 12
Service Meter .......................................... 12
SWITCHES ................................................ 13
TRANSMISSION CUT-OFF SELECTOR SWITCH ...................... 13
El-HER STARTSWlTCH ..................................... 14
HORN BlJlTON ........................................... 14
HAZARD LAMP SWITCH ..................................... 14
PARKING BRAKESWITCH.. .................................. 15
WORKING IAMP SWITCH ..................................... 16
STARTING SWITCH ........................................ 16
LAMPSWrrCHES .......................................... 16
Lamp switch ........................................... 16
Turn signal lever ........................................ 17
Dimmer switch .......................................... 17
ROOM LAMP SWITCH ...................................... 17
CIGARETTE UGHTER ._..................................... 18
Page 4
CONTENTS-Continued
PAGE
DESCRIPTION
KICKDOWN SWITCH ...................................... ;;

FRONT WIPER SWITCH ....................................
REARWIPERSWITCH .....................................
LEVERSAND PEDALS ..................................... :
DlRECTlONALLEVER ..................................... g
SPEEDCONTROLLEVER.. .................... . ............
SPEED CONTROL LEVER STOPPER ............................ ;; -
STEERING COLUMN TILT LEVER .............................
ACCELERATOR PEDAL .................................... 21
BRAKE PEDALS ......................................... g
Riiht brake pedal ......................................
Leftbfakepedal ....................................... 2$.
LlFTARMCONTROLLEVER..........................._ .....
BUCKETcONTROLLo/ER............._._._......_.._ z
SAFElY LOCK ................................................
AIR CLEANER SERVICE INDICATOR ............................ g
SAFETY BAR ...........................................
WORK EQUIPMENT CONTROL LEVER .......................... 25
ClRCUlT BREAKER (MAIN) ..................................
DOOR-OPEN LOCK.. ..................................... 2
HOODTILTLOCK .................................................................................... g
FUSE BOX
OPERATOR’SSEAT......................._ ............... 29
Forward-backward adjustment ..............................
Seat angle adjustment ................................... z
Seat cushion adjustment .................................. z
Backrest adjustment ....................................
Seat height adjustment ................................... 29
RIGHTSIDEARMREST .................................... 29
Forward-backward adjustment .............................. 2
Angle adjustment ......................................
SEATBELT .............................................. 30
CHECKBEFORESTARTING ..................................... ;;
WALK-AROUNDCHECK ......................................
CHECKMONITOR PANEL.........................._ ..........
CHECK AND REFILLCOOLANT ................................. z
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN .................. g
CHECK FUEL LEVEL AND REFILL FUEL ............................
CHECK AIR CLEANER SERVICE INDICATOR ........................ z
DRAIN WATERFROMAIRTANK .................... .‘. ..........
CHECK FOR SEDIMENT AND WATER IN II-lE WATER SEDIMENTOR ........ 34
FUEL-WATER SEPARATOR - DRAINING WATER AND SEDIMENT ........... 35
DRIVE BELT - INSPECTlON ................................... g
FAN -INSPECTION .........................................
OPERATlNGYOUR MACHINE .................................... 37

BEFORE STARTlNG THE ENGINE ............................... 37
Page 5
CONTENTS
DESCRIPTION
TOSTARTTHEENG~E...................................... 38
SPECIAL STARTING 38
CHECKsAFTERSTARTIN’G’::::::::::::::::::::::::::::::::::: 39
TO MOVE THE MACHINE OFF . . . . . . . . . . . . . . . . . . . . . .‘: . . . . . . . . . . 39
CHANGINGGEARSPEED..~.................................. 40
CHANGING DlRECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TURNING 41
TOSTOPTHE’MACHINE’::::::::::::::::::::::::::::::::::::: 42
TO STOP THE ENGINE 43
MAXIMUM DEPTH OF W/+&i : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 43
IF WHEEL BRAKE DOES NOT WORK . . . . . . _ . _ . . . _ . . . . . . . . . . . . . . . . -43
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . 44
LOWER THE CENTER OF GRAVITY WHEN TURNING 44
BRAKING ON DOWNHILL SLOPES . . . . . . . . . . . _ . : : : : : : : : : : : : : : :: 44
IF ENGINE STOPS 44
PROPERBUCKETANDjidE’:::::::::::.:::::::::::::::::::::::: 45
ADJUSTMENT OF WORK EQUIPMENT 46

ADJUSTING BOOM KICKOUT _ . . _ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 46
ADJUSTING BUCKET POSITIONER ............................... 47
BUCKET LEVEL INDICATOR ................................... 47
HANDLlNGTHETlRES ......................................... 48
PRECAUTlONS WHEN HANDUNG TIRES ........................... 48
PRECAUTlONS WHEN DRIVING MACHINE .......................... 49
TIREPRESSURE ............................................ 50
INFLATING TIRES ........................................ 50
TOWING .................................................. 52
TOWINGTHE MACHINE.. .................................... 52
WHEN ENGINECAN BE USED ............................... 52
..
WHEN ENGINECANNOT BE USED ............................ 52
RELEASING PARKING BRAKE .................................. 53
COLD WEATHER OPERATION .................................... 54

PREPARATION FOR LOW TEMPERATURE .......................... 54
FUEL AND LUBRICANTS ................................... 54
COOLANT ..__.................................._ ...... g
BAlTERY
STARTlNGINC~LDih;EAM’Ek’::::::::::::::::::::::’::::::::::: 55
CAUTIONS AFTER COMPLETlON OF WORK 56
AFTERCOLDWEATHER ............. . . . . . . . . . . . . . . . . . . . . . . . . 56
Page 6
CONTENtS
DESCRIPTION . PAGE
MAINTENANCE
PERIODIC MAlNTENANCE ... . .................... ) ............... 2
BLEEDING AIR FROM ClRCUlf ......................................

BLEEDING AIR FROM HYDRAULIC CIRCUIT ..........................
BLEEDING AIR FROM FUEL SYSTEM ..............................
LOW PRESSURE LINES AND FUEL FILTER(S) VENTING ...............
HIGH PRESSURE LINES-VENTING ..............................
PERIODICAL PART REPLACEMENT .................................. 4
MAINTENANCETABLE .......................................... 5‘
OIL FILLER AND LEVEL GAUGE POSITIONS ............................ 9
CHECK BEFORE STARTING ....................................... 10
EVERY 50 HOURS SERVICE ....................................... 10

FUELTANK ................................................ 10
TIRE..................................................._. 10
EVERY100 HOURS SERVICE ...................................... 11

HYDRAULICTANK ........................................... 11
LUBRICATING ............................................... 11
AIR CONDITIONER FILTER-IF EQUIPPED ............................ 12
INITIAL250 HOURS SERVICE.. .................................... 12

TRANSMISSION OIL FILTER ..................................... 12
EVERY 250 HOURS SERVICE ...................................... 13

ENGINE OIL PAN AND FILTER ................................... 13
AIR INTAKE SYSTEM . INSPECTION ............................... 14
AIR CONDITIONER COMPRESSOR BELT-IF EQUIPPED ................... 14
WHEEL HUB NUTS ........................................... 15
LUBRICATING .............................................. 16
CHECK ELECTROLYTE LEVEL IN BATERY .......................... 16
EVERY 500 HOURS SERVICE ......................... . ............ 19

FUELFILTERS.. ............................................ 19
TRANSMISSION OIL FILTER ..................................... 20
LUBRICATING ..............................................
AIR DRYER ................................................ iii
ANTIFREEZE CONCENTRATION . CHECK ........................... 21
COOLANT ADDITIVE CONCENTRATION .............................. 21
COOLANTFILTER . . . . . . . . . . . . . . . . . . . . .._.................... 22
Page 7
CONTENTS
DESCRIPTION PAGE
EVERY loo0 HOURS SERVICE ...................................... 23

TRANSMISSION CASE AND STRAINER ............................. 24
TRANSMISSION CASE BREATHER ................................ 24
LUBRlCATlNG .............................................. 25
ENGINEVALVES ............................................ 26
DRIVE BELT TENSION - CHECK .................................. 30
DRIVE BELT,.,TENSIONER BEARING AND FAN HUB . INSPECTION .......... 31
EVERY2000 HOURSSERVICE ..................................... 33

HYDRAUUCTANKAND FILTER .................................. 33
HYDRAULICTANK BREATHER ................................... 34
DRIVE AXLES 35
AIRCONDTnON’iR’~I~~d:i~EbUif;f;E’d::::::::::::::::::::::::::: 36
BRAKEDISC ................................................ 36
INTERNALPARTOFAIRDRYER.. ................................. 36
COOLANT CHANGE AND FLUSHING THE SYSTEM ..................... 37
COOLANT ............................................... 37
DCA4 UNlT MAINTENANCE GUIDE .............................. 37
VIBRATION DAMPER - INSPECTION ............................... 41
AIR COMPRESSOR . INSPECTION ................................ 41
AIR COMPRESSOR DISCHARGE . INSPECl-lON ..................... 42
AIR COMPRESSOR INTAKE . INSPECTION ........................ 43
WHEN REQUIRED .............................................. 45

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................. 45
CHECKING .............................................. 45
CLEANING OR REPLACING OUTER ELEMENT ...................... 45
REPLACING INNER ELEMENT ................................. 46
CLEANING OUTER ELEMENT ................................. 46
CHECK AND REFILL TRANSMISSION OIL. ............................ 47
CLEAN RADIATOR FlNS ....................................... 48
..
CHECK AND REFILL DRIVE AXLE OIL .............................. 48
CLEAN DRIVE AXLE HOUSING BREATHER .......................... 49
CLEAN AIR CONDITIONER CONDENSER-IF EQUIPPED .................. 49
CHECK AIR CONDlTlONER REFRIGERANT CHARGE-IF EQUIPPED .......... 50
LUBRlCATlNG .............................................. 51
CHECK AND REFILL WINDOW WASHING FLUID ....................... 51
WATER SEDIMENTOR.. ....................................... 52
REPLACING BUCKET TEETH ..................................... 52
IF THE BUCKET IS EQUIPPED WITH BOLT-ON TOOTH ................. 52
IF THE BUCKET IS EQUIPPED WITH BOLT-ON TOOTH ................ 53
IF THE BUCKET IS‘EOUIPPED WITH TIP TOOTH .................... 53
ADJUSTMENT ................................................ 54
ADJUSTING PARKING BRAKE ................................... 54
ADJUSTING LENGTH OF LEVER .................................. 55
TROUBLE SHOOl-lNG GUIDE ...................................... 56

ELECTRICAL SYSTEM.. ....................................... 56
Page 8
CONTENTS
DESCRIPTION PAGE
ENGINE .......... 57
CHASSIS:::::::::::::::::::::::::::::::::::::: .......... 58
TRANSMISSION ......................................... 58
AXLE ..... .._........................;> .............. 58
DISCBRAKE : ........................................... 58
PARKlNG BRAKE ........................................ 59
STEERING.. ........................................... 59
HYDRAUUC SYSTEM ..................................... 59
SERVICE METER ............................................. 60
MACHINE AND ENG!NE SERIAL NUMBERS ........................... 69.
FUEL, COOLANT AND LUBRICANTS ................................ 61
MEMORANDA . . . . _ . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 64
SAFETY AND OPERATION
SAFElY HINTS. . . g, .._.. .................................... 2

OPERATION . . . . _ . . . . . . .................................... 2
GENERAL .......... .................................... 2
CHECKING JOBSITE CONDlTlONS .............................. 4
BEFORE STARTlNG OPERATION ................................. 5
CHECKBEFORESTARTING .................................. 5
PRECAUTIONS WHEN GlXRNG ON THE MACHINE .................. 7
PRECAUTIONS WHEN STARTlNG THE ENGINE ..................... 7
CHECKS AFTER STARTING THE ENGINE .......................... 8
DURING OPERATION ......................................... 8
ATTENTiONTO SURROUNDINGS .............................. 9
RESTRICTIONS CREATED BY JOBSITE .......................... 11
PARKING.....................................~ ........... 13
..
PRECAUTIONS FOR MAINTENANCE ................................ 14
GENERAL ............................................... 14
BEFORE MAINTENANCE ..................................... 16
DURING MAINTENANCE.................................._ ... 17
MISCEUANEOUS .......................................... 18
BUCKETOPERATlON................_...._.._:’...: ............. 19
EXCAVATION ............................................. 19
PRECAUTIONS WHEN SCOOPING UP MATERIALS .................. 22
LEVELING ...............................................
LOAD AND CARRY OPERATIONS ................................ z
LOADING.. .............................................. 23
CROSSDRIVELOADING ........................... .........
V-SHAPE LOADING .......................................
Page 9
CONTENTS
DESCRIPTION PAGE
OPERATING THE CAB HEATER ................................... 24

EQUIPMENT ON,CONTROL PANEL .............................. 24
FAN SPEED SWITCH ....................................... 24
TEMPERATURECONTROLLEVER ............................. 24
AIR INTAtiE SEiECTOR LEVER ............................... 24
METHODOFOPERATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATlNG THE AIR CONDITIONER-IF EQUIPPED ...................... 26

EQUIPMENT ON CONTROL PANEL .............................. 26
FAN SPEED SWITCH.. .................................... 26
AIR CONDlTlONER SWITCH ................................. 26
AIR INTAKE SELECTOR LEVER ............................... 26
TEMPERATURE CONTROL LEVER ............................. 27
PRECAUTIONS FOR USING AIR CONDITIONER ......... : .......... 28
HANDLING THE AIR CONDiTlONER IN SEASON .................... 28
HANDLING THE AIR CONDITIONER IN OFF-SEASONS ................ 28
LOCKING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _............... 29
HANDLING OF BATTERY ............... 30

PRECAUTIONS FOR CH-ARtiid Bii-ibi+ : : : : : : : : : : ............... 30
REMOVAL AND INSTALLATION OF BAlTERY . . . . . . . . ............... 30
STARTlNG ENGINE WITH A BOOSTER CABLE . . . . . . . ............... 31
TRANSPORTATION . .._........._.............._.............. 32
STORAGE ...... .._........_

BEFORE STORAGE .................
DURING STORAGE .................
........ .......
.......
.......
z
...............
...............
...............
34
AFTER STORAGE .................. ....... ............... 34
..
COOLANT AND LUBRICANTS ............ . . . . . . . . . . . . . . . 35
MEMORANDA .. . ............................................ 36
SECTION 1
OPERATION
A
WARNING ! REFER TO AND READ ALL
..
SAFE+ PRECAUTIONS IN SECTION 3.
SECTION 1 OPERATION
Page 2
GENERAL LOCATIONS AND SPECIFICATIONS
GENERAL LOCATIONS
_ - . _ : _.__....___.
_- .__.-.-. . --. _ _._- - -
WA42O-1LC With Cab and POPS Canopy
1. lilt lever 4. Turn signal lamp 7. Lift cylinder

2. Liftarm 5. Rear wheel 8. Dump cylinder
3. Head lamp 6. Front Wheel 9. Bucket
PERFORMANCE
Bucket capacities - Heapad

Excavatingtype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 yd3 (3.0 m3)
tight material type . . . . . . . . . . . . . . . _ . . . . . . , . . . . . . . . . . . 5.5 yd3 (4.2 m3)
Travel speeds:
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum of 24.1 mph (38.8 km/h)
Reverse . . . . . . . . . . . . . . _ . . . . . . . . . . . _ Maximum of 26.5 mph (42.6 km/h)
Operating weight . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . 43 980 lb (19 949 kg)
ENGINE
Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KDC614TA diesel engine
Flywheel horsepower - at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . 224 HP (167 kW)
NOTE: Specifications are subject to change without notice.

OPERATION SECTION 1
Page 3
INSTRUMENTS AND CONTROLS

MONITOR PANEL
Thii monitor panel consists of monitor lamp groups (A, 6, C), mater group (D) and warning
np (0
l To check the monitor system, turn the starting switch to ON before starting the engine.
Then all the monitor lamps, the gauges and the warning lamp light up for about 3
seconds and the Alamobuzzer sounds for about 1 second. Three figures, 133, are
:
diiptayad on tha speedometer while tha monitor system is being chacked. After that, all
lamps go off and the buzzer stops. If any monitor lamp does not light up, ask your
diiutor to inspect that monitor lamp.
* When the starting switch is turned to ON, if the directional lever is not at neutral, the
warning lamp willflash and the alarm buzzer will continue to sound. lf this happens, return
the lever to neutral. The lamp will go out and the buzzer will stop.
* To check the monitor immediately when tha engine is stopped, waft for at least 30
seconds after the engine is stopped.
CHECK MONITOR GROUP

(Chsck items before starting)
lf there is any abnormalii, the appropriate monitor lamp will flash.
* When the engine is started, these monitor lamps will go off even if there are abnormalities.
SECTION 1
Page 4
CAUTION MONITOR GROUP

(Caution items)
If any abnormalityoccurs while the engine is running, the appropriate monitor lamp will flash to
indicate the abnonnalii.
* Even if any monitor lamp flashes, the machine can operate, but it should be repaired as
soon as possible. ’

(Emargency stop items)
If any abnorrMi occurs while the engine is running, the appropriatemonitor lamp will ilash and
thealarmbuzzarwiilsoundintermittenUyatthesarnatima.
* lf any monitor lamp flashes, stop the engine or run it at a low idling speed, and repair it
Immediately-
METER GROUP
Thii group consists of air pressure gauge, engine water temperature gauge, torque converter
oil temperature gauge, fuel gauge, speedometer, service meter and pilot display.
WARNING LAMP
The warning lamp will flash when there is an abnormalityin any (B) group item.
Tha warning lamp will flash and the alarm buzzer will sound when there is an abnormalii in any
(C) group item or when the parking brake is applied, but the diiectional lever is not at neutral.
OPERATION SECTION 1
Page 5
CHECK MONITOR GROUP

(Check itams before starting)
* Do not raly on ‘CHECK MONITOR GROUP (Check before starting)” only for the check
before starting. Always make the check by referring to the section on CHECK BEFORE’
STARTING.
Engine Oil Level Monitor

l
This monitor indicates a low oil level in the I

engine oil pan.
lf the monitor lamp flashes, check the oil level in
the engine oil pan and add oil as required.
SECTION 1 OPERATION
Page 6
Coolant Level Monitor
This monitor indicates a low radiator coolant

IWet.
If the monitor lamp flashes, check the coolant

level and add water as required.
‘* Park the machine on level ground and
check the monitor lamps.
* Confirmthat these monitor lamps light for
about 3 seconds after turning the starting
switch to ON. If any monitor lamp does
not light, ask your distributor to inspect
that monitor lamp.
‘CAUTION MONITOR GROUP

(Caution items)
lf any abnormality occurs while the engine is running, the appropriate monitor lamp and the
warning lamp will flash to indicate the abnormalii at the same time.
Charge Monttor
This monitor indicates an abnormal&y in the

charging system while the engine is running.
If the monitor lamp flashes, check the charging
circuit
* This monitor lamp flashes and the alarm

buzzer sounds, when the starting switch
is turned to ON immediately after the
engine is started or immediately before
the engine is stopped. It does not
indicate an abnormalii.
Fuel Level Monitor
This monitor indicates there is less than 35 liters

of fuel in the tank.
lf the monitor lamp flashes, add fuel. I 1
* Park the machine on level ground and

.
check the monitor lamps.
* Confirmthat these monitor lamps light for

about 3 seconds after turning the starting
switch to ON. ff any monitor lamp does
not light, ask your distributor to inspect
that monitor lamp.
OPERATION SECTION 1
Page 7

(Emergancy stop items)
lf any abnom-talii occurs while the engine is running, the appropriate monitor lamp and tha
warning lamp will ffash and the alarm buzzer will sound intermittentlyat the same time.
Brake Line Failure Monitor
This monitor indites a drop in the brake oil

pressure when the brakes are operated.
lf the lamp ffashas, stop the machine

immediately and check the brake system.
* After checking ‘and repair of brake

system, push in over-stroke sensor rod
on tht3brake chamber. If this operation is
not done, a buzzer and lamp will
continue to warn of brake line trouble.
Engine Oil Pressure Monitor
lhii monitor indicates a low engine oil pressure.

lf the lamp flashes, the engine oil pressure is
below the lower limit. Immediately stop the
engine.
* Thismonitorlampflashesandthealarm
buzzer sounds, when the starting switch
is turnad to ON immediately after the
engine is started or immediately before
the angina is stopped. lt does not
indicate an abnomlalii.
Coolant Level Monitor
This monitor indicates a low radiator coolant

level.
Check the coolant level when the monitor lamp
flashes, stop engine and add water as required.
SECTION 1 OPERATION
Page 8
Air Pressure Monitar
This monitor indicates a drop in the air prassura

in the air tank.
If the lamp flashes, increase the engine spaad
andwaituntilthalampgoasout.~ ...*
. ..
...
Coolant Temperature Monitor
This monitor indicates a rise in the cooling water
e
temperature.
When the monitor iamp flashes, run the engine
with no load at midrange speed until the green
range of tha angine water temperature gauge
lights.
Torque Converter Oil Temperature Monitor
Thii monitor indicates a risa ‘in the torque

convertar oil temperature.
when the monitor lamp flashes, stop the
machine and run the engine with no load at
midrange speed until the green range of the
temperature gauga lights.
* Park the machine on level ground and che& the monitor lamps.
* Confirm that these monitor lamps light for about 3 seconds after turning the starting
switch to ON. If any monitor lamp does not light, ask your distributor to inspact that
monitor lamp.
OPERATION SECTION 1
Page 9
METER GROUP PILOT DISPLAY
When the starting switch is turned to on, this lights up to indicate that the display items are
working. (
9 10 9
11
12
Parking Brake Pilot Lamp
This lamp lights up when the parking brake is

applied.
*
SECTION 1 OPERATION
Page 10
Pilot Lamp for Workhg Lamp
This lamp lights up when the working lamps are

switched on.
Transmission Cut-off Selector Pilot Lamp
This lamp lights up when the transmission cut-

off selector switch is turned to ON.
* If the monitor lamp is ON and the left

brake pedal is depressed, the trans-
mission will be returned to neutral.
04k
Air Pressure Gauge
This gauge indicates the air pressure in the air

tank. The green range should be lighted dting
normal operation.
lf the red range lights up during operations, the

alarm buzzer will sound, the warning lamp will Green
flash, and the air pressure monitor lamp will
flash.
If this happens, stop the machine, increase the Red

engine speed and wait until the green range
lights up.
* lf the air pressure drops even lower, the parking brake will tk autcimaticallyapplied.
OPERATION SECTION 1
Page 11
Engine Cooling Water Temperature Gauge

This gauge vindicatesthe temperature of the
cooling water. lf the temperature is normal
during operation, the green range will light lf the
red range lights during operation, stop the
machine and run the ,engine with no load at Green
midrange speed until the geen range lights.
lf the top lamp in the red range lights up, the
alarm buzzer will sound, the warning lamp will White
flash and the coolant temperature monitor lamp
willflashatthesametime.
Torque Converter 011 Temperature Gauge

This gauge indicates the temperature of the
torque cdnverter oil. lf the temperature is normal
during operation, the green range will light. lfthe
red range lights during operation, stop the
machine and run tha engine with no load at
midrange speed until the green range lights.
lf the top lamp in the red range lights up, the
alarm buzzer will sound, the warning lamp will
light up and the torque converter oil temperature
monitor lamp will flash at the same time.
Fuel Gauge
This gauge indicates the amount of fuel in the
fuel tank. ffthere is enough fuel in the tank while
the engine is running, the green range lights. If
yhyhz&gkM, there is less than 21 liirs
: When the red range lights, add fuel.
Turn Signal Pilot Lamp

When the turn signal lamp flashes, the pilot
lamp also flashes.
* lf the wiring of the turn signal lamp is

disconnected, the pilot lamp will flash
faster.
SECTION 1 OPERATION
Page 12
High Beam Pilot Lamp
. This lamp lights up when the head lamp is at

high beam.
Speedometer
__-_.._ . .
This meter indiies the running speed of the __.-
machii.
I[aTzi==Tr>ll
* A speedometer for MPH is also available.
serviceMeter
This meter shows the total operation hours of 1
the machine. The service met& advances while
th0 engine is running - even if the machine is
not traveling.
Refer to the section “SERVICE MEJER.” I

F-l
I ** I
* ”
While engine is running, green pilot lamp on [JINGFS&u]
theservicemeterflashestoshowtheservice
meter advances.
OPERATION SECTION 1
Page 13
SWITCHES
TRANSMISSION CUT-OFF SELECTOR SWITCH
Thii switch selects the operation of the left

brake pedal. Normally, put this switch in ON
position.
OR:
Depressing the left brake pedal operates the
wheel brakes (like right brake pedal).
ON:
Depressing the left brake pedal operates the
wheel brakes, and also returnsthe transmis-
sion to NEUTRAL
* if the switch is at Oti, the transmission cut-off selector pilot lamp will,light up.
A
WARNING! tf the machine has to be started on a slope, always turn the
transmission cut-off selector switch to OFF and depress the left brake pedal.
Then depress the accelerator pedal while releasing the left brake pedal to start
the machine off slowly.
SECTION 1 OPERATCON
Page 14
ETHER START SWITCH
This switch is used when starting the engine in

cold weather.
(c) ON:
A fixed amount of ether (approx. 3 cc each time)
is injected into the engine air intake to make it
easier to start the engine in cold weather.
(d) OFF:
Whentheswitchisr&ased,it~
retumstotheOFFpos&ion.
A WARNING! Do not keep the switch at the ON position for more than 5 seconds.
HORN BUrrON
When the button in the center of the steering

wheel is pressed, the horn will sound.
HAZARD IAMP SWITCH
This switch is used in emerg8nci8s. such as

when the machine breaks down.
ON: All turn signal lamps flash.
* All turn signal lamps and pilot lamp on

the steering column flash, when this
sw$hisputtoON.
A WARNING! Do not use this switch

unless abnormality has occured.
OPERATION SECTION 1
Page 15
Ths switch operates the parking brake.
(1) ON position:
The parking brake is applied, and the parking
brake pilot lamp lights up.
.. (2) Off position:

The parking brake is released.
A
WARNING! Always apply the
parking brake when leavng the
machine or parking it.
If the directional lever is placed in F (FORWARD) or R (REVERSE) with the parking brake
applied, the warning lamp will flash and the alarm buzzer will sound.
When the starting switih ‘is turned to OFF, the parking brake is automaticallyapplied.
Before starting the engine, turn the parking brake switch to ON, then turn it to OFF.
The machine does not start when the directional lever is operated with parking brake
applied.
SECTION 1 OPERATION
Page 16
WORKING LAMP SWITCH
When the front and rear working lamps are

turned ON, the pilot lamp and illuminationlamp
for monitor panel will also light up.
ON: Working lamps are ON.
WARNING! When traveling on

public roads, turn the working
&L lamps OFF.
STARTINGSWITCH
This switch is used to start or stop the engine.

OFF OFF
Key insertion-withdrawal position. None of I
I
electrical circuits activate.
The hazard lamp and the parking lamp will
remain on, however, when the switch is turned v,
_(
OFF. 9
P
To stop the engine, turn the switch to OFF.
ON
Charging and lamp circuitsactivateJeep key at
ON after starting.
START
At this key position, the starting motor will crank the engine. Release the key immediatelyafter
starting, and the key will return automaticallyto ON.
LAMP SWITCHES
(for lamps, turn signal lamps, dimmer switch)
Lamp switch
Position (1):
Parking lamp lights up.
Position OFF (2):
Lamps-go off.
Position (3):
Cfearance iamps, tail lamps and machine
monitor fiihting light up.
Position (4):
Head lamps light up in addition to the lamps
in position (3):
* The lernp switch can be operated regardless of the position of the lever. ..
OPERATION SECTION 1
Page 17
Turn signal lever

This lever operates the turn signal lamps
(1) LEFT TURN:
Push lever FORWARQ
(2) RIGHT TURN
Pull lever BACK. :
* When ttw lever is operatad, the turn

signal pilot lamp will also light up.
* When the steering wheel is turned to the

neutral position, the turn signal lever will
return automaticallyto Off. If not, return
the lever to OFF manually.
Dimmer switch
This switches the head ltip between high
beam and low beam.
(A) Low beam
(8) High beam
ROOM LAMP SWITCH
when this switch is moved to ON position, room

lamp will1light.
SECTION 1 OPERATION
Page 18
CIGARETTELIGHTER
This is used to light cigarettes. To use, push

the lighter in. After a few seconds it will spring
back At that time, remove the lighter and tight
your cigarette.
KEKDOWN SWITCH
If this switch is pushed when the speed control

lever is in 2nd, the transmission shii down to
1st.
This switch is used to increase the drawbar pull

in digging operations.
* To cancel the kickdown switch, move the

directional lever to REVERSE or NEU-
TR& or move the speed control lever to
any posit& except 2nd. It is also
possible to cancel the kickdown switch
by operating the parking brake switch or
by turning the starting switch OFF.
0.
OPERATION SECTION 1
Page 19
FRONT WPER SWITCH
(1) The wiper is actuati..; low speed.
(2) The wiper works at high speed.
When this switch is turned dockwiie,

solvent will be sprayed on glass.
REAR WlPER SWITCH
When thii switchis pulled to ON position, wiper

operates on rear glass.
When this switch is turned clockwise, solvent

*. Wnlbe sprayed on glass.
SECTION 1 OPERATl.ON
Page 20
LEVERS AND PEDALS
DIRECTIONAL LEVER
This lever is used to change the direction of

travel of the machine.
(1) Forward.
(2) Reverse
(N) Neutral
The engine cannot be started if the

directiorkl lever is not at N (neutral). 2
I
When operating the directional lever,
place your hand on a steering wheel and
operate it by your fingers.
lt is possible to change the length of the lever. For details of changing the length, see
ADJusThENT.
OPERATION SECIION 1
Page 21
SPEED CONTROL LEVER 7

Thii lever controls the travel speed of machii.
This ma&ii has a CFORWARD, 4REVERSE

speed transmission. Place the speed control
lever in a suitabfeposition to obtain the desired
speed range.
* 1st and 2nd speeds are used for working.

3rd speed is used for traveling.
* It is possible to change the length of the

lever. For details of changing the length,
see ADJUSTMENT.
SPEED CONTROL LEVER STOPPER
This stopper prevents the spaed control lever

from entering the 3rd and 4th positions, when
working.
Posii (1)
Stopper actuated.
Position (2)
Stopper released.
STEERING COLUMN TfLT LEVER
This lever allows the steering column to bs

’ tilted forward or backward.
Pull the fever up and move the steering wheel

to the desired position. Then push the lever
down to kxk the steering wheel in position.
* Range of adjustment:100 mm (stepless)
A
WARNING! Stpp the machine
before adjusting the angle of the
steering wheel.
ACCELERATOR PEDAL
This padal controls the engine speed and output. The engine speed can be freely controlled
between low idling and full speed.
SECTION 1 OPERATION
Page 22
BRAKE PEDALS
Right brake pedal
The right brake pedal operates the wheel brakes, and is used for normal braking.
A WARNING! On downhill slopes, apply the engine brake, and also use the right
brake pedal.
Left brake pedal
The left brake pedal operates the wheel brakes, and if the transmissii cut-off selector switch
is at ON, it also returns the transmission to neutral.
If the transmission cut-off selector switch is at OFF, the left brake pedal acts in the same way”
as the right brake pedal.
A WARNING! Do not use the brake pedals repeatedly unless necessary.
A WARNING! Do not use the brake pedals as footrests. Use them only when
applying the brakes.
* When the accelerator is being used for operating the work equipment, always use the left
brake pedal to slow or stop the machine after putting the transmission cut-off selector switch
in ON.
OPERATION SECTION 1
Page 23
UFT ARM CONTROL LEVER
This lever is used to opera+ the iii arm.

1. Raise:
2. Hold: The Iii amn is kept in the same
3. Loweer:mon.
4. moat: The iii arm moves freely under
external force.
* When the lift arm control lever is pulled

further from (1) position, the lever is
stopped in this position until Iii arm
reaches the preset position of kick-out,
and the lever is backed to hold position.
SECTION 1 OPERATION
Page 24
BUCKET CONTROL LEVER
This lever operates the bucket.
(1) Tilt:
(2) Hold:The bucket is kept in the same
position.
(3) Dump:
* When the bucket control, lever is pulled

further from (1) position, the lever is
stopped in this position until bucket reaches
the preset position of positioner, and the
lever is backed to hold position.
SAFETY LOCK
T&G&i; ~IJ.SJ.S~
to lock the lii an-n and bucket
A
WARNING! When parking or
leaving the machine, or when
performing maintenance, always
lower the bucket to the ground,
put the work equipment levers in
hold position and check that
safety lock lever is locked.
AIR CLEANER SERVICE INDICATOR
Thii device indicates clogging of the air cleaner

element. When red piston (1) appears in the
transparent part of the indicator,the element is
clogged. immediately clean element.
After cleaning, push indicator button (2) to

return red piston to original position.
Service indicator is on air cleaner in engine

hood. 1
OPERATION SECTION 1
Page 25
SAFETY BAR
:
The safety bar is used during maintenance or
when transporting the machine. It locks the
front frame and rear frame, and prevents the
front and rear frames from bending.
A
WARNING1 Always us8 the safety
bar for maintenance or when
transporting the machine.
WARNING! Always remove the

safety bar during normal travel
:A operations.
WORK EQUIPMENT CONTROL LEVER (MONO-LEVER TYPE)
This lever is used to operate the iii arm and

the bucket.
(1) Raise:
(2) Hold: The lift arm and the bucket are kept
in the same position.
(3) Lower:
(4) float: The Iii arm moves freely under
external force.
(5) Tilt:
(6) Dump:
* When the work equipment control lever

\ is pulled further from (1) position, the
lever is stopped in thii position until the
lift an-n reaches the preset position of
kick-out, and the lever is backed to hold
position.
SECTION 1 OPERATION
Page 26
* When the work equipment control lever

is pulled further from (5) position, the
lever is stopped in thii position until the
bucket reaches the preset positron of
bucket positioner, and the. lever is
backed to hold position.
CIRCUIT BREAKER (MAIN)
This prevents damage to the electrical

components and electric wiring.
When the breaker has been actuated, press the

reset button to reset the system. However, if
the circuit breaker is actuated again after the
button is pressed, or the circuit breaker is
frequentlyactuated, there may be a short circuit
in the electrical system. In such cases, contact
your diiutor for repairs.
* The circuit breaker is not reset for 45

seconds after the breaker is actuated.
DOOR-OPEN LOCK
This can be used to hold the door open.
Open the door so that tip (2) of the lever is

aligned with groove (1) for the lock, then pull
down knob (3) as shown in the diagram.
When relasing the lock and closing the door,

push up knob (3) and insert pin (4) securely in
the groove.
* When using the door-open k&c, be sure 1

to apply the lock securely.
OPERATION SECTION 1
Page 27
r
HOOD TILT LOCK
This is a safety device for the engine hood, and

is used when operat@g with the engine hood
raised, such as. during inspection and
maintenance.
L
Open the engine hood fi~liyand apply the lock.
A
WARNING! When carrying out
inspection or maintenance with
the engine hood raised, always
use the lock.
..
FUSE SQX
The fuses protect the electric devices and

wiring from burning out. If any fuse is rusted or
coated with white powder, replace it.
* Replace a fuse with another of the same

capacity.
A
WARNING! Before replacing a
fuse, be sure to turn off the
starting switch.
SECTION 1 OPERATION
Page 28
FUSE AFIRANGEMENT AND ClRCUlT
Fuse box I (Lower side) Fuse box I
Fuse
No. capacity circuit
1 2QA Woiking lamp
2 1OA Parking brake
3 1OA Monitor lamp
4 1OA Bucket positioner
6oom kick-out
5 1oA _
6 1OA _
7 20A Air condiioner
(Fan outside room)
‘s 20A Air conditioner
(Fan inside room)
9 1OA Radii, Room lamp
10 1OA Cigarette lighter
11 1OA Rear wiper
12 1OA Front wioer
Fuss box II (Upper side) Fuse box II

I 1
[~_a 1 ~~ 1OA 1Riaht head larn~

OPERATION SECTION 1
Page 29
OPERATOR’S SEAT
The seat adjustmant should ba checked at the
beginning of each shii and when operators
change.
FORWARD-BACKWARD ADJUSTMENT
Move lever (1) to the rig& move the seat to the
best position and releasathe lever. The seat
can be moved forward or backward within a
range of 140 mm in 7 stages.
SEAT ANGLE ADJUSTMENT
Move lever (2) up, sat the seat to the desired
angle, and release the lever.
The seat can be tilted up or down about 3”.
SEAT CUSHION ADJUSTMENT
Rotate grip (3) under the seat to adjust scale
(4) on the cushion adjustmentto your own weight. (50 to 120 kg)
BACKREST ADJUSTMENT
Pull lever (5), move the backrest to the best position and release the lever. The backrest can
ba set to 11 steps.
SEAT HEIGHT ADJUSTMENT

Move lever (6) upward, set the seat to the desired height and release the lever. The seat can be
set within 50 mm.
..
A WARNING! Park the machine in a safe place and stop the engine when carrying
out adjustment of the operator’s seat.
RIGHT SIDE ARMREST
FORWARD-BACKWARD ADJUSTMENT
Loosen bolts (1) to move the arm-rest to the

desired position, and tighten the bolts.
ANGLE ADJUSTMENT
Loosen bolts (2) to move the arm-rest to the

desired angle and tighten the bolts.
SEClION 1 OPERATION
Page 30
SEAT BELT
A
WARNING! Before fastening the
seat belt, inspect the securing
brackets and belt for abnormal
conditions.
Fasten the belt and remove it in the following
manner.
1. Adjusttheseatsothatthebrakepedalcan
be depressed all the way with the
operato&backagainstthebackrest
2. After po&ioning the seat, install the tether
belt (1). Wti the seat unoccupied, tense the
belt slightly across the seat and install.
A WARNlNGl Check that there are no kinks in the belt.
3. Si in the seat. Hold buckle (2) and insert (3) into the buckle (2). Check that the belt has
focked by pulling it.
4. When removing the belt, raise the tip of the buckle lever to release it.
* When leaving the operator’s seat, release the seat belt and hang it over the arm rest.
* Fasten belt along your body without kinking it_Adjust the lengths of the belt on both the
buckle and the insert sides so that the buckle is located at the mid-point of your body front.
_ ..__-.
Adjust the belt length in the following manner. 1 1
To shorten the belt, pull the free end of the
belt on either the buckle body or insert side.
To lengthen, pull the belt while holding it at
a right angle to buckfe or insert
When operating a machine equipped with
ROPS. be sure to use the seat belt.
Inspect bolts and fittings on the chassis for

tightness. Retighten any loose bolts to 2 to
3 kgm torque.
lf the seat is scratched or frayed or if any of the fittings are broken’or deformed from long
service, replace the seat belt immediately. /
OPERATION SECTION 1
-Page 31
CHECK BEFORE STARTING

Pre-opefation Ukks forestall machine trouble. Never neglect them.
WALkAROUND CHECK
Lookaroundthe machineand under the machine to check for loose nut or bolts. collection of
dirt, or leakage of oil, fuel, or coolant, and check the condiion of the work equipment and
hydraulicsystem. Check also for loose wiring, play, and collection of dust at places which reach
h@h temperatures.
1. Check bucket for wear.
2. Check tire for wear and damage.
3. Check transmission case joints for oil leak.
; 4. Check brake system for air leak and oil leak.
5. Check tightness Of air cleaner mounting bolt
6. Check tightness of battery terminal.
6. Check radiator and sub-tank for water leaks.
6. Check around the engine for water and oil leaks
9. Check axle for oil leak.
10. Check hydraulic tank joint for oil leak.
11. Check for oil leak at high pressure hose and high pressure hose joints.
CHECK MONITOR PANEL
Turn the starting switch to ON.
Check that all the monitor lamps, the

gauges and the warning lamp light up for
about 3 seconds and the alarm buzzer
sounds for about 1 second.
II any monitor lamp does not kght up, ask

your distributorto inspectthat monitorlamp.
Always make the check by referring to this section on CHECK BEFORE STARTING.
SECTION 1 0PERATI:ON
Page 32
CHECK AND REFILL COOLANT
1. Open the engine hood and apply the hood

lock at the side of the radiator.
2. Check the level of the coolant. The water

level must be between the FULL and LOW
marks on subtank (1).
3. If the level is too low. add water to suMank

(1).
A
WARNING! Do not open the radia-
tor cap unless necessary. Always
check the coolant level of the sub-
tank when engine is cold.
*If the volume of coolant added is more than

usual, check for possible water leakage.
*Never use a sealing addiie to stop leaks in

the coolant system. This can result in coolant
system plugging and inadequate coolant flow.
CHECK OIL LEVEL AND REFIL
Open the engine hood and apply the hood

Use dipstick (G) to check the oil level.
The oil level should be between mark L and

H, if necessary, add oil at oil filler (F).
Never operate the engine with the oil level

belowthaLmarkorabovatheHmark.
OPERATION SECTION 1
Page 33
The type of lubricant used depends on the

ambient temperature. Select according to
the table “FUEL, COOLANT AND
LUBRICANTB.” ..
When checking the oil level, park the ma-

chine on a level surface and make an oil
level check before starting engine or 5
minutes or more after the engine is stopped.
CHECK FUEL LEVEL AND REFILL FUEL

Check the fuel level using fuel gauge (G) on
the monitor panel. G
2. Upon completion of work, pour in additional

fuel from filler (F) until the fuel tank is full.
* Fuel capacity: 305

* When adding fuel, never let the fuel over-
flow. This may cause a fire.
..
CHECK AIR CLEANER SERVICE INDICATOR

When air cleaner element is dogged, the red
piston of service indicator (1) reaches service
level and gets locked.
In that case, clean element referring to the

section “WHEN REQUIRED.”
After cleaning element, push button to return

red piston.
SECTION 1 OPERATION
Page 34
DRAIN WATER FROM AIR TANK

Upon completion of work, open drain valves
(l), (2) and (3), and drain water out of the tank_
CHECK FOR SEDIMENT AND WATER IN THE WATER SEDIMENTOR
The water s&mentor separates water mixed in

the fuel. When the water is accumulated in
sedimentor bowl (1). drain the water. For the
draining procedure, see section “WHEN
REQUIRED”.
* Even if a water sedimentor is installed, be

sure to check the fuel tank to remove water
and sediment in the fyel.
OPERATION SECTION 1
Page 35
FUEL-WATER SEPARATOR - DRAINING WATER AND SEDIMENT
Open tha valve on the bottom of the fuel filter

td allow water to drain. Close the drain when
dean fuel is visible. - _
Caution: Do not dver-tighten the plastic valve.
Note: Also drain the sediment bowl on the pre-

filter if one is installed between the Iii pump
and the supply tank.
FAN - INSPECTlON
Warning: Never use the fan to rotate the

engine. The blade(s) can be damaged causing
a fan failure which can result in personal injury
or property damage. Use the engine barring
tool or threaded dowels temporarily installed in
the front of the crankshaft.
Check the fanfor cracks, loose rivets and bent

or loose blades. Make sure it is securely
mounted. Tighten the capscrews if loose.
Replace damaged fans.
DRIVE BELT - INSPECTION
Vkually inspect the belt. Checkthe belt for

- intersecting cracks. Transverse (across the belt
width) cracks ara acceptable. Longitudinal
(direction of belt length) cracks that intersect
with transverse cracks are not acceptable.
Replace the belt if it is frayed or has pieces of
material missing. Refer to Adjustment and
Replacement.
A. CHECK THAT PARKlNG BRAKE WORKS PROPERLY.

B. CHECK THAT BRAKES WORK PROPERLY.
C. CHECK THAT HORN SOUNDS PROPERLY.
D. CHECK THAT LAMPS FLASH PROPERLY; CHECK FOR DIRT OR DAMAGE.
E. CHECK DlRECTlON OF REAR VIEW MIRROR; CHECK FOR DIRT OR DAMAGE.
SECTION 1 OPERATION
Page 36
F. CHECK THAT ENGINE EXHAUST GAS COLOR AND SOUND +RE NORMAL
G. CHECK THAT GAUGES AND INSTRUMENTS WORK PROPERLY.
H. CHECK STEERING PLAY; CHECK THAT STEERING WORKS PROPERLY.
I. CHECI( THAT BACK-UP BUZZER SOUNDS PROPERLY.
J. CHECK ELECTRICAL WIRING
Che& for any sign of disconnection or short circuit in the electricw@g. Check also for loose
terminals and tighten any loose parts.
check the following points cart3flJlly.
l -v
. StaRingmotor
0 Alternator
OPERATION SECTION 1
Page 37
O,PERATlNG YOUR MACHINE

BEFORE STARTING THE ENGINE
1. Carry out an initialinspection. (For details of
the inspection, see CHECK BEFORE
STARTING.)
2. W&h your back against the backrest of the

operator’s sea: adjust the seat position so
that the brake pedal can be easily
depressed.
.. 3. Is parking brake switch (1) in ON position?
4. Is directionallever (2) in N (neutral) position?
* The engine will not start while the directional

lever (2) is in any position other than N
(new.
5. Are work equipment control levers (3) locked

by safety lock (4)?
6. Is the machine monitoring system working

properly?
SECTION 1
Page 38
.. TO START 7‘HE ENGINE

1. Depress accelerator pedal (1) lightly.
2. Turn the key of starting switch (2) to the

START position to start the engine.
3. When the engine is startad,‘relaasethe key

of starting switch (2) and the key will return
automaticallyto ON.
* If engine will not start, repeat the starting

procedure after about 2 minutes.
* Do not leave the key in START for more

than 20 seconds.
OFF OFF
i
* To start engine in cold weather, refer to
COLD WEATHER OPERATION.
SPE&AL STAFITING
When statingafter running out of fuel, fill with fuel, then fill the fuel filter cartridge with fuel and
bleed the air from the fuel system before starting.
Refer to FUEL FILTER in every 500 hours services.

x OPERATION SECTION 1
Page 39
CHECKS AFTER STARTING
After starting make the following checks.

1. Depress accelerator pedal (1) lightlyand run
the engine with no load at midrange speed
for about 5 minutes.
2. After wam%up run is completed, check
monitor lamps for proper operation.
* Continue to run the engine at light load until
the green ranges of the engine water tem- I-
perature gauge and torque converter oil

gauge light.
3. Check if the exhaust color is normal or whether there is any abnormal noise or vibration.
* Avoid abruptly accelerating the engine until the completion of warm-up.
* Continuous operation with low coolanttemperature (white range) or high coolanttemperature

(red range) can damage the engine.
TO MOVE THE MACHINE OFF
1. Check that the warning item is not displayed

on the monitor panel.
2. Free the safety lock for work equipment

control lever. Bring the work equipment in
the traveling posture.
SECTION 1 OPERATlON
Page 40
3. Depress right brake pedal (1) and turn the

parking brake switch (2) to OFF (release) to
release the parking brake.
* When the parking brake is applied with
parking brake switch (2) put in OFF, put
switch (2) to ON and return it to OFF again.
4. Set speed control lever (3) and directional

lever (4) to the desired position.
5. Release right brake pedal (1) then depress
accelerator pedal (5) to move the machine
Off.
A
WARNING! It me machine has to
be started on a slope, always turn
‘me transmission cut-off selector
switch to OFF and depress me left
brake pedal. Then depress me
accelerator
.. ._~. pedal while releasing
me left brake pedal to start me machine off slowly.
CHANGING GEAR SPEED
Move speed control lever (1) to the desired

position.
* To use 1st or 2nd speeds for digging and

loading operations, actuate speed control
lever stopper.
* This machine is equipped with a kickdown

switch that shifts the gear down to 1st if the
button at the tip of the Iii arm control lever
is pushed when the machine is traveling in
2nd gear.
We recommend the use of the kickdown

switch when carrying out digging or loading
operations in 1st or 2nd gear. For details of
use, see INSTRUMENTS AND CONTROLS.
OPERATION SECTION 1
Page 41
CHANGING DIRECTION
There k no need to stop the machine even

when switching between FORWARD and
REVERSE. % .
Place directional lever (1) in the desired
position.
A WARNING! Before changing dlrec-

tion, check that It is safe.
A
WARNING! Never change between
FORWARD and REVERSE at high
speed-
TURNING
When traveling, use steering wheel (1) to turn

the machine.
* Witt this machine, the front frame is joined
totherearframeatthecenterofthema-
. chine by the center pin. The front and rear
framas bend at this point, and the rear
wheels follow in the same track as the front
wheels when turning.
* Turn the steering wheel lightly to follow the
machine as it turns. When turning the steering wheel fully, do not turn it beyond the end of
the stroke.
A WARNING! It is dangerous to turn the machine suddenly at high speed, or to

turn on steep hills.
A
WARNINGI If the engine stops when the machine is traveling, the steering
cannot be used.
This is particularly dangerous on hills, so the engine must never be stopped
when traveling.
If the engine should stop, stop the machine immediately in a safe place.
SECTION 1 OPERATION
Page 42
TO STOP THE MACHINE
1. Release accelerator pedal (l), and depress

brake pedal (2) to stop the machine.
2. Place directional lever (3) in N (neutral).
3. Turn the parking brake switch to ON to

apply the parkiig brake.
* When the parking brake is applied, the

transmission is automatically returned to
neutral.
4. Operate work equipment lever (5) and lower

the bucket to the ground, then locate work
equipment control levers (5) to hold position
surelyandthenlocksafetyiockofcontrol
levers.
A
WARNING! Stop the machine in a
safe place on firm level ground. If
the machine has to be stopped on
a slope, put blocks under the
wheels. In addiion, dig the bucket
into the ground to increase safety.
OPERATION
TO STOP THE ENGINE
Runtheengineatlowidliispeedforabout
5 minutes to allow it to graduallycool down.
Return starting switch (1) to the Off posi-

tion and remove the key.
If the engine is abruptly stopped before it

has cooled down, engine life may ba greatly
shortened. Consequently. do not abruptly
stop tha engine apart from an emergency.
In particular, if tli6 engine has overheated,

do not abru$ly stop it but run it at medium
speed to allow it to cool gradually,then stop
it. OfF
:‘is
,’
P+
Ifi& 3p
____--
1.
MAXIMUM DEPTH OF WATER
When working in water or on swampy ground,

donotletthewatercomeabovethebottomof
- tha axla housing. Axle housing
* Aftar finishing the operation, wash and

check the lubricating points.
: I .r
IF WHEEL BRAKE DOES NOT WORK
If the machine is not stopped by depressing brake pedal, use the parking brake to stop the
machine.
SECTION 1 OPERATION
Page 44
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES
LOWER THE CENTER OF GRAVI-IY WHEN TURNING

When turning on slopes, lowerthe work equipmentto lower the center of gravity before turning.
lt is dangerous to turn the machine with the work equipment raised.
BRAKING ON DOWNHU SL;OPES

When driving down a slope, put the speed control lever in a low speed position and fully appiy
theenginebrake.Toap~theservicebfake,depresstherightbrakepedal.
lf the speed control lever is not placed in a proper speed position, the torque converter oil may.
ovemeat.nit~~,pbcethespeedcontrdleverintheneJd:rOwergearspeedtolowerthe
oil temperature.
if the temperature gauge does not indicate the green range of the scale even with tha lever in
tha 1st speed position, stop the machii, place the lever in neutral, and run the angina at
medium speed until the gauge indicates the green range.
IF ENGINE STOPS
If tha engine stops on a slope, depress the right brake pedal fully. Next, lower the work
equipment to the ground and apply the parking brake. Then put the directional and speaci
control levers in neutral, and start the engine again. (If the directionallever is not in neutral, the
engine will not start).
SECTION 1
Page 45
PROPER BUCKET AND TIRE
Selectthe mostsuitablebucket and tires for the type ofwc~rkand the ground conditions on the
BLoading materials
Loading and carry-
ing materials
lading blast+
rock side steel breaker)
Hard ground 23.~2!512PR (Rock)

General ground
2352512PR (Rock)
lLoading and cany- Spade nose COlldiiOllS
ingbiastedrock bucket (3.1 m’) Ground with
2352516PR (Rock)
many rocks
SECTION 1 OPERATION
Page 46
ADJUSTMENT OF WORK EQUIPMENT

The boom kickout makes it possible to set the bucket so that it automatically stops at the
desired lifting height (Iii arm higher than horizontal)and the bucket positioner makes it possible
tasetthebudcetsothatitautomaticallystopsatthedesireddiggingangle.Thesettingcanbe
adjusted to match the working conditions.
ADJUSTING BOOM KICKOUT
1. Raise the bucket to the desired height, set

the work equipment control lever at HOLD
andlocktheleverinposition.lhenstopthe
engineandadju.stasfouows.
2. Loosen two bolts (I), and adjustplate (2) so

that the bottom edge is in line with the
center of ths sensing surface of proximity
switch (3). Then tighten the bolts to hold the
plate in position.
3. Loosen two nuts (4) to make a clearance of

3 to 5 mm between plate (2) and the sens-
ing surface of proximity switch (3). Then
tighten the nuts to hold in position.
* lightening torque: 1.75 f 0.25 kgm
4. After adjusting, start tha engine and operate

the lift arm control lever. Check that the
lever is automatically returned to HOLD
whenthebucket reachesthedesiiedheight_
OPERATION SECTION 1
Page 47
ADJUSTING BUCKET POSITIONER
1. Lower the bucket to tha ground and adjust

the bucket to the desired digging angle. Set
the bucket control’lever at HOLD, stop the
engine and adjust as follows.
2. Loosen two bolts (1) and adjust mounting

bracket (4) of the proximity !Switchso that
the rear tip of angle (2) is in line with the
center of the sensing surface of proximity
switch (3). Then tighten the bolts to hold the
bracket in position.
3. Loosen two nuts (5) and make a clearance

of 3 to 5: mm between angle (2) and the
sensing surface of proximityswitch (3). Then
tighten the nuts to hold in position.
* Tightening torque: 1.75 -c 0.25 kgm
4. After adjusting, start the engine and raise the

tii arm. Operate the bucket control lever to
the DUMP position, then operate it to the
TtLT position and check that the bucket controllever is automaticallyreturned to HOLD when
the bucket reaches the desired angle.
BUCKET LEVEL INDICATOR
(A) and (B) at the top rear of the bucket are the
level indii. so the bucket angle can be
checked during operations.
A: Parallelwith cutting edge
B: 9CPtocuttingedge
SECTION 1 OPERATION
Page 48
HANDLING THE TIRES

PRECAUTIONS WHEN HANDLING ilRES
If the following defects are found in tires, for

safety reasons the tire should be replaced with
,anawtire.
Bead wire is broken or bent, or the tire is

Mb
gmatiy deformed.
Wear is excessive and the carcass ply

(excluding breaker) is exposed for more
than l/4 of the circumferance. ,
c
Damage to the carcass exceeds l/3 of the
tire width.
Tire layers are separated.
Radial cracks reach the carcass.
Deformation or damage which makes the tire unsuitable for use.

OPERATION SECTION I
Page 49
PRECAUTIONS WHEN DRIVING MACHINE
when the machine travels at high speed for a long dii, the tires becoma extremely hot
Thiscausesearfywearofthetires,so1shouMbeavoidedasfaraspossible_Ifthemachine
must be driven for a long distance, take tha following precautions.
Folbw the regulations related to this machine, and drive c.areMly.
The most suitable tire pressure, travel speed, or tire typa diier according to the condii of
the travel surface. Contact your diiutor or tire dealer for information.
The following is a guide to suitable tire pressures and speeds when traveling on a paved
surface with standard tires.
Tire pressure: i-5 kg/cm*

speed: 15 km/h (9.3 MPH)
Check tha tire pressure before starting, when the tire is cool.
After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage;
also chack the oil and coolant levels.
Ahvaystravel with the bucket empty.
Never put calcium chloride or dry ballast in the tires when traveling.
SECTION 1 OPERATlOlr)
Page so
TIRE Pressure
Measure the tire pressure before starting operations, when the fires are cool.
If the inflation pressure is too low, it causes overload on the tires: if the inflation pressure is too
high, the tire may be cut or may’ burst under shock. Therefore adjust the inflation pressure to
the values in the following tabte.
INFLATtNG TIRES
Connect the air charge hose to air pickup (1) to

inflate the tires.
Inflation pressure xdcrn*)

Tire size (pattern) Ply rating Soft grounc Normal road
When shipped
(sandy from factory
ground) Stockpile Digging
12
23.5 - 25
16
(L3 Rock) 20
Front tire: 4.0
-1 2.4-3-6
2.6 - 3.6 2.6 - 3.6
Rear tire: 3.5
26.5 - 25 16
(S Rock) 20 3.5 - 4.0 3.5 - 4.0
OPERATION SECTION i
Page Si
For operations on normal road sutface~, rock

dii~ingoperations: . ..s t 6, a . . . . . . . . . . . 6. HighendofrangeinairpraWteChart
Stockpiiao~onEoftgtoUndz . . . . . . . . . . AveragepressureinakpressuredrPrt
Opetatlons on sand (opatations not using

mtidigglngfotce): . . . . . . . . . . . . . . _ . . . . . . Lowsndoftangeinairptersuredrart
tf the dafktlon of the the is axcaasivf3,raise the inflatbn ptesslrte wtIhir(the ri ghtenM ttto
table to give asuitable deflection (see d&action tatio).
stockpile opetations Inean the bding of sartd and othar loose materials.
Dafktion tatio (deWon/ftee height) _- .--- --
H-h
- - xial
H
H: Free height
h: Haight when loaded
2 &g;fgr visual checks, thb deflection ratio (dektiorl/ftea height) of the ftont the should
.
Normal kxxling and battying operations (Iii arm horizontal): approx. 1525%
Digging operations (rear whaala d ground): approx.w-35%
* When checking tha tire pressure, check also fot small ctacks and damage, and for wire Or
small pieces of metal which may cause punctures. Check also fot abnormal wear.
.- * Oparakg costs earl ba reduced and tire tie increased by icwpklg the operating ataa in good
condition and free from fallen todcs.
SECTION 1 OPERATION
Page 52
TOWING
TOWING THE MACHINE
This machine must not b& towed except in emergencies. When towing the machine, take the
folkWing precautions.
A WARNING! If there is a failure in the brake line, the brakes cannot be used, so
be extremely careful when towing.
WHEN ENGINE CAN BE USED
l Always keep the engine running when towing the machiie, so that the steering and braking *
canbeused.
WHEN ENGINE CANNOT BE USED
No lubrication oil flows in the transmission, so disconnect the front and rear drive shafts
before moving the machine.
The steering cannot be used, so disconnect the steering cylinder and steering linkage.
The machine should be towed only to the nearest place for inspection and maintenance. Do
not tow the machine for long distances.
If leakage in the air circuit has caused the pressure inside the air tank to drop, the parking
brake will be applied. When towing the machine, release the parking brake.
OPERATION SECTION 1
Page 53
RELEASING PARKING BRAKE
1. &move the air charge socket (1) installed

onthefrontleftoftherearframa.
2. Remova the air hoq for the parking brake

chamber, then install the socket again.
3. Install the air charge hose for the tire to tha

air charge socket.
A
WARNING! If there is a failure in
the air circuit, the brakes cannot
be used. This is dangerous, so
always tow the machine at low speed. Keep the engine running so that the
steering can be used.
4. Push the end of the hose on the tire valve, and +r will be supplied to’the brake chamber to
release Uk brake.
5. When tha parking brake is released, removti the air charge hose. Tow the machine
immediily to a safe place.
A
WARNING! Stop the machine on a fiat surface when releasing the parking brake,
and check that the surroundings are safe. In emergencies or when the parking
brake must be released on a hill, block the tires carefully before releasing the
brake.
SECTION 1 OPERATION
Page 54
COLD WEATHER OPERATION

PREPARATION FOR LOW TEMPERATURE
ifthetemperaturebecomeSlow,itbecomesdiffiadttostarttheengine,andthecoohntmay
freeze,
so do asfollows.
FUEL AND LUBRICANTS
changetofuelandoilwithlowviscosityforallcomponents.Fordetailsofthespecifiedviscosity,
see the TABLE OF FUEL, COOLANT AND LUBRICANTS.
COOLANT
Use antifreeze during all saasons to protact the cooling system from corrosion as well as’
~fraazingdamaga.
A mixture of 5096water and 50% ethylene-glycolbase antifreeze is required for operation of the
engine in temperature environments above -3X. A mixture of 40% water and 60% antifreeze
is recommended for temperatures below -3X.
MlTERY
As ambient temperature drops, battery capacitywill drop, and elactrolytemay sometimesfreeze

if battery charge is low. Maintain battery at a charge level of approx. 100% and insukte it against
cdd~esothatmachinecanbereadilystartedthenextmoming.
* Measure specific gravity of fluid and obtain rate of charge from the following convsrsion
table:
Tamp. of fluid
0°C -10°C -20°C -30°C
Rata of charge
100% 1.20 1.29 1.30 1.31 1.32
1.26 1.27 1.28 1.23 1.30
1.24 1.25 1.26 1.27 1.28
75% 1.23 1.24 1.25 1.26 1.27
* when electrolyte level is low, add distilled water in the morning before work instead of after
the day’s work. This is to prevent fluid frorr!freazhg at night
WARNING! To avoid gas explosions, do not bring fire or sparks near the
A battery-
WARNING! If the electrolyte gets on your skin or clothes, immediately wash

with plenty of clean water.
A
OPERATION SECTION 1
Page 55
STARTING IN COLD WEATHER
When starting the engirp in low temperatures, do as folknws.
1. Turn the key in starting switch (1) to the .

START position.
OFF
2. Move ether injection switch (2) to the ON I
position, then release it immediately.(Do not
hold it at the ON position for more than 5
seconds. This will cause failure of the
SOlMOii.)
* lftheenginedoesnotstart,repeatthis23
times.
3. When the engine starts, release the key in
: starting switch (1) to return it to the ON
position.
A
WARNING! Never operate ether
injection switch (2) pxcept when
starling the engine.
* The ether cylinder.ican be used for about

230 times. (Amount of ether injected: 3 cc,
total capacity for one cylinder: 710 cc)
SECTION 1 OPERATION
Page 56
The standard specification machine is

designed to work in ambient temperature OFF
from -20to 40°C. I
6 ,?4
When operatingthe machineat temperatures I
below - 2V’C,special equipment is needed.
Contact your distributorfor details.
For machines where the air dryer is installed
as an option, in cold temperatures below
- lo”(=,when operating the machine after it
has been stopped for several hours, run the
engine for at least 10 minutes after starting
before moving the machine.
CAUTIONS AFTER COMPLETION OF WORK
1. Mud and water on the machine body should be completely removed.
Park the machine on concrete or hard ground. If this is impossible, park the machine on
wooden boards. This will prevent the accessories from freezing to the ground thereby
preventingmachiie movementthe next morning. Particular attention should be given to water
drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be
fullywiped off because if water is frozen to the rod when the cylinder is utilized, the cylinder
oil seals may be damaged.
2. Drain water collected in the air tanks and fuel system so that such water may not be frozen
at night.
3. As battery capacity drops at low ambient temperature, cover the battery or remove it from
the machine to be kept warm at night.
AFTER COLD WEATHER
When weather becomes warm, perform the followingwithout fail:
* Replace lubricating oils for various units with the ones specitied for warm-weather use.
* Drain ‘antifreeze coolant (without corrosion inhibitor), flush the inside of cooling system
completely, and fill with dean soft water (such as city water).
SECTION 2
MAINTENANCE
A
WARNING ! REFER TO AND READ ALL
SAFETY PRECAUTIONS IN SECTION 3.

SECTION 2 MAINTENANCE
Page 2
PERIODIC MAINTENANCE
Proper lubrication and maintenance assure trouble-free operation and long machine life. Time
and money spent for scheduled periodic maintenance will be amply compensated by prolonged
machine operation and reduced operating cost.
All hourly figures given in the following descriptions are based on service meter readings. In
practice, however, it is recommended to rearrange all of them into units of days, weeks and
months to make the maintenance schedule more convenient. Under rough job site or operating
conditions, it is necessary to somewhat shorten the maintenance intervals stated in this manual.
BLEEDING AIR FROM CIRCUIT

BLEEDING AIR FROM HYDRAULIC CIRCUIT
l After replacing oil, fiker element or strainer, bleed the air from the circuit.
l To bleed the air from the hydraulic cylinders or hydraulic piping, run the engine at low idling
and do as follows.
1. Operate each hydraulic cylinder (of steering, bucket and lift am-r) 4 to 5 times, stopping
100 mm from stroke end.
2. Next, operate each cylinder3 to 4 times to the end of its stroke, then stop the engine and
loosen the air bleeding plug (1) of the hydraulic tank to bleed the air.
3. Increase the engine speed, and repeat step 2 to bleed the air until no more bubbles
come out from plug (1).
* If the engine is run at high speed at first, or if the cylinder is moved to the end of its
stroke, the air in the cylinder may damage the piston packing, etc.
4. After bleeding the air, tighten air bleed/ng _
plug (1).
* Tightening torque of the plug:
1.15 + 0.15 kgm
MAINTENANCE SECTION 2
Page 3
BLEEDING AIR FROM FUEL SYSTEM
LOW PRESSURE LINES AND FUEL FILTER(S) VENTING
8mrn :
1. Open the bleed skew.
2. Operate the plunger on the iii pump until

the fuel flowing from the fitting is free of air.
Tighten the bleed screw.
HIGH PRESSURE LINES-VENTING
17 mm
WARNING! The pressure of the
A fuel in the line is sufficient to pen-

etrate the skin and cause serious
bodily harm.
A
WARNING! Do not bleed a hot
engine as this could cause fuel to
r
spill onto a hot exhaust manifold
creating a danger of fire.
1. Loosen the ftiings at the injectors, and

crank the engine to allow entrapped air to
bleed from the lines. Tighten the fittings.
2. Start the engine and vent one line at a time

until the engine
_ runs smoothly.
Page 4
PERIODICAL PART REPLACEMENT

The users of the machine should carry out periodicalmaintenance in order to ensure proper and
safe operation. The parts, listed below, should be replaced periodicallyso that the highest safety
standard can be maintained.
These parts with the passage of time may have a tendency to deteriorate in quality and to wear
or deform. These parts must be replaced with new ones after a predetermined replacement
interval even though there is no apparent abnonnalii.
If any abnonnali should be found, these parts must be replaced or repaired even before the
predetermined period expires.
Periodical part replacement cost does not imply reimbursement under the manufacture’s .
warranty policy. Refer to the warranty manual for further details.
Replacement
Part Description Remarks
Interval
1 Wheel brake hose Every year
Replace with
2 Rubber parts for wheel brake power clusters Every year
repair kii
3 Packings, seals, O-rings of steering cylinders Every 2 years
4 Rubber hoses for steering cylinders Every 2 years
5 Fuel hoses Every 2 years
Replace with
6 Rubber parts for wheel brake valves Every year
repair kit
Rubber parts for parking Replace with
7 Every year
brake spring cylinder repair kit
Replace with
I 8 I Rubber parts for wheel brake slack adjusters I Every year I reoair kit I
Page 5
.’ MAINTENANCE TABLE
ITEM : I SERVICE PAGE
Walk around check : 131

Monitor panel Check 131
Coolant Check and supply l-32

Engine oil pan Check and supply 1-32
Fuel tank Check and supply l-33
Air cleaner se&e indicator Check l-33
Air tank Drain water l-34
Water sedimentor Check 1-34
Fuel-water separator Drain water l-35
Fan Check and replace l-35
Drive belt Check and replace l-35

Parking brake Check function l-35
Service brakes Check function l-35
Horn Check function l-35
Lames Check function l-35
Rear view mirror Check 136
Exhaust gas and color Check l-35
Instruments Check l-36
Steering wheel Check play l-35
Back-up buzzer Check function l-35
Electricalwiring Check l-35

EVERY 50 HOURS SERVICE ’
Fuel tank Drain water and sediment 2-10
Tires Check air pressure and damage 2-10

Page 6
ITEM I SERVICE 1 PAGE

EVERY 100 HOURS SERVICE
Hvdraulic tank I Check and suoolv I 2-11
1 Lubricatina I 2-11 I
Rear axle pivot pin Lubricate 2 points 2-11
Air condiioner filter-tfequipped clean element 2-12
INITIAL 256 HOURS SERVICE
Transmission oil fitter I Replace element 1 2-12 *
Engine oil pan and fitter Change oil and replace cartridge 2-13
Air intake svstem Check 2-14
Air conditioner compressor belt-
check tmsiorl 2-14
Jfesuipped
Wheel hub nuts Check and retighten 2-15
Lubricating 2-16
Bucket pin Lubricate 2 points 2-16
Bucket link pin Lubricate 2 points 2-16
Dump cviinder oin t&&ate 2 ooints 2-17
IJft cylii pin Lubricate4 points 2-17
Lilt arm pivot oin Lubricate 2 points 2-17
Tit lever pin Lubricate 1 point 2-18
Steering cylinder pin Lubricate 4 points 2-16
Battery electrolyte Check fluid level 2-18
Fuel titter ! Replace cartridge 1 2-19
Transmission oil fitter I Replace element 1 2-20 1
Lubricating 2-20
Center drive shaft spline Lubricate 1 point . 2-20
Air dryer Check 2-29
Antifreeze concentration Check 2-21
Coolant additive concentration Check 2-21
coolant iilter I Replace cartridge 1 2-22
Page 7
SECTION 2 MAINTENANCE .
Page 8
I
ITEM I SERVICE PAGE
WHEN REQUlRED
Air cleaner element Check. dean or repiace
when required 245
I I
Transmission ’ Check and supply 247
Radiator fins Ckl 24B
Drive a& Check and supply 2-48
Drive axle housinn breathers 2-49
Air condiier condenser-tf equipped Ch8ckandd8an 249
Air conditioner refrig8rantcharge-
CheCk 2-50
if equipped
Lubricatina 2-51
Work equipment control valve linkage !hficate 2 points 2-51
Steering column Lubricate 1 point 2-51
Window washer Check and supply 2-51
Water Sedimentor Drain water I
2-52
Bucket t88ttl I Replace 1 2-52
Page 10

See the section on CHECK BEFORE STARTING aforementioned.
FUEL TANK
Loosenvahm(1) on the bottom of the tank so _

that the precipitation and mixed water will be
drained in accompanimentwith fuel.
TIRE
Measure the tire pressure before operationswhen the tires are cool. (Referto HANDLING TIRES)
Page 11

* Maintenance for evby 50 hours should be carried out at the same time.
HYDRAULIC TANK
‘1. Lower the bucket horizontallyto the ground

and stop tha engine. Wait for 5 minutes.
then check sight gauge (G). The oil should
bs visible in sight gauge (G).
: 2. Add engine oil frv oil filler (F), if necessary.
* The type of &b&ant used depends on the

LUBRICANTS.”
A WARNING! When removing the cap, turn it slowly to relieve
LUBRICATING
inner pressure.
Applygrease to the grease fittings shown by arrows.
1. Rear axle pivot pin (2 points)

Page 12
AIR CONDITIONER FILTER-IF EQUIPPED
If the air conditioner has been used, the air filter

should be cleaned.
\_;? ?
* Stop the air conditioner before cleaning the
element.
1. Move the operator’s seat forward, then tilt

me backrest forward.
2. Loosen the bolts and remove me cover.

I
3. Loosen screw (2) and cover (1) holding the
filter element, pufl out element (3) and clean it.
4. After cleaning the element, align it with me

direction shown by the arrow, and instafl.
* Direct dry compressed air (less than 7

kg/cm*) to element from inside along its
folds, then direct it from outside along its
folds and again from inside, and check
element.
a WARNING! When using com-

pressed air, wear safety glasses
and other things required to main-
tain safety.
INITIAL 250 HOURS SERVICE

Perform me following maintenance after running the machine for me first 250 hours.
TRANSMl&lON OIL FILTER
For details of the method of replacing or maintaining,see the section on EVERY 500 HOURS
SERVICE.
Page 13

+ Maintenance for every 50 hours should be car&d out at the same time.
ENGINE OIL PAN AND FfLTER
1. Warm up and stop the engine.

2. Open the engine hood and apply tha hood
3. Open oil filler (F) and remove drain plug (1)
to drain oil. After draining, tighten the drain
plug.
4. Using a filter wrench, .removeengine oil filter
(2) by turning it counterclockwise.
5. Clean the fitterbase and fill a new fitterwith
dean engine oil. Then, apply a thin coat of
engine oil to tha seat.
6. Install the filter as specitied by the fitter
manufacturer.
* Be careful not to tighten it up excassivety.
* Be sure to fit a genuine Cummins filter.
7. After replacing tha oil filtsr, pour in the

specified quantity of engine oil from oil filler
0%
a. After refiging with oil, start tha engine and
idleitforawhiie. lnspectforoilleaksatths
fitter and drain plug. Then stop the engine
and check the oil level. Wait for 5 minutes
before checking.
The type of lubricant used depends on the

LUBRICANTS.”
lf engine oil filter is ramoved immediately

after stopping the engine, oil will spill. Wait
at (east 10 minutes after stopping the engine
before replacing the oil filter.
Page 14
AIR INTAKE SYSTEM - INSPECTION
inspect the intake piping for damage, cracked

hoses, toose clamps, or punctures whii may
damage the engine.
Tighten or replace pans as necessary to make

sure the air intake system does not leak.
AIR CONDlTlONEl? COMPRESSOR BELT-IF EQUIPPED
The belt tension should normally deflect

about 10 mm when pressed with the finger
at a point midway between the air
condftioner pulley and the fan pulley
(approx 3 kg).
To adjust the belt tension, loosen bolt (1)

and shift compressor (2) slightly.
After adjustment, tighten bolt (1) securely.

when adjustingthe V-be%.do not attemptto
push compressor (2) directly with a bar or
the like, but use a wood pad to prevent
damage to the core.
Check each pulley for damage, and V-

grooves and V-belt for wear. Particularly,
check whether V-be& is in contact with
bottom of V-groove through wear.
Replace heft if it has stretched, leaving no

allowancefor adjustment,or if there is a cut
orcr&konbelt.
i :
Page 15
WHEEL HUB NUTS
If wheelhudnuts (1) are loose, tire wear will be

increased and accidents may be caused. If any
hub nuts are ‘loose, tighten them to the
specified tightening torque.
Tightening torque: 48 f 5 kgm
If any wheel bolt is broken, replace all bolts

/
for that wheel.
Always rotate in the direction of tightening

when checking for loos43nuts.
Page
16
LUBRICATING
Apply grease to the grease Wings shown by arrows.
1. Bucket pin (2 points)
2. Bucket link pin (2 points)

Page 17
3. Dump cylinder pin (2 points) -7
4. Liftcylinder pin (4 points)
5. Lift arm pivot pin (2 points)

Page 18
6. lii lever pin (1 point)
7. Steering cylinder pin (4 points)
CHECK ELECTROLYTE LEVEL IN BAlTERY
1. Open the battery box covers.
2. If the electrolyte level is lower than the

prescribed level (10 to 12 mm above the
plate), supply diilied water.
* Should any of the acid be spilt, have it

replenished by the nearest battery shop with
acid of the correct specific gravity.
* When inspecting electrolyte level, clean the

air hole of the battery cap.
A’ WARNING! If the ektrolyte

plenty of clean water.
gets on your skin or clothes, immediately wash with
A WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.
Page 19

* Maintenance for every 50,100 and 250 hours should be carried out at the same time.
FUEL FILTERS
1. Open the engine hood and apply the hood

2 Clean the area around the fuel filter header.

Remove the filters. Clean the gasket surface
of the filter header.
Replace the o-ring.
3. Fill the new filter(s) with clean fuel and

lubricate the o-ring seal with clean lubricat-
ing oil.
.. 4. Install the filter as specified by the filter

manufacturer.
* Mechanical over-tightening may distort the
threads or damage the filter element seal.
5. Vent air from fuel system as outlined under
“BLEEDING AIR FROM FUEL SYSTEM.”
* After replacing the filter(s), start up the
engine and check the filter surface for
possible fuel leakage. ‘,
* Be sure to use a genuine Cummins filter.
Page 20
TRANSMISSION OIL FILTER
1. Remove drain plug (1) at the bottom of the

fitter case, and drain the oil. After draining
the oil, tighten the plug.
2. Hold case (2) and loosen center bolt (3)
then remove case (2).
3. Remove the element. and clean the inside of
the case. Assemble a new element, then
install the case.
* Be careful not to apply excessive torque to
canter bolt (3).
..
Tiihtening torque: 18.5 + 1.5 kgm
4. Run the engine for a short time at idling speed, then stop the engine. Check that the oil is
at the specified level (for details, see WHEN REPUIRED).
* Use a genuine filter element.
* Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean
engine oil before installing.
* When tightening center bolt (3). install so that chamfered surface of the washer faces the
hexagonal head of the center bolt.
LUBRICATING
Apply grease to the grease fitting shown by

arrows.
1. Center drive shaft spline (1 point).
AIR DRYER
If the air dryer is installed as an option, carry out the following‘&&tion, and if there is any
abnormality, contact your distributor.
l Open the air tank drain valve and check that nothing is drained. Note that if the temperature
around the tank is lower than 16”C, a small amount of water may be collected in the drain.
l Check that there is no abnormal inclusion of oil in the water drain from the.exhaust port of
the air dryer.
Page 21
ANTIFREEZE CONCENTRATION - CHECK
Checkthe antifrwzeconcentration. Usa ethyl-

ene-glycol base antifreezeto protectthe engine
to -3?X [-34’Fj @arround.
COOLANT ADDITIVE CONCENTRATION
Inadequate concentration of the coolant

addii can result in major corrosive
damage to cooling system components.
Over concentration can cause formation of
“gel” that can causa restriction,plugging of
passages, and overheating.
If the engine coolant is changed, the coolant

filters must also be changed.
The cooiimg system must contain the proper

coolant addiie units to providethe best chemi-
cal protecbn.
. WA4 Test Kit: Use only DCA4 Coolant Test

Kit, Fleetguard Part No. CC-2600 to check the
cooht additiva concentration in the cooling
system-
Page 22
COOLANT FILTER
l.Tum cap (1) slowly until it domes off.

1
A WARNING! Do not remove the

radiator cap from a hot engine.
Hot steam will cause serious per-
sonal injury.
2. Openthe engine hood and apply the hood

3. Open drain valve (2) at the bottom of the
radiator to drain off the cooling water.
4. Drain off ail the water, then dose up drain
valve (2).
5. Remove and did the coolant filter (3).
Clean the gasket surfaca.
6. Apply a light tilm of lubricating oil to the
~~xz&ng surface before installingthe
* Mechanical over-tightening may distort the

threads or damage the filter head. I ,,
Install the filter as specified by the filter
manufacturer.
7. Supply water up to tha vicinity of tha water
filler.
8. Run the engine for 5 minutes at low idling to
eliminate air trapped in the cdoling system,
and run the engine for 5 minutes at high
idling. (leave water filler cap (1) off during
this operation.)
9. Stop the engine and 3 minutes later supply
water again up to vicinity of the water filler
and tighten water filler cap (1).
10. Drain the cooling water inside sub-tank (4),
then dean tha inside of the sub-tank and fill
again with water to a point between the H
andLlines.
A
WARNING! Do not remove the cap ’
while cooling water Is hot. Hot water may spout out.
When removing radiator cap, lilt the lever to relieve inner pressure.
Page 23
EVERY
, . 1000 HOURS SERVICE
* Maintenance for eveiy 50,100,250 and 500 hours should be carried out at the same
time.
TRANSMISSION CASE AND STRAINER
1. Loosan drain plug (P) to drain oil. After

draining off the oil, tighten up drain plug (P).
* After loosening drain plug (P), pull out the

plug slowly to prevent the oil spouting out.
2. Loosen drain pl$ (1) of transmission oil

filtar to drain oil. Aftar draining off the oil,
tighten up drain plug (1).
3. Rf3movebolt (2) and cover (3), then remove

spring (4) together with strainer (5).
4. Remova all dirt from the surface of strainer

(5), then wash in clean light oil. if strainer (5)
is damaged, replace with a new part.
5. Install spring (4) and strainer (5) in cover

(3). Replace tha O-ring of the cover with a
new par& then install the cover.
Page 24
6. Pour in the spcified amount of engine oil

from oil filler (F).
7. After refilling, check the oil level and ensure

tha;ha;~~ correct. (Refer to WHEN RE-
* Thatypaoflubricantuseddepandsontha
ambiant tamparature. 6alect according to
tha tabla “FUEL, COOLANT AND LUBRI-
CANTS’.
* Refiucapaay47
* Check for oil leak at transmission case and

tiiter.
TRANSMISSION CASE BREATHER
Remove all mud and dirt from around the

breather, then remove the breather. Put in
cleaning fluid and clean the breather.
Page 25
LUBRICATING
A~#p&grease to the grease Gttingsshown by

‘.
1. Center hinge pin (2 points)
2. Front drive shaft (2 poi,nts)
3. Drive shaft center support (1 point)

Page 26
4. Rear drive -shaft (2 points)
5. Centerdriie shaft (2 points)
6. Parking brake caliper (1 point)
ENGINE VALVES
Screwdriver
Remove the air crossover tube.

Page 27
13 and 18 mm
Disoonnect the support damps, hose clamp

and remove the crankcasa vent tube.
15 mm
Remove the valve cover
l/2 Inch Drive, 3904682 Barring Gear
Locata Top Dead Center (TDC) for Cylinder

Number 1 by barring engine slowly while
pressing the engine timing pin.
When the pin engages the hole in the camshaft CAMSHAFT --

aear, Cylinder Number 1 is at TDC on the GEAR
&p&ion stroke. ENGINE
ITIMING PIN
:-
I
Page 28
Caution: Be sure to disengage the pin after

locating IDC.
FeelerGauge
Intake Clearanca: 0.30 mm [0.012 inch]
,ExhaustClearance: 0.61 mm [0.024 inch]
Check/set valves with engine cold - below

60% [14OTj.
Note: The claarance is correct when some

resistance is “felt” when the feeler gauge is
slipped between the Mhre stem and the rocker
lever.
14 mm, F&Made Screwdriver
Locate Top Dead Center (KIC) for Cylinder

Number 1.
Chack/adjust the valves indicated for STEP A

(1 = Intake; E = Exhaust).
Tghten the locknut to 24 N*m [18 ft-lbs] and

ra-check the valve lash.
Mark the vibration damper and rotate the

crankshaft 360 degrees.
Be sure timing pin is disengaged.

Page 29
14 mm, Flatblade Screwdriver
Set the valves indicated @r STEP B
Tighten the lock nut to 24 Nom [18 ft-lbs] and

recheckthevalvelash.
install the rubber seal into the groove in the 1

: vahm cover. Start th.9 insfallationat the overlap
area shown in Fe dlustraQon.Do not stretchthe
rubber seal.
15 mm
Install the valve cover.
Torque Value: 24 Nom [18 ft-lbs]
13 and 18 mm
Install the crankcase vent tube and secure with

the support clamps and hose clamp.
Page 30
lnstail the air crossover tube.
DRIVE BELT TENSION - CHECK

..-.
Measure the belt deflf3ction at the longest span
ofthebelt
Maximum Deflet3io.n:9.5 to 127 mm [3/8 to

l/2 inch]
Noter The Cummins belt tensiorfgauge

ST-1293 can be used. The required gauge
value is 80 to 110 Ibs.
Page 31
DRIVE BELT, TENSIONER BEARING AND FAN HUB - INSPECTION
Wrench Size: l/2 Inch Square Drive
Remove the drive t&t and complete the follow-

ing steps:
l inspect the belt for damage.
Note: The tensioner pulley should spin freely

with no rough spots detected under hand
pressure.
l Check the tensioner bearing.

Page 32
Note: The fan hub should spin freely without

any wobble or excessive end play.
l Check the fan hub beating.
Maximum End Play

0.15 mm {0.006 in.] _.
l/2 Inch Square Driie
Install the drive belt.
Service Tip: if diiculty is experienced installing

the drive belt (the belt seems too short),
position belt over the grooved,pulleys first and
then, while holding the tensioner up, slide the
belt over the water pump pulley.
Page 33

Maintenance for every 50,100,250,500 and 1000 hours should be carried out at the
same time.
~RAULIC TANK AND FILTER
Lowerthe bucket horizontallyto the ground

and apply the parking.brake, then stop the
engine.
/
Remove the cap of oil filler (F) and air vent
plus(Von---
1
A
WARNING! ‘When removing the
cap, turn it slowly to relieve Inner
pressure.
3. Open drain valve (2) to drain oil. After

draining, ,Jightenthe drain valve.
* After loosiig drain valve (2). pull it out

slowly to drain oil.
4. Remove mounting bolt (4) of the filter cover,

then remove cover (3).
A
WARNING! The cover is pushed
by a spring, so hold the cover
when removing the bolts.
5. Remove spring (5) and bypass valve (6), .

then remove element (7).
* Check that there is no foreign matter inside
the tank before cleaniig it.
6. Install a new element, then install bypass
valve (6), spring (5), and cover (3).
If the O-ring of the cover is damaged or
de-rated, replace it with a new part.
When installingthe cover bolts, push dowti

the cover and tighten the bolts evenly.
Pour in the 5peciiied quantity of engine oil from filler (F).
Page 34
Bleed the air from the hydrauliccircuit, lower the bucket horizontallyto the ground, and stop
the engine. See “BLEEDING AIR FROM CIRCUlT” for the air bleeding procedure.
Check the oil level,and ensure that is correct. (Refer to EVERY 100 HOURS OF SERVICE.)
The type of lubricantused depends on the ambienttemperature.Select according to the table

“FUEL, COOLANT AND LUBRICANTS’.
Refillcapacity:‘103e
Check that there is no oil leaking from the filter cover mount.
HYDRAirLlC TANK BREATHER

Remove cap of oil filler (F).
I
A
WARNING! When removing the
cap, turn it slowly to relieve inner
pressure.
2. Remove snap ring on breather (l), then

remove breather cap. /
3. Replace filter element with a new part, then
install cap and snap ring.
* lt is possible to replace the element with the breather installed in the tank. However, if the
breather is removed, do not wrap the taper thread of the breather with seal tape when
assembling again, and be careful not to tighten too much.
‘Page 35
DRIVE AXLES
Front
1. Fbnove front and r&r oil filler plugs (1),
then r?move drain plugs (2) to drain the oil.
After draining the oil, tighten drain plugs.
2. Remove drain plugs (3) and (4). and drain

the oil.
Rear
r
Page 36
3. Stopthemachiisothatdrainplug(6)of
the final drive is at tha bottom. Remove oil
filter plug (5) and drain plug (6) and drain
the oil.
4. After draining the oil, dean drain plugs (3),
(4) and (6) then instatlthem.
5. Add oil to the specified level through the oil
filler ports (1). (5) of the axle housing and
iaftandrightfinafdrives.
6. Chack the oil level and ensure that is
correct (Refer to WHEN REQUIRED.)
* Use the same procedure to change the oil for the front and rear axles.
* RsfilfCapacQ 56 (each axle)
* The type cjf lubricant used depends on the ambient temperature. Select according to the
tabte “FUEL, COOLANT AND LUBRICANTS’.
AIR CONDITIONER FILTER - IF EQUIPPED
1. Move the operator’s seat forward, then tilt

the backrest forward.
2. Open the panel and loosen screw (1) hold-

ing the fittar element, pull out element (2).
3. Install a new element and dose tha panel.
4. Return the operator’s seat to its original

position.
BRAKE DISC
Ask your distributor to check and repair brake disc.
INTERNAL PART OF AIR DRYER
If the air dryer is installed as an option, replacethe following internal parts of the air dryer:
Desiccant, oil filter, filter, and all rubber parts.
Contact your diibutor to have these parts replaced.
Page 37
COOLANT CHANGE AND FLUSHING THE SYSTEM
coolANT
Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze, and
supplemental coolant additive (DCA4). Supplemental coolant additive recommendations are
included in this Section.) Drain and replace the mixture every 2 years.
DCA4 is recommended to inhibit corrosion in the cooling system.
Antifreeze.concentration level in coolant should not exceed required protection levels.
l A XI/!50 antifreeze/water mix provides protection to -34°F. This is more than adequate for
most geographic locations.
l Never exceed a 70/30 antifreeze/water mix ratio.
l Never use 100 percent antifreeze for makeup coolant.
DCA4 UNIT MAINTENANCE GUIDE
Use the supplemental coolant additive to protect the engine cooling system from corrosion.
Antiieeze alone does not provide enough corrosion protection for a heavy-duty diesel engine.
Supplemental corrosion protection must be supplied through periodic additions of the coolant
additive to the coolant.
DCA4 can be used for in service engines provided the cooling systems are drained and flushed,
and the old coolant is disposed of prior to installationof new coolant and the appropriate DCA4
filter.
Ming of DCA4 and other supplemental coolant additives is not recommended because there
is currently no test kit available to measure concentration levels with mixed chemical solutions.
With the use of DCA4 or the continued use of other supplemental coolant additives, Cummins
Engine Company recommends the following steps to prevent overconcentration and gel
formation:
. l Antifreeze concentration level in coolant must not exceed the required protection levels.
l Maintain proper supplemental coolant additive levels (do not overconcentrate)
l Wnh the use of any supplemental coolant additive,we recommend an antifreeze containing
less than 0.1 percent of silicate (measured as anhydrous alkali metasilicate).
To protect against corrosion, a new coolant charge must be brought up to one DCA4 unit per
3.8 litres [l.OO U.S. gallon] of coolant (initial charge).
Each time the coolant is drained and replaced, the coolant must be recharged with DCA (or
equivalent). New coolant can be correctlycharged with supplemental coolant add&es by using
liquid DCA4 concentrates or DCA4 filters listed in the following table.
If coolant is added between drain intervals, additional DCA4 will be required. See Maintenance
Guidelines (Section 2) or Engine Specif=tions (Section 5) for the correct test kit to check DCA
concentration.Check the coolant periodically.The DCA4 concentration must not fall below 1.0
unit per 3.8 lies [l.OClU.S. gallon] or exceed 2 units per 3.8 liires [l.OClU.S. gallon]
Page 38
DCA4 UNlT MAINTENANCE GUIDE
fleetguard Part No. . , Cummins Part No. DCA4 Units
DCA4 Liquid
DCMOL 3315459 4f
DCA4 Filter
WF-2070 3318157 2
WF-2071 3315116 4
W-2072 3316201 6 *
WF-2073 3315115 8
WF-2077 Nona 0
1
* If DCASOL is used, do not usa a filter that contains coolant addiies. The combination of
liquid and filter coolant addiies will result in overconcentration.
DCA4 Maintenance Guide

I
Maintenance Intervals
6 Months
TotalCooting6ystem 500 liours
QpacityLitres 16,CNXlKM
[U.S. Gallons] (A) Initial Charge (8) (10,ODoMI)
30 to 57 [8-151 WF-2072 WF-2070
Notes:
A Total cooling system capacity: 50
B. After draining and replacing the coolant, install the initialper charge coolant filter to provide
the recommended level of DCA4 concant3ation.
C. Change coolant fitters at regular intervals to protect tha cooling system.
D. Check the coolant additiva concentratjonregularly.Check co@ingsystems using DCA4 only

with DC%4 CoolantTest Kit,Fleetguard Part No. CC-2600.
Page 39
1. stoptheengine.
2. Turn cap (1) slowly until it comes off.
A
WARNING! Wait until the
temperature Is below 50°C
[12o”FJ before removing the cool-
ant system pressurecap. Failure
to do-so can-cause persdnal injury
lrom heated coolant spray.
3. Open drain vaIve (2) at’the right side of the

fuel tank to drain off the coolant-
4. Drain off all the water, then dose up drain

valve (2).
5. Check for damaged hoses and loose or

damaged’ hos$ clamps. Replace as re-
quired. Check the radiator for leaks,
damage and build up of dirt. Clean and
repair as required.
6. Fti the system with a mixture of sodium

cabnate and water (or a commercially
available equivalent).
Note: Use 0.5 kilogram il.0 pound] of
sodium carbonate for every 23 liies [6.0
U.S. galkxls] of water.
Caution: Do not install the radiator cap.
7. operate the engine for 5 minutes with the
coolant temperature above 80% [lXPF].
Shut the engine off, and drain the cooling
system
8. Fill the cooling system with clean water.
Caution: Do not install the radiator cap or
the new coolant filter.
9. Operate the engine for 5 minutes with the
cooJanttemperature above 80% [18o”F].
Shut the engine ofi, and drain the cooling
system-
Note: If the water being drained is still dirty,
the system must be flushed again until the
water is clean.
Page 40
10. Replace the coolant filter. I
* For details of coolant filter replacement, see

COOLANT FILTER under NERY 500
HOURS SERVICE.
11. Use a mixture of 50 percent water and 50 percent ethylene giycol antifreezeto fill tha cooling
System
CooiantCapabty .Litre
(Engin W) [U.S. Quafts]
6C8.3 SCTAb.3 6CT8.3

11.4 j12.01 11.4 [12.0] 12.3 [13.0]
Note: Use the correct amount of DCA4 corrosion inhibitor to protectthe cooling ~yst8m.
12 Run the engine for 5 minutes at low idling to eliminateair trapped in the cooling system, and
run th8 engine for 5 minutes at high idling. (t8avt3water fillercap (1) off during thii operation.)
13. Stop the engine and 3 minutes later supply

water again up to vicinii of the water filler
and tighten watar filler cap (1). Drain th8
cooling water bide sub-tank (4), then clean
theinsideofthesub-tankandfillagainwith
watertoapointbatweentheHandLlines.
* B8 sure to replace the coolant fitter.
A
WARNING! Do not remove the cap
while coolant Is hot. Hot coolant
may spout out. When removing
radiator cap, lift the lever to relieve Inner pressure.
Page 41
VlBRATlON DAMPER - INSPECTION.
Check the index lines (B) on the damper hub

and the inertia member (A). If the lines are
more than 1.59 mm [l/16 inch] out of align-
ment, replace the damper.
inspect the rubber member for deterioration. If

piecesofrubberaremissingoriftheelastic
member is more than 3.18 mm [l/8 inch]
below the metal surface, replace the damper.
Note: Also look for forward movement of the

damper ring on the hub. Replace the damper if
any movement is detected.
AIR COMPRESSOR - INSPECTlON
NoWAUaircompmssorshaveasmallamount
of oil carryoverwhii lubricatesthe piston rings
alldrlWVingpattSWhWlthisoilisexposedto
normal air compressor operating temperatures
over a period of time, it will form varnish or
carbon deposits. tfthe followinginspectionsare
* not done, the air compressor piston rings will
be affwted by high operatingtemperaturesand
pressures and will not seal cwrecUy.
Page 42
AIR COMPRESSOR DISCHARGE - INSPECTION
Drainme air systemwet tank (1) to releasethe

system air pressure. Remove the air discharge
line from the air compressor.
Measure the total carbon depqsit thickness

inside the air discharge line as shown. If the
totalcarbondeposit(X+X)exceeds2mm
[1/164nchJ, dean and inspect the cylinder
head, the vahre assembly, and the discharge
line. Replace if neceswy. Contact your
Cummins authorized repair location for
. procedures.
If the total carbon deposit exceeds specifb-

tions, continue checking the air discharge line
connections up to the first tank until total
carbon & less than 2 mm [1/164nch]. Clean or
replace any lines or connections that exceed
this spe&iation.
Page 43
Inspect any air driers, spitter valves, pressure

relief valves, and alcohol injectors for carbon
deposits or malfunctioningparts. Inspect for air
leaks. Maintain and repair the parts according
to the manufacturer’s’specikMons.
AIR COMPRESSQR lNT+KE - INSPECTION
WARNING! Hold the unloader

valve down when removing the
a capscrews. Personal Injury can
result from the sudden release of
the spring-loaded unloader valve.
Remove the capscrews, the lock washers, and

the fiat washers that secure the unloader valve
assenUy to the cyliier head cover. Remove
the unloader valve assembly and the spring
from the cylinder head and the cover.
._ - -- -.
0
Vialiy inspect the unloader valve for carbon
buildup. If carbon or heavy varnish is present,
remove, clean, and inspect the compressor OK
head and the valve assembly. Replace parts as
necessary. Contact your nearest authorized
. repair location for procedures.
Page 44
Note: The open side of the rectangular seal

must face the top of the unloader body.
if the unloader valve is clean or only lightly

varnished, install a new O-ring on the unloader
body and a new rectangular seal inside the
unloader body cavity.
Lubricate the unloader cap with anti-seize

compound. Lubricatethe unloader body O-ring
with engine oil. Assemble the unloader
assembly the cyiindar head cover. lighten the
capscrews to 14 Nom [lo ft-lbs] torque.
Page 45
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CHECKING
Whenever the red piston in service indicator (1)
appears, clean the air cleaner outer element.
Stop the engine when cleaning the element.
CLEANING OR REPLACING OUTER ELEMENT

1. loosen wing bolt (2) and remove outer
element.
2. Clean the air cleaner body interior.
3. Clean and inspect the element (See the

item “Cleaning outer element” for cleaning
procedure_) Install the cleaned element.
4. Push the service indicator reset button to

return the red piston to the original position.
5. Push the service indicator reset button to reb
* Replace the outer element which has been cleaned 6 times repeatedly or used throughout
a year. Replace the inner element at the same time.
* * Replace both inner and outer elements when the service indicator red piston appears soon
after installing the cleaned outer element even though it has not been cleaned 6 times.
* Remove one seal from the outer element. The number of times the outer element has been
deaned can be seen by the number of removed seals.
* Check inner element mounting nuts for looseness and, if necessary, retighten.
* Replace seal washer (3) or wing nut (4) if

they are broken.
Page 46
REPLACING INNER ELEMENT
1. Fust remove the cover and the outer element, and then remove the inner element.
2. Place the cover o&r the air intake part to prevent dust entering.
Clean the air cleaner body interior, then remove the cover from the air intake port
3. Fti a new inner element and tighten it with nuts.
4. install the outer element and the cover. Push the dust indicator reset button.
NOTE: Do not attempt to reinstall a cleaned inner element.
WARNING! Do ,not clean or replace the air cleaner element wlth the engine ’
A running.
CLEANING OUTER ELEMENT
Wlth compressed air
Direct dry compressed air (less than 7 kg/cm2)

to element from inside along its folds, then
direct it from outside along its folds and again
from inside, and chack element
A
WARNING! When using com-
pressed air, wear safety glasses
and otherthings required to mai*
tain safety.
The following methods require spare parts.
withwater
Dash city water (less than 3 kg/crn2) on element from inside along folds, then from outside and
againfrominside.Dyandcheckit.
With cleaning agent
For removing oils and fats as well as carbon etc. attached on the element, the element may be
cleaned in lukewarm solution of mild detergent, then rinsed in c&an water and left to drip dry.
* Drying can be speeded up by blowing dried compressed air less than 7 kg/cm2) from the
insids to the outside of the element.
Never attempt to heat theelement.
* Using warm water (about 40%) instead of soapy water may also be effective.
Page 47
lf small holes or thinner pa& are found on

elementwhenitischehkedwithanelectric
bulb after cleaning and drying, replace the
lfelementisusable,vwapitandstoreitin
dryPla=
Do not use element whose folds or gasket
orsealaredamaged.
1
When cleaning element, do not hit it or beat
it against something.
CHECK AND REFILL TRANSMISSION OIL
TM gtt$ pro+ure if there is any sign of

ansmisston case, or I there is oil
mixed with the cooling water.
1. Stop the engine and remove the cap of oil
filler Q-
2. Use dipstick (G) to check the oil level.
3. TheoillevelshouldbebetweenmarkLand
H, if necessary, add oil at the oil filler (F).
* The type of lubricant used depends on the 1
the table “FUEL, COOlANT AND LUBRICANTS.”
* There are two sets of level marks on the same side of the dipstick: one is for measuring
when the engine is stopped (ENGINE STOP), and the other is for measuringwhen the engine
is idling (ENGINE IDLE).
* When measuring the oil level, wait for at
least 60 minutes after stopping the engine,
and measure with the ENGINESTOP marks.
lt is also possible to measure when the
engine is at low idlim, but in such cases, do
as follows.
Start the engine and nh it until the oil level
is stable, then wait for 5 minutes and
measure the ENGINE IDLE marks.
A WARNING! When checking the oil

level, apply the parking brake, and lock the front and rear frames with the safety
bar and pin.
Page 40
CLEAN RADlATOl? FINS

1. Loosenbolt (1) and remove radiator grille
(2).
2. Clean the radii’fins and oil cooler fins
clogged with mud, dust and ‘leaves with
compressed air. Steam or watsr may bs
ussdinsteadof6ompresssdair.
* Therubberhoseshouidbscheckedatths
sametime.tftJwhose~isfoundtohave
cracks or to be hardened by aging, such
hosa should bs replaced by new one.
Further, loosened hose clamp should also
be checked.
CHECK AND REFILL D-RIVE AXLE OIL
Carry out this procedure if there is any sign of Front

oilontheaxlecasa.
Removeoillevelplug(1),andcheckthattheoil
levelreacbesthebcsttomoftheplughole.If
mcesmy,addoilthroughtheholeofplug(2).
* Thk typa of lubricant usad depends on the

LUBRICANTV.
Rear
Page 49
CLEAN DRIVE AXLE HOUSING BREATHER
Canyoutthiiprocedureifthereisanymudor Front.
dirt stuck around ttwj breather.
Remove all ‘mud and dirt from around the

breatherwith brush.
* Clean the breathers if the front and rear lr

.--- ._. - -.. _._._._..
aXkSintheSameWay.
CLEAN All? CONDlTlONER CONDENSER-IF EQUIPPED
If there is mud or dust on the air condiioner

cxMenser, dean itwith water.
* lfthewaterpressureistoohgh,thefins
may get defonwd. When washing with a
Mt&~~~r~d~~kwHy the
A
WARNING! Do not wash the
condenser with a steam cleaner.
Otherwise, the condenser will get
hot and may break down.
Page 50
CHECK All? CONDlTlONER REFRIGERANT CHARGE-IF EQUIPPED
Chack twice a year, in spring and autumn.
Cperata the cooler of the air conditioner for 5-10 minutes, then touch the high pressure portion
and tow pressure portion and low pressure portion of the compressor (or high pressure hose
and low pressure hosa jbint) by hand. At the same time, inspect the flow of refrigerant gas
(freon 12) through the sight glass to check the gas level.
Please contact your diibutor for thii inspection.
The sight glass is installed at the side of the window washer tank inside the cover at the top
behind the operator3 seat.
1.
I-
Normal Abnormal
condition
Tamp. of high High pressure pipe is Hgh pressure pipe is Almost no difference in
andlow hot. warm. temperature batwaen
pressure pipes Low pressurs pipe is Low pressure pipe is high and low pressure
cold. cold. pipes.
Clear difference in Little difference in
temperature tamperature
Bight glass AJmost transparent. Bubbles are always Misty substance is
Any bubbles disappea flowing. Sometimas flowing.
if the angine speed is becomes transparent,
raisad or lowered. or whiie bubbles
..- =
appear-
0
z
0 0
0 -__z_
-0 -. 3 ---
0 0
z-_o_ .- -_-_=
---=--
-o-o_-
0 .- _ =:
-_-
connections Propertyconnected
fJfP4= ~p*dimm
Gewral condi- Coolant level correct, Maybe a leak some- Almost all coolant has
tion of cooler no abnormaiiies. where. Call service leaked out.
Readjrfor use repair shop for Contact service repair
inspection. shop immadiataly.
A
WARNING! The cooler refrigerant is colorless and ocioriti and does not cause
pollution of the atmosphere. However it may cause injury if it gets in the eyes
or on the hands, so never loosen any par@of the refrigerant circuit.
Page 51
LUBRICATING
Apply grease to the grease fittings shown by 1

arrows.
Work equipment ~control’ valve linkage

(2 points)
If the work equipment control lever is heavy
or does not move smoothly, apply grease.
steeringcolumn (1 point)
If the play of the steering column is heavy or
does not return properly, apply grease.
CHECK AND REFILL WINDOW WASHING FLUID
Do thii, when there is air in the window wash-

ing fluid.
Check the washing fluid level in washer tank

(1). When the fluid has run short, add
automotive washing fluid.
* To prevent the nozzles from dogging, be,

careful not to let dust get into the fluid.
Page 52
WATER SEDIMENTOR
If water has coltected in sedimentor bowl (1).

drain the water as folfows. .-A-l
1. Move wire (2) in the directionof the arrowto

retease sedimentor bowl (1).
2. Remove sediintor bowl (1) and drain out

thewater.
3. tf the air is sucked into fuel ii when drain-

2
ing the water, be sure to bleed air in the
same manner as for the fuel fitter. (See
Fuel-Water Separator i.nCHECK BEFORE STARTING.)
REPLACING BUCl$ET TEETH
IF THE BUCKET IS EQUIPPED WITH BOLT-ON TOOTH

_ _ _
Whenthebucketteeth arewom, replace them ‘. ” -.
a!2folkws. 1
1. Raise the bucket to a convenient height,
and put bbcks under the bucket to prevent
itfromcomingdown.
* Raisethebucketsothatthebottomis
hortzontat.
2. Remove the bolts and nut (l), (3) and then
remove bucket tooth (2). J
3. Instaftthe new teeth on the bucket. When

installingthe teeth, insert the shim so that there is no clearance between teeth and the top
surfaceofthebucket.
* Continue to adjust with shims until it becomes impossible to insert a shim of thkMess
0.5 mm.
4. To prevent any clearance between the tooth and the edge of the bucket, tighten the nut
partialty,then hit the tip of the tooth with a hammer.
* Tiihtening torque of mounting bott.
mounting bott (1): 92.2 4 kgm
mounting boft (3): 63 + 3 kgm
* After opera@j the machine for a few hours, tighten the mounting bolts again.
. Page 53
IF THE BUCKET IS EDUIPPED WITH BOLT-ON TOOTH
If the bolt-on cutting edge is worn, turn the

edge.
1. Raise the bucket to a convenient height,

and put blocks under the bucket to prevent
it from coming down. ,
* Raise the bucket so that the bottom is

horizontal.
24
2. Loosen nut (1) and remove belt (2). Then,
turn the cutting edge.
3. Exchange cutting edges (3) and (4) and install edge (5) in the opposite direction.
4. After exchanging, tighten with bolts (2) and nuts (1).
* Tightening torque: 76 2 11 kgm
IF THE BUCKET IS EQUIPPED WITH TIP TOOTH
Replace the teeth before they wear down as tar

as the adaptor.
1. Extract pin (2) fitted to the bucket and then

remove tooth (1).
* When extracting pin (2) strike the part

(either the left or right part) with a sharp
object. This will enable the pin to be ex-
tracted from the opposite side.
2. insert the new tooth (I’) into the adaptor (3), I

and insert pin (2) part way as shown in the
diagram. Then drive it home by means of a
hammer.
Page 54
ADJUSTMENT
. ADJUSTING PARKING BRAKE
If the effect of the parking brake is poor,

1.
adjust as follows. \
1. Turn the parking brake switch to OFF,
release the parking brake and release
caliper (1).
2. Turn adjustment bolt (3) of caliper lever

(2) to clockwise so that pad (4) is in
contact with disc (5) lightly.
* If adjustment bolt (3) is turned until pad
(4) comes into contact with disc (5)
tightly, it causes brake noise and heat
generation on disc.
3. Turn adjustment bolt (3) one click to
counterclockwise. The total clearance (a
+ b) on the both side between pad (4)
and disc (5) becomes 0.3 to 0.6 mm.
.a WARNING! When adjusting, always put blocks under the tires to prevent
the wheels from moving.
A
WARNING! To prevent the parking from being applied automatically
during adjustment, raise the air pressure, and put a warning tag on the
parking brake switch to prevent other people from touching it.
Page 55
When the pad wears to a thickness of less

than 8 mm (including backing plate),
replace the pad.
* Replace two pads as one set
* Have the pads replaced by your distributor.
8mm
A .WARNINGI DO not get any oil or

grease on the surface of the brake pad or disc.
ADJUSTING LENGTH OF LEVER
It is possible to adjust the length of the direc-

tional lever and speed control lever.
1. Pull out knob (1).
2. Loosen locknut (2) and turn bolt (3) to

adjUSt.
3 After adjusting,tighten locknut (2) and push

in knob (1) fully.
* Keep distance I under 43 mm. If it is not

screwed in far enough it is dangerous.
Page 56
TROUBLE SHOOTING GUIDE

This guid? is not intended to cover all conditions, however many of the
more common possibilii are tided.
ELECTRICAL SYSTEM
Lamp does not glow biightly even when engine runs at high speed.
Lamp fllckera while engine runs.
0 Check for toose terminals and open-circuit wiring.
. Adjustbefttension.
Charge monltor does not go out even when engine runs at high speed.
. Replscetllealternator.
0 inspect and repair wiring.
Unusual nolse k emltted from the alternator.

0 Rep&cethe&emator.
Starting motor does not turn when starting switch is turned on.
0 Inspect and repair the wiring.
l Chargethe battery.
The pinion of the starting motor keeps going in and out.

l Chargethe battery.
Starting motor turns the engine sluggishly.

l (;hargetf@battery.
0 Repiam the starting motor.
The starting motor disangages before the engine starts up.

* 0 Checkand repairthe wiring.
0 Charge the battery.
The engine preheating monitor. does not flash.

l Check and repair wiring.
0 Replace the heater relay.
. Replacethemonitor~
The engine oil pressure monitor does not light up when engine ls .stationary (when the
starting swttch ls ln ON posltion.)
l Replace the monitor.
l Replawthemonitorswitch.
Charge monltor does not light up when the engine is stationary. (When the starting switch
is in ON position.)
l Replacethemonitor.
0 InsDect and rewir the wirina
Page 57
Outside the eiectrkai intake air heater is not warm when toudwd with the hand.
0 Checkandre@airting.
l Replace the ektrkai intake air heater.
0 Check and repair.the heater switch.
ENGINE
The engine oil pressure monitor flashes when engine speed is raised after completion
of w8mwp.
l Add the oii to the specked level.
l Repiacetheoileiement.
0 Cbckoiiieakagefromthepipeorthejoint.
0 Repiace the monitor.
Steam is emitted from the top part of the radiator (the pressure valve).
The radiator cooling water level monitor flashes,
0 Suppiy the cooling water and check leakage.
l Adjust fan beit tension.
0 Wash out inside of cooling system.
l Ciean or repair the radiator fin.
l Repiacethetbrmostat.
l Tighten the radiator cap firmly or replace the gasket of it.
l Replace the monitor.
The engine does not start when the starting motor is turned over.
Add fuel.
Repair where air is &king into fuel system.
Replace the injection pump or the nozzie.
Ch0cktheMhreciearance.
Check engine compression pressure.
Refer to the section of eiectrical system.
Exhaust gas is white or blue.

l Adjust to specifM oil quantity.
l Replace with specifhd fuel.
Exhaust gas occasionally turns black.

l Clean or replace the air cleaner element.
l Repiacethenozzie.
l Checkengine compression pressure.
l Ciean or rep&e the turbocharger.
Combustion noise occasionally changes to breathing sound.

l Repiawthenozzie.
Page 58
Unusual combustion noise or mechanical noise.

Replacewilhspedfiedfuel.
chackover-h8ating.
Replace the muffler.
Adjust vaive ckarance.
CHASSIS
RIANSMIBBION
Engine k running but machine will not move.
0 Release parking brake.
l Put directional lever in position properly.
l Add oil to transmission case to th? specified level.
Even at full throttle, machlne moves slowly and lacks power.

0 Addoiltotransmissioncasetothespecifiedlevel.
0 Disassemble transmission strainer and dean.
oil overheats
l Addoiltotrans- case to the speciiied if3velor drain oil.
0 Usaasuitablegearspeed.
0 Reducetimeusingtorquf3wnverteratstaUspeed.
0 Checkengine.
Abnormal noise k produced

0 AddoiltotransmMoncasetothespeckdlevel.
Abnormal noise k produced.

. l AddoiltoaJdecasetothespEJcifiedlabel.
DISC BBAKE
Brake does not work when pedal Is depressed.
0 Raise air pressure to specified level.
0 Replacedisc.
l Bleed air from brake system.
Brake drags or st8iys applied

0 Clean exhaust hole of treadle valve.
0 Claan breather of power duster.
l Check and repair slack adjuster.
Brake slips
0 Replacedi.
Page 59
PAFlKlNG BRAKE
Brake does notwork poperly.

0 Adjustliikaga.
. cleanbrakepad.
l replace spring in air cylinder.
l Adjust or replace brake pad.
STEERING
Steering wheel ls heavy.

. AdjlKt steeringgear.
0 Check linkage,replaceparts.
HYDRAUUC SVSTEM
Bucket lacks lifting power.

Bucketlifting speed is slow.
0 Add oil.
l Replacefilterin hydraulic tank.
Many bubbles form In oil

0 Repiacewith specifiedoil.
l Addoil.
l Bleedair fmm oil line.
Oil pressure is too low.

0 Add oil and bleedair.
Cylinder vibrates when operating.

0 Addoil.
Page 60
SERVICE METER
This meter indicates the integratedwork hours.
So, use it according to the following in-
Record the readings at the W.and the end

of work, this is the work ‘record of the
machii.
ihis record will indicate, when periodical
maintenanwisdue.
It also indkates the integrated working
hours when machine problems are en-
countered.
How the meter progresses
The service meter progresses by 1 when the engine is operated for one hour, regardless of
.
the engine speed.
Consequentiy, itthe machine is running, the service meter will advance even if the machine
does not move.
while engine is running, green pilot lamp on the service meter flashes to show the service
meter advances.
MACHINE AND ENGINE SERIAL NUMBERS

When’callingfor a service of mechanic or when making replacement-partsorder, be sure to give
diitributor the machine and engine serial numbers as well as the service meter readiig before
mentioned. These numbers are found on the plates shown in the photos below.
Location of the machine serial number -
PI*
This is seen on the center right of the front

frame.
Location of the engine serial number

Plate
This is seen on the right side of the timing

gear box when seen from the fan side.
Page 61
FUEL, COOLANT AND LUBRICANTS

PROPERSELECllONOFFUEL$OOUWTAND'iUBRICANlS
0
-
wiu
-
l&Q
25
-
75
lath
See NOTE 3 24
API: Arnetican Petroleum lnstibte

ASTM:
SAG wtiSocW 9’ Testing and Mated
Automobe Engineers
Specified capacity:Total amount of oil including oil for components end oil in piping.
Refillcapacity:Amount of oil needed to refillsystem during normal inspection and maintenance.
NOTES:
1. ENGINE OIL
Normal Opeqtion
Oil performance recommendations are as follows:

Page 62
The use of a qualii engine lubricating oil combinad with appropriate oil and filter change
intervals are critical factors in maintainingengine performance and durability.
SAE 15W4 mufti-visc&ity oil meeting the American Petroleum Institute (API) Classification
of CE/SF is recommeMed. CD/SF oil may be used in areas where CE/SF oil is not available.
A sutfated ash limit of.l.0 mass percent is suggested for optimum valve and piston deposit
and oil consumption control. The sulfated ash must not exceed 1.65 mass percent. The
sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils
recommended for use in the engine. Higher ash oils can cause valve and/or piston damage
and lead to excess& oil consumption. .
The API service symbol displays the following information.The upper half of the symbol
displays the appropriate oil categories; the lower half may contain words to describe oil
energy conserving features. The center section identifiesthe SAE oil vixosky grade. *
Oil viscosity recommendations are as foflows:
The use of a multi-graded lubricatingoil has been.found to improve oil consumption control
and improve engine crank@g in cold temperatures while maintaining lubrication at high
operating temperatures.
While SAE 15W-40 multi-viscosityoil is recommended for most operating climates, refer to
the previous chart for oil viscosity recommendationsfor extreme cliites.
Limited use of low viscosity oils, such as SAE lOW-30 may be used for easier starting and
providingsufficientoil flow at ambienttemperaturesbelow + 23°F (-SC). However, continuous
use of low viscosity oils can decrease engine life due to wear.
Do not use special ‘break-in’ lubricatingoils for a new or rebuilt engine, Use the same type
of oil during the ‘break-in’ as specifredfor normal operation.
Arctlc Operation
ff an engine is operated in ambient temperatures consistently below -10°F (-23%) and there
are no provisionsto keep the engine warm when jt is not in operation, use a synthetic CE/SF
or CD/SF engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-
30.
The oil supplier must be responsible for meeting the performance service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals.
Extended oil change intervals can decrease engine lii due to. factors such as; corrosion,
deposits and wear.
Additional informationregarding lubricatingoil availabilii throughout the world is available in

the ‘E.M.A Lubricating Oils Data Sook for Heavy Duty Automotive and Industrial Engines.”
The data book may be ordered from the Engine Manufacturers Association, One Illinois
Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone number is (312)
6446610.
Page 63
2. ENGINE OIL
Use API ciassiicatbn CD engine oil. If API ciassiticationCC is:used, reduce the oil change
intarvaito half.
3. AXLE OIL
Foraxiaoii,useoniyther ecommended oil as follows:
SHELL: DONAXlTOTTD
CALTEX: RPM TRACTOR HYDRAULiC FLUID
CHEVRON: TRACTOR HYDRAUUC FLUID
TEXACO: TDH OIL
MOBI1: MOBIL AND SUPER UNIVERSAL
* lt is possible to substituteengine oil SAE 30W API classificationCD for axfeoil. lf noise comas
from the brake, it is no problem of durabilii.
4. DIESEL FUEL
A WARNING! Do not mlx gasoline or alcohol with diesal fuel. This mixture can
cause an explosion.
IMPORTANT: Due to the precise tolerances of diii injection systems, it is extrarnsfy

importantthat the fuel ba kept &an and free of dirt or water. Dirt or water in the system can
cause savare damage to both the injection pump and nozzles.
The usa of ASTM No. 2-D dii fuel with a minimum Catane number of 40 is recommendad.
The usa of No. 2-D diesel fuel will resuft in optimum engine perfonanca under most
operating condiions. Fuels wfth Cetane numbers higher than 40 may be naadad in high
akkudas or extremely low ambient temperatures to prevent misfiresand excessive smoke.
At operating tempemtums below +32”F (O’C), acceptable performance can ba obtained by

using a blend of No. 2-D and No. 1-D fuels. The usa of lighter fuels can reduce fuel economy.
Use a iow sulfur content fuel having a cioud point that is at least 10 degrees below tha lowest
x$fuei temperature. Cloud point is the temperature at which crystals begin to fwm
The viscosii of the fuel must be kept above 1.3 cSt to provide adequate fuel system
lubriqation.
5. COOLANT
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and
supplementalcoolantadditives.Supplementalcoolantadditiverecommendationsare included
in the s&on entitled ‘CHANGE THE COOLANT AND FLUSH THE COOUNG SYSTEM’. The
coofant should ba changed at the specified service interval shown in the ‘MAINTENANCE
TABLE’.
Page 64
DCA4 is recommended to inhibit corrosion in the cooling system.
In climates where tha temperature is above -34°F (-3X), usa a coolant mixturethat contains
50 percent anweeze Antifreeze is essential in any climate. It broadens the operating
temperature range ‘b; lowering the coolant freezing point and by raising its boiling point. Do
not use more than 50 percent antifraeza in the mixture unless additionalfraeze protectionis
required. Never usa more than 58 parcant antifreeze under any condii.
Low silii ethytane giycol antifraaze is recommended. The antifmaze should contain no
more than 0.1% anhydrous alkali metasiliie. Low skate antifreeze is recommended to
avoid ths fom@ion of silica-gel (hydra-gel). This gel formation can cxcur when the cooling
systemcorwnsanover concentrationof high silicateantifraezeand/or supplementalcoolant
additive.DONOTusemethandoralcoholasansntiireetebecauseofitslowboilingpoint.
Antifmeze may retain its freeze protectionfor more than one season but coolant conditioners *
must lx added to maintain corrosion protection.
Antifreaza form&ted wtth methoxy propanol, or propylene glycol, is not n3commendadfor

this systam.
NOTEz Do not mix typas of antifreeze sofutions.Mixed sofutionsmake it impossible to

datafmina the pro&&on against bezing. Antifreezecontahfng sealer or anti-leak
additivesshould NOTbe usedin thissystam.Sealer oranti-laakadditivas willcause
plugging problams in the cooling system.
Check the solution periodically‘and at normal operating tamparature,to be sure the cooling
system has wfficient protection against freezing.
Usa water which has a low mineralcontent. Water usad in conjunctionwith antifreeze,coolant
filters and inhibited water must maat the followingstandards:
Totat Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to
prevent state deposits. Water containing dissolved magnesium and calcium (the usual
reason for water hardness) above the specSed amount will cause scale deposits to
develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent
CorrOSiOtl.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent
corrosion.
Dissohfed 6cWs - Not to exceed 340 parts per million (20 gmins/gallon maximum) to
minimize sludge deposii, scale deposits, corrosion or a combination of these.
lf any of the above requirements cannot be met, use distilled, de-ionized, or de-mineraliied
water. To datermine if tocal water supplies meat these standards, water samples can ba
tested by water treatment laboratories.Softened’ water that is prepared using common salt
(sodium chtorfde)contains excessive amounts of chloridas and should not be used.
NOTE: Never use water alone in the cooling systembecause corrosion will occur’.
Page 66
Maintain supplemental coolant additive levels at 1 unit DCA4 par I U.S. gal (3.8 liters) of
coolant.
Use antifreeze during all seasons to protect the cooling system from corrosion as well as
freezing damage.
A rn-ktureof 5096watk and 60% ethylene glycol bass antifreeze is required for operation of
the angina in temperature environments above -34.VF (-37%). A mixture of 4096 water and
60% antifreeze is recommended for temperatures below -34.6”F (-37%).
In tropkal di where antifreeze availability may be limited, use a corrosion inhibitor

(Cummins liquid DCA), or an equivalent to protect the engine cooling system.
Do not operate eiqine without a thermostat.

Page 66
MEMORANDA
SECTION 3
SAFETY AND OPERATION
A WARN’
NG ! REFER TO AND READ ALL
SAFETY PRECAUTIONS IN THIS
SECTION.
SECTION 3 ’ SAFETY AND OPERATION
Page 2
SAFETY HINTS. . . A
Protect yourself and ofhers. Safety is ahmys first.
OPERATION
GENERAL
Wear well-fitting helmet, safety shoes and

workingclothes.#thenatureofthework
ra@res safety, waar protactivegoggles or
mask, thick gloves, ear plugs or other
protaction.
Take care of your health. Do not operate

when tirec$ or after drinking.
When there is a leader, fix standard signals

and always follow these signals when
operading-
Learn tha prohibitions, cautions and rules

about work procedures in the work site.
Read the Operation and Maintenance Man-

ual carafully. Learn how to use the control
devicas, gauges and warning devices. Be
sure you UndersUM the meaning of the
Wtionpiatas.
SAFETY AND O.PERATlON SECTION 3
Page 3
Confirmthat all gauges andwarning devices

are functioning correctty,and that the gauge
readings are within the prescribed range.
Learn about the safety de&es on your own

machineandabouthowtousethem.
Never allow another person to operate the

machine.
If there should be q accident or fire or any

other such unexpected mishap, deal with it
quickly, using the nearest apparatus.
Learn beforehand the locations of the first

aid boxes and fire extinguishers and how to
usethem.itisakoimportanttoknowthe
emergency contact system.
Fuel or oil are dangerous substances.
Never handle fuel, oil, grease or oily cloth in

places where there is any fire or flame.
SECTION 3 SAFETY AND OPERATION
Page 4
CHECKING JOBSITE CONDITIONS
Examinetheiayofthelandandthekindof
soilattheworksitetodeterminethedan-
gerous points and the best mettM of
opera&n.
Proceed with the work only after making

=f&&-ngeme”o about the dangerous
.
Donotworkwhenvisibilityisreducedby
smoke, fog or dust. If the jobsii is dark,
instalilightingifrKaSaly.
By continlJaliygrading the work site, work

efkiency will be improved and machines
willbeabletodrivesmoothiyoverthesite.
If the work site is very sandy or dusty,
sprinkle water over the ground before
workingonthesite.
Check the load limits of bridges before

crossing.
SAFETY AND OPERATION SECTION 3
Page 5
0 whenoperatingamachinein wateror 1
fording streams, sun7ey the water depth,
‘groundcondiiandvelocityofthewater
inadvance.Donottakethemachinein
water exceedii the allowable depth (up to
the underside of the axle housing).
0 The overajl tight of the machine is

rest&ted by tunnels, roof height or over-
head ehtric wires, so check first whether
the jabsite is safe. Be particularly careful
whenworkingnearpoweriiiaseh3ric
shockcanbecausedifthemachina
tOlJChSthe8ledriCcaMes.
BEFORE STARTING OPERATION
CHECK BEFORE STAFUING
0 Carryoutchecksbefores@itingthema-
chine.lfanyproblemisfound,donotstart
the engine, but informthe foreman immedi-
2-m keep the machii in good
Page 6
Before operating the maohiie, be sure to

C&Ckthebarandpinsforsettinginstorage
F.
The machine Can not be steered with
frames locked. (In art&Me fratne model)
Always stop the engine when adding fuel.
After adding fuel, tighten the fuel cap
property-
Inspect the inside of the engine room and

remove any dead leaves or papers. Dead
leaves or papers are highly inflammableand
cancausefires.’
Do not leave pa& or tools lying around in

thevkinityoforontheflooroftheoper-
at&rnt. Keep everything in its
wipe off thoroughly any grease, oil or mud

on the handrail, floor or control levers.
Failuretodothismaycauseywtoslip.
Page 7
PRECAUTIONS WHEN GETTING ON THE MACHINE

IfthemachinaisfWdwithacab,make
surethawindowsaredaanandchacktha
visibility. Always lock the door before start-
ingopamtbns.
When getting on or off the machine, usa the

handrail and step provided. Do not jump up
ontoordownfrornthemachinf3.
Ifaseatbeltisprovidad,alwaysu~it. lfthe
bakisdamagadorwom,replaa3itwitha
rlewona.
PRECAUTIONS WHEN STARTING THE ENGINE

Before starting the angina, confirm that ail
control levers are in neutral position. I
hhaust gas is dangerous. When working

inside, be particularly careful to have good
ventilation.
To ansure the safaty of workers near tha

machine, ahrfays sound the horn to warn
tham before starGngtha engine and moving
thamachina.6apartiarlarlycarefultochack
thattharearisdaarbaforabackingthe
machii.
Page 8
CHECKS AFlER STARTING THE ENGINE

Before startingwork, ‘kt drive the machii
inasafeplaceandcheckthatthetransmis-
sion, brakes, accelerator, and steering are
workingproperiy.Atthesamethne,check
thatthereisnotabnomul noise or vibration,
oranyabwmahyintheinstrumentsand
gauges.
DURING OPERATION
AJws-~ti=a- seatwhen
.
Do not allow anyone except.the operator on
themachine.
Always be aware of the operating capacity

ofthemachii.Usingthemachinetodo
workbeyondilScapacityWiUtUBtonlydam-
age the machine, but may even cause
lJrW=@dB
Themachinetxmdith&bejudgedfrom r
many factors.changes in the FJW,
sound, vibration, exhaust gas color or
responseoftheaw7trollt3verscanindicate
the ocasrence of some disorder. If any
diso&roccurs,parkthemachineimmedi-
atelyinasafeplaceandtakeappropriate
action.
SAFETY AND O.PERATION SECTION 3
Page 9
AlTENTlON TO SURROUNDINGS
TO ensure the safetyof workers near the

machine. always sound the horn to warn
them before starting the engine and moving
tha machiie. Be partia~larly’careful to check
that the rear is dear before backing the
machine.
Do not allow unauthorized persons into the

workare&
Always concentrate.It is extremely dan-

geroustoailowyoursalftobedistractedor
to think of other things when operating a
machine.
When loading trucks or hoppers, be careful

nottohitthetruckorhopperwiththa
bucket. Do not bring the bucket over
people’sheadsoroverthecabofthetruck.
In dangerous places or in piaces where the

vi&Iii is poor, get down from the machine
and check that it is safe before continuing
the operation.
SECTION 3 SAFETY AND OPERATION *
Pa+ 10
AIwaysoperateslowlyinorowdedplaoes.
onhaulroedsorinnarrowpleces,givewey I ‘G
toloadedmachines.
When traveling, keep the work 6quipment

closetothegroundtomaintainthestabilii
of the machine. Pay particularly careful
attentiontothestabiliiofthemachine
whantravelingwithak8ad.
If the machine has to travel on rough 1

ground,becarafultoavoidobsWasasfar
aspossible.
Ahwaystravel at a slow speed, and do not

suddenly change diiection.
Do not usa the bucket as a brake except in emergencies.
lf the engine stops when the machine is traveling, it is impossible to use the steering. This
is dangerous, so apply the brake immediatalyto stop the machine.
Whentraveling&hiUswithaloadedbucket,
travel forward up the hi and in reverse
downthehiu.
Page 11
mlemaohineshouldatwaysbeoperatedal
aspeedwhereltcanbec4mcttyoontrolled.
Never do the follow&g:
SpeedinS
Sudden starting, sudden braking, sudden

turning
snaking
Q=ting
RESTRICTIONS CREATED BY JOBSITE

Donotapproachtheedgeofthecliffor
road shoulder. I L
In dangerous places, always work in teams

of two; one man to operate the machine,
andttleottlertogiveillstr@ons.
On windy days, always load downwind.
When amtinuii operdom after rain,

remember that conditbns will have changed
fromthosebeforetherainstarted,sopro-
ceedwithcautbn.
Be caMd when working on the place made

of piled soil, after earthquakes or after
Masting.
Page 12
Ah3ystraveldirectfyupordownsfopes.
Whentrawhgdownaslope,usethesame
g~speed=~goeluptheslope.
Whentravelingdownaslope,neverputtM
transmissioninneutral.
If the engine stops bn a slope, apply the

brake quickly and carefully. Next, lwver the
work equipment to the ground and apply
the parking brake. Then put the directional
and speed control levers in neutral, and
start the engine again.
Becar&dwhentravehgonphnksorsteel
pkt9S,sSth8S8CanCWS6Siippge.
when operating at nigM, re the

fohwingpoints:
Besuretoarrangeanaclequetelighting
system.
Atnightitisveryeasytomakemistakesin
assumingthediiancih0ightofobjects
andlanci.
Page 13
&for8 tOWing OpefstiOnS, ahyS Ch8Ck th8

Wire fop.
&for8 starting towing OpetationS, make

sure that no one is near the machine. SM
the machine Slowly to take up the slack in
the Wire rope; Then start towing CZU8fdy.
Do not tow any machine whose brakes or
steering have broken down.
PARKING
When oarkincl the machine. oark it in a safe I
place butsid the wok& Korea,or in the
specified place. The following factors should
be WISid8red when choosing a parking
place: it should be on flat, firm ground
where there is no danger of rockfalis, land-
slides or floods.
If the machine has to be parked on a slope. I

it should be parked facing directly up or
down th8 slope, and chocks should be
placed wtd8r the tires.
VVh8nleaving the machine, always lower the

work equipment completely to the ground,
and put ail control levers in neutral. Next,
apply the parking brake and lock all levers.
Then put blocks under the tires.
After stopping the engine, always remove’

the starting key.
I
I
Page 14
PRECAUTIONS FOR MAINTENANCE

GENERAL
. Wear well-fitting helmet, safetyshoes end

working clothes. when drilling, grinding or
hammering,alwaysWearprotecthe goggles.
‘
l when working with others, choose a group I
leader and work according to his instruc-
tions. Do not perform any mainunance
beyond the agreed work.
Hang a caution sign in the operator’s com-

partment (for example “Do not start” or
“MaifWnance in progress”).
This will prevent anyone from starthg or

moving the machine by mistake.
Page 15
Smoke only in designated places. Never

smokewhiiworking. _
Alwayskwptheworkshopingoodcondi-
tion. Make sure there is ti mud or oil on
the floor.
Keep oily cloths and other combustible

things in a safe place away from fire. In
additbn,learnttlelocatbnandmethodof
operath offire extinguishers.
Always stopthe engine before cleaning the

madline qr adding fuel.
Flame should never be used instead of

lamps. Neveruse a naked flame to check
leaks or the level of oil, fuel, anti-freeze or
eiectroiyte.
Page 16
BEFORE MAINTENANCE
Before statingwork, stop the machine on a

firm, level surface, and ,usa bkxks to keep
the machii from movingduring operations.
Lower the bucket to the ground. If this is

impossible, use the safety pin and blocks to
hold the work equipment securely in posi-
tion.Inaddition,appiythelockstoailcon-
tilevets.
Alwav!slockthefrontandrearframasbefore I
insphng and servicing the machine.
(In articulate frame model)
l Remove all oil and mud from the machine. I

In particular, be sure that tha steps, hand
grips, and the floor of the operator’s com-
pwlment are dean.
l Always use tha standard ROPS equipment_

Do not modii tha ROPS equipment.
Page 17
DURING MAINTENANCE
Whengatingonoroffthemachine,usethe
steps,handgr@sandiadders.Neverjump
onoroffthemachine.lfthesteps,hand
grfpsorJaddercannotbelJ&,useastand
togivaiimIfooting.
ovethecabksfromthe
EF2E!!Z-
Exhaust gas is dangerous. When working

in&da. ba particularly careful to have good
when opening inspection covBrs, stop the

engine.lfthehoodorothercoversarefTttad
withalock,alwaysapplytheiockssecurely
whsnopeningordosingthehoodorcover.
Always stop the angina before adjusting bett

tensionorbeforet9l&ingorservicingtha
waterpwnp.
Be particularly careful when removing the

radii cap or the hydraulic oil tank filler
cap. If this.is dona immediately after using
the machine, there is a danger that boiling
waterOroil~yspwtwt
Always release the pressure in the circuit

before chscking or sankzing tha oil, water
oraircircuits.
When the engine stop& the water and oil in

theckuitishot,sobecarefulnottoget
bumed.Waitfor~waterandoltocoolbeforestartinganywMkM1themachine.
SECTION 3 SAFETY AND. OPERATION
Page
18
MISCELIANEOUS
0 lhorougNyw&h themachine, particularfythe oiling and greasing parts and the Wnity,
thereof, in order to prevent the ingress of dust.
a Usegenuinerepl&mentpartsspecibdinthepartslii 1 _
b Use specified oil and grease. Use oil and grease having the recommended bcosity for the
pal%aWambieflttemperatWe.
b Inspect or replace oil in a dust free location to prevent the ingress of dirt
l Drain off used oil after heating it to a &able temperature (about Xl to 40%).
b After greasing up, always wipe off the old grease that was forced out.
l When changing the oil or fitter, check the drained oil and filter for any signs of excessive
metal panicles or other foreign materials.
. When removing parts crx&Mng C-rings, gaskets cr seals, clean the mounting surface and
replace with new sealing parts.
b When washing the machii, ensure that water does not get onto the altemator.
l Special measuring apparatus is needed for testing hydraulic pressure.
0 lhoroughty wash the machii. In particular,be careful to clean the filler caps, grease Gttings
andtheareaaroundtfiedipsticks.Becarefulnottoletanydirtordustintothe~~m.
b a
When checking an open cover there is risk of dropping things in. Before removing the
covers WWex stpty everything from your pockets. Be panicularty careful to
0 When wcrking on the sea shore, carefullyclean all elect&al equipment to ensure that it does
notcorrode.
b Before working in muddy water, rain or snow, check that the various~plugs, valves, are
properly screwed up. Upon completion of work, wash the machine, then check the varbs
parts of the machine for cracking, scratching, loose or missing nuts and b&s. Also, oil and
greasetflevarious parts of the machine.
l When working on rocky ground, be careful of damage to the undercamage, loose nuts and
bolts, cracks;wear and other damage.
Page 19
. Whanworkinginadustylocation,becarefulofthefoUowing:
1) lnspecrtheservice~~toseewhethertheairdeaner$~edup.cleantheak
deanerassoonasitbecomesdirty.
2) Cleanther8diat&coresothatitdoesnotbecomeMockedup.
31 Cleanorreplacethefuelfitterassaonasitbecomesdirly.
4) Cleantheelectricalequipment,partiarlartythestartingmotorand~mator,toprevent
aa%mulation of dust.
l When,installingcarradioandawalkie-tslkieorcithenband,contactyourdistriknor.
l When washing the machine, take care not to splash water over the electrM equipment. if
it is soaked with water, it may not operate normally.
l Afterdisconnectingthecormedor,wveritwithavinylbagtopteventoilordustfromsticking
toitscontactsecGon.
0 When welding, be ca&ul of the following:
11 Turn OFF th& power (starting switch).

2) Donotcontinuoustyappiymorethan2oov.
3) lnstallthegroundcableatleast1 mfromtherangetobewekied.
4) Takecantnottoinstallthesealsbetweenthegroundedpointandtherangetobewelded.
* UseordinaryautMobilewasherfluid.BecareMnottoletdbtordustgetin.
BUCKET OPERATION
Various types of attachments8re availableto extend the range of application beyond the
applk8tions described below.
EXCAVATION
Always keep the operating jobsiie ftat, and remove any fallen rocks.
Pago 20
1. When driving the machine forward and

lowaring the bucket, stop tha bucket about
30 cm from the ground, then lower it slowly.
* lf the bucket hi the ground, the front tires

will come off the ground, and.the tires will
slip.
.2. Shiftdownimmediiinfrontofthemater-
ialtobaloadf3d.whencompletingtheshi
down, depress the accelerator pedal at the
sametimeandthrustthebucketintothe
load.
3. When the material is in a stockpile, keep the

cuttingedgaofthabucketho&ontal;when
loading blasted rock, have the bucket tilting
slightly down.
* Be careful not to get blasted rock under the
bucket. This will make the front tires come
offthegroundandslii.
. * Trytokeeptheloadinthecenterofthe
bucket; if the load is on one side of the
bucket,theloadwillbeunbalanced.
4. At the same time as thiusting’ the bucket

intothemaMal,raisetheliftarmtopn3vent
the bucket from going too far. By raisingthe
lii Amy,ample tract&~ will be produced by
the front tires.
Page 21
5. Checkthattherelsenoughmaterialloaded
into the bucket, then operate the bucket
controllevertotiltthebucketandloadthe
bucket fully.
* lftflebucketedge.ismovedilpanddown
wbii pushing in ,tie bucket and digging, the
front tiras will come off the ground and this
will cause the tires to slip.
6. lf there is too much material loaded in the

bucket, dump and tit the bucket quickly to
remove the excessive load.
This prevants spillage of tha load during

hauiing-
When digging and loading on level ground,

set the bucket edge facing down slightly as
fokws and drive the machine forward.
AIwaysbecarefulnottoloadthebucketon
onesideandcausetiunbaiancedload.
This operation should be carried out in 1st

gear.
6at the edge of the bucket facing slightly

down.
Page 22
2. Drive the machine fonwardand operate the

liftarmwntrolleverforwardtocutathin
layarofthesurfaceeachtimewhenexca-
vating the soil.
3. Operate the lift arm control lever slightly up

and down to reduce the resistance when
driving the machine forward.
* Whan diiging with the bucket, avoid impos-
ingthediggingforceontoonlyonesideof
thebucket.
A
WARNING! Never dig or scoop
when the machine body b
articulated.
PRECAUTIONS WHEN SCOOPING UP MATERIALS
When scooping up materials, ba careful not to let the counterweight at the rear touch the
ground.
* Do not allow tires slipping to oaw during operation. Tres slipping shortens tire’s Me.
LEVELING
1. ScoopsoiiintothebucketMovethema-
chine backward while spreading soil from
thebucketliibylii.
2. Goovarthespraadsoilwiththebucket
teeth touching tha ground and level tha
ground by back-dragging.
3. Scoopsomemoresoilintothebucket,put ‘.’
the lift arm in fioat. level the bucket at
ground level, and smooth the ground by
movingbackward.
* Ahwaysmove the machine backward during
leveling operations.
A
WARNING! lf leveling by forward travel can not be avoided, do not dump the
bucket beyond 2fP. This will prevent quick wear and damage of the work
equipment and frame.
Page 23
LOAD AND CARRY OPERATIONS

Load end carry Operation is a series of
processes (scoopingcanying-loading to a
~orgloryhole)carriedoutbythewheel
.
* Always maintain thwoad in &od condiion.
A
WARNING! Lower the bucket to
bring down the center of gravity
when carrying material.
LOADING
select and proceed effectiveoperationwhich avails lessturning and the shortest hauling distance
according to ground csndwns.
CROSS DRIVE LOADING
When 8 wheel loader is operated, the digging
should be mada at a right angle toward
acwmulatedsoil.Whenthescoopingiscom-
pleted,themachineshouldbetraveledback-
wardsasitis.Then,bringthebuckbetween
theaccumulatedsoilandthewheeiloaderfor
thepuqxseofioadinguponthedumptruck.
A
WARNING! Provide a flat road
free of rocks and hollows. When
theboomkraisedwtththebucket
loaded, do not make quick turns
or quick brakingbecause It is very
dangerous.
*A
WARNING! Do not load the
bucket by thrusting into a pile of
soil or gravel at high speed
because it is dangerous.
V-SHAPE LOADING
Stop the truck with the angle of about 60”
toward the scooping’ direction of the wheel I
loader. After scooping the soil, back the wheel
ioaderinsuchawaythatitmakesarightangle
tothetruck.Theloadingonthetruckismade
by the wheel loader going farward.
The smaller the turning angle, the higher the

efficiency.However,tumingof90”canbe
madeifneceswy.
Page 24
OPERATING THE CAB HEATER

~ispossiMetousethecabheatertogoodeffectindustyjobsites.Theoutsideairispassed
through the filterand $ sent to the operator’s cab to increase the pressure inside the cab. In this
way, dust ispreventedfrom entering, so comfortableoperatingcom&ons afeahJvaysmaintained
fortheoperator_.
EQUIPMENT ON CONTROL PANEL
FAN SPEED SWITCH
0 This oontrols the air f&w when the cab

heaterisusedforheating.
* There are 3 levels:

LO (Low), ME (Medium)’and HI (High)
TEMPERATURE CONTROL LEVER

0 This is used to control the temperature for I
coolingorheating. ’
* ThefarthertheieverismovedtotherigM,
the hiiher~the temperature ofthe air blown
out from the vent.
I
AIR INTAKE SELECTOR LEVER
This switches the air intake port when heating.
FRESH: Operate the lever to the right.
Fresh air is taken in from outside in additionto the air inside the compartment. m is used
for ordinary heating, and when pressurizing ,?heinside of tha cab.)
RECIRC: Operate the lever to the‘left.
Only the air @side the compartment is used. (This is mainly used for quick heating.)
Page 25
METHOD OF OPERATlOfl
OPERATION OF CONTROL PANEL
Leverswitca Airintake
. Fanswitch Temperature control lever
sektorlever
_ Quick HI Movefullytoright Left

Normal HI - LO From center to near riaht side Rifht
From center to near right side
(movefullytotherightwhen
Defrosting HI Right
carrying out quick defrosting
or demisting.)
ventilationor
Hi - LO Move fully to left Right
txasswitina
* lf the outside air is extremely dusty, set the fan switch to the H position. This will preswrize
the cab and prevent the ,dust from entering.
SELECTING AIR VENT
Vent
FACE FDDT DEF
Purpose
Heating Openorclosed Open Open or dosed
Defrosting Closed Openorclos6d Open
VMltilation Open Open
* The effectiveness ofthe heating system can be increased by selecting the most suitable vent
* Donot~mthefanswitchonwhenalltheventsaredosed.
Page 26
OPERATING THE AIR CONDITIONER-IF EQUIPPED

it is possible to use the air condiner to good effactin dusty job&es. Tha outside air is passed
through tha filterand is sent to tha operator’s cab to increase the pressure inside tha cab. In this
way, dust is prevented from entaring, so comfortableoperating condMns are alwaysmaintained
fortheoperaw.
EQUIPMENT ON CONTROL PANEL
FAN SPEED SWITCH
l This is used for controllitwthe air flow when I
cooling or heating. - I r \
. * lt can control the.air flow to three levels:

LO (Low), ME (medium) and HI (High)
AIR CONDITIONER SWITCH

0 This is the switchfor cooling.
ON: Push tha button to carry out dehumidii-
cation and cooling. The blue lamp lights
up to indicata that the cooling system is
on.
OFF: IfthesystemisONandthebutton’is
prassed again, tha switch returns to its
original position and the air conditioner
is witched off.
* Turn the air conditioner switch on after turning the fan switch on.
AIR INTAKE SELECTOR .&/Ed

l This switches the air -we port when cooliig or heating.
* FRESH: Operate the lever to the right
Fresh air js taken in from outside in addition to the air inside the compartment.
(lhii is used for ordinary cooling or heating, and when pressurizing the inside of
the cab.)
* RECIRC: Operate the lever to the left.
Only tha air inside the compartmentis used.. m is mainly used for quick cooling
or heating.)
Page 27
TEMPERATURECONTROL LEVER
0 Thisis used to control the temperature for coolii or heating.
.
* The farther the lever is moved to the left, the lower the temperature of the air blown out from
thevent.
* ThefartherthelevefismovedtotherigM,thehigherthstemperatureoftheairblownout
fromthevent.
METHOD OF OPERATION
OPERATION OF CONTROL PANE&
Air
Airintake
Lever
switchFanswitch condii ~emperaturecontrollever
Selectof level
SWibh
I
- thick HI ON MoveJullyto left Left
Normal HI-LO ON From left side to near center Riht
Dehumidifying,
HI-LO ON From center to near right side lwht
hsatingI 1 ,
Heating Ouick HI OFF Move fully to near right side Left
Normal HI - LO OFF From center to near right side Right

From center to near right side
(move fully to the right when
Defrosting HI ON fwt
carrying out quick defrosting
or demisting.)
VentiWun or
HI-LO OFF Move fully to left Riam
pre=rwI
* gtheoutsideairisextremelydusty,setthefanmvitchtotheHposition.Thiswillpresswize
the cab and prevent the dust from entering.
Page 28
SELECTING AIR VENT
IkIlt
’ purpose FACE FOOT DEF
cooling Open openorclosed cksed
Heating Open or closed Open Open or closed

Defmsting OpOrCbSd Open
VtiktiOtl Open open Open
* The effectiveness of the air condiioning system can be increased by sei&ng the most
witablevent.
* Donottumthefanswitchonwhenalltheventsareclosed. .
PRECAUTIONSFOR USINGAIR CONDITIONER’
When cooling, change the air occasionally.
Smoking in tha air-condiion6d cab will cause your eyes to get sore. While smoking, open
thewindowtolstthesrnokeoutofthecab.
While using the air condii, open the window once every hour.
Be careful not to overcooi the cab.
The cab should feel cool when entering there from outside (5% or 6°C lower than the
outside temperature). It is not good for the health to have the temperature in the cab too low.
Ahuays give careful consideration to temperature regulati6n.
HANDLING THE AIR CONDITIONERIN SEASON
To use the air conditioner comfortably during its season, ask your @stributor to check the air
co&tMerandaddtherefrigerantifnecessary.
l ThesCendarddeaningcycleforthefreshairfi~erisNERYlWHOURS,butrtbecomes
clogged, it will be impossibleto pressurizethe inside of the cab, and in addition, it may Cause
failures, so check and dean the filter immediately.
For detailsof cleaning,
see PERIODIC MAINTENANCE.
l Ifalargeamountofdir!Mdustcdlectsonthecondenser,thecoolingcapacitydrops,so
check and clean &en neceswy. For details, see WHEN REOUIRED.
HANDLING THE AIR CONDITIONER IN OF&SEASONS
To l&&ate each part 6f the compressor during the off-seasons, operate the air condiioner for
afewminutestwoorthreetimesamonth.
Page 29
LOCKING CAP
A locking cap is available as an optional fuel tank &p or hydraulic tank cap. Open and dose
f
locking caps as follows:
1. Toopenthecap I
1) Insert the key into the cap.
Q5izP
6
* lnsertthekeyasfarasitwillgo.Ithe
.I i
key is turned before it is inserted all the
way, it may break.
I “2/: d’ Opn
2) Turn the key counterclockwiseand bring
--I;’ lao’
the rotor groove in line with the aligning

markonthecap.Tumthecapslowly
until a Wcking” sound is made. This
releasasthelockandallowsthecapto ,
be opened.
2. Tolockthecap
Aligningrtwk
1) Turn the cap into place.
2) Tum the key counterclockwiseand take
thakeyout.
* when the cap is locked (against van- shwldrr
dalism), it rotates freely. I
lhefueltankfillerportisequippedwithalock.
* Usethestartingkeytoopenanddosethecap.
. open and close locking cap, as follows:

0
Toopen~cap I
1. lnsertthekeyintothecap.
* insert the key as far as it will go. If the key
is turned before it $ inserted all the way, it
may break.
Page 30
2. Turn the key dockwise, align the match

markonthecapwiththerotorgroove,then
remove the cap.
. Tolockthecap
1. Tumthecapintoplace.
2. Turn the key counterdockwise and take the K ..
key out. shouldor
HANDLING OF BAlTERY
PRECAUYONS FOR CHARGING BATIERY
1. Wore charging, d&conn& the cable from the negative (-) terminal of the battery.
Othewise; an unusually hiih voltage will damage the alternator.
2 While charging the battery, remove all battery plugs for satisfactoryventilation.
To avoid gas explosions, do not bring fire or sperks near the battery.
3. lf the electrolytetemperature exceeds 45°C. stop charging for a while:
4. Turn off the charger as soon as the battery is charged.
Overcharging the battery may cause the following:
1) Overheating the battery.
2) Decreasing the quantity of electrolyte.
3) Damaging the electrode plate.
5. lf the elecWyW gets on your skin or clothes, immediatelywash with plenty of dean water.
6. Do not mix up cables (posiie (+) to negative (-) or negative (-) to positive (+)), as it will
damage the alternator.
7. When inspecting or servicing a battery, be sure to stop the engine and turn the starting
switch key to “OFF” position.
8. When performingany service to battery besides checking the electrolyte level or measuring
the speci6c gravity, d&connect cables from the battery.
REMOVAL AND INSTALLATION OF BATIERY
When removing battery, first disconnect the cable from the ground (normally, from the
negative (-) tetinal). ff a tool touches a cable connecting the positive terminal and the
chassis, there is danger of sparks being emitted.
When installingbattery, the ground cable should be connected to the ground terminal as the
last step.
The batteries are mounted on both side of the machine. The groundktg cable is connected
to the left side battery.
SAFETY AND OPERATION SECTION3
P8ge 31
STARTING ENGINE WITH A BOOSTER CABLE f
When starting up the engine with a booster
cable, do as fokwx~ . A
dl
1. Beforeconnectingthe‘boostercable: 1
8
1) SizeofbobstercabIeanddipshoukJbe
suiweforthebattetysize.
2) chedccablesanddipsforbreaks,cor- lknory for
roded surfaces, etc.
3) Make sure cables and dips are firmly Engina blodr to b starad -
4)
5)
2. Connect the booster cables in the following manner.

1) Connedonedipof.booster~Atothepositive(+)terminaioftheenginetobe
stara.
2) Connect the other dip to the positive (+) terminal to the engine whii is running.
3) ConnectonedipofboostercaMeBtothenegative(-)terminalaftheenginewhichis
running.
4) ConnecttheotlwrdtptotheengineModctobestarted.
* Make sure the dips are firrntyconnected to battery terminals. Then, start the engine.
WARNING! When connecting the cables, never contact the positive (+) and
negathre (-) termlnab.
A WARNING! Make sure that the booster cable connections are correct. Connect
the booster cable to the engine block as far as possible from the battery.
3. Startiq engine
1) Tumthe~switchtoSTARTpositionandstartuptheeng~.
2) Iftheenginedoesn’tstartatfrst,tryagainafter2minuteswso.
Page 32
Aftertheenginehas!stamd,theboostercaMes
shouid be discmnected in the reverse order in
which they were connected.
1. oisconnectingtheboostercabl8s
1) DiithedipofboostercabieB
fromtheengineblockwhiiwasstatted.
. -
2) &cowwct the other dip from the nega-
tive (-) terminal of the running engine.
31 Disawwt the dip of booster cable A from the positive (+) terminal of the running
engine.
4) Disconne~ the other dip from the positive (+) terminal of the engine which was started.
TRANSPORTATION
When transporting the machine, observe the various road rules, road transportation
vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain a special
platfofm for loading and unloading the machine. When it is unavoidably n- rytouse
a gangplank, however, at the very least observe the following for the Sake of safety.
1.
If the gangplank sags appreciably, reinforce it with blocks, etc.
* 2 Determine the direction of the gangplank, then slowly load or unload the machine.
* When transmission cut-off switch is put in OFF, the I&t brake pedal and acxxWator pedal
areoperaWatthesametirn+
A WARNING! Remove the mud from the undercarriage to prevent the machine
from slipping to the slde on slopes.
WARNING! Do not on any account change the dikctio~ of the machine while
it is on the gangplank. To change the direction of the machine, first take it down
A from the gangplank.
3.
4.
5.
6.
A WARNING! when loading fhe machine, park the frailer on a fiat, firm roadbed.
Keep a fairly long distance between the road shoulder and fhe machine. .
STORAGE
BEFORE STORAGE
To place the machine in storage for an extended period of time, the following measures must
be taken to insure that it can be returned to operation with minimum of service.
In case it is indispensable to leave it outdoors, lay wood plates on the ground, and park the
m8chineonthewoodplatesandwveritwithcanvasetc.
Completely fill fuel tank, lubricate end change oil before storage.
Apply a thin coat of grease to metal surface (hydraulic piston rods and splined shaft).
As to better&, remove the terminals and cover them, or remove them from the machii end
store separately.
When the ambient temperature is anticipated to drop below 0°C. always add antifreeze in
the cooling water.
Set C+I control lever to neutral or hold position, lock them and apply the parking brake.
Page 34
DURING STORAGE
l Operate the engine and move the machine for a short distance once a month so the new oil
film will be coated over movable parts and component surfaces.
l Before opeiating the work equipment, wipe off the grease on the hydraulic piston rod.
A
WARNING! If it is unavoidably necessary to carry out r&preventive operation
,while the machine is indoors, open up doors and windows to improve
ventilation and prevent the gas poisoning.
AFTER STORAGE
After storage (when it is,kept without cover or the rust-preventiveoperation once a month is not
made), you shall apply the followingtreatment before operation.
Mpe off the grease on the hydraulic piston rod-
Loosen the drain plugs on oil pan and other cases and drain mixed water.
Completely fill fuel tank, lubricate and add oil.
After the engine is started, operate it until it is warmed up completely.
You should request your distributorfor followingservice.
Remove the cylinder head cover and lubricate sufficiently valves and rocker arms. And
inspect the valve operation.
‘Page 35
COOLANT AND LUBRICANTS’
Performance 3c
Page 36
MEMORANDA
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-6112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 9704186
FOR INTERNAL USE ONLY - No. PMR
B NAME OF COMPANY: LOCATION:
: PHONE NO:
; DEPARTMENT: DATE:
i NAME:
AANUAL NAME:
AANUAL NO:
AACHINE MODEL:
i/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
ittach photo or sketch.

f more space is needed, use another sheet.
FOR INTERNAL USE ONLY

:ORRECTIVE ACTION:
PFMRI 081696

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Operation & Maintenance SEAMU424KD10

SERIAL NUMBERS wA420-1 :~5001 and UP

DISTRIBUTOR’S NAME 8 TELEPHONi NO.

PERIODIC SERVICE ITEM DATE SERVICE METER

CONSUMABLE PARTS PARTS NO. PARTS NAME QTY.

Please read this manual carefully BEFORE operating the machine.

Materials and specifications are subject to change without notice.

BREAKING IN YOUR NEW MACHINE

0 Avoid operation with heavy loads or at high speeds.

l Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning’

1) Replacement of transmission oil filter element.

* Hours of operation are indicated by the service meter.

GENERAL LOCATIONS AND $PEClFlCATlONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTRUMENTS AND COtiROLS . . ..................................

KICKDOWN SWITCH ...................................... ;;

OPERATlNGYOUR MACHINE .................................... 37

ADJUSTMENT OF WORK EQUIPMENT 46

COLD WEATHER OPERATION .................................... 54

PERIODIC MAlNTENANCE ... . .................... ) ............... 2

BLEEDING AIR FROM ClRCUlf ......................................

PERIODICAL PART REPLACEMENT .................................. 4

OIL FILLER AND LEVEL GAUGE POSITIONS ............................ 9

CHECK BEFORE STARTING ....................................... 10

EVERY 50 HOURS SERVICE ....................................... 10

EVERY100 HOURS SERVICE ...................................... 11

INITIAL250 HOURS SERVICE.. .................................... 12

EVERY 250 HOURS SERVICE ...................................... 13

EVERY 500 HOURS SERVICE ......................... . ............ 19

EVERY loo0 HOURS SERVICE ...................................... 23

EVERY2000 HOURSSERVICE ..................................... 33

WHEN REQUIRED .............................................. 45

TROUBLE SHOOl-lNG GUIDE ...................................... 56

SERVICE METER ............................................. 60

MACHINE AND ENG!NE SERIAL NUMBERS ........................... 69.

FUEL, COOLANT AND LUBRICANTS ................................ 61

SAFETY AND OPERATION

SAFElY HINTS. . . g, .._.. .................................... 2

OPERATING THE CAB HEATER ................................... 24

OPERATlNG THE AIR CONDITIONER-IF EQUIPPED ...................... 26

LOCKING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _............... 29

HANDLING OF BATTERY ............... 30

STORAGE ...... .._........_

WA42O-1LC With Cab and POPS Canopy

1. lilt lever 4. Turn signal lamp 7. Lift cylinder

Bucket capacities - Heapad

Operating weight . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . 43 980 lb (19 949 kg)

Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KDC614TA diesel engine

Flywheel horsepower - at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . 224 HP (167 kW)

NOTE: Specifications are subject to change without notice.

INSTRUMENTS AND CONTROLS

CHECK MONITOR GROUP

lf there is any abnormalii, the appropriate monitor lamp will flash.

CAUTION MONITOR GROUP

CAUTION MONITOR GROUP

CHECK MONITOR GROUP

Engine Oil Level Monitor

This monitor indicates a low oil level in the I

Coolant Level Monitor

This monitor indicates a low radiator coolant