PART No. OW-619BE(H) Operator’s Manual LX7O0- 7 LX8O0- 7 Wheel Loader Serial No. LX70-7 02101 and up LX80-7 01101 and up H ITACHIFOREWORD This Manual was written to provide the owner/operator with information about the safe operation and maintenance of your wheel loaders. Read this manual thoroughly and become completely familiar with the loader before using it. If you have any questions, see your dealer. Due to improvements in design, it is possible that the description contained herein may not compietely apply to the loader delivered to you. Before operating the loader, be sure to read all of the decals on the loader which give advice about safe care and operation of the loader. Damaged or missing decals should be replaced with new ones. This Manual must be kept with the loader. Safe operation means the operator must be qualified. A qualified operator must have training and possess any required licenses to operate this loader. If the loader is to be leased, loaned or sold to anyone, this manual must be with the loader. Do not try to modify your loader. If any failure or accident occurs due to modification of the loader, without prior written consent by us, you might void your warranty. This Manual uses the following safety alert symbols. When you see those symbols in the text, follow the safety message to avoid personal injury or death. FES Failure to follow the instructions in the message will cause a serious accident or death. | A WARNING | Failure to follow the instructions in the message might cause a serious accident or death. A CAUTION | Failure to follow the instructions in the message may cause personal injury or damage to the | loader. |CONTENTS SAFETY INSTRUCTIONS . DECALS (MACHINE SIGNS) 6 QUALIFIED OPERATOR AND REGULATIONS ecco 10 SAFETY COMPONENTS ... " OPERATION PICTORIAL NOMENCLATURE fone 14: INSTRUMENTS AND CONTROLS cso 16 CAB, HEATER, AIR CONDITIONER, AND RADIO TRAVELING SAFE TRAVELING 42 BREAK-IN PERIOD 47 BEFORE STARTING THE ENGINE..... 48 STARTING THE ENGINE 49 AFTER STARTING THE ENGINE ... 49 STARTING AND STOPPING THE LOADER, 50 TRANSPORTING THE LOADER veins 52 TOWING worn 54 MEASURES TO BE TAKEN IN AN EMERGENCY .. 55 HANDLING IN COLD WEATHER vascsncnee 58 HANDLING TIRES 59 HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) LOADING OPERATION .. SAFE LOADING OPERATION... 68 BEFORE LOADING... 73 DIGGING 74 GROUND DIGGING (DIGGING ON A LEVEL SURFACE) 78 DUMPING .. 7 76 LEVELING worsen Tr BULLDOZING .... — 78 SNOW REMOVAL..... 78 HOISTING THE LOADER .ivcnssssnnnnnnnnee 78 ADJUSTING BUCKET AUTO- (VER a 79 STORING THE LOADER DAILY STORING LONG-TERM STORAGE OPERATING THE LOADER AFTER LONG-TERM STORAGE worn 83 MAINTENANCE SAFE SERVICING AND MAINTENANCE... 86 LOCATIONS OF FILLER PORTS. 90 GREASE FITTING LOCATIONS a1 ENGINE COMPARTMENT 92 PERIODIC INSPECTION. PERIODIC INSPECTION LIST 04 BEFORE STARTING (EVERY DAY) CHECKS: 96 50 HOURS CHECKS 105 100 HOURS CHECKS — 108 250 HOURS CHECKS wnneesennnneeiees 109 500 HOURS CHECKS ......sesesesesnnnnnnsene 118 1000 HOURS CHECKS.... 116 2000 HOURS CHECKS winsnnnninnnnnnnns 119 4000 HOURS CHECKS... 121 MAINTENANCE OF AIR CONDITIONER... 122 MAINTENANCE OF BATTERY 125 MAINTENANCE OF COOLANT 127 MAINTENANCE OF TIRES AND WHEELS orn 128 PERIODICAL REPLACEMENT OF SAFETY PARTS. 129 LIST OF LUBRICANTS... senoneee 180) OIL CAPACITY .. ial TROUBLESHOOTING GUIDE or INFORMATION. SPECIFICATIONS. eneee 186 NAME PLATE & SERIAL NUMBER 138 ENGINE SERIAL NUMBER 138 WRITE DOWN YOUR LOADER DATA HERE 139 ISUZU ENGINE WARRANTY STATEMENT... 2140 MAINTENANCE LOG .esccsnnnnsninnnnen 148 NOlEG = oe 150)SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS This safety alert symbol is used for important safety messages. When you see this symbol in this manual, follow the precautions given in safely message to avoid personal injury or death It is important to abide by safety rules for your fellow workers as well as yourself The SAE J153 guidelines contain safety instructons for the operators of off-road working ‘equipment and agricultural tractors under the title of “OPERATOR PRECAUTIONS.” The portion of those safety instructions which apply to the operation of wheel loaders is presented on the pages that follow. Read them carefully and follow the instructions. (source: SAE J153. Revised, May 1987). Reprinted with permission from SAE J153 © | 1987 Society of Automotive Engineers, Inc. Basic safety instructions are described in pages that foliow. Read them carefully and follow the instructions. This manual also covers “SAFE TRAVELING,” “SAFE LOADING OPERATION," and "SAFE SERVICE AND MAINTENANCE”. Read them carefully, too, and become familiar with your loader's traveling, loading, and servicing. Safety is your business and an element of profi. K ‘The marking (\) on the pictures means actions that are prohibited or dangerous. The pictures have been drawn based on our medium-sized wheel loaders.SAFETY INSTRUCTIONS. r ‘The numbers naw to the safty rules do not indicate the priority ofthe rule's importance or the dagres of risk associated with the situation 3. PERSONNEL PRECAUTIONS: 3.4 32 3.3 34 aa 42 43 44 ‘Avoid loose fitting uncovered long hair, personal articles, Know and use the protective equipment that is to be worn when operating this loader. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respira- tors and ear’ protection are examples of types of equipment that may be required. clothing, loose or jewelry and loose HARD HAT. PROTECTIVE GLASSES. EAR PROTECTION PROTECTIVE SHOES. Do not rush. Walk, do not run. Know and use the hand signals required for particular jobs and know who has the responsibility for signaling, OPERATOR - GENERAL PRE- CAUTIONS: It is the responsibility of the operator to read and understand the Operators Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators. Wear the seat belt to maximize the protection cepability of a ROPS (Roll Over Protective Structure) canopy when the machine is so equipped Do not permit riders on the machine if there is no manufacture's designated place for a rider. Make sure that all protective guards, canopies, doors, etc. are in place and secure. 4.5 Remove all loose objects stored in the machine. Remove all objects which do not belong in or on the machine and its equipment. 5. MOUNTING AND DISMOUNTING PRECAUTIONS: Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean. Face the access system when climbing up and down. 54 _ NO . 5.2. Do not jump off the machine, 5.3 Do not dismount while the machine is in motion,SAFETY INSTRUCTIONS. 61 62 63 64 65 66 STARTING AND STOPPING PRECAUTIONS: Walk around the machine and war all personnel who may be servicing the machine or are in the machine's path prior to starting. Do not start until all personnel are clearly away from the machine. Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, and disen- gage the PTO before starting the machine. ‘Adjust, secure and latch the seat and fasten the seat belt (if provided) before starting the machine. Start and operate the machine only from the ‘operator's station. Do not bypass the machine's neutral-start system. The neutral-start system must be repaired if it malfunctions. Use jumper cables only in the recom- mended manner. improper use can result in battery explosion or unexpected machine motion. Do not operate the engine in an enclosed area without adequate ventilation. 68 Park the machine on level ground whenever possible and apply the parking device. On grades, park the machine with the wheels or track’securely blocked. 6.9 Before leaving the operator's station, place the transmission in the park position as specified by the manufacturer, lower the equipment to the ground or ‘put in the locked position, disengage the PTO, set the parking device and shut off the engine. 6.10 Remove the starter key or disconnect switch key when leaving the machine parked or unattended. 7. OPERATING PRECAUTIONS: 7.4 Check brakes, steering and other machine control devices in accordance with the manufacturer's instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to Insure proper operation. If any malfunctions are found, follow the shutdown procedure cf paragraph 6.9, and report the malfunction for resolution,‘SAFETY INSTRUCTIONS 7.2 If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine's motion as quickly’ as possible, follow the shutdown procedure of paragraph 6.9, and keep machine securely parked until the malfunc- tion is corrected or the machine can be safely towed. 7.3 Understand the machine’s Ih keep the machine under control. 7.4 Drive the machine with care and at speeds compatible with conditions. Use extra caution when operating over rough ground, ‘on slopes, and when turning the machine. 7.5. Note and avoid all hazards and obstructions ‘such as ditches, underground fines, trees, dliffs, overhead ‘electrical wires or areas where there is danger of a slide. tations and 7.8 Carry loads in recommended positions for maximum stability. 7.7 Never lft loads in excess of capacity. 7.8 Use the recommended machine ballast and counterweighting. 7.9 Know and understand the job site traffic flow patterns and obey flagmen, road signs and signals. 7.10 Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating, 7.11 Select a gear that will prevent excessive speed when going downhill. Do not coast downhill. 7.12 When foading a machine, know and use the signaling devices required on the machine. Provide an escort for loading where required. 7.13 On machines with independently operated wheel brakes, lock the brake pedals together when roading to provide equalized brake application 7.14 Use the recommended transport devices when roading the machine. 7.15 Use the approved drawbar and/or attach- ment point when using the machine for towing. If a cable or chain is used, keep People away from the tow line (see Paragraph 8.12), 8. MAINTENANCE PRECAUTIONS: 8.1 Do not attempt repairs unless trained. Refer to manuals and experienced repair person- nel for help. 8.2 Wear protective glasses and other required safety equipment when servicing or repairing the machine. 8.3 Wear gloves to protect hands when handling cables. 8.4 Disconnect the battery before working on the electrical system.SAFETY INSTRUCTIONS. 8.5 Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply’ the parking device, place the equipment in a safe Position, securely block the wheels and use extreme caution. machine or component that may fall before working on the machine or component. 8.6 Securely block the any Ox 8.7 To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges. 8.8 Never make — repairs on pressurized ‘components, fluid, gas or mechanical units until the pressure has been relieved according to the manufacturer's instructions. 8.9 Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps. Park the machine and let it ‘cool down before opening a pressurized compartment. 8.10 Release all pressure before working on systems which have an accumulator. Use a piace of cardboard or wood to check for pressurized leaks to prevent fluid from penetrating the skin. Repressurize accumu- lators with the proper gas according to manufacturer's recommendations. 8.11 When inflating tires, use a self-attaching inflation chuck with’ remote shut-off and stand clear of the tire. 8.12 When necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. if the towed machine cannot be braked, a towbar must be used or two towing’ machines must be used - one in front pulling and one in the rear to retard. Avoid towing over long distances (see paragraph 7.15) 8.13 Observe proper maintenance procedures. 8.14 Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. 8.15 Keep the brakes and steering systems in good operating condition. 8.16 Replace all missing, illegible or damaged safety signs. Keep all safety signs clean. 9, FUEL HANDLING PRECAUTIONS: 9.1 Do not smoke or permit open flames while fueling or near fueling operations. 9.2. Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. 8.3 Maintain control of the fuel filler nozzle when filling the tank. 8.4 Do not fill the fuel tank to capacity. Allow room for expansion 8.5 Clean up spilled fuel immediately 8.6 Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturer's approved cap. Use of a non-approved cap. without proper venting may result in pressurization of the tank. 9.7 Never use fuel for cleaning purposes. 9.8 Use the correct fuel grade for the operating ‘season. — END —DECALS (MACHINE SIGNS) DECALS (MACHINE SIGNS) A WARNING The operator must read the warnings on the loader and in this manual before trying to operate the loader. There are three kinds of decals attached to the loader: ones for operation of the loader, ones for ‘maintenance of the loader; and ones for safety. Follow the instructions on the decals. Damaged or missing decals must be replaced with new ones. All decals are available from your authorized dealer.DECALS (MACHINE SIGNS) © Hydraulic Ol! Tank HYDRAULIC OIL | ‘on rep me 0 ene Hf brave ature Can cause injury on hans or face @ Engine Hood(near_ muffler tail pipe), Side Panel (right/left) avoid burns from is, | Pt oas: Do not touch, until coo! 7 ae [ Ye Stay clear of fan when eine” | | To avsisiniy ke Trea an beste i ty on @ Inside of Battery Box Cover (righteft) 2, # ., [Sook lanes, sack. 7 aterts See Operation & Maintenance Mana for emergeney starting and eharing| instroctiens Keep a metal away trom termnas| {ota Shorts fame Setstzacreetie slenisac? ines ec ee, @ Hydraulic Oil Tank @ Left Inside of Engine Room Uso ony ot section Oparators fi i same) | Do not use non-mineral Brake ol Hot coolant will cause bur SS} |e nt open ra trict ar presse has ead And se heavy ra anytime 2ap is emved soa © Grill Support (rightiett), Front Fender (right/left) Slipping oft tre can cause savere inuury sr deatn end can olace You In position fo berun over By 8 moving loader De not climb or got on ties @ Fill Port of Fuel Tank FUEL @Litting Lug Mounting Area (4 points) Lift nere fo avord machine falling oversor causing otherDECALS (MACHINE SIGNS) @ Left Side of Rear Frame CRADLE | CRADLE || (FRONT) | (REAR) @ Left Side of Rear Frame A CAUTION @ Left Side of Seat Mount (_@ WARNING | ‘Never touch engine and hydraulic equipments. Those components have been adjusted betore factory shipment. @ Top of Valve Control Box Fite er Pollo ese RASS [fare str Stig et ta re ara we ees on ssw a Ie acs eae ane ETB etn a sad erin may Sere ay sates rows Seals nodal esol a Soe om Sen tne re pets er wt te a yi dace me mn ee ® Left Side of Valve Control Box AADANGER To avoid! inuy securely. brace] fit arm votore assembly ot corning. | @ Left Side of Valve Control Box CONTROL LEVER | (on) * © mae | {Ae tor | (OFF) RELEASE |[-a_omeen | lotenese ay eou damageDECALS (MACHINE SIGNS) @ Starter Motor ® Top of Battery (R & L) @ Top of Battery (R & L) [@repeeyron maces ara macys | |@essensnnazoe | |@ tee nay rom cree. | ADs sw cnt act | \@ rose nson cy | Aira ce ee @ Left Side of Front @ Left Side of Front Frame 1 SEVERE CRUSHING Aa OBESE rsd ry teeth ron scare yn ein [Lowder wit ot stage with [esa neste, "YOU MUST FOLLOW THESE RULES TO AVOD SEVERE INGURY OR DEATH TO YOURSELF OR OTHERS ye mtn te ‘+ Repair allowed only by trained authorized mechanics. es st + Koow Operation & Maintenance Manual blore starting prety cetint es Fepalrs or namtenance. + Use boom lack, safety lnk, and parking brake for all ea teaming ee repairs body, eothing, and tools away from hot or noving parts and slecirical components. * Keep engine congartnent clean nao erease, ass, of sof ibe famable mateies y eaammmrencs sane tush coe pret polsoous extaist te avoid or cap with eagine hot. Use cardboard to check for hyarauic leaks, Wear ‘ogales and heavy goes. is Nea tts « Replace all steering system hoses every two H+ Simrem wets @ Left Side of Front Frame BUCKET | STEERING |STEERING, CYL. | (RH) | (LH)QUALIFIED OPERATOR AND REGULATIONS QUALIFIED OPERATOR AND REGULATIONS QUALIFIED OPERATOR MUST: ‘+ When the operation of wheel loaders is regulated by law in your country or state, be sure to get necessary license and permit and carry them. ‘+ Avoid using diugs or alcoholic drinks which impair his alertness or coordination while working, ‘+ Contact tne dealer it he has any questions about operation of the loader. + Get operator training before operating the loader. The operator training must consist of a demonstration and verbal instruction. ‘© Start in an area without bystanders if he is a new operator. © Wear tight fitting clothing, + Know the rated capacity and weight of the loader and the characteristics of the load he is to handle, such as its specific gravity and hazardousness. Only authorized personnel shall operate a wheel loader. REGULATIONS The operator must check: ‘+ Regulations on the use of a wheel loader at the work area, © Noise-contro! regulations. © Exhaust-control regulations. * Regulations on work near utility supply line. The operator shall observe the rules and regulations in using the wheel loader. 10SAFETY COMPONENTS SAFETY COMPONENTS Safety components help protect operators and service personnel from danger during work. (For the hom, sideview mirror, and safety link, see “INSTRUMENTS AND CONTROLS.") A WARNING Never try to remove the safety components mounted on the loader without the | manufacturer's prior permission. Failure to do so may cause a serious accident or death. ROPS CANOPY AND ROPS CAB (Optional) The ROPS (Roll Over Protective Structure) canopy and ROPS cab protect the operator from severe Injury or death in the event of a tip-over. A CAUTION | The ROPS cannot be installed on loaders whose weight (including loader, ROPS and operator) exceeds 10 tons. Use the ROPS cab instead. For more information, contact your authorized dealer. SEAT BELT The seat belt protects the operator from being thrown out of the operator's seat in the event of the loader turning over. It is equipped on the ROPS canopy and ROPS cab. The seat belt functions as a unit with a ROPS canopy or ROPS cab. If you find either of them defective or damaged, replace it with a new one. | & WARNING if the loader turns over, replace its ROPS canooy or ROPS cab and seat belt new ones. BACK-UP BUZZER (Standard) ‘The back-up buzzer sounds when the shift lever is placed into reverse gear. It is equipped to let other workmen and bystanders know you are backing up. If the work area is noisy or there is any person who is hard of hearing in the work area, It is advisable to install a beacon light for visual warning, EMERGENCY STEERING (Optional) I the steering (main) pump fails to operate properly, this device activates the emergency steering pump to allow the operator to steer the loader. If the emergency steering device operates, move to a level, out-ot-traffic area immediately and repair the loader. NEUTRAL-START SAFETY SYSTEM (Standard) The engine won't start unless the shift lever is in neutral. This prevents the loader from moving abruptly when the starter switch is turned on. "SAFETY COMPONENTS: NEUTRAL LOCK (Standard) The neutral lock is a safety device which locks the F/R lever in neutral. This safety device helps prevent accidental movement of the shift lever or vandalism. Before leaving the loader, make sure to engage the neutral lock FAN GUARD (Standard) This prevents the hand or fingers from becoming entangled in the radiator fan. i A WARNING Do not inspect the radiator fan with the engine running. 4 WARNING if the above satety components are provided as standard equipment, do not remove them without the manufacturer's prior permission. If you want to install any of the optional safety equipment given above, contact your authorized dealer. In addition to the safety components shown above, the following safety equipment is optionally available from us: ‘Sun visor (for loaders with cab) (standard) Fire extinguisher Belly guard (protection of the bottom of the loader) Tire chain ‘Smoke pot 12OPERATION OPERATION PICTORIAL NOMENCLATURE INSTRUMENTS AND CONTROLS: CAB, HEATER, AIR CONDITIONER, AND RADIO. This Manual uses the following safety alert symbols. When you see those symbols in the toxt, follow the salety message to avoid personal injury or death, PNET Failure to follow the instructions in the message will cause a serious accident or death. A WARNING Failure to follow the instructions in the message might cause a serious accident or deatt A CAUTION Failure to follow the instructions in the message may | cause personal injury or damage to the loader. 14 16 33 13PICTORIAL NOMENCLATURE PICTORIAL NOMENCLATURE AWNING CANOPY (Standard equipment for LX70.) Note: The sketcn shows the LX/Us, SIDE PANEL (see page 30) REAR WORK LIGHT (see page 21) SIDEVIEW MIRROR, RIGHT (see page 31) TOW PIN (see page 30) REAR COMBINATION LAMP, RIGHT (TURN SIGNAL, TAIL, BRAKE, BACK-UP) = BATTERY BOX, RIGHT a se pan (see page 23) HEAD LIGHT, LEFT (see page 21) BUCKET CYLINDER CAB (OPTION) BELL CRANK BUCKET (see page 31) LADDER (see page 31 REVERSIBLE Sole CUTTING EDGE | SAFETY LINK (see page 30) BOOM, LEFT 4PICTORIAL NOMENCLATURE INSIDE THE LOADER HST MOTOR HST PUMP ENGINE FRONT AXLE \ PROPELLER SHAFT PROPELLER SHAFT rransuission ———— | |_____ pare saan 15INSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS HAZARD LAMP SWITCH (see page 21) NEUTRAL LOCK (see page 22) WORK LIGHT SWITCH (see page 21) — F/R LEVER (see page 22) ‘SPEED RANGE CONTROL — KNOB (see page 22) METERS (see page 17) & MONITORS (see page 18) HORN BUTTON (see page 23) TURN SIGNAL LEVER (see page 23) PARKING BRAKE SWITCH (see page 22) LIGHTING SWITCH (see page 21) STARTER SWITCH (see page 20) — LOAD HANDLING LEVER (soo page 23) Quick-SHIFT ‘SWITCH (Bui in) (620 page 23) LOAD HANDLING LEVER LOCK (see page 29) ~ ACCELERATOR PEDAL (see page 23) BRAKE PEDAL (see page 24) 16INSTRUMENTS AND CONTROLS FUEL GAUGE | SPEEDOMETER HOUR METER METERS GJ cootant Temp This gauge indicates the temperature engine coolant {A caution | When the pointer indicates “H” mark (red | area), it means the engine is overheated. Stop the operation, let the engine run at low rpm and wait for it to cool down. { Bi Fue! This gauge indicates the level of the fuel in the ful tank. “F means that the tank 1s “ull” means the tank is “emply. I the pointor comes close to the “E" mark, add {vel ao. soon” a8 possible. km/h: Speedometer This indicates the traveling speed of the loader. Hy Hour Meter The hour meter registers tolal time the loader has operated Note thatthe right-most column indicates figures in i/10 hour unt. For example, ithe figure 8 is displayed in this column, it means. 8/10. x 60 (minutes) = 48 minutes. The second column from the right most Indicates. working time. of the engine in hours Use the hours recorded for planned mainie- hance. When you call the dealer about any trouble, let him know the reading ‘on the hour meter for quicker response. 17INSTRUMENTS AND CONTROLS ENGINE OIL. PRESSURE BATTERY VOLTAGE ¢ / A \ —\ crmeon tee MONITORS The fed monitor lights indicate that the corresponding units or systems are not working properly or need to be serviced; the green (blue) monitor lights indicate that the corresponding units or systems are working properly. When the starter switch is tumed to the ON position, the three monitor lights (engine oil pressure, battery charge, brake oil level) come on. If any light fails to come on, it suggests that the bulb is burned out, When the starter switch is turned further to the START position, the engine will start and the three monitor lights go out in a few seconds. If any monitor light stays lit, check the corresponding unit or system. A CAUTION if any monitor jight comes on during operation, stop the operation and check the cause immediately -&> B/G O11 Light comes on when the engine lubrication oil pressure drops below the specified value. It also Gomes on when the engine il filter becomes clogged. £3 Charge Light comes on when the condition of battery charge is insufficient. 18INSTRUMENTS AND CONTROLS HIGH-BEAM INDICATING LIGHT PARKING BRAKE ENGINE PREHEXTING © Parking Light comes on when the parking brake is applied ® GLOW (engine preheating) Light comes on when the engine is preheated. <] [> Turn Signal indicating Light When the turn signal lever is operated to a turning position, the corresponding turn signal and monitor light () come on &D High-beam Indicating Light Blue light comes or when the head lights are in the high-beam mode. Work Light Green light comes on when the work light is turned ON. SO nicear The green light comes on when the speed range contfol knob of the F/R lever is placed in the Hi position WORK LiGHT INDICATING LIGHT HIGEAR INDICAT. ING LIGHT, EMERGENCY STEERING (OPTIONAL) 4S) Brake Oil Light comes on when the brake oil level drops below the specified value. ® Ema. steer (Optional) Light comes on when the emergency steering pump Is ut in operation, 4 WARNING It the emergency steering system starts operating, immediately move to a level, out- of-traffic area and repair the trouble. 19INSTRUMENTS AND CONTROLS STARTER SWITCH A WARNING Before trying to start the engine, make sure that the F/R lever is in neutral, parking brake is applied, and the load handling lever is locked. For details, see the section TRAVELING later in this manual. 4 CAUTION Do not run the starter for more than 10 seconds at a time. Wait until the starter motor and engine come to a complete stop or about 30 seconds before trying again, to protect the battery and starter motor. A WARNING Do not turn off the starter switch during traveling; otherwise the electrical system will be damaged or the loader might malfunction. The starter switch starts and stops the engine. Key insertion, Draw-out position: OFF | Engine is OFF. Electric circuit is closed. Engine preheating positios Engine starts up. START | Switch automatically returns to ON position when hand is removed from key. Engine Preheating Use the ON position to preheat the engine quickly. It is not necessary to preheating the engine when the engine is hot or when the ambient temperature is higher than 0°C or 32°F. When the engine is dificult to start or when the ambient temperature is below 0°C or 92°F, tun the starter switch to the ON position, Usualy it takes about 8 seconds to preheat the engine. While the engine is being preheated, the monitor lamp @ stays on. When the lamp goes out, tum the starter switch to the START position to crank the engine. If the engine won't start, retum the starter switch to the OFF position. Wait about 30 seconds before preheating the engine again 20INSTRUMENTS AND CONTROLS LIGHTING SWITCH When the tum signal lever knob is turned, the lights turn on. 3045 | Width, tail, license number plate, and | monitor panel lamps come on WD |The head lights in addition to the above lights come on. OFF | All lights go out Dimmer Switch The head light high and low beams can be selected by operating the dimmer switch. The high beam is selected by lifting the tun signal lever, and the high beam monitor lamp comes on. Usually use the low beam. Use the high beam when there is no one or vehicle ahead of you. Hazard Lamp Switch Use the hazard lamps to give an alert to fellow workers around your loader. When the hazard lamp switch is pulled out, all the turn signal lamps start blinking, This switch is enabled regardless of the starter switch. Note that the battery will be exhausted if the hazard lamp switch is kept on for a long time with the starter switch OFF. WORK LIGHT SWITCH Pressing the “2” mark will tum the work lights ON. Press the GFF to tum them OFF. A CAUTION Do not turn the work lights on when traveling con public roads. Loaders with a cab have both front and rear work lights. Loe | a \ | SwiTeH [x ¥i RESERVOIR 35HANDLING CAB, HEATER, AIR CONDITIONER, AND RADIO. ROOM MIRROR A large room mirror is equipped inside the cab. ‘Adjust it to gain full rear view before starting the loader. ASHTRAY A WARNING Take due care to prevent fire hazards. An ashtray is equipped for a smoker's convenience. CIGARETTE LIGHTER A WARNING Do not touch the areas other than the knob. You could get you fingers burnt. ROOM MIRROR CIGARETTE, UicHTER Use to light cigarette. Push in the knob. When the lighter is hot enough to light a cigarette, it pops out. 36HANDLING CAB, HEATER, AIR CONDITIONER, AND RADIO HEATER SYSTEM CONFIGURATION Hot air is discharged from the positions indicated by large arrows. You can adjust the air volume and temperature by turning the heater switch, / \ \_ Sm swircn — = a i tow dstoowr Ot AIR CONDITIONING SYSTEM CONFIGU- RATION Discharge opening selector switch 3 8.0.0 up |© + Discharge openings are represented by symbols inpooR + The condenser and receiver are TIRPILTER located at the step section at the right side of the loader 37HANDLING CAB, HEATER, AIR CONDITIONER, AND RADIO AIR CONDITIONER SWITCH PANEL Air Conditioner Power Switch Tums on and off the air conditioner. Fan Switch The fan switch turns on and off the fan and controls the air volume in four stages (LO, », Hn). Temperature Control Switch Press the switch VENTILATION CONTROL SWITCH DISCHARGE OPENING ‘SELECTOR SWITCH [AIR CONDITIONER, | POWER SWITCH ones ‘TewpeRaTune Fan switch Use the 9 for cooling and for defrosting; «,g for Ce Tel heating, Ventilation Control Switch (&) for circu- lating indoor air; J for introducing outside air) When working in a dusty environment, tum the switch to “Introducing outside air’ mode to increase the pressure inside tho cab. This prevents the entrance of dust into the cab. Use this mode while the air conditioner is. being operated for a prolonged period of time. While the air conditioner is in operation, the pilot lamp of each switch shows the operating Status. COMBINATION AND PROCEDURE FOR OPERATING AIR CONDITIONING SWITCHES AND CONTROLS ‘Sw — power-on | Discharge open-| temp. ‘venti. control Operaion | ow rosintor | ew fe ‘aia MI ow | BF] a enotog . . : ; yey ceaved ceses somal | tO-HI wn | Ww ‘tng eng ehumiasvent cosrod cored proseure to-HI on | Seng erg | od ‘ap rn oF won baarg _| sel . Goned desired oral o-H OFF ) os a OFF or = ceaved detroster 4 on A ‘sewing a Notes: » Warm up the engine sufficiently prior to operating the fan switch. It Is good practice to ventilate the driver's room i cooling. + You will get better cooling and heating effect with the ventilation contro! It is however recommended to ventilate the driver's room used for a prolonged time. air circulation position. sometimes if air conditionin its temperature is high before the indoor 38HANDLING CAB, HEATER, AIR CONDITIONER, AND RADIO. RADIO To receive broadcasting clearly, extend the antenna, @ Power On/Volume Switch Turn the switch clockwise until it clicks, to turn on the radio. Tum it clockwise further to turn up the sound volume. @ Tone Control Turn the switch clockwise to enhance the treble and counterclockwise to enhance the bass part. @ Display The time or radio frequencies are shown on the display. They can be switched over by pushing the CLK switch @ @ CLK Switch Push the switch to show the time on the display @. When the switcr is pushed again, the radio frequency appears on the display. @ AST Switch Every time the switsh is pushed, preset stations are called in turns. When the station you want is called up, push the switch once more to lock the station, If the switch is pressed and held for more than 2 seconds, the radio gets in the auto memory mode, The auto memory mode automatically calls up stations wnich can be clearly received one after another, programming them into preset memory (1 - 6). © Seek Switch © When the @ switch is pushed, the radio starts looking for a station which’ can be clearly received. When the radio finds a station which can be received clearly, it tunes into the station, ANTENNA 39HANDLING CAB, HEATER, AIR CONDITIONER, AND RADIO © Tuning Button Switches @x, @» = Press the @ switch to increase the frequency and the © switch to decrease it. Press and hold down either switch to increase or decrease the | frequeney contin sously. Changing the stations programmed to preset | switches: Change the stations programmed to the preset ‘switches in the following manner: Select the station you want to change from among the 6 preset switches. Use the tuning switch @ or ©) to select the frequency of the station you want Press and hold down the preset switch to which you want to program the station, for more than 2 seconds. The number of thé preset switch appears on the display and the station is programmed to the preset switch You can also use the same manner to program other stations to the rest of the preset switches. If the battery is removed from the loader, the contents in memory will be erased. You need to program the preset switches again. @ Preset Switches (1 ~ 6) Press one of the preset switches to tune into the station you want, from among the stations programmed in memory. @ Setting Time Turn the starter switch on. If the display shows a radio frequency, press the CLK to display the time. Press and hold down the CLK switch while pressing the @) switch to adjust the time in minutes, Press and hold down the CLK switch while pressing the @ switch to adjust the time in hours. 40TRAVELING Si TRAVELING = SAFE TRAVELING 42 BREAK-IN PERIOD. 47 BEFORE STARTING THE ENGINE 48 STARTING THE ENGINE, 49 AFTER STARTING THE ENGINE 49 STARTING AND STOPPING THE LOADER ....... 50 TRANSPORTING THE LOADER 52 TOWING 54 MEASURES TO BE TAKEN IN AN EMERGENCY 55 HANDLING IN GOLD WEATHER 58 HANDLING TIRES 58 HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) : 2 This Manual uses the following safety alert symbols. When you see those symbols in the text, follow the safety message fo avoid personal injury or death, Failure to follow the instructions in the message will cause a serious accident or death. A WARNING Failure to follow the instructions in the message | ht cause a serious accident or death. | A CAUTION Failure to follow the instructions in the message may cause personal injury or damage to the loader aSAFE TRAVELING SAFE TRAVELING Before trying to operate the loader, the operator must know safe operating procedures and prohibited uses; otherwise the operator might injure himself ‘or bystanders. The safety instructions given on the pages that follow are just @ few of the rules and regulations you are required to observe when operating the loader. If you have any questions about the safety instructions described herein, please feel free to ask your authorized dealer ‘marking (G) on he puree means acon that are prohibited or dangerous. The pictures have been drawn based on our medium-sized whee! loaders. Protect the planet!! Do not make “jerky” stars or acceleration; It wil result In bac fuel economy and discharge of harmful exhausts. ‘Operate the loader while keeping in mind that you shouldbe king to the environment. We are is committed to protecting the planet 42SAFE TRAVELING ‘The numbers next tothe safety rules do not indicate the priority ofthe rule's importance or the degree of risk associated wit the situation, Do not offer rides to others. Never mount or dismount a moving loader. Use the safety step(s) and safety grip when mounting and dismounting a stationary loader. Before starting the engine, make sure: + The parking brake is applied. * The direction control lever is in neutral +The load handling lever is in neutral with the lever lock Get familiar with the loader. Train with actual Operation. Do not try to start the engine or drive the loader unless you are properly seated; otherwise you might confuse the direction or the shift position of the hand and foot controls, thus leading to an accident. Except for the one-touch coupler lever, no control lever should be operated unless you are seated properly. 10, oh 12. 13, Park the loader on a level surface and apply the parking brake securely. Put the bucket on the ground flatly, block the wheels and remove the engine starter key. Do not park the loader where exhaust or hot components can contact flammable debris (leaves, paper, etc.) Don't use an open flame to check fluid level or leaks. Never smoke while handling fuel or lubricants, Do not use the loader in an atmosphere with explosive gases or where exhaust or hot components such as the engine and muffler can contact flammable materials (lubrican's, chemicals, leaves or waste paper). Do not lift the bucket or front attachment more than necessary. Keep the loading equipment at minimum ground clearance height during traveling, See page 50 for the basic traveling posture of the loader. It is dangerous to travel with the bucket igher than is appropriate regardless of whether loaded or not. Keep the bucket at clearance height. Always brake to a full stop before reversing the direction of travel. Never play games with the loader. Operate the controls smoothly. Don’t jerk the steering wheel. Avoid sudden stops, starts, or turns. minimum ground‘SAFE TRAVELING 14,Do not manipulate the bucket or front attachment too abruptly. There is danger of loads dropping or the loader upsetting, 15. When traveling through doorways, ensure that there is sufficient clearance for the loader, operator and load. 16. Slow down at night. Judging distances and the level of the ground is more difficult at night, Use head lights and clearance lights to let other workmen know you are coming. 17. Be aware of the weather and the ground condition. Slow down when it is raining, snowing or foggy, because vision is impaired. Avoid working on rough, soft or swampy grounds if possible. If unavoidable, check the ground condition in advance. 18. Go around obstacles on the road. They might upset the loader or damage assets or injure people around the loader. 19. When working with a loader with special ‘equipment which restricts your vision or handling a high load which obstructs your front vision, use extreme caution, especially when operating the load handling lever. It is ‘good practice to have a guide. 20. Stop and sound hom, if necessary, at corners and other locations where vision is restricted. It is good practice to have a guide. 21. Use extreme caution when traveling or making a turn in congested areas.SAFE TRAVELING 22. When ascending or descending grades, the loader should oe driven with the loader’s center of gravily uphill. That is, a loaded loader shall be driven with the load facing uphill and a unloaded loader shall be driven with the front attachment facing downhill Do not make sudden stops, 23. Stop the loader before descending grades. Use the engine brake. If the loader goes faster than you want, press the brake pedal from time to time. Do not keep the brake pedal pressed: otherwise poor or no braking effect might result. 24. Do not make tums on a gradient and drive the loader across a gradient. There is danger of the loader upsetting, 5) IY yy 5 x y : 26, Before starting the engine, make sure no one is under, on, or close to the loader. Let other workmen and bystanders know you are starting up by sounding the hom. Accidents often occur immediately after starting, 26. Look in the direction of, and keep a clear view of the path of travel. Honk when approaching pedestrians and bystanders. 27. Know the rated capacity of your loader and its attachment (if any). Observe all traffic regulations including authorized plant speed limit. Make the rules and procedures of operation known to all personnel involved. 28. Check work area in advance. Look for rough spots. Look for anything that might cause you to lose control, bog down or upset. Before driving over a bridge plate or dockboard, ensure that it is properly secured. The supervisor shall keep a record of the result of inspections. 10 rc‘SAFE TRAVELING 29. Any time you find that the loader is not functioning properly, move to an out-of-tratfic place, report the condition to the supervisor, and take necessary measures. Operation of the loader should be halted until the trouble is corrected. 30. Stay alert. Don't drink. (and keep yourself in good shape before and during work.) 31. When you leave the loader, remove the starter key and keep it; otherwise you wil take responsibility when’ an accident occurs due to someone operating the loader without permission.BREAK-IN PERIOD BREAK-IN PERIOD Our Wheel loaders have been subjected to careful inspection and thorough running-in before shipping. We, however, recommend that you operate the loader under light conditions for the first stage of operation. The loader should be operated especially for the first stage of operation (for initial 100 hours of operation) following the requirements giver below: * Be sure to perform preoperational checks EVERY DAY. ‘+ Always warm up the loader sufficiently before putting it to work irrespective of the seasons. * Do not run the engine at high rpm without a load, especially while the engine is cold. A. Avoid sudden stops, starts or turns. "7BEFORE STARTING THE ENGINE BEFORE STARTING THE ENGINE Inspect the general condition of the loader to check for: Damage or breakage + Foreign material + Signs of oll or water leakage WARNING | If itis difficult to check for leaks due to dirt, | clean the area you are trying to check. Start the engine and then shut it off to see if oll or water leakage occurs. Hydraulic pres- sure can drive hydraulic oil through the skin. Never check for leaks in the hydraulic system with your bare hands. Use a piece | [of cardboard. ‘Services required [See page Eaxueonuunnara ne) ‘Check any defects found by previous inspection - = Flomove dust, mud, oil and snow from the | og loader ‘Check all of the parts for oil leak 96 ‘Check hydraulic hoses and piping for damage = ‘Check engine oil for level and contaminati ‘Check fuel tank for level DANGER Check exhaust gases outdoors. If exhaust Check Is to be performed indoors, be sure to have good ventilation and wear a mask. Exhaust gases can kill. xe area Saari SeaT at waar | he seig wa ore an 8 | ag Check air cleaner dust indicator | 98 ann ee meen Sa Eee te| 90 eres Check brake oil supply tank for level “| 100 Somatea acme itera eal vor Ses Soares eran te ee jes ange rowan aera | Gok senor paul mean a8 | yaa ~ Cheat pang be tor pmaion and] op effect ‘Check steering wheal for play and operation | 103, ‘Check windshield washer licuid for level (loaders with operator's cab) ie (Check sideview mirrors and interior mirror (optionally available for loaders with Sperator's cas) for eamage and mounting | 102 Bole tor looseness, Check ROPS canopy, ROPS cab, seat belt {optionally avaliable for loaders with ROPS | 494 Canopy and ROPS cab) for damage and ‘mounting bolts for looseness. 48STARTING THE ENGINE STARTING THE ENGINE 4 PRE-STARTING CHECK ‘* Make sure no one is under, on or close to the loader * Clean up any water, grease or oil sticking to the floor, pedals, levers or operator's hands, * Make sure the F/R lever and load handling lever are in neutral and that the parking brake is applied. The engine won't start unless the FIR lever in neutral. STARTING ‘© Insert the key into the starter ewitch and turn it to the ON position. ‘+ Press the accelerator pedal lightly. + Tum the key fully clockwise to crank the engine. (Once the engine is started, remove your hand from the key immediately.) Do not engage the starter switch (starter motor) for more than 10 seconds. If the engine won't start in about 5 seconds, remove your hand from the key. Wait 30 seconds after engine stops completely, and try again. Do not hold the starter switch in the START position for over 10 seconds at a time; otherwise it will cause damage to the starter. + The engine may be hard to start when the ambient temperature is below 0°C (32°F). To help start a cold engine, tur the starter to the ON position to preheat the engine. The engine preheat monitor lamp @ turns on and stays on for about 8 seconds. When the monitor lamp goes out, turn the engine to START to crank the engine. If the engine won't start at the first try, return the starter switch to the OFF position and wait about 30 seconds before preheating the engine. AFTER STARTING THE ENGINE * Warm up the engine sufficiently, at least 5 minutes, regardless of the ambient tempera- ture. * Check the general condition of the loader and move the load handling lever to check to see if the load handling system operates properly. Check exhaust sound and color. Check the meters and warning lights. * Check for oil, fuel, or water leaks. A CAUTION With the engine running, do not turn the starter switch from the ON position; otherwise, the electrical parts will be damaged. 49STARTING AND STOPPING THE LOADER STARTING AND STOPPING THE LOADER STARTING GEARSHIFTING (SPEED)| Raise the booms and tilt back the bucket so that the loader gets ready for traveling, Press the brake pedal and release the parking brake. Shift the F/R lever in the forward position. pT ~ —_I Release the brake pedal while pressing the accelerator pedal slowly. Select your design speed range using the F/R. lever knob, [GEARSHIFTING (DIRECTION)| (Make sure no one Is around the loader.) + You can reverse the direction of travel without stopping the loader. Never try to reverse the direction of travel at a high speed; it is very dangerous. Holding the steering wheel knob turn the steering wheel in the direction you want to turn. A 2 | | A WARNING | |Do not make turns at high speeds; otherwise the loader might upset. Turn the steering wheel a little to turn | | slowly. \ ¥ A CAUTION When the steering wheel is turned fully in| either direction, the front and rear frames Swivel around the ‘center joint of the loader, Bo ‘not try to turn the steering wheo! farther: | otherwise the engine might stall or the Steering wheel unit might fail to operate | properly. 50STARTING AND STOPPING THE LOADER [STOPPING Release the accelerator pedal and press the brake pedal to bring the loader to stop. Do not use the parking brake to brake the loader except inan emergency PARKING | [Bis brane Alter making sure the loader comes to a stop, place the shift lever in neutral and press the parking brake ON switch Lower the bucket on the ground horizontally. It is advisable to park the loader on a level surface. Block the wheels. | A CAUTION ‘The engine with a turbocharger must be cooled down by letting it run at idle rpm for about 5 | minutes before shutting of | Let the engine run at low rpm for about 5 minutes to cool it down. On loaders equipped with a turbo-charger_ must be cooled down before shutting off, ‘Turn the starter twiteh OFF | Place the load handling lever in neutral and ‘engage the lever lock. Turn the starter switch to the OFF positior to shut off the engine. + Remove the key Remove the key and keep it secure. 51‘TRANSPORTING THE LOADER TRANSPORTING THE LOADER TRANSPORTING THE LOADER ON A TRAILER ACAUTION Securely lock the loader in place on the | truck to prevent it from moving with chains | | or straps and by blocking the wheels. When | transporting the loader over public roads, | | observe local traffic regulations relating to the overall length, width, height, and weight | | ef both the loader’and the truck CAUTIONS TO BE TAKEN WHEN LOADING AND UNLOADING THE LOADER It is advisable to ask a specialist to load and unload the loader onto and from the trailer. The operator may not be familiar with this kind of work. When using ramps Seting angle Set ramps with an angle of less than 15°, using the table as a rule of thumb, ee Bed height Ramp length 1000 mm (39 in)_| 3700 mm (146 in) 750 mm (80 in) | 2775 mm (109 in) ‘500 mm (20 in) | 1850 mm_ (73 in) | WARNING |The loader must be driven straight onto the ramps. Both front wheels (and or rear wheels) must be in contact with the ramps simultaneously. * Use ramps of sufficient length, width and strength '* Before loading or unloading the loader, make sure to apply the parking brake to the trailer truck and block the wheels. * Ramps must be spaced evenly from the center of the trailer's bed and securely locked to the trailer. The ramp surface must be clean and dry. + Loading and unloading must be carried out on a level surface. The right and left ramps must be the same height. + When loading the loader onto the truck, go up slowly in forward or reverse (according to the type of the bed), making sure the right and left wheels are properly aligned on the ramps. + If the loader is not aligned properly with the ramps, go down the tamps and start over again. + Use anti-skid ramps when you are going to work in the rain or the snow; otherwise the loader may skid and fall off the ramps causing a serious accident. When using a crane. AWARNING + Use a crane of sufficient capacity to hoist the weight of the loader (including the weight of an attachment, if so equipped.) ‘+ Lock the front and rear frames with the safety link. ‘Install optional 4 lifting lugs on the specified positions. Perform 4-point hoisting. Do not make 3-point or 2-point hoisting. + Consult your authorized dealer about the ;stallation of optional lifting lugs. ‘Lift the loader a little off the ground and | make sure the chains or ropes are properly secured to the lugs and the | loader is stabi 52‘TRANSPORTING THE LOADER When running on its own AWARNING After driving for an extended hour, the loader's tires may heat up, causing the internal tire pressure to rise excessively, and in the worst case the tires could explode. Make sure to park the loader for 20 to 30 minutes for every one-hour driving, to cool down the tires. ‘* Observe all traffic regulations including any special regulations authorized within the work area, for example, speed limitations. ‘* Drive slow, and go round pot holes or other obstacles, if any, in the work area. ‘+ When driving on public roads, carry necessary license and permit. Be alert for other vehicles and pedestrians. Abide by traffic regulations and drive safely. 53TOWING TOWING The loader is not equipped with any towing pin. When necessary to tow another vehicle, the tow rope must be tied to the positions specified on page 30. The loader must be used for towing only in an emergency A WARNING | Do not tow another vehicle a long distance. | Itis dangerous. A WARNING When towing another vehicle on a public road, take necessary measures to let other vehicles and people know that you are towing another vehicle. Use a flag, rotating lamp, or hazard lamp. There are several requirements you must abide by when towing another vehicle. Leam the regulations and rules about towing another vehicle and observe them. * Check the weights of your loader and the vehicle to be towed and make sure you loader has sufficient braking capacity to stop the towed load. © Check if the vehicle to be towed can be braked and steered properly. If not, do not allow anyone to ride on the towed vehicle, © Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work. + When necessary to descend a gradient, another towing vehicle must be used in the rear to retard, © Start slowly. A sudden start can lead to a broken tow rope. * The tow line must be along the centerline of both your loader and the vehicle to be towed. ‘+ If you use any other towing device, refer to the Instruction Manual supplied with the towing device. When the loader is towed by another vehicle It the engine can be started and the steering wheel and brakes function normally, have someone get on the loader you are going to tow for steering it If the engine won't start, remove the front and rear propeller shafts; otherwise the transmission will rotate without being properly lubricated, causing seizure. Before removing them, apply the parking brakes and block the wheels securely. It it is difficult to tow the loader, transport it by a trailer truck to your nearest repair shop. When towing the your loader, observe the Iohowing aosaions Ye sdshion to the ‘shove @ If the engine won't start or the pump fails to operate normally, remove the front and rear Prapaler rate” Release the. parting brake Borbro removieg the: rear propels shat, refering to on page oF Pattove the stosring cylinders because the Heotng whee! eesbicd ® The hydraulic booster of the brake system is disabled and thus the brake pedal needs to be pressed harder than usual. 8 54MEASURES TO BE TAKEN IN AN EMERGENCY MEASURES TO BE TAKEN IN AN EMERGENCY If engine stalls during traveling The brake system is 2 hydraulic booster type which goes disabled when the engine stalls, thus causing @ hard brake pedal which requires a greater pedal effort for braking. ‘The parking brake is automatically apolied when the engine stalls, Steering system: The steering wheel becomes hard to turn due to an inoperative hydraulic system. If the engine stalls during traveling, park the loader in an out-of-traffic area and check the cause of the trouble. For complicated trouble, contact your authorized dealer, CUE od Do not enter water whose depth exceeds the loader's minimum ground clearance height or is high enough to wet the bottom of the axle housing As a tule of thumb, the allowable water depth is, about 400 mm (15.7 in). This means that the loader should not be used in a river. Observe the following conditions: * Check the water depth in advance when crossing across a river. + Use the same precautions before crossing across a swampy area. + Do not enter rivers whose river bed is steep or whose flow is rapid. A CAUTION Avoid use of the loader in salt water. Salt water will cause the development of rust to shorten the life of the loader. | After working in a swampy area, carefully wash the loader and apply anti-rust coatings. Battery is discharged WARNING Batteries give off explosive gases. Do not smoke. away. Take care when using metallic tools. If a | metallic tool is placed between the terminal and the engine block or the loader body, sparks may develop, causing explosion or fire hazards. If battery electrolyte comes in contact with the skin or the eyes, it will cause a burn or blindness. Wear safety glasses, rubber gloves and apron. If electrolyte comes in contact with the skin or gets in the eye, flush repeatedly with cold water and seek medical attention. Keep flame and sparks © Make sure to shut off the engine and turn off the starter switch before working on the battery. (to be continued) 55MEASURES TO BE TAKEN IN AN EMERGENCY A WARNING Betore trying connectors, make sure to lower the bucket on to. disconnect the battery the ground horizontally, apply the parking brake, turn the starter switch to the OFF position and shut off the engine. Do not put metal tools or the like on the top surface of the battery. |To prevent the development of sparks, | disconnect the (-) side (grounding side) first. To reconnect, the (-) side should be connected last. ee Removing the battery unit from the loader and charging with a stationary charger + Read the Instruction Manual for the charger carefully and follow the specified charging procedure. * If the battery is to be charged indoors, have good ventilation, Remove the battery caps to allow gases to escape, ‘+ While the battery is being charged, never bring flame close to the battery. Care should be exercised not to let any metallic object contact the battery terminals, ‘= After charging, clean the battery terminals and apply grease before mounting the battery on the loader. 2. Replacing discharged batteries with charged batteries ‘= Once comple-ely discharged, the battery will have a shor service life. Replace the two baiteries with new ones as soon as possible. ‘+ Make sure the battery and cable polarities are the same; the (+) battery terminal to the (+) cable terminal and the (-) battery terminal to the C) cable terminal. Tighten the nuts securaly. + The disposal of a discharged battery must be left to the dealer from which the battery was bought or to a specialist. Do not throw it away without permission. 3. Using a booster cable to temporarily restore the battery performance A WARNING ‘When connecting a booster cable, use caution not to short-circult the battery's positive and negative terminals with a cable clip; it shortec, the battery can explode. ‘+ Use caution when connecting the booster cable to the engine block of a disabled loader, because sparks may develop. The cable must be connected to the engine block placed as far away as possible, from the battory. *Do not let a disabled loader contact the operative loader. When starting the engine of a disabled loader, wear protective glasses. ‘= The loader has two 12-volt batteries, 24 volts in total, Make sure the mating battery has the ‘same voltage. = Connecting two booster cables: @ Turn the starter switches of the operative vehicle and the disabled loader to OFF Connect the red cable clip to the (+) battery terminal of the disabled loader and connect the other red clip to the (+) battery terminal of the operative vehicle; @® Connect one black end of the booster cable to the (-) battery terminal of the operative vehicle; ® Connect the other black end of the booster cable to the engine block of the disabled vehicle placed as far away as possible, from the battery + Make sure the four clips are secure and making good contact. + Start the engine of the disabled loader. Alternator bracket (engine Bock) a. / a oe ‘Alter the engine of the disabled loader stars, remove the clips in descending numerical order of @, @, @, and ©. 56MEASURES TO BE TAKEN IN AN EMERGENCY GOrreur rn ice) A WARNING If the loader is disabled for any reason, needs to be towed, and the parking brake cannot be released with the parking brake switch, release the parking brake in the following procedure. Do not try to drive the loader by its own engine. However, this procedure must be used only when you cannot release the parking brake with the parking brake switch. Under any other circumstance should not this proce- dure be used. Before you try to release the parking brake in the following manner on a grade, block the wheels securely enough to withstand the weight of the loader. Have a guide and make sure there is no one around and under the loade If the parking brake cannot be released with the Parking brake switch, due to a defective brake oil pump or other failure in the brake system, release the parking brake in the manner given below. | A WARNING In the step @, a small amount of oil flows It is advisable to make sure the loader is | sufficiently cooled down. Procedure for releasing the parking brake without using the parking b rake switch Clean the plugs, bolts and areas around them, @ The parking brake cover has four plugs (bolts). Remove two diagonally opposite plugs (bolts) among them which can be more easily removed @ Remove the releasing bolts (top and bottom), @ Install brake releasing bolts (without washer) in diagonally opposite holes from which the bolts were removed in step @ and tighten them evenly and little by little as far as they go. @ Alter each of the brake releasing bolts contacts the brake cover, give additional 2 or 3 tums to release the parking brake. ‘fer exiting an emergency situation, contac your authorized dealer for servicing orrepat. | RELEASE BO.T olf |] Peeler 37HANDLING IN COLD WEATHER HANDLING IN COLD WEATHER In cold weather or when the ambient temperature is 0°C (82°F), bear in mind that: * The water and lubricants used in the loader may freeze. + The surface on which the loader travels is slippery. Keeping the above in mind, observe the following conditions: 1. Add water and lubricants before working, not after working, (This does not apply to fuel.) 2. Add LLC (Long Life Coolant) to the radiator cooling water. The wheel loaders are delivered from the factory with LLC in the radiator and in general you don’t worry about the coolant. However, when your loader is to be used in 2 cold region where the ambient temperature might drop to -10°C to -40°C. (14°F to -40°F), increase the concentration Of the LLC 3. Change the engine crankcase oil to cold- weather engine oil 4. Use hard-tofreeze fuel. To prevent the condensatior of moisture to the inner wall of the tank, take care to leave half the fuel in the tank when finishing the day's work. Add cold-weather fuel to fill up the tank. 5. Always keep the battery in a well charged condition since there is danger of the battory being damaged if the electrolyte freezes. After work, be sure to let the engine run at low rpm ‘for about 5 minutes. As an alternative method, dismount the battery and keep it in a warm indoor place. Keep the specific gravity of the electrolyte at 1.280 or below. Use the cautions given below when traveling and operating the loader. 6. After preheating the engine, crank the engine and warm up the engine sufficiently. PREY Exhaust gases can kill so the loader must be warmed up with adequate ventilation. 7. Warm up the load handling system. Operate the hydraulic pedals slowly to actuate the cylinders several times 8. Attach tire chains to all four wheels when working on a road covered with snow, especially on an icy road. 9. After work, take measures to prevent the freezing of water on the paris as follows: + Tape the key insertion slit ‘The rubber paris like the wipers might freeze. Take care not to allow them to contact other parts. + Remove snow and water at the bottom and inside of the loader with a rod and brush, * Park the loader indoors, if possible. Park it on a level surface and cover with a large vinyl sheet 58HANDLING TIRES. HANDLING TIRES A WARNING Tires are one of the most important components of the loader: they sustain the weight of the loader, transmit the driving force and brake force, alleviate shock from the road surface, and help the loader turn. Neglect of the maintenance of the tires will lead to poor performance of the loader. A flat tire can cause serious injury or death. TIRE IDENTIFICATION © Tread © inner iner 2 Shoulser © Carcass ® Side walls © Breaker @ Beads © or Bor Not: The standard tie nasa traction toad patton, TIRE SIZE + LX707 16.9- 24 10PR Tire width (inch) Rim diameter (inch) Ply-Rating The “Piy-Fating” is an index of tire strength. The larger the number, the higher the inflation pressure becomes available and the higher load the tie can support. 10PR indicates the strength equivalent to 10 cord piles in the tire. e860 TIRE INFLATION PRESSURE ‘The tie inflation pressure must be as specified, not 100 high or too low. Make sure that the tires are inflated to proper pressures. Unaerinflation Correct Overintlation Siandard ifaton mode! | size came 235 kPa LxTO7 |16.9-26-10PR | 4 glen oF 34.1 pl) 216 KPa 1x80 [10.426-10PR | 99 yg ne APB, 9 pa The inflation pressure may be properly adjusted according to the ground condition or work area. It is advisable to inflate the tires a little lower than standard when the loader is to be used on sand or soft ground. Consult your authorized Gealer about the selection and inflation pressure of tires. Tire inflation pressure checks must be performed when the tires are cold It the inflation pressure is too the following troubles can occur: + Large detlection. It will lead to separation or cord breaks due to the generation of heat + The development of cracks in side walls. Vulnerable to damage from the outside. + Increased road resistance will increase fuel consumption. low, If the inflation pressure is too high, the following troubles can occur: © The tread is susceptible to damage from the outside. Cut burst, shock burst or cord breaks will be apt to occur. © The tires are apt to skid when starting or braking. The center of the tread wears prematually, {A caution | Do not travel long distances over rough terrain. | Use paved roads when traveling. This will | prolong the tire service life and lead to safe travel, 59HANDLING TIRES TIRE ROTATION If one or both of the front tires show deeper wear than those of the rear tires, rotate the tires properly. This lets the tires wear uniformly, thus making it possible to prolong the entire service life of the tires. How to rotate the tires: ‘* Rotate the tires between the front and rear wheels. Do not swap the tires diagonally. * All tread pattern must face forward. The traction pattern affects fuel consumption and the safety of travelling. Rotating direction Forward travel A WARNING The wheels should have tires which are free from cuts and show less wear, because the tires sustain a lot more weight when loading, unloading and | braking. Damaged or excessively worn | tires can cause a puncture or burst, thus | leading to personal injury or death. How to check the extent of tire wear Measure the extent of wear at an area 1/4 of the tread’s outermost part. (points marked x) ead wan Pt ae Teed width ‘The useful limit (replacement time) is when the tire is worn 85% compared to a new one Replace any tire showing excessively uneven wear or 2 cord layer exposed to view with a new one, even if it is not worn 85%. A CAUTION Equalize wear of the front and rear tires. Do not use tires of different types, constructions or sizes. Failure to observe these conditions will adversely affect the power train including axles or transmission, causing the malfunction of the loader. When replacing tires, make sure to use tires of, the same type, construction and size for four wheels. It is advisable tc replace the four tires at the same time. 60HANDLING TIRES REMOVING AND REINSTALLING TIRES A WARNING ‘A tire with a wheel is heavy. Servicing it is difficult and dangerous. It also needs a hoist for removing and reinstalling ti It is advisable to ask your authorized dealer or a specialist to do the work. It you are going to jack up the loader for tire maintenance, observe the following condi- tion * Park the loader on dry, flat and hard ground. “Carry out the work by at least two people: one for working on tires and ‘one as a helper who keeps bystanders from standing near the loader. ‘* Do not use the bucket to raise the front | wheels. | « Jack the loader up just enough to remove |_ tires. Do not raise the loader too high. *Block the rear wheels when you are about to remove the front wheels and | block the front wheels when you are about to remove the rear wheels. * Be sure to use supports under a jacked- up loader. Do not try to keep the loader raised up with a jack or jacks. The rear axle may cradle. To prevent this, wedge a rigid squared timer between the axle and frame, * When removing the wheel bolts, the one at the top position must be removed last, P | | | | with the tire lifted with a hoist. © The tightening torque of the wheel bolts is 862 N-m (88 kg-m or 636.5 Ibf-ft). WHEELS ] A WARNING | When disassembling of a tire and rim assembly is needed, ask a specialist. | | Remove rust (if any) from the rim. An excessively rusty rim often indicates the | development of cracks. Replace such a| assembly. a1HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAU- LIC TYPES) The one-touch coupler allows easy exchange between load handling attachments such as buckets. Non-hydraulic one-touch coupler A WARNING Do not allow bystanders to stand near the loader. The lock lever should be moved from the ground, not in the operator's seat. Removal Place a pallet under the attachment you are about to remove. ® Keep the bucket horizontal about 20 cm (0.8 in) above the pallet. ®@ A WARNING: Set the parking brake ‘Securely. Hold the lock lever and turn it to the left and make sure the right and left pins are disengaged from the attachment @ Make sure the bucket (attachment) is located ‘on the near-side edge of the pallet for easy ‘operation of the one-touch coupler. @® Lower the booms a little and slowly and carefully tit the bucket forward, and the bucket (attachment) will disengage from the ‘one-touch coupler. al Place bucket horizontally ‘about 20 om (0.8 in) \ \ AV ure locke lever to let \y | Tit bucket forward, towering booms. 62HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) Install @ n With the lock lever in the “release” (left) position, slowly bring the one-touch coupler close to the bucket (attachment) hook and insert it, 4A WARNING: Set the parking brake. Raise the booms a little and tilt the bucket attachment) backward to almost upright or until the one-touch coupler touches the stopper. Shut off the engine. Turn the tock lever to the pin insertion Position (right). TA WARNING: Hold the lever securely not fo get your fingers caught between the lever and the push rod pin set plate. Make. sure the right ‘and left pins are’ completely engaged raising 200ms. Turn tock lever toright Use caution not to hit against set plate 7 63HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) Hydraulic one-touch coupler [A WARNING Do not allow bystanders to stand near the | | loader. Control the operation of the coupler | | pins from the operator's seat. Installation and removal The procedures for installing and removing a hydraulic attachment are basically the same as those for non-hydraulic attachments, except that the operation of the coupler pins is controlled with the hydraulic one-touch lever in the operator's compartment. Make sure right and ett A WARNING The use of the hydraulic one-touch lever must be limited to installation and removal of hydraulic attachments. When not used, it should be locked with the lever lock; otherwise the coupler pins might be disengaged due to an accidental move of the lever, so that the attachment may drop, thus causing personal injury. Make sure right and let pins are dison- (92900 and engages Property WI frrson IRB Hydrautic ono sooniane 64HANDLING ONE-TOUCH COUPLER (NON-HYDRAULIC AND HYDRAULIC TYPES) Installing and removing hydraulic hose lt your loader is equipped with a hydraulic attachment, it is necessary to install and remove the hydraulic hose when drawing hydraulic power from the loader. Installing and removing + A WARNING Set the parking brake and ‘shut off the engine. Operate the attachment control lever a few times to release the pressure from the piping. A__CAUTION Clean dust and dirt from the hydraulic hose connections. * Connect the hydraulic hose of the loader side with the hydraulic hose of the attachment. * Start the engine. Operate the attachment control lever slowly to move the attachment, to make sure there is no oil leak from the connections. * After removing the hydraulic attachment, connect the hydraulic hoses of the attachment to each other. Dust cap the hose ends of the loader body side to prevent dirt from entering the circuit. Connecting >~ «+ Kone ae ull sleeve, insert plug and return sieeve in| positon to connact | Disconnecting Pull eloove t disconnect. moving hydraulic hose Kee BN. si ve (20) pulled, instal or remove dust cap. Insta ust eap onto convex part 65Memo 66LOADING OPERATION ‘This Manual uses the following safety alert symbols. When you see those symbols in the text, follow the safely message to avoid personal injury or death: Failure to follow the instructions in the message will cause a serious accident or death. | & warning - Failure to follow the instructions in the message might cause a serious accident or death. A cauTION Fallure to follow the instructions in the message may ‘cause personal injury or damage to the loader. LOADING OPERATION td ‘SAFE LOADING OPERATION 68 BEFORE LOADING 7 DIGGING 74 GROUND DIGGING (DIGGING ON A LEVEL SURFACE) DUMPING. LEVELING BULLDOZING SNOW REMOVAL HOISTING THE LOADER ADJUSTING BUCKET AUTO-LEVELLER 67‘SAFE LOADING OPERATION SAFE LOADING OPERATION You should understand the capabilities and construction of the wheel loader to operate it safely. All of the loader's functions can be relatively easily controlled with the load handling lever, but the loader can be very dangerous if you fail to use proper caution. You should bear in mind that, the bucket or attachment is heavy and hard and that they will sometimes hinder your view of the area in front of you. Before starting an operation, make sure there is no one near the work area. The wheel loader is a versatile piece of equipment. This does not mean that it can be used for just any type of work. Basically, it is designed to scoop up loads with the bucket, transport the loads, and dump them into a hopper or onto a dump truck. In terms of performance, you should know the bucket capacity of the loader and the size, weight, and material of the load you will be handling. In addition, you absolutely must check to see if the soil or working surface of the work area is firm enough and strong enough to operate the loader safely. The loader is not suitable for work on soft soil, such as muddy or sandy ground. In soft soil it is unable to achieve sufficient traction for sate operation The wheel loader has an articulated frame design which allows the front and rear frames to swivel around the center pin for steering. In some positions, the loader is sufficiently unstable that it may easily turn over if you try to maneuver too heavy a load. Before trying to operate the bucket or an attachment, make sure the frames are in a relatively straight alignment to each other. Failure to observe this requirement can lead to malfunctions and serious accidents involving the loader. | A WARNING | The operator must fasten his seat belt if the | wheel loader is equipped with a ROPS (Roll- | Over-Protective-Structure) canopy or a ROPS cab; otherwise, if the loader turns over, the | operator might be thrown out and, in the worst case, the operator can be crushed by the loader’ causing severe injury or even death. Do not try to modify the ROPS canopy or a ROPS cab without prior permission from the manufacturer. Use only the ROPS canopy approved by us. If the loader turned over, be sure to replace the ROPS canopy with a new one before putting the loader in service again. that are prohibited or dangerous. The pictures have been drawn based on our medium-sized wheel loaders. Protect the planet! Operate the loader while keeping is mind that you shoul be ied 10 the environment. This pracice wl led to lower amounts of exhaust and operating noige. 1 wil ago be welcomed by both elow workers And the resents around the works ‘We are commited to protecting he planet 68SAFE LOADING OPERATION Tho numbors next tothe safety rules do not indicate the priority ofthe rle’s importance or the degree of risk associated wit the situation 1. Know the rated capacity of the bucket or attachment and never exceed it. Before starting work, check the weight and center of gravity of the load you are going to handle. 2. Check the specific gravity of the load. Take it into account before trying to move it. 7. Make sure your load is centered in the bucket. Use caution to avoid spilling or accidentally dumping the load. Exercise special caution when handling a long load or oddly shaped load. Make sure that the load's center of gravity is aligned with the center of the loader as much as possible. 8. Use an appropriate attachment, taking into account the shape and specific gravity of the load. 4, Use the bucket and booms properly. Do not try to use them to shift, push or pull the load while it is on the ground. Such an action might damage the bucket or attachment and it can cause an accident. 5. Do not hoist a load with chains hung from the bucket or the attachment. The chains may slide off 6. Never allow anyone to ride in the bucket. Loads center of gravity 8. Ifa fork attachment is used, adjust the fork spacing properly according to the shape of the load. 9. If you work on the shoulder of an embankment or beneath an overhang, always have a person present to guide you, and follow his instructions. 10. Before trying to dump earth or rocks from an elevated position, make sure there is no one in the dump area. 11. Stay away from the edge of drop-off. 69SAFE LOADING OPERATION 12, When articulated in the middle, the loader is unstable and might roll over due to the application of undue force on the frames. Make sure the front and rear frames are aligned each other before handing loads. Failure to do so can also cause a Premature failure of the loader. 13. Do not try to lift the booms excessively high or perform work on grades, especially when the loader Is not straight. Otherwise, the loader could tip over. 14. Remember that the loader is unstable when the bucket is raised high. Use appropriate caution and move slowly when loading and unloading. 15. When dumping the bucket, first slowly tilt the bucket forward and then dump the whole load at once, quickly. Do not stop dumping halfway through; otherwise the loader my tip over due to the reaction from suddenly stopping the bucket. In particular, if the bucket is stopped at the maximum range of its reach, the chances of the loader tipping 16. Don't drive into a pile of earth or material at high speed. You might be thrown out of the loader by the sudden stop. The loader can also be damaged. 17. Do not stand near a load handling operation. Some kinds of attachments move sideways as well as forwards and backwards. 18. When it is necessary to walk under the bucket or attachment for servicing or for any other reason, make sure to support the bucket or attachment with safety blocks and have another person present who stands clear of the loader. 19. Operators may get dust or sand in their eyes when working in a dusty area. Pay attention to the direction of wind, and wear goggles, if needed. When loading a trailer, approach the trailer from the side (at a right angle). 70SAFE LOADING OPERATION 20. When lifting the loader itself, attach four chains each of which is strong enough to sustain the loader's weight, to the four points of the loader. Always have another person present to guide guidance, and follow his instructions, 21. When lifting the loader, do not allow anyone to ride on or to stand under the loader. 22. When performing snow removal, make sure to install tire chains on all four wheels. 23. Avoid sudden starts, stops, and tums on snowy or icy roads. Drive slowly. 24. Know where the ditches and curbs are before starting snow removal 25, Make sure there is good ventilation when working in an enclosed area. Exhaust fumes can kill 26. Have fire protection equipment _handy whenever working indoors. Replace old fire extinguishers with new ones at the specified intervals. 27. Check the surface over which you will run. Clear away debris or anything that might cause you to lose control, bog down or tip over. 28. Do not leave the loader unattended in the middle of work, especially on a grade or in a city area. The loader might be vandalized or boarded by children. If it is unavoidable to leave the loader unattended, make sure to: * Lower the bucket on the ground and apply the parking brake. * Place the load handling lever in neutral and set the lever lock. ‘Remove the starter key and block the wheels securely. 71SAFE LOADING OPERATION 29. Do not change specifications, add an additional counterweight or modify the bucket without the manufacturer's prior permission. 30. Do not try to make any modification that affects the performance or strength of the loader. 31. When loading the loader onto a trailer, make sure to: + Apply the trailer’s parking brake and block its wheels. + Use ramps of sufficient strength and width. ‘* Use nonskid ramps. When installing ramps (if they are not permanently attached to the trailer), engage them securely on the rear of the trailer and put supports under the middle of them. * Usually back the loader up the ramps, but the direction of loading may change due to the condition of the trailer. When going up a ramp, make sure the centers of the rear wheels are aligned with the centers of the ramps. Drive up slowly. Never try to turn the steering whe when halfway up a ramp. If the loader is not aligned properly with the ramp, drive back down to the ground and start over again. * If you have difficulty seeing if the tires are aligned on the ramp correctly, have someone else guide you. Follow their instructions. 82. Another attachment with hydraulic tubing may be installed and it is operated by manipulating an additional load handling lever (for attachment). Do not confuse it with the other levers. 33. If a fork attachment is installed, use caution ot to drop the loads from the pallet by controlling the angle of the forks properly 72