TCM E820-3 Wheel Loader Operation & Maintenance Manual OW-62M-MAE - PDF DOWNLOAD

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TC輔 CORPORATIO閥

INTRODUCTION Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.

This standard specification machine can be operated under the following conditions without being modified.

Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest TCM dealer.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen.

Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of TCM support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you with the assurance that TCM will back its products where defects appear within the warranty period. In some circumstances, TCM also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

The EC Declaration of conformity includes the machine without equipment unless fitted with equipments approved by TCM Corporation Refer to enclosed list for approved equipments. TCM Corporation will not cover conformity of machines fitted with OEM equipments.

Use only diesel fuel with quality specified in JIS K-2204, EN-590, ASTM D-975, GOST R52368 or GB252.

Failure to use diesel fuel with quality as specified above may allow the engine to emit exhaust gas which cleanness can not conform to the requests in various relevant regulations. In addition, serious damage to the engine may result. Consult with your nearest TCM dealer for detailed information.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

CONTENTS ENGINE EMISSION CONTROL LABEL .......................................1 MACHINE NUMBERS .......................................................................3 SAFETY ..............................................................................................S-1 Recognize Safety Information ...................................................S-1 Understand Signal Words ............................................................S-1 Follow Safety Instructions ...........................................................S-2 Prepare for Emergencies ..............................................................S-3 Wear Protective Clothing .............................................................S-3 Protect Against Noise ...................................................................S-4 Inspect Machine .............................................................................S-4 General Precautions for Cab .......................................................S-5 Use Handrails and Steps ..............................................................S-6 Never Ride Attachment .................................................................S-6 Adjust Operator’s Seat ..................................................................S-6 Ensure Safety Before Rising from or Leaving Operator’s Seat ..........................................................S-7 Fasten Your Seat Belt .....................................................................S-7 Move and Operate Machine Safely ..........................................S-8 Handle Starting Aids Safely ........................................................S-8 Operate Only from Operator’s Seat .........................................S-9 Jump Starting ..................................................................................S-9 Investigate Job Site Beforehand ............................................ S-10 Equipment of Head Guard, ROPS, FOPS .............................. S-11 Provide Signals for Jobs Involving Multiple Machines ... S-11 Keep Riders Off Machine .......................................................... S-12 Drive Safely .................................................................................... S-12 Drive Machine Safely (Work Site) ........................................... S-13 Drive Safely with Bucket Loaded ........................................... S-14 Drive on Snow Safely .................................................................. S-14 Travel on Public Roads Safely .................................................. S-15 Avoid Injury from Rollaway Accidents ................................. S-15 Avoid Accidents from Backing Up and Turning ............... S-16 Avoid Positioning Bucket or Attachment Over Anyone ................................................... S-17 Avoid Tipping ................................................................................ S-17 Never Undercut a High Bank ................................................... S-18 Dig with Caution .......................................................................... S-18 Perform Truck Loading Safely ................................................. S-18 Avoid Power Lines ....................................................................... S-19 Precautions for Operation ........................................................ S-19 Precautions for Lightning ......................................................... S-19 Object Handling .......................................................................... S-20 Protect Against Flying Debris ................................................. S-20 Park Machine Safely .................................................................... S-21 Store Attachments Safely ......................................................... S-21 Transport Safely ........................................................................... S-22 Handle Fluids Safely−Avoid Fires ........................................... S-23 Practice Safe Maintenance ....................................................... S-24 Warn Others of Service Work .................................................. S-25 Support Machine Properly ....................................................... S-25 Stay Clear of Moving Parts ....................................................... S-26 Support Maintenance Properly .............................................. S-26 Prevent Parts from Flying ......................................................... S-27 Prevent Burns ................................................................................ S-27 Replace Rubber Hoses Periodically ....................................... S-28

Avoid High-Pressure Fluids ...................................................... S-28 Prevent Fires .................................................................................. S-29 Evacuating in Case of Fire ......................................................... S-30 Beware of Exhaust Fumes ......................................................... S-30 Precautions for Welding and Grinding ................................ S-30 Avoid Heating Near Pressurized Fluid Lines ...................... S-31 Avoid Applying Heat to Lines Containing Flammable Fluids ................................................................... S-31 Remove Paint Before Welding or Heating .......................... S-31 Beware of Asbestos and Silicon Dust and Other Contamination ......................................................................... S-32 Prevent Battery Explosions ...................................................... S-32 Service Air Conditioning System Safely .............................. S-33 Handle Chemical Products Safely .......................................... S-33 Dispose of Waste Properly ........................................................ S-34 SAFETY SIGNS ............................................................................. S-35 COMPONENTS NAME .................................................................1-1 Components Name .......................................................................1-1 Canopy Vehicle ..........................................................................1-1 Cab Vehicle (Optional) .............................................................1-2 OPERATOR’S STATION ................................................................1-3 Cab Features .....................................................................................1-3 Front Console ...................................................................................1-4 Right Console ...................................................................................1-5 Monitor Panel ..................................................................................1-6 Stop Indicator (Red) .......................................................................1-7 Service Indicator (Yellow) ............................................................1-7 Parking Brake Indicator (Red) .....................................................1-8 Brake Oil Low Level Indicator (Red) .........................................1-8 Discharge Warning Indicator (Red) ..........................................1-8 Overheat Indicator (Red) .............................................................1-9 Engine Oil Low Pressure Indicator (Red) ................................1-9 Air Filter Restriction Indicator (Red) .........................................1-9 HST Warning Indicator (Red) ......................................................1-9 Engine Coolant Temperature Gauge .................................... 1-10 Fuel Gauge ...................................................................................... 1-10 Preheat Indicator (Yellow) ........................................................ 1-11 Turn Signal Indicator (Green) .................................................. 1-11 High Beam Indicator (Blue) ...................................................... 1-11 Work Light Indicator (Yellow) .................................................. 1-11 Clearance Light Indicator (Green) ......................................... 1-11 Monitor Display ............................................................................ 1-12 Forward/Reverse and Shift Position Indicator .................. 1-13 F-N-R (Forward/Reverse) Position Indicator ................. 1-13 Shift Position Indicator ......................................................... 1-13 Speedometer ................................................................................ 1-14 Ride Control Indicator (Optional) .......................................... 1-14 Machine Information Display .................................................. 1-15 Shifting Item to Be Indicated on Machine Information Display ....................................... 1-16 Hour Meter ............................................................................... 1-16 Odometer ................................................................................. 1-16 HST Error Code Readout Switch ............................................. 1-17 Error Code ...................................................................................... 1-18 Switches, Steering Wheel and Pedals ................................... 1-19

CONTENTS F-N-R Lever .................................................................................... 1-20 Neutral Lever Lock (F-N-R Lever) ............................................ 1-20 Steering ........................................................................................... 1-21 Horn Switch ................................................................................... 1-21 Turn Signal Lever ......................................................................... 1-21 Dimmer Switch ............................................................................. 1-21 Light Switch ................................................................................... 1-22 Hazard Switch ............................................................................... 1-23 Work Light Switch (Cab Vehicle) ............................................ 1-24 Hi-Lo Selector Switch ................................................................. 1-25 Parking Brake Switch .................................................................. 1-26 Wiper Operation .......................................................................... 1-27 Front Window Wiper Switch (Cab Vehicle) ......................... 1-28 Rear Window Wiper Switch (Cab Vehicle) ........................... 1-28 Accelerator Pedal ......................................................................... 1-29 Brake/inching Pedal ................................................................... 1-29 Right Console (Front Attachment) ........................................ 1-30 Loader Control Lever .................................................................. 1-31 Lever Locks .................................................................................... 1-32 Right Console/Switch Panel .................................................... 1-33 Key Switch ...................................................................................... 1-34 eco Mode Switch ......................................................................... 1-34 Ride Control Switch (Optional) ............................................... 1-35 Ride Control Operation ........................................................ 1-35 Heater (Optional) Operation ................................................... 1-36 Heater Switch .......................................................................... 1-36 Vent ............................................................................................. 1-36 Adjusting Operator’s Seat (Standard Type) ........................ 1-37 Components Name ............................................................... 1-37 1. Damper Adjustment ......................................................... 1-37 2. Fore-Aft Position Adjustment ....................................... 1-37 Adjusting Operator’s Seat (Suspension Type) ................... 1-38 Components Name ............................................................... 1-38 1. Suspension adjustment .................................................. 1-38 2. Fore-Aft Position Adjustment ....................................... 1-39 3. Armrest Angle Adjustment ............................................ 1-39 4. Reclining Angle Adjustment ......................................... 1-39 Seat Belt .......................................................................................... 1-40 Seat Pocket (Suspension Seat)................................................. 1-40 Fuse Box .......................................................................................... 1-41 ROPS Cab (Optional) .................................................................. 1-43 Room Light .................................................................................... 1-45 Sun Visor (Optional) .................................................................... 1-45 Drink Holder .................................................................................. 1-45 Coat Hook ...................................................................................... 1-46 Rear View Mirror ........................................................................... 1-46 Room Rear View Mirror .............................................................. 1-46 FM/AM Radio (Optional) Operation ...................................... 1-47 Controls on the Radio ........................................................... 1-47 Tuning Procedures ................................................................ 1-48 Station Presetting Procedure ............................................. 1-48 Auto Station Presetting Procedure .................................. 1-49 Digital Clock Setting Procedure ........................................ 1-49 Alarm Setting Procedure ..................................................... 1-49 Upper Switch Panel (Optional) ............................................... 1-50

Rotary Beacon Switch (Optional) ........................................... 1-50 Cab Door ......................................................................................... 1-51 Door Lock Knob ........................................................................... 1-52 Door Open/Close Lever ............................................................. 1-52 Window Open/Close Levers .................................................... 1-52 When Fully Opening the Door ................................................ 1-53 Door Lock Disengage Lever ..................................................... 1-53 Articulation Lock Bar .................................................................. 1-54 Towing Pin ..................................................................................... 1-54 Engine Hood ................................................................................. 1-55 Maintenance Side Cover ........................................................... 1-55 Steps ................................................................................................. 1-56 Vandal-Proof Devices ................................................................. 1-56 BREAK-IN ..........................................................................................2-1 Observe Engine Operation Closely ..........................................2-1 OPERATING ENGINE ....................................................................3-1 Inspect Machine Daily Before Starting ...................................3-1 Check Before Starting ...................................................................3-3 Starting Engine ...............................................................................3-5 Check After Starting ......................................................................3-7 Using Booster Batteries ................................................................3-8 Warming Up Operation ............................................................. 3-10 Warming Up Operation in Cold Weather ............................. 3-11 Stopping Engine .......................................................................... 3-12 DRIVING MACHINE ......................................................................4-1 Driving Machine .............................................................................4-1 Starting to Move .............................................................................4-2 Parking Brake Switch .....................................................................4-4 Drive Speed Change ......................................................................4-5 Changing Forward/Reverse Drive Direction .........................4-5 Steering ..............................................................................................4-6 Provisional Stop and Restart of Driving .................................4-7 Precautions for Driving on Slopes ............................................4-9 Precautions to Be Taken if Machine Failure Occurs ......... 4-10 Precautions for Driving Speeds .............................................. 4-11 Stop .................................................................................................. 4-12 Parking ............................................................................................ 4-13 Emergency Evacuation .............................................................. 4-15 OPERATING MACHINE ................................................................5-1 Loader Control Lever .....................................................................5-1 Lever Locks .......................................................................................5-2 Adjustment of Bucket Auto Leveler .........................................5-3 Before Operation ............................................................................5-4 Precautions for Operation ...........................................................5-4 Ensure Safety When Operating on Road Shoulders ..........5-4 Avoid Overloading .........................................................................5-5 Avoid Rapid Steering Changes and/or Sudden Braking .........................................................................5-5 Avoid Operation with Biased Loads ........................................5-5 Excavation .........................................................................................5-6 Grading ..............................................................................................5-8 Loading ..............................................................................................5-9 Dozing ............................................................................................. 5-13

CONTENTS Scooping ........................................................................................ 5-13 Removing Snow ........................................................................... 5-14 Lifting Wheel Loader .................................................................. 5-14 Precautions for After Operations ........................................... 5-15 TRANSPORTING ............................................................................6-1 Transporting by Road ...................................................................6-1 Transporting by Trailer .................................................................6-1 Loading/Unloading on Trailer ....................................................6-2 Transporting .....................................................................................6-4 Transporting Wheel Loader (Urgent Situation) ...................6-5 Towing Method ...............................................................................6-9 Lifting Machine ............................................................................ 6-10 MAINTENANCE ..............................................................................7-1 Correct Maintenance and Inspection Procedures ..............7-1 Check the Hour Meter Regularly ...............................................7-2 Use Correct Fuels and Lubricants .............................................7-2 Layout .................................................................................................7-3 Maintenance Guide Table ............................................................7-4 Preparations for Inspection and Maintenance ....................7-5 Lock Frames ......................................................................................7-6 Maintenance Side Cover ..............................................................7-7 Engine Hood ....................................................................................7-8 Opening Engine Hood ............................................................7-8 Closing Engine Hood ...............................................................7-8 Periodic Replacement of Parts ...................................................7-9 Maintenance Guide .................................................................... 7-10 A. Greasing (See Page 7-19) ................................................ 7-10 B. Engine (See Page 7-22)..................................................... 7-11 C. Power Train (See Page 7-25) ........................................... 7-11 D. Hydraulic System (See Page 7-30) ............................... 7-12 E. Fuel System (See Page 7-42) ........................................... 7-12 F. Air Cleaner (See Page 7-48) ............................................. 7-12 G. Cooling System (See Page 7-49) ................................... 7-13 H. Electrical System (See Page 7-55) ................................ 7-13 I. Brake System (See Page 7-65) ......................................... 7-13 J. Tire (See Page 7-68) ............................................................ 7-14 K. Heater (Optional of Cab Vehicle) (See Page 7-74) .. 7-14 L. Miscellaneous (See Page 7-75) ...................................... 7-15 Kind of Oils ..................................................................................... 7-16 Grease ........................................................................................ 7-16 Engine Oil ................................................................................. 7-16 Brake Oil .................................................................................... 7-17 Transmission Oil, Axle Oil .................................................... 7-17 Hydraulic Oil ............................................................................ 7-17 Long-Life Coolant .................................................................. 7-18 A. Greasing ..................................................................................... 7-19 B. Engine ......................................................................................... 7-22 Check Engine Oil Level ......................................................... 7-22 Change Engine Oil ................................................................. 7-23 Replace Engine Oil Filter ...................................................... 7-24 C. Power Train ............................................................................... 7-25 Change Transmission Oil ..................................................... 7-25 Change Axle Oil ...................................................................... 7-26 Check Oil Level ........................................................................ 7-27 Clean Transmission Air Breather ....................................... 7-28

Check Surrounding Areas Around Axles and Covers for Oil Leaks ................................................. 7-29 Clean Axle Housing Air Breather ...................................... 7-29 D. Hydraulic System .................................................................... 7-30 Inspection and Maintenance of Hydraulic Equipment .. 7-30 Check Hydraulic Oil Level ................................................... 7-31 Change Hydraulic Oil/Clean Hydraulic Oil Tank .......... 7-32 Change/Cleaning ................................................................... 7-32 Bleed Air from the Hydraulic System .............................. 7-33 Procedures ................................................................................ 7-33 Clean Suction Filter ............................................................... 7-34 Replace HST Oil Filter Element .......................................... 7-35 Replace Return Filter ............................................................. 7-37 Replacement ............................................................................ 7-37 Check Hoses and Lines ........................................................ 7-39 Kinds of Hose/Line Fittings ................................................. 7-41 Precautions for Use ............................................................... 7-41 E. Fuel System ............................................................................... 7-42 Check Fuel Level ..................................................................... 7-42 Recommended Fuel .............................................................. 7-42 Refueling ................................................................................... 7-42 Drain Water and Sediment from Fuel Tank ................... 7-43 Check and Drain Water from Fuel Pre-Filter ................. 7-44 Fuel Pre-Filter Drain Procedures ....................................... 7-44 Clean Fuel Pre-Filter Element ............................................ 7-45 Bleed Air from the Fuel System ......................................... 7-45 Replace Fuel Filter Element ................................................ 7-46 Check Fuel Hose ..................................................................... 7-47 F. Air Cleaner .................................................................................. 7-48 Clean and Replace Air Cleaner Element ........................ 7-48 G. Cooling System ....................................................................... 7-49 Long Life Coolant (LLC) ........................................................ 7-49 Precautions for Handling Long Life Coolant (LLC) ..... 7-50 Check Coolant Level ............................................................. 7-51 Check Fan Belt ......................................................................... 7-52 Check Fan Belt Tension ........................................................ 7-52 Adjust Fan Belt Tension ........................................................ 7-52 Change Coolant ...................................................................... 7-53 Clean Radiator and Oil Cooler ........................................... 7-54 H. Electrical System ..................................................................... 7-55 Check Monitor Function and All Other Instrument Operation .................................. 7-55 Check Work Lights ................................................................. 7-56 Check Horn, Backup Buzzer and Backup Light ........... 7-56 Check Electrical Harnesses and Fuses ............................ 7-57 Check and Replace Fuse ...................................................... 7-57 Fuse Box .................................................................................... 7-58 Battery ........................................................................................ 7-59 Precautions for Handling Batteries .................................. 7-59 In Case the Batteries Were Discharged .......................... 7-61 Method to Recharge the Removed Battery .................. 7-62 Method to Replace with Charged Auxiliary Batteries ............................................................ 7-62 Check Electrolyte Level ........................................................ 7-63 Check Electrolyte Specific Gravity ................................... 7-64

CONTENTS I. Brake System .............................................................................. 7-65 Check Brake Oil Level ........................................................... 7-65 Check Right and Left Brake Interlocking Performance ............................................. 7-66 Check Brake Performance ................................................... 7-66 Check Play in Brake Pedal Stroke ..................................... 7-66 Check Parking Brake Force ................................................. 7-67 Check Brake Disc (Service and Parking) ......................... 7-67 Change Brake Oil .................................................................... 7-67 J. Tire ................................................................................................. 7-68 Check and Adjust Tire Pressure ......................................... 7-68 Check Tire Pressure ................................................................ 7-68 Check Tire for Damage ......................................................... 7-69 Check Wheel Bolt Torque .................................................... 7-69 Replace Tire .............................................................................. 7-69 Tire Sizes to Be Used ............................................................. 7-70 Tire Rotation ............................................................................ 7-71 Rotation Method .................................................................... 7-71 How to Check Wear Amount (Tread Design Groove Depth) ...................................... 7-71 Removal and Installation of Tire.............................................. 7-72 Tire Wheel ....................................................................................... 7-73 K. Heater (Optional of Cab Vehicle) ....................................... 7-74 Check Heater for Any Damage .......................................... 7-74 Check Heater Piping ............................................................. 7-74 L. Miscellaneous ........................................................................... 7-75 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear ............................................. 7-75 Replacement............................................................................. 7-75 Check and Replace Seat Belt .............................................. 7-76 Check Canopy/Cab for Damage and Mounting Bolts for Tightness ....................................... 7-76 Check Windshield Washer Fluid Level (Cab Vehicle) ....................................................................... 7-76 Check Play in Steering Wheel Stroke .............................. 7-77 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise ............................... 7-78 Exhaust Gas Color and Noise ............................................. 7-78 Check Rearview Mirror and Inside Rearview Mirror .. 7-79 Check Steps and Handrails for Damage and Tightness ................................................... 7-79 Clean Engine Compartment and Hood ......................... 7-79 Check and Adjust Valve Clearance ................................... 7-80 Check Sound Absorbing Mat Around Engine ............. 7-80 Check Fuel Injection Timing ............................................... 7-80 Check Engine Compression Pressure ............................. 7-81 Check and Clean Starter and Alternator ........................ 7-81 Retighten Front Axle, Rear Axle and Transmission Mounting Nuts .................................................................. 7-81 Tightening and Retightening Torque of Nuts and Bolts .................................................................... 7-82 Nuts and Bolts Tightening Torque ................................... 7-83 Tightening Torque ................................................................. 7-83

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ...................................................................................9-1 Maintenance Under Special Environmental Conditions .....................................9-1 Precautions for Maintenance During Cold Weather Season ................................................9-2 STORAGE ....................................................................................... 10-1 Storing Machine .......................................................................... 10-1 Removing Machine from Storage ......................................... 10-2 TROUBLESHOOTING ................................................................ 11-1 Troubleshooting .......................................................................... 11-1 Engine .............................................................................................. 11-1 Control Lever ................................................................................. 11-2 Hydraulic System ......................................................................... 11-3 Drive Function .............................................................................. 11-4 Others .............................................................................................. 11-5 SPECIFICATIONS ........................................................................ 12-1 Specifications ................................................................................ 12-1 OPTIONAL ATTACHMENTS .................................................... 13-1 Handling Quick Coupler (Mechanical Type) ...................... 13-1 Handling Quick Coupler (Hydraulic Type) .......................... 13-3 INDEX ............................................................................................. 14-1

ENGINE EMISSION CONTROL LABEL

EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA) Emission control label is attached on the cylinder head cover.

E820-3

M4FG-00-003 M4FG-00-004

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ENGINE EMISSION CONTROL LABEL MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

MACHINE TYPE: _______________________________ PRODUCT IDENTIFICATION NUMBER: ___________________________

PRODUCT IDENTIFICATION NUMBER M4FG-00-001

PRODUCT IDENTIFICATION NUMBER: ___________________________ NOTE: *HFK4FG00A00000101*

Label

Marks to indicate the start and end of the PIN

PRODUCT IDENTIFICATION NUMBER (PIN)

ENGINE M4FG-00-003

TYPE: _______________________________ MFG. NO.: ___________________________

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MACHINE NUMBERS MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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SAFETY Recognize Safety Information • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

f NOTE indicates an additional explanation for an element of information.

S-1

SA-1223

SAFETY Follow Safety Instructions • Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair its function and / or safety and affect machine life.

• Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and / or service life. In addition, personal accident, machine trouble, and / or damage to material caused by unauthorized modifications will void TCM Warranty Policy.

• Do not use attachments and / or optional parts or equipment not authorized by TCM. Failure to do so may deteriorate the safety, function, and / or service life of the machine. In addition, personal accident, machine trouble, and / or damage to material caused by using unauthorized attachments and / or optional parts or equipment will void TCM Warranty Policy.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and / or your authorized dealer before operating or performing maintenance work on the machine.

S-2

SA-003

SAFETY Prepare for Emergencies • Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing • Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

S-3

SAFETY Protect Against Noise • Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection, be sure to cover all points described in the “Inspect Machine Daily Before Starting” section in the operator’s manual.

SA-435

S-4

SAFETY General Precautions for Cab • Before entering the cab, thoroughly remove all dirt and / or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and / or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Do not leave parts and / or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and / or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and / or tobacco.

• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

S-5

SAFETY Use Handrails and Steps • Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as handholds.

• Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

SA-439

Never Ride Attachment • Never allow anyone to ride attachment or the load. This is an extremely dangerous practice.

Adjust Operator’s Seat • A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

• Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

S-6

SA-462

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat • Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever lock to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the loader control lever lock to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

Fasten Your Seat Belt • If the machine should overturn, the operator may become injured and / or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every four years regardless of its apparent condition.

S-7

SA-237

SAFETY Move and Operate Machine Safely • Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

Handle Starting Aids Safely Starting fluid: • Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid.

• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

• Do not incinerate or puncture a starting fluid container.

S-8

SA-293

SAFETY Operate Only from Operator’s Seat • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator's seat.

• NEVER start the engine while standing on the track or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control levers are in neutral.

• Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

Jump Starting • Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING ENGINE” chapter in the operator’s manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

S-9

SA-032

SAFETY Investigate Job Site Beforehand • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

S-10

SA-447

SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.

ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

Provide Signals for Jobs Involving Multiple Machines • For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

S-11

SAFETY Keep Riders Off Machine • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine. Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-427

Drive Safely • Beware of the possibility of slipping and / or turning over the machine when driving on a slope.

• When driving on level ground, hold the bucket at mark (A) 300 mm (12 in) above the ground as illustrated.

• Avoid traveling over any obstacles.

• Drive the machine slowly when driving on rough terrain.

• Avoid quick direction changes. Failure to do so may cause the machine to turn over.

• If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the brake to prevent personal accident.

SA-448

S-12

SAFETY Drive Machine Safely (Work Site) • Before driving the machine, always confirm that the steering wheel / and F-N-R lever (switch) direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

SA-449

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

WRONG

SA-451

S-13

SAFETY Drive Safely with Bucket Loaded • If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.

• When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.

• Do not exceed the rated load capacity. Always operate the machine within the rated load capacity.

• Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and / or death.

• Avoid rapid drive direction changes which could possibly cause personal injury and / or death.

SA-400

Drive on Snow Safely • Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces.

• The machine may slip more easily than expected on frozen snow surfaces even if the inclination is small.

Reduce speed when driving. Avoid fast starts, stops and quick turns.

• Road shoulder and / or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow.

• Be sure to use tire chains when driving on snow.

• Avoid applying the brake for quick stops on snow. If a quick stop is required, lower the bucket to the ground.

S-14

SA-452

SAFETY Travel on Public Roads Safely • This machine is not allowed to drive on public roads with the bucket loaded.

• Be sure to empty the bucket.

• Hold the bucket at mark (A) 300 mm (12 in) above the road surface as illustrated.

SA-453

Avoid Injury from Rollaway Accidents • Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways: • Select level ground when possible to park machine.

• Do not park the machine on a grade.

• Lower the bucket to the ground.

• Put the F-N-R lever (switch) in neutral, and pull up the park brake switch (lever) in the ON (parking brake) position.

• Run the engine at low idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and remove the key from the key switch.

• Turn the loader control lever lock to LOCK position.

• Block both tires and lower the bucket to the ground.

• Position the machine to prevent rolling.

• Park at a reasonable distance from other machines.

SA-457

SA-458

S-15

SAFETY Avoid Accidents from Backing Up and Turning • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine.

• Keep all personnel away from the machine by sounding the horn and / or using hand signals. Use extra care to be sure no one is in from the articulation area before turning the machine.

• Keep windows, mirrors, and lights in good condition.

• Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility.

• In case good visibility is not obtained, use a signal person to guide you.

SA-383

SA-312

S-16

SAFETY Avoid Positioning Bucket or Attachment Over Anyone • Never allow the bucket or attachment to pass over coworkers and / or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.

• Avoid carrying the bucket or attachment over the coworkers to ensure safe operation.

SA-518

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE SA-463

FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping: • Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

S-17

SAFETY Never Undercut a High Bank • The edges could collapse or a land slide could occur causing serious injury or death.

SA-519

Dig with Caution • Accidental severing of underground cables or gas lines may cause an explosion and / or fire, possibly resulting in serious injury or death.

• Before digging, check the location of cables, gas lines, and water lines.

• Keep the minimum distance required, by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area , and / or the utility companies directly.

Have them mark all underground utilities.

SA-396

Perform Truck Loading Safely • Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and / or death.

• Do not lower the bucket with the loader control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and / or death.

• Always select a level surface for truck loading.

SA-397

S-18

SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length.

SA-455

Precautions for Operation • If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.

• Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

Precautions for Lightning • The machine is vulnerable to lightning strikes.

• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

S-19

SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED. • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example). They may come off, causing the load to fall.

SA-132

Protect Against Flying Debris • If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

SA-432

S-20

SAFETY Park Machine Safely To avoid accidents: • Park the machine on a firm, level surface.

• Lower bucket to the ground.

• Put the F-N-R lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.

• Run the engine at low idle speed without load for 5 minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Turn the loader control lever lock to the LOCK position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

SA-456

Store Attachments Safely • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034

S-21

SAFETY Transport Safely • Take care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.

• Observe the related regulations and rules for safe transportation.

• Select an appropriate truck or trailer for the machine to be transported.

• Be sure to use a signal person.

• Always follow the following precautions for loading or unloading: 1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use the low speed gear.

4. Never steer the machine while being on the ramp. If the traveling direction must be changed while being on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Wedge the front and rear of tires. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANSPORTING chapter.

S-22

Less than 15 ° SA-454

SAFETY Handle Fluids Safely−Avoid Fires • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and / or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler caps.

SA-018

SA-019

S-23

SAFETY Practice Safe Maintenance To avoid accidents: • Understand service procedures before starting work.

• Keep the work area clean and dry.

• Do not spray water or steam inside cab.

• Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Run the engine at low idle speed without load for 5 minutes.

SA-028

4. Turn the key switch to OFF to stop engine.

5. Relieve the pressure in the hydraulic system by moving the control levers several times.

6. Remove the key from the key switch.

7. Attach a “Do Not Operate” tag on the control lever.

8. Turn the loader control lever lock to the LOCK position.

9. Lock bar connects the front and rear frames.

10. Allow the engine to cool.

SA-312

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• Never work under a machine raised by the lift arm.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

SA-134

SA-527

S-24

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

Warn Others of Service Work • Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS2045102

Support Machine Properly • Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

S-25

SAFETY Stay Clear of Moving Parts • Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

Support Maintenance Properly • Explosive separation of a tire and rim parts can cause serious injury or death.

• Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Have it done by your authorized dealer or a qualified repair service.

• Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure.

• When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage if available.

• Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts.

• Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

S-26

SA-249

SAFETY Prevent Parts from Flying • Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

SA-344

Prevent Burns Hot spraying fluids: • After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.

• Avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces: • Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

S-27

SAFETY Replace Rubber Hoses Periodically • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.

SA-031

SA-292

SA-044

S-28

SAFETY Prevent Fires Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or hoses.

Check for Shorts: • Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

Check Heat Shields: • Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine.

S-29

SA-019

SAFETY Evacuating in Case of Fire • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time.

• Exit the machine.

SA-393

Beware of Exhaust Fumes • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

Precautions for Welding and Grinding • Welding may generate gas and / or small fires.

• Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

S-30

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

Remove Paint Before Welding or Heating • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.

• Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

SA-029

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

S-31

SAFETY Beware of Asbestos and Silicon Dust and Other Contamination • Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer.

Inhalation of silicon dust and other contamination may cause sickness.

• Depending on the work site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only genuine TCM Parts.

SA-029

Prevent Battery Explosions • Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

S-32

SA-032

SAFETY Service Air Conditioning System Safely • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the instructions described on the container for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

SA-405

Handle Chemical Products Safely • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

S-33

SA-309

SAFETY Dispose of Waste Properly • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with TCM equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

S-34

SA-226

SAFETY SIGNS All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the TCM dealer.

4

6

5

2

1

8

7

3 19 18

16

17

16

15

20

9 11

10

13 14

12 SS-4FGE-001

S-35

SAFETY SIGNS 1. Both sides of bucket

SS-4EK-017_E

SS-4FGE-002

• Sign indicates a hazard of falling.

• Do not stand on this place.

2. Front Maintenance Access Cover for Front Frame

SS-4EK-019_E

• The front attachment may unexpectedly be lowered, possibly resulting in personal injury. Lower the front attachment to the ground before inspecting/maintaining the machine. In case inspection and/or maintenance work must unavoidably be performed with the front attachment raised, lock the front attachment control levers in position.

Then, securely support the front attachment with safety stays and/or blocks.

SS-4FGE-003

3. Both sides of Lift Arm

SS-4EK-020_E

S-36

SS-4FG-002

SAFETY SIGNS 4. Left Side of Front Console

SS-4EK-021_E

SS-4EK-005 E

5. Right Side of Front Console

SS-4EK-022_E SS-4EK-005 E

6. Left side of steering wheel support

•

WARNING: To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine.

SS-4FGE-004 SS-4EK-023_E

S-37

SAFETY SIGNS 7. Steering wheel support

SS-4FGE-004

SS-4EK-026_E

8. Steering wheel support

SS-4FGE-004

SS-4EK-024_E

S-38

SAFETY SIGNS 9. Both Side Vicinity of Step’s

SS-4EK-027_E

SS-4FGE-005

SS-4FGE-006

10. Left Side of Fender

SS-4EK-028_E

• If the engine is started following an incorrect method, the machine suddenly may start to move. Start the engine from the operator’s seat only.

S-39

SS-4FGE-007

SAFETY SIGNS 11. Vicinity of Battery

SS-4EK-029_E

SS-4FGE-008

• Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte.

12. Vicinity of Radiator Cap

SS-4EK-031_E

SS-4FGE-007

• Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. Allow radiator or hydraulic tank to cool before removing cap.

13. Vicinity of Radiator Cap

SS-4EK-032_E

• Avoid skin contact with highly heated parts such as the engine, muffer, etc. immediately after operation of the machine. Severe burns may result.

SS-4FGE-007

S-40

SAFETY SIGNS 14. Both Sides of Radiator Fan Guard

SS-4EK-033_E

• Side indicartes a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.

SS-4FGE-007

15. Vicinity of Brake Oil Tank

SS-4EK-035_E

SS-4FGE-007

16. Both Sides of Counterweight

SS-4EK-039_E

• Avoid injury from backing-over accident. Keep everyone far away from the machine during operation.

S-41

SS-4FGE-009

SAFETY SIGNS 17. Left Side of Front Frame

SS-4EK-040_E

SS-4FGE-010

• The articulation area becomes a pinch point when steering the machine. Be sure to install the articulate lock bar during the inspection/maintenance work and transportation of the machine.

18. Both Sides of Front Fender

SS-4EK-041_E

• The articulation area becomes a pinch point when steering the machine. Keep all personnel away from the articulation area during operation of the machine.

SS-4FGE-011

19. Both Sides of Front Fender

SS-4EK-042_E

• Sign indicartes a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.

SS-4FGE-011

S-42

SAFETY SIGNS 20. Vicinity of Fuel Tank Cap

SS-4FGE-005 SS-4FGE-012

S-43

SAFETY SIGNS MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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S-44

COMPONENTS NAME Components Name 9

Canopy Vehicle 8

1- Bolt-On Cutting Edge (BOC)

7

2- Bucket 6

3- Bucket Link

5 4

4- Bell Crank 3

5- Bucket Cylinder 6- Front Combination Lamp (Turn Signal/Clearance Light/Hazard Light) 7- Headlight 8- Outside Rear View Mirror 2

9- ROPS Canopy

11

1

10- Fuel Filler Port 11- Articulation Lock Bar

14

13

12

10 M4FGE-01-001

12- Front Fender 13- Lift Arm Cylinder 14- Lift Arm 15- Hydraulic Oil Tank 16- Counterweight 17- Rear Combination Lamp (Turn Signal/Hazard Light/Tail Light/Brake Light) 18- Back Light 19- Backup buzzer 20- Towing Pin 21- Radiator/Oil Cooler 21

15

20 19

M4FGE-01-002

18

1-1

17

16

COMPONENTS NAME Cab Vehicle (Optional) 1- Bolt-On Cutting Edge (BOC)

9

10

11

8

2- Bucket 3- Bucket Link 7

4- Bell Crank

6

5- Bucket Cylinder

5

6- Front Combination Lamp (Turn Signal/Clearance Light/ Hazard Light)

4 3

7- Headlight 8- Outside Rear View Mirror

2

9- Front Work Light 10- ROPS Cab 11- Rear Work Light

13

1

12- Fuel Filler Port

16

13- Articulation Lock Bar

15

12

14 M4FG-01-003

14- Front Fender 15- Lift Arm Cylinder 16- Lift Arm 17- Hydraulic Oil Tank 18- Counterweight 19- Rear Combination Lamp (Turn Signal/Hazard Light/Tail Light/Brake Light) 20- Backup Light 21- Towing Pin 22- Radiator/Oil Cooler

22

17 21

20

1-2

M4FG-01-004

19

18

OPERATOR’S STATION Cab Features 2

4

3

1

5

M4FG-01-005

1- Front Console 2- Right Console 3- Operator’s Seat 4- Fuse Box 5- Floor Mat

1-3

OPERATOR’S STATION 1

Front Console

2

3

1- Steering 2- Horn Switch 3- Monitor Panel 4- Accelerator Pedal

4

5- Brake/Inching Pedal (Both right and left sides are interlocked.)

6- Brake/Inching Pedal (Both right and left sides are interlocked.)

7- Neutral Lever Lock (F-N-R Lever) 8- F-N-R Lever 9- Hi–Lo Selector Switch 6

10- Work Light Switch (Cab Vehicle)

5

M4FG-01-006

11- Hazard Switch 12- Turn Signal Lever 13- Parking Brake Switch

11

14- Front Wiper Switch (Cab Vehicle)

10

15- Rear Wiper Switch (Cab Vehicle)

9

16- Light Switch

fNOTE: Cab Vehicle is optional.

8

7

M4FG-01-007

12

13

14

15 16 M4FG-01-008

1-4

OPERATOR’S STATION Right Console

1

2

Mono-Lever Type 3

1- Loader Control Lever

4

2- Auxiliary Control Lever (Optional)

5

3- Auxiliary Control Lever Lock

6

4- Auxiliary (Optional)

7

5- Ride Control Switch (Optional) 6- eco Mode Switch 7- Heater Switch (Optional for Cab Vehicle) 8- Key Switch 9

9- Loader Control Lever Lock

8 M4FG-01-009

1-5

OPERATOR’S STATION Monitor Panel 1

2

3

4

5

6

7

8

9

10

11

22 12 21

20

19

18

17

16

15

14

13

1- Engine Coolant Temperature Gauge

12- Brake Oil Low Level Indicator

2- Left Turn Signal Indicator

13- Not Used

3- High Beam Indicator

14- Discharge Warning Indicator

4- Monitor Display

15- HST Error Code Readout Switch

5- Work Light Indicator (Optional)

16- Preheat Indicator

6- Right Turn Signal Indicator

17- Monitor Display Selector

7- Stop Indicator

18- Not Used

8- Service Indicator

19- Overheat Indicator

9- Parking Brake Indicator

20- Engine Oil Low Pressure Indicator

10- Clearance Light Indicator

21- Air Filter Restriction Indicator

11- Fuel Gauge

22- HST Warning Indicator

1-6

M4FG-01-010

OPERATOR’S STATION Stop Indicator (Red) WARNING: Prevent possible casualty and/or machine d damage.

If the stop indicator flashes and the alarm buzzer sounds, immediately stop machine operation.

Then, check and service the section displaying the trouble.

The stop indicator flashes and the alarm buzzer sounds if one of the following cases below occurs. Immediately, stop operating the machine. Move the machine to a safe area. Park the machine and stop the engine. Contact your nearest TCM dealer for machine inspection:

M4GB-01-010

• If the engine oil pressure decreases, • If the engine coolant temperature abnormally increases, • If the brake oil level decreases,

Service Indicator (Yellow) The service indicator comes ON if one of the following cases as described below occurs. Immediately, stop the engine. Check the cause of the trouble.

• If the alternator voltage decreases or becomes excessively high, • If the air cleaner is restricted, • If any abnormality is found in HST operation, • If the indicator comes ON when the parking brake is applied,

1-7

M4GB-01-011

OPERATOR’S STATION Parking Brake Indicator (Red) The parking brake indicator will light when the parking brake is applied.

Return the FNR lever to neutral (N) and release the parking brake.

M4GB-01-012

Brake Oil Low Level Indicator (Red) WARNING: Stop the machine operation if the brake d oil level decreases. Failure to do so may result in personal injury or death. If the red indicator comes ON, immediately stop the machine operation.

If the brake oil level decreases, the brake oil low level indicator will come ON, and the stop indicator will flash.

Immediately stop the machine operation and inspect the brake system for any brake oil leaks.

M4GB-01-014

Discharge Warning Indicator (Red) If any abnormality occurs in the battery charging system such as low alternator voltage, the discharge warning indicator and the service indicator will light. Inspect the alternator and the battery system. The alternator output voltage can be checked at the monitor in the operator’s station. Inspect the alternator and the battery system.

1-8

M4GB-01-018

OPERATOR’S STATION Overheat Indicator (Red) If the engine coolant temperature increases to the abnormally high range, the red indicator will light and the stop indicator will flash.

Stop machine operation and reduce the engine speed to the low idle range to cool the coolant temperature.

M4GB-01-020

Engine Oil Low Pressure Indicator (Red) WARNING: If the engine is kept running with the d engine oil pressure low, damage to the engine may result. Immediately stop machine operation and stop the engine if the indicator lights.

If the engine oil pressure becomes low, the engine oil low pressure indicator will light and the stop indicator will flash.

Immediately stop machine operation and stop the engine.

Inspect the engine oil pressure system and the oil level for any abnormality.

M4GB-01-021

fNOTE: Cold oil temperature or operating on a steep slope may also cause the indicator to light.

Air Filter Restriction Indicator (Red) If the air cleaner is restricted, both the air filter restriction indicator and the service indicator come ON. Immediately stop the machine and the engine, check the air cleaner. Clean or replace the element as needed.

M4GB-01-023

HST Warning Indicator (Red) Caution is advised if any serious abnormality occurs in the HST or the HST relevant parts. If both the HST warning indicator and the service indicator come ON, immediately stop the machine and the engine in a safe position and then contact your nearest TCM dealer.

M4GB-01-024

1-9

OPERATOR’S STATION Engine Coolant Temperature Gauge The engine coolant temperature is indicated with a needle.

When the needle stays in the blue range (1) during operation, the coolant temperature is normal.

If the engine coolant temperature becomes abnormally high, the stop indicator will flash. Stop machine operation and run the engine at low idle to lower the coolant temperature.

After the coolant temperature lowers, stop the engine for inspection. In case the needle does not swing at all, Error in the electrical system is suspected. Contact your nearest TCM dealer for machine inspection.

1

M4GB-01-028

Fuel Gauge The remaining fuel amount is indicated by the needle.

Fuel the machine before the needle indicates the red range (E).

M4GB-01-030

1-10

OPERATOR’S STATION Preheat Indicator (Yellow) The preheat indicator lights when the key switch is turned to HEAT position, and it goes OFF when the engine preheating is completed.

M4GB-01-031

Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the indicator start flashing.

M4GB-01-032

High Beam Indicator (Blue) When the head lights are used at the high beam position, the indicator will light.

M4GB-01-033

Work Light Indicator (Yellow) When the work lights are turned ON, this indicator will come ON.

M4GB-01-034

Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator will come ON. M4GB-01-035

1-11

OPERATOR’S STATION 1

Monitor Display 1- Monitor Display 2- HST Error Code Readout Switch 3- Monitor Display Selector 4- Not Used 5- Speedometer 6- Ride Control Indicator (Optional) 7- Machine Information Display

4

3

2

M4FG-01-011

8- Forward/Reverse and Shift Position Indicator 8

5

6

7

1-12

M4FG-01-012

OPERATOR’S STATION 1

Forward/Reverse and Shift Position Indicator F-N-R/Shift position indicator (1) displays the selected travel mode.

• Forward : 2 stages • Reverse : 2 stages

M4FG-01-012

F-N-R (Forward/Reverse) Position Indicator When F-N-R lever (4) is placed in forward (F), neutral (N), or reverse (R) position, F-N-R position indicator (2) indicates the selected F-N-R lever position by lightening the corresponding indicator in square ( ).

(F-N-R indicates the selected F-N-R lever position.)

2 3

Shift Position Indicator When F-N-R lever (4) is in either the forward or reverse position, shift position indicator (3) displays the shift stage selected by Hi - Lo selector switch (5).

M4FG-01-013

4

• Hi : Auto Shift 2-Speed Mode • Lo : 1-Speed Mode F N

R

5 M4FG-01-014

5

M4FG-01-056

1-13

OPERATOR’S STATION Speedometer Speedometer (1) indicates the present machine driving speed.

M4FG-01-011

1

Ride Control Indicator (Optional) Ride control indicator (2) lights when ride control switch (3) is turned ON.

2

1

M4FG-01-012

3

M4FG-01-015

1-14

OPERATOR’S STATION Machine Information Display When the key switch is turned ON, the machine information area (2) displays the machine information.

M4FG-01-011

1

When the key switch is turned ON, the machine information display indicates engine start-ready screen (3).

Each 0.5 seconds, the most left side indication is counted down as shown in display illustration (4).

Hour meter (5) will be displayed. Press monitor display selector (1) to shift the display item from the hour meter (5) to odometer on the machine information display.

2 1

M4FG-01-012

Engine Start-ready Screen (3)

Engine Start-ready Screen (4)

Hour Meter (5)

M4FG-01-016

1-15

OPERATOR’S STATION Shifting Item to Be Indicated on Machine Information Display Press monitor display selector (1) to shift the display item once at a time.

M4FG-01-011

1

Hour Meter

When monitor display selector (Δ) (1) is pressed once:

Indicates the total machine operating hours up to present.

In case the operating hour exceeds 99999.9 h, the meter restarts counting the hour from 0 hour. The hour meter will be locked after third round of 99999.9 h.

When this display is indicated, press monitor display selector (1) once to display the odometer.

Hour Meter

Press button

press button

Odometer

Odometer Indicates the total machine traveling distance up to present.

M4FG-01-017

1-16

OPERATOR’S STATION 2

HST Error Code Readout Switch Press HST error code readout switch (3) when HST warning indicator (1) and service indicator (2) light. HST warning indicator (1) flashes and abnormal contents of HST related parts (Electrical system) are detected.

fNOTE: In case multiple abnormalities are found, each time

1

HST error code readout switch (3) is pressed, the flashing state of HST warning indicator (1) changes according to the detected abnormality.

3

M4FG-01-011

HST error code readout switch (3) detects only electrical system related abnormities. Several possible reasons other than the electrical system may occur, contact your nearest TCM dealer for machine inspection.

Abnormality occurs at:

Flashing state of HST warning indicator (1)

Error Flashing Light Off Flashing Code (1 sec.)

(2 sec.)

(1 sec.)

Detecting Condition

Start-up condition

Once

→

Once

1-1

Low or high controller supply voltage

HST motor output

Twice

→

Once

2-1

Open circuit of HST motor solenoid output cable

HST pump output

Twice

→

Twice

2-2

Open circuit of HST pump solenoid output cable

Parking Brake

Twice

→

3-times

2-3

Open circuit of parking brake relay output cable

Overrunning Buzzer

Twice

→

4-times

2-4

Open circuit of overrunning buzzer output cable

Speed Sensor

3-times

→

Once

3-1

Speed sensor is abnormal

Engine Speed Sensor

3-times

→

Twice

3-2

Engine speed sensor is abnormal

Inching Sensor Low Voltage

3-times

→

3-times

3-3

Low voltage of inching sensor

Inching Sensor High Voltage

3-times

→

4-times

3-4

High voltage of inching sensor

F-N-R Lever

3-times

→

5-times

3-5

F-N-R Lever is abnormal

Low Voltage

4-times

→

Once

4-1

Low controller supply voltage (10 V or less)

4-times

→

Twice

4-2

High controller supply voltage (17 V or higher)

High Voltage

1-17

OPERATOR’S STATION Error Code 1

If the letters of “ERROR” are displayed on the machine information area (1), immediately stop operating the machine, move the machine to a safe area, park the machine and stop the engine. Contact your nearest TCM dealer for machine inspection.

M4FG-01-011

2

M4FG-01-018

1-18

OPERATOR’S STATION Switches, Steering Wheel and Pedals

1

2

3

1- Steering Wheel 2- Horn switch 3- Monitor Panel 4- Accelerator Pedal

4

5- Brake/Inching Pedal (Both right and left sides are interlocked.)

6- Brake/Inching Pedal (Both right and left sides are interlocked.)

7- Neutral Lever Lock (F-N-R Lever) 8- F-N-R Lever 9- Hi-Lo Selector Switch 6

10- Front Work Light Switch (Cab Vehicle)

5

M4FG-01-006

11- Hazard Switch 12- Turn Signal Lever 11

13- Parking Brake Switch

10

14- Front Window Wiper Switch (Cab Vehicle)

9

15- Rear Window Wiper Switch (Cab Vehicle) 16- Light Switch

fNOTE: Cab vehicle is an optional.

8

7

M4FG-01-007

12

13

14 15 16 M4FG-01-008

1-19

OPERATOR’S STATION F-N-R Lever

1

WARNING: To ensure operator’s safety and ensure d the longevity of the power train system, change the machine drive direction only after sufficiently reducing the drive speed.

Changes the machine drive direction from forward to reverse and vice versa.

Move F-N-R lever (1) to the (F) position to travel the machine forward.

Move F-N-R lever (1) to the (R) position to drive the machine in reverse.

F N R

M4FG-01-014

When F-N-R lever (1) is placed in the (R) position, backup light (2) lights and the backup buzzer sounds.

fNOTE: The engine will not be started if the F-N-R lever (1) is not in the neutral (N) position.

2

M4FG-01-019

Neutral Lever Lock (F-N-R Lever) WARNING: When the machine is parked or serviced, d be sure to place the neutral lever lock in the LOCK position.

The neutral lever lock makes the F-N-R lever immovable so that the machine does not starts moving even if a body part comes in contact with the F-N-R lever by mistake.

Before starting the engine, set neutral lever lock (3) in the LOCK position.

LOCK UNLOCK

Pull: UNLOCK Push: LOCK

3

1-20

M4FG-01-014

OPERATOR’S STATION Steering IMPORTANT:

When the steering wheel is fully turned, the front and the rear frames come in contact with the stoppers so that the steering wheel does not rotate further. If the steering wheel is forcibly turned moreover, the engine may stall or malfunction of the steering system may result.

1

2

M4FG-04-002

Horn Switch Press horn switch (2) to sound the horn.

3

Turn Signal Lever Indicates the drive change direction to persons and/or other vehicles by operating turn signal lever (3).

Return turn signal lever (3) to neutral manually.

L

N

L : Left Turn R : Right Turn

R

Dimmer Switch

M4FG-01-020

The dimmer switch shifts the headlight beam high and low.

4

Travel the machine with the headlight d inCAUTION: the low beam position when other vehicles are present in the vicinity.

After turning the headlight ON, when turn signal lever (3) is lowered, the headlight beam is set in the high position and high beam indicator (4) comes ON. When the turn signal lever is raised, the headlight beam is set in the low position and high beam indicator comes OFF. M4FG-01-011

1-21

OPERATOR’S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( ) according to the selected position of the light switch.

2- Headlight 3- Turn Signal/Hazard Light/Clearance Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light 1

Light Switch Position OFF

Headlight

Clearance Light

Tail Light

Monitor Panel Light

● ●● IMPORTANT:

M4FG-01-020

2

2

3

3

Take care not to use the below switch function for a long time. The batteries are discharged.

fNOTE: Even though the key switch is turned OFF, as long as

M4FGE-01-021

the light switch is in (●) position, all lights except the headlight stay ON. This function is used as a parking light on a public road.

4

4 5

5 M4FGE-01-019

1-22

OPERATOR’S STATION Hazard Switch 1

IMPORTANT: Do not hold hazard switch (1) in the “ ” position for a long time with the engine stopped. The batteries will become discharged.

When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.

When the position marked with “ “ on hazard switch (1) is pressed, front and rear turn signals (hazard light) (2) on both right and left sides starts flashing.

Press the opposite side of hazard switch (1) to turn the hazard signals OFF.

M4FG-01-014

1

M4GB-01-065

2

2

M4FGE-01-021

2

2

M4FEG-01-019

1-23

OPERATOR’S STATION Work Light Switch (Cab Vehicle) CAUTION: Do not turn the work lights ON while d driving on a public road.

1

With the light switch in either (●) or (● ●) position, press side, front work lights (2) are turned ON. Rear switch (1) to work lights (3) stay OFF. Press switch (1) to side, front work lights (2) and rear work lights (3) turn ON.

M4FG-01-014

1

M4GB-01-067

3 2

2

3

M4FG-01-022

1-24

OPERATOR’S STATION Hi-Lo Selector Switch Hi-Lo selector switch (1) is used to shift the travel speed stage.

Select the position to match the desired travel/work mode.

Lo ..... Travel speed is kept maintained to the first stage.

0 to 14 km/h (8.7 mph) Hi ..... Travel speed is automatically shifted within the range of the first to 2nd speed stage by operating the accelerator pedal.

0 to 34 km/h (21 mph)

1

fNOTE: When eco mode switch (2) is in the ON position while Hi-Lo selector switch (1) is in the Hi position, the machine travels in below speed.

0 to 28 km/h (17 mph)

M4FG-01-014

1

M4FG-01-056

2

M4FG-01-015

1-25

OPERATOR’S STATION Parking Brake Switch To prevent the occurrence of accidents d WARNING: due to running away of the machine, be sure to

1

apply the parking brake when parking the machine and before leaving the machine.

Do not apply the parking brake while traveling the machine except in an emergency. Apply the parking brake only after the machine has stopped.

Failure to do so may cause sudden deceleration of the machine travel speed, possibly creating a dangerous situation. Premature wear and/or damage to the parking brake may result. After the parking brake has been applied in an emergency while traveling the machine, have the parking brake checked at your nearest TCM dealer.

When parking brake switch (1) is turned ON, the parking brake is applied, and parking brake indicator (2) and service indicator (3) come ON. Press the OFF side of parking brake (1) to release the parking brake. Check that parking brake indicator (2) and service indicator (3) go OFF by pressing the switch twice with clicks.

fNOTE: • The parking brake is released by hydraulic pressure only when the engine is running.

• To ensure safe operation, when the parking brake is applied, even though the F-N-R lever is moved to forward (F) or reverse (R) position, the machine does not travel.

• To ensure safe operation, when the engine is stopped, the parking brake is applied even if parking brake switch (1) is in the OFF position.

Before starting the engine, check that the F-N-R lever is in the neutral (N) position. Then, turn the parking brake switch (1) ON.

1-26

M4FG-01-020

1

ON

OFF

M4EK-01-025A

3 2

M4FG-01-011

OPERATOR’S STATION Wiper Operation IMPORTANT:

The wiper may damage the glass surface, or the wiper blade, wiper motor and the relay may be damaged according to the condition of the glass surface such as snow coverage and freeze up.

• Before operating the wiper, remove snow and dust from the window. When the window becomes frozen, defrost the window pane by using the defroster.

• Use nonfreezing washer fluid.

• When the window pane is dried out, operate the wiper after dispensing the washer fluid. When continuously operate the wiper under the semiarid condition such as spatter of snow or rain, severe load may be applied to the wiper, possibly damage to the wiper. Operate the wiper with intermittent mode or frequently ON/OFF the wiper.

• Do not operate heating wire in the window pane (If equipped) for a long time. The wiper blades may be burnt.

1-27

OPERATOR’S STATION Front Window Wiper Switch (Cab Vehicle) IMPORTANT:

The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.

Take care about the switch operation time and the fluid level in the washer tank.

1

Operate front window wiper switch (1) to move the windshield wiper.

2 M4FG-01-020

OFF ....... The wiper stops moving and the wiper blade is returned to the pre-start position.

LO .......... The wiper operates at slow speed.

HI ........... The wiper operates at fast speed.

PUSH..... As long as wiper switch (1) is depressed, the washer fluid is dispensed.

1

2 M4FG-01-044

Rear Window Wiper Switch (Cab Vehicle) IMPORTANT:

The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.

Take care about the switch operation time and the fluid level in the washer tank.

Operate rear window wiper switch (2) to move the windshield wiper.

OFF ....... The wiper stops moving and the wiper blade is returned to the pre-start position.

LO .......... The wiper operates at slow speed.

PUSH..... As long as wiper switch (2) is depressed, the washer fluid is dispensed.

1-28

OPERATOR’S STATION Accelerator Pedal When accelerator pedal (1) is stepped on, the engine speed increases. When released, the engine speed decreases.

1

Brake/inching Pedal WARNING: Avoid sudden brake application during d travel operation, possibly creating a hazardous situation. The machine may lose its balance.

Unless necessary, do not place your foot on the brake pedal to prevent the brake discs from wearing out prematurely.

Keep the installation areas around the brake pedals clean to prevent dust and/or grit from accumulating.

Failure to do so may cause the brake pedals to become inoperable.

2

3

WARNING: Do not allow your foot to ride on the d brake pedal unless necessary.

M4FG-01-006

4 5

The machine brake is applied by stepping on the brake/ inching pedal (2) or (3).

When the brake pedal is stepped on, inching (4) operates and the HST pump becomes neutral, causing the travel speed to reduce. When the brake pedal is stepped on further, service brake (5) is activated, increasing braking force.

M4FG-01-043

When the pedal is fully stroked, the machine stops regardless of the position of the F-N-R lever. Thus, the engine power is transmitted only to the working devices. Accordingly, when controlling the loader control lever while depressing accelerator pedal (1), the operator can be concentrate on operating the front attachment.

1-29

OPERATOR’S STATION Right Console (Front Attachment)

1

2

Mono-Lever Type 3

1- Loader Control Lever 2- Auxiliary Control Lever (Optional) 3- Auxiliary Control Lever Lock 4- Loader Control Lever Lock

4 M4FG-01-009

1-30

OPERATOR’S STATION C

Loader Control Lever

B

Mono-Lever Type Is used to operate the lift arm and/or bucket.

(C) Float

E N

: The lift arm free falls and can be moved as loads are applied.

D G

A

(B) Lift Arm Lower (N) Hold

: The lift arm and bucket are stopped and held in that position.

(A) Lift Arm Raise (E) Bucket Dump : The bucket is tilted forward to dump the bucket load.

(D) Bucket Tilt

: The bucket is tilted back, taking the transportation position.

(G) Detent

: When the loader control lever is moved from the bucket dump position to the bucket tilt position, the loader control lever is maintained in this position.

M4FG-01-023

fNOTE: After dumping the bucket, when loader control lever (1) is pulled further from the TILT position (D), the lever is held in that position (G). Then, as soon as the bucket is tilted up to the position set by the bucket auto-leveler, loader control lever (1) is automatically returned to the HOLD position (N).

C B

D

E N A M4GB-01-074

M4EJ-01-031A

1-31

OPERATOR’S STATION Lever Locks WARNING: When locking the loader control lever d and the auxiliary control lever (optional), securely

1

shift lever locks (2) and (4) to the LOCK position.

Unless lever locks (2), (4) are fully moved to the LOCK position, the control levers are not locked, possibly creating a hazardous situation.

LOCK

Before leaving the operator’s seat, be sure to stop the engine. Then, move lever locks (2), (4) to the LOCK position.

UNLOCK

Always check to be sure that the lever locks are moved to the LOCK position before: • Transporting the machine.

• Leaving the machine at the end of the shift.

2 M4FG-01-023

4

3

Refer to section 5-2 for details.

Lever locks (2), (4) are provided to prevent the machine is unexpectedly operated even if the operator mistakenly comes in contact with loader control lever (1) or auxiliary control lever (3) (optional) when getting on or off the machine. When loader control lever (1) and auxiliary control lever (3) (optional) are placed to the UNLOCK position, the levers become operable.

UNLOCK

LOCK

f

NOTE: Auxiliary control lever (3) and lever lock (4) are optional.

Auxiliary Control Lever (Optional)

1-32

M4FG-01-024

OPERATOR’S STATION Right Console/Switch Panel 1- Auxiliary (Optional) 1

2- Ride Control Switch (Optional)

2

3- eco Mode Switch

3

4- Heater Switch (Cab Vehicle)

4

5- Key Switch

5

1-33

M4FG-01-023

OPERATOR’S STATION Key Switch WARNING: Before starting the engine, return d the F-N-R lever to neutral (N) position, apply the parking brake, and lock the loader control lever and the auxiliary control lever (optional). Refer to the descriptions in the “OPERATING ENGINE“ chapter for the detail information.

1

WARNING: Never turn key switch (1) OFF while d traveling the machine. Failure to do so may cause

M4FG-01-015

steering wheel and brakes are out of control, possibly creating a dangerous situation.

Failure in the electrical system and/or base machine may result.

A : HEAT

B A

C D

(Preheat)

B : OFF

(Engine Off )

C : ON

(Engine On)

1

D : START (Engine Start)

M4EJ-01-025

eco Mode Switch

2

When eco mode switch (2) is turned ON, HST pump and motor control programs are changed in order to prevent rapid increase of the engine speed.

This function helps to reduce fuel consumption.

When eco mode switch (2) is turned ON, orange light (3) comes ON.

M4FG-01-015

3

ON

2

OFF M4FG-01-045

1-34

OPERATOR’S STATION 1

Ride Control Switch (Optional) Ride control switch (1) damps the vertical vibration of the front attachment during travel operation so that comfortable machine ride quality is obtained. As stable drive operation is achieved, bucket load spill can be reduced.

WARNING: When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn ride control switch (1) OFF. Failure to do so may allow the front attachment to unexpectedly move up or down when the ride control system is activated.

d

WARNING: When operating the front attachment d while the ride control is activated, sufficiently reduce the machine travel speed. If impact loads is applied to the front attachment, high pressure may apply to the ride control accumulator, possibly resulting in gas leakage.

Ride Control Operation

M4FG-01-015

1 ON 2

OFF

WARNING: To ensure safety, operate ride control d switch (1) only after parking the machine with the

M4FG-01-025

bucket lowered to the ground.

When the ride control switch (1) is turned ON, the travel speed sensor and the controller is activated. Then, when the travel speed becomes faster than 10 km/h (6.2 mph), the ride control system automatically operates. When the travel speed becomes slower than 8 km/h (5.0 mph), the ride control system becomes inoperable.

When ride control switch (1) is turned ON, green lamp (2) of the switch and ride control indicator (3) on the monitor display comes ON. When ride control switch (1) is turned OFF, green lamp (2) of the switch and ride control indicator (3) on the monitor display goes OFF and ride control does not operate.

When the key switch is in the OFF position, the ride control system does not operate even if ride control switch (1) is turned ON. When the engine is stopped while ride control switch (1) ON, the ride control is turned OFF.

1-35

3

M4FG-01-012

OPERATOR’S STATION 1

Heater (Optional) Operation 1- Heater Switch 2- Vent 3- Front Window Defroster Heater Switch Operate heater switch (1) to activate the heater.

M4FG-01-015

OFF .... The heater operation is stopped.

LO ....... Blown out warm air volume decreases.

HI ........ Blown out warm air volume increases.

Vent Manually open heater unit cover (2) to adjust heater operation.

1

fNOTE: When the front window pane becomes frozen: If the

M4EJ-01-060

front window pane becomes frozen in winter or when atmospheric temperature is low due to snow falling, close vent cover (2) and turn heater switch (1) to the HI position. Full warm air is blown out from three front window defrosters (3), allowing the frozen front window pane to be quickly defrosted.

2

M4FG-01-049

3

M4EK-01-060

1-36

OPERATOR’S STATION Adjusting Operator’s Seat (Standard Type) CAUTION: Adjust the seat position so that all the d pedals, levers and switches can be easily and correctly operated. Adjust the seat position while the machine is parked.

Components Name 1- Damper Adjustment 2- Slide Lever 2

M4FG-01-026

1

1. Damper Adjustment The damper stiffness can be adjusted in 5 steps in accordance with the type of work engaged in or the conditions of the road surface.

Pull up lever (1) and pull down at the proper point.

A: Soft B: Hard

A B 1

M4FG-01-027

2. Fore-Aft Position Adjustment Fore-after position of the seat adjustment allows for proper fitting to the operator. Pull up slide lever (2) to adjust the front/rear position of the seat assembly. The seat assembly position can be adjusted in the range of full stroke 160 mm (6.3 in) by 10 mm (0.4 in) interval. Return the lever to the original position after the seat assembly is moved to the desired position. Check that the seat assembly is locked in the desired position.

2

2

M4FG-01-028

1-37

OPERATOR’S STATION Adjusting Operator’s Seat (Suspension Type) CAUTION: Adjust the seat position so that all the d pedals, levers and switches can be easily and correctly operated. Adjust the seat position while the machine is parked.

3

Components Name 1- Suspension Handle 2- Slide Lever 3- Armrest 4- Reclining Adjusting Lever 5- Indicator

2

4 1 5

M4GB-01-155

1. Suspension adjustment Adjust the suspension to protect the operator.

Adjustment procedure 1. Seat on the operator’s seat.

2. Turn suspension handle (1) rightward to raise the seat height, turn leftward to lower the height.

1

3. Ensure that indicator (5) is in the green range. If the indicator is in red range, rotate the suspension handle and re-adjust the height.

The adjustable range: 50 kg (110 lb) to 120 kg (265 lb)

fNOTE: If the indicator is in upper red range, the seat stiffness is too hard and difficult to ride.

If the indicator is in lower red range, the seat stiffness is too soft and the seat may come down to the bottom end.

Red Green Red M4GB-01-156

1-38

OPERATOR’S STATION 2. Fore-Aft Position Adjustment Fore-after position of the seat adjustment allows for proper fitting to the operator. Pull up slide lever (2) to adjust the front/rear position of the seat assembly. The seat assembly position can be adjusted in the range of full stroke 160 mm by 10 mm interval. Return the lever to the original position after the seat assembly is moved to the desired position.

Check that the seat assembly is locked in the desired position.

2

M4GB-01-157

3. Armrest Angle Adjustment The angle of the armrest can be adjusted by turning knob (6) provided under the armrest.

A: Raise B: Lower

6

M4FG-01-046

4. Reclining Angle Adjustment The reclining angle can be adjusted up to 66 ° forward and 72 ° backward by pulling up reclining adjusting lever (4).

Return the reclining adjusting lever to the original position.

Check that the backrest is locked in the desired position.

M4FG-01-047

4

1-39

OPERATOR’S STATION Seat Belt

1

2

WARNING: Always use the seat belt when operating d the machine.

Before operating the machine, be sure to examine the seat belt and attaching hardware for any failure.

If any damage and/or wear is found, replace the part concerned.

Replace the seat belt every four years regardless of its appearance.

3

1. Seat belt (1) on this machine is a recoiling type.

2. Confirm that seat belt (1) is not twisted. Securely insert the end of seat belt (1) into buckle (2).

M4FG-01-050

fNOTE: When trying to insert seat belt (1) into buckle (2), in

case the belt is suspended to extend and does not come out further, fully retract the belt to the original position and try to extend again.

3. Push button (3) on buckle (2) to unfasten seat belt (1).

Seat Pocket (Suspension Seat) A pocket is provided on the back of the operator’s seat. Use it as a storage space to keep goods such as the Operator’s Manual.

fNOTE: The seat pocket is not a water resistant type. For the

canopy vehicle, protect the seat pocket against water using a vinyl bag as needed.

M4GB-01-139

M4GB-01-160

1-40

OPERATOR’S STATION Fuse Box IMPORTANT:

If a fuse blows, turn the key switch OFF. After checking and correcting the cause of the trouble, replace the fuse with a new one.

The fuses function as a safety valve to prevent excess current from flowing in the electrical system. Slow blow fuses (2) are used.

Each fuse capacity differs depend on the corresponding circuit. Replace the fuse with one having the corresponding specific capacity.

When checking fuses, check the fuse (1) and slow blow fuses (2) (2 used) in this order.

1

M4FG-01-029

2

2: 100 A

M4FG-01-048

1-41

OPERATOR’S STATION Fuse Box No.

Ampere

Corresponding Circuit

1

10

HEAD LIGHT (LEFT)

2

10

HEAD LIGHT (RIGHT)

3

15

HEAD LIGHT (HI BEAM)

4

5

CLEARANCE LIGHT (LEFT), TAIL LIGHT (RIGHT)

5

5

CLEARANCE LIGHT (RIGHT), TAIL LIGHT (LEFT)

6

15

HST [F], [R] SOLENOID, PARKING BRAKE SOLENOID, BACKUP LIGHT, BACKUP BUZZER, RELAY [1], RELAY [2]

7

15

HORN, BRAKE LAMP

8

10

ENGINE STOP SOLENOID, FUEL PUMP

9

10

SAFETY RELAY, ALTERNATOR, ENGINE SPEED SENSOR, RELAY [3]

10

10

BUCKET AUTO LEVELER PROXIMITY SWITCH, CONTROL VALVE DETENT (TILT)

11

10

MONITOR

12

30

HEAD LIGHT, CLEARANCE LIGHT, TAIL LIGHT

13

15

HST CONTROLLER

14

10

MONITOR BACKUP POWER SUPPLY

15

−

OPTIONAL POWER

16

−

OPTIONAL POWER

17

−

OPTIONAL POWER

18

NOT USED

19

−

OPTIONAL POWER

20

15

HAZARD LIGHT, FLASHER UNIT

M4FG-07-047

1-42

OPERATOR’S STATION ROPS Cab (Optional)

1

ROPS Cab (1) is an optional equipment.

1- ROPS Cab 2- Room Light 3- Room Rear View Mirror 4- Sun Visor (Optional)

fNOTE: The ROPS cab may not be equipped for the special

M4FG-01-032

specification machine such as snow removal vehicles.

2

3

4

1-43

M4EK-01-030

M4FG-01-055

OPERATOR’S STATION 5- Radio (Optional)

5

6- Cab Switch Panel (Optional) 7- Drink Holder 8- Speaker (Optional) 9- Coat Hook

6

M4EK-01-031

8

7

9

1-44

M4EK-01-032

M4EK-01-033

OPERATOR’S STATION Room Light

1

When the switch knob is in the ON position, room light (1) comes ON. When the switch knob is in the OFF position, room light (1) goes OFF.

M4EK-01-030

ON

OFF

1

M4EK-01-034A

Sun Visor (Optional) Pull the sun visor down when blocking strong sun light radiation from the cab top side.

M4FG-01-055

Drink Holder IMPORTANT:

Be sure to put a plug or cap on a drink bottle when placing it on the drink bottle holder.

M4EK-01-032

1-45

OPERATOR’S STATION Coat Hook Use coat hook (1) for hanging up your jacket and hat.

1

M4EK-01-033

Rear View Mirror

d

3

WARNING: Do not travel the machine in reverse by relying on only the range of vision the rear view mirror (2) provides. Use the rear view mirror only as an assistant during travel operation. Be sure to confirm the safety by using your own visibility when traveling the machine in reverse.

2

2

After taking the seat, adjust the rear view mirror so that the good rearward visibility can be obtained.

Always keep the mirror clean.

Cab Vehicle

Canopy Vehicle M4FGE-01-033

Room Rear View Mirror Always keep room rear view mirror (3) clean.

1-46

OPERATOR’S STATION FM/AM Radio (Optional) Operation Controls on the Radio 1- Power/Volume Switch Each time switch (1) is pressed, electric power is turned ON or OFF alternately. Turn switch (1) clockwise to increase the sound volume. Turn switch (1) counterclockwise to decrease the sound volume. While pulling out switch (1), turn it clockwise to intensify the right side speaker volume, or turn it counterclockwise to intensify the left side speaker volume.

M4EK-01-031

3

2- Tone Adjusting Knob

2

1

Turn knob (2) clockwise to intensify high-pitched tone or turn knob (2) counterclockwise to intensify low-pitched tone.

3- Display 4

Displays time or frequency.

5

6

7

8

9

10 M4EK-01-036

4- Memory Button 5- AM/FM Switch Button Each time button (5) is pressed within an interval less than 5 seconds with the frequency kept displayed, the modulation mode is shifted in the order of AM1 → AM2 → FM1 → FM2.

fNOTE: When a stereo broadcasting is received, stereo

12

indicator (11) comes ON.

6- AS Button 7- Search Button 8- Channel Button

11

9- Alarm Button

1-47

M4EK-01-038A

OPERATOR’S STATION Tuning Procedures • Manual Tuning Procedure Repeatedly press at intervals shorter than 0.5 seconds one of tuning buttons (7) until the desired station is reached.

Each time the tuning button is pressed, the frequency phase changes at the intervals of AM: 9 kHz and FM: 0.1 MHz. ) to increase the frequency.

Tap the tuning switch [UP] ( Tap the tuning switch [DOWN] ( ) to decrease the frequency.

• Automatic Tuning Procedure Press and hold search button (7) for more than half a second. When a station is received, an electronic tone is heard and operation automatically stops.

Tap the tuning switch [UP] ( ) to increase the frequency.

Tap the tuning switch [DOWN] ( ) to decrease the frequency.

7

7

M4EK-01-039

fNOTE: If the receiving radio waves are weak, i.e. such as

when the machine is located between high rising buildings, etc., use the manual tuning procedure to select the desired station.

Station Presetting Procedure 6 stations in each modulation mode (AM1, AM2, FM1 and FM2) can be preset (24 stations in total).

3

1. Press memory button (4) while receiving radio broadcasting. The channel No. indicated on display (3) starts blinking.

2. Select the station desired to preset by pressing channel button (8). Channel No. indicated on display (3) is shifted.

4

8

M4EK-01-036

3. After selecting the station, press memory button (4).

Then, the selected station is preset.

4. Each time when channel button (8) is pressed, stations stored in the preset memory (1 CH to 6 CH) can be received in order.

When required to change the preset station, repeat the same procedures as described in steps 1 to 4 above.

• Deletion of Presetting Memory When the battery power is disconnected from the radio due to machine maintenance work or removal of the radio, memories stored by memory button (4) are deleted. Retry presetting in this case.

1-48

M4EK-01-038A

OPERATOR’S STATION Auto Station Presetting Procedure AM/FM

Automatically received station is stored in the preset memory.

1. Select either AM or FM using AM/FM Switch button (5).

AS

CLOCK

2. Press and hold AS button (6) for longer than 2 seconds.

An electronic tone is heard and one of 6 stations is automatically stored at good sensitivity.

5

M4EK-01-040

6

Digital Clock Setting Procedure Set the clock with the key switch ON. 1. Press and hold AM/FM switch button (5) until an electronic tone is heard. A time display starts blinking so that time setting becomes ready. If no operation is made for 15 seconds afterwards, the clock setting mode is deactivated.

H

2. Press tuning button (7) to change the time. Press “H” button and “M” button to adjust “Hour” and “Minute” respectively.

7

M

7

M4EK-01-039

3. Press AM/FM switch button (5) to set the time.

fNOTE: When putting the clock by the time signal, press

memory button (4) during the clock display blinking.

Alarm Setting Procedure

4

Alarm can be set to emit at desired time. Each time alarm button (9) is pressed, alarm ON and OFF is repeatedly set.

9

M4EK-01-036

13

1. Press and hold alarm button (9) until an electronic tone is heard. Alarm mark (13) starts blinking so that alarm can be set. If no operation is made for 15 seconds afterwards, the alarm setting mode is deactivated.

M4EK-01-037

2. Press tuning button (7) to change the time. Press “H” button and “M” button to adjust “Hour” and “Minute” respectively.

3. When the set time arrives, the alarm continues to sound for 3 minutes. Press alarm button (9) to stop the alarm.

1-49

OPERATOR’S STATION Upper Switch Panel (Optional)

1

2

1- Rotary Beacon Switch (Optional) 2- Auxiliary

M4EK-01-031

Rotary Beacon Switch (Optional) 1

Press the ON side of rotary beacon switch (1) to turn the rotary beacon ON. Press the OFF side of rotary beacon switch (1) to turn rotary beacon OFF. When rotary beacon switch (1) turn ON, green light (3) on rotary beacon switch turns ON.

ON

3

OFF

M4FG-01-025

1-50

OPERATOR’S STATION Cab Door CAUTION: When closing the door, securely close the d door.

If the door is unexpectedly opened, hazardous

1

situation may be created.

Before leaving the operator’s seat, fully open the cab door and lock the door in position.

2

1- Door Lock Key 2- Door Open/Close Lever M4EK-01-045

1-51

OPERATOR’S STATION Door Lock Knob

5

CAUTION: After closing the door, always check that d the door lock is securely engaged.

Depress door lock knob (5) to engage the door lock.

Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock.

6

Window Open/Close Levers

M4EK-01-046

7

When window open/close levers (7) on both sides are simultaneously pressed, the window is unlocked, allowing the windowpanes to move.

When window open/close levers (7) are released, stoppers are engaged in the nearest steps so that the window is locked in that position.

M4EK-01-047

7

LOCK UNLOCK

M4EK-01-048

1-52

OPERATOR’S STATION When Fully Opening the Door Push the door toward the outside of the cab to fully open the door (180 degrees).

M4EK-01-049

Door Lock Disengage Lever CAUTION: When keeping the door open, open the d door until a latch (8) on the cab securely locks the

8

door.

When disengaging the door lock, push door lock disengage lever (9) or (10) downward.

M4EK-01-051

9

Left Door Lock Disengage Lever

M4EK-01-050

10 M4EK-01-032

Right Door Lock Disengage Lever

1-53

OPERATOR’S STATION Articulation Lock Bar WARNING: Before servicing or transporting the d machine, always be sure to engage articulation lock bar (1).

Before traveling or operating the machine, be sure to disengage articulation lock bar (1) from rear frame (4) and fasten it to the front frame (3) with ring pin (2).

3 2

1 M4FG-01-034

Articulation lock bar (1) locks the front and rear frames to prevent articulation between the front (4) and rear (5) frames when servicing or transporting the machine.

3

4

1

2 M4FG-01-035

Towing Pin

5

WARNING: Since towing is a potentially dangerous d operation, perform only when emergency and crisis situation.

IMPORTANT:

Available towing forces by machine model are as follows. To prevent excessive wear of tires, avoid towing operation requiring more than the available towing force.

42.2 kN (4300 kgf ) (9480 lbf ) M4FG-01-036

Towing pin (5) is located on the back end of the base machine.

It is used for towing other machine or fastening the machine on a trailer deck for transportation.

1-54

OPERATOR’S STATION Engine Hood 1

WARNING: Open/close engine hood (1) only after d stopping the engine. Failure to do so may cause 2

personal injury or death due to entanglement into the engine fan.

Before travelling the machine, check that engine hood (1) does not open.

Opening Engine Hood Press lock key (2) of engine hood (1), engine hood (1) opens upward for daily check.

1

M4FG-01-039

3

Closing Engine Hood Pull band (3) down and slowly push engine hood (1) until a click sound is heard.

M4FG-01-040

Maintenance Side Cover WARNING: Open/close side cover (4) only after d stopping the engine. Failure to do so may create a

4

very dangerous situation such as entanglement with the rotating parts.

Be sure to install side cover (4) before travelling or operating the machine.

Remove bolts (5) (4 used) to open side cover (4).

5

M4FG-01-037

fNOTE: Side covers (4) are located at the left and right side of

the base machine. Open left side cover (4) to check the engine oil level and to replace the engine oil filter.

M4FG-01-038

1-55

OPERATOR’S STATION Steps WARNING: When getting on and off the machine, d always support your body with at least three points.

Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.

Although the steps are provided on both sides of the machine, mainly use the steps on the left side. The control levers are located on the right side, obstructing easy access.

M4FGE-01-052

1

Vandal-Proof Devices A lock key can be installed to fuel tank cap (1) and engine hood (2).

M4FG-01-042

2

M4FG-01-054

1-56

BREAK-IN Observe Engine Operation Closely IMPORTANT:

Be extra cautious during the first 100 hours, until you become thoroughly familiar with the sound and feel of your new machine.

1. Operate the machine limit the engine horsepower up to about 80 % of full load.

2. Avoid excess engine idling.

3. Check indicator lights and gauges frequently during operation.

2-1

BREAK-IN MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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.................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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.................................................................................................................................................................................................. ..................................................................................................................................................................................................

2-2

OPERATING ENGINE Inspect Machine Daily Before Starting The operator must perform the daily inspection before operating the machine.

Refer to MAINTENANCE chapter for more information.

Inspection Items 1. Brake system

2. Tire

Inspection Criteria 1. The brake pedal stroke is appropriate, the brakes apply sufficiently, and the brakes are balanced.

2. The parking brake applies sufficiently.

3. Check the brake oil level and leaks.

1. Tire pressure is appropriate.

2. No cracks and damages are observed.

3. No excessive wear is observed.

4. No foreign matters such as metal pieces or stones are pinched in the tread.

The lights turn ON or blink normally. No dirt and damage are observed.

3. Lighting system and turn signals 4. Rearview mirror Rearview is normal.

5. Machine identification No dirt and damages are observed. plate 6. A device operated The device works normally. abnormally in the previous operation day.

7. Engine 1. Level of engine oil and coolant are sufficient. No dirt is found.

2. Check the alternator drive belt for damage and tightness.

3. Starting ability, exhaust gas color, and noise are within allowable range.

4. Check the engine for oil and water leaks, check hoses and pipe lines for damage.

5. Check the radiator and oil cooler for clogging and damage.

6. Check bolts and nuts for loosening and dropping.

(to be continued)

3-1

OPERATING ENGINE Inspection Items 8. Chassis

9. Working device

10. Others

Inspection Criteria 1. Check the transmission and axle for oil leaks.

2. Level of fuel is sufficient. No leaks and foreign matter is found. Drain fuel tank sump.

3. Level of hydraulic oil tank is sufficient. Check the tank for oil leaks.

4. Operation, play and control force of control levers are within allowable range.

5. Operation of hydraulics is normal. Check piping and hoses for oil leaks and damages.

6. Check each part for deformation, damage and abnormal noise.

7. Level of windshield washer fluid is sufficient.

1. Check the cylinder, piping and hoses for oil leaks and damages.

2. Check the cutting edge for tightness, wear and missing.

3. Check the bucket for wear and damage.

4. Check lubrication condition of the loader front.

5. Check pin lock bolts, stopper and links for damage.

6. Check bolts and nuts for loosing and dropping.

1. Check meters, switches and horns for operation condition.

2. Check ROPS cab for damages and deformation.

3. Check appearance of the machine.

4. Check the battery terminal for looseness.

5. Check the seat belt for wear and damage.

6. Check the step for damage.

3-2

OPERATING ENGINE Check Before Starting 1. Check that F-N-R lever (1) is in the neutral (N) position and that neutral lever lock (2) is in the lock position.

fNOTE: Unless forward/reverse lever (1) is in neutral (N), the engine will not start.

2. Check that parking brake switch (3) is ON. After starting the engine, check the indicator bulbs (Refer to page 3-3) and then check that parking brake indicator (4) is ON.

2

1

M4FG-01-014

3

M4FG-01-020

4

M4FG-01-011

3. Check that loader control lever (5) is in the neutral position.

5 LOCK

4. Check that loader control lever lock (6) is in the LOCK position.

UNLOCK

6

M4FG-01-015

3-3

OPERATING ENGINE 8

5. Adjust the position of outside rear view mirror (7) and room rear view mirror (8) (Cab vehicle) so that the best rear visibility can be obtained.

7

7

Cab Vehicle

Canopy Vehicle M4FGE-01-033

6. While seated on the operator’s seat with your back in contact with the backrest, adjust each function of the seat so that the brake pedal can be fully stepped on.

SA-462

7. Fasten seat belt.

SA-237

3-4

OPERATING ENGINE Starting Engine

1

Start the engine following the procedures below.

1. Check that parking brake switch (1) is in the ON position.

2. Check that F-N-R lever (2) is in neutral (N) position.

3. Check indicator bulbs When key switch (3) is turned ON, all indicators and the warning lights come and stay ON for 2 seconds. Then, they go OFF afterward. Any indicator and/or warning light that fails to light at this time is a burned bulb. After checking indicator bulbs, check that the six square segment marks displayed on the LCD will be sequentially erased one at a time. Charge warning indicator (4) will stay ON until the engine starts.

2

M4FG-01-007

4. Check that parking brake indicator (5) is ON and preheat indicator (6) comes OFF (Engine preheating is completed). And then, sound the horn to clear any personnel away from the area surrounding the machine.

IMPORTANT:

3

Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

Prevent starter damage and/or battery discharge.

5. Turn key switch (3) to START position to rotate the starter. The engine starts running.

M4FG-01-015

3

6. As soon as the engine starts, release the key switch. The key switch will automatically return to the ON position.

M4EJ-01-025

5

6

3-5

4

M4FG-01-011

OPERATING ENGINE Manual Starting in Cold Weather Preheating 1. Turn key switch (2) to HEAT position to preheat the engine. The coolant temperature sensor is activated so that the engine is automatically preheated.

2. Preheat indicator (1) comes ON. As long as preheat indicator (1) stays ON, the engine is being heated.

fNOTE: Preheating time varies depending on the coolant

1

temperature.

M4FG-01-011

3. As soon as preheat indicator (1) goes OFF, turn key switch (2) to the START position to rotate the starter. As soon as the engine starts, release the key switch. The key switch will automatically return to the ON position.

After starting the engine, perform warm-up operation as described on page 3-8.

2 M4EJ-01-025

3-6

OPERATING ENGINE Check After Starting IMPORTANT:

1

2

If any abnormality is found in the monitor functions, immediately stop the engine and investigate the cause of the trouble.

Check the Monitor Operation

fNOTE: When the parking brake switch is ON, service

indicator (2) comes ON. When the parking brake is turned OFF, service indicator (2) comes OFF.

5

1. Check that stop indicator (1) and service indicator (2) come OFF. 2. Check that discharge warning indicator (3) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine. Inspect the alternator and battery system for any abnormality.

3. Check that low engine oil pressure indicator (5) is OFF. In case low engine oil pressure indicator (5) stays ON, immediately stop the engine. Inspect the engine oil pressure system and the oil level.

4. Check that engine coolant temperature gauge (4) is within the blue range.

fNOTE: To check indicator bulbs, when the key switch is

turned ON, all monitor indicators including the service indicator, and stop indicator come ON and continue to stay ON for approx. 2 seconds.

Check Engine Noise and Exhaust Gas Color Check that the engine noise and exhaust gas color are normal.

fNOTE: Check the exhaust gas color as follows. (After warmup operation, run the engine with no loads.)

Exhaust gas color Engine operating condition Clear or light blue Normal (Perfect combustion) Black Abnormal (Imperfect combustion) Abnormal (Oil is leaking into the White combustion chamber.)

3-7

4

3

M4FG-01-011

OPERATING ENGINE Using Booster Batteries DANGER: An explosive gas is produced while d batteries are in use or being charged. Keep open flames and sparks away from the battery area.

Park the machine and a machine with the booster batteries on a dry or concrete surface, not on steel plates. If the machine is parked on steel plates, the machine is equivalent to a continuously grounded machine so that creating unexpected sparks may result.

When connecting the booster cables, never connect a positive terminal to a negative terminal, as a dangerous short circuit may occur.

IMPORTANT:

The machine electrical system is a 12 volt. Use only 12 volt booster batteries which have sufficient capacity to start the machine.

If the machine batteries are completely discharged so that when starting the engine using booster batteries is necessary, follow the procedures describe below.

3-8

OPERATING ENGINE 1. Connecting the booster batteries 1.1 Stop the engine on the booster battery mounted machine.

1.2 Connect one end of red booster cable (1) to the positive (+) terminal of the machine batteries, and the other end to the positive (+) terminal of the booster batteries.

1.3 Connect one end of black booster cable (2) to the negative (-) terminal of the booster battery, and the other end to radiator mounting bolt on the machine.

In the last connection to the bracket, sparks may fly so keep the machine batteries as far away as possible from the bracket.

1.4 After securely connecting the booster cables, start the engine on the booster battery mounted machine.

1.5 Start the engine on the machine.

1.6 After the engine starts, disconnect booster cables (1 and 2) in the following steps.

2. Disconnecting the booster cables 2.1 Disconnect one end of black booster cable (2) from the radiator mounting bolt.

2.2 Disconnect the other end of black booster cable (2) from the negative terminal of the booster batteries.

2.3 Disconnect one end of red booster cable (1) from the positive terminal of the booster batteries.

2.4 Disconnect the other end of red booster cable (2) from the positive terminal of the machine batteries.

Body Ground Mounting Bolt

2 (Black)

Machine Batteries

Booster Batteries

(Red)

1 M4FG-03-001

3-9

OPERATING ENGINE Warming Up Operation 1

CAUTION: Operating the machine without warming d up operation may cause the engine to be seizure or damaged and hydraulic system to be damaged. Be sure to perform warm up operation also to ensure safe operation such as protecting any accidents caused by unstable motion of hydraulic system.

N Tilt

If the machine is excessively operated with the hydraulic oil temperature below 20 °C (68 °F), damage to the hydraulic components may result. After starting the engine, sufficiently perform warm up operation as described below before operating the machine until the hydraulic temperature increases to higher than 20 °C (68 °F).

1. While slightly depressing accelerator pedal, run the engine at medium speed for about 5 minutes with no load.

2. Increase the engine at medium speed. Raise the bucket above the ground and move loader control lever (1) to the tilt position and neutral position. Repeat this cyclic motion for 10 seconds.

IMPORTANT:

Do not operate loader control lever (1) other than the tilt and neutral position at this time.

3-10

M4FG-01-023

OPERATING ENGINE Warming Up Operation in Cold Weather In case the hydraulic oil temperature d isCAUTION: low, perform warm up operation. Operate the machine only after the loader front operating speed becomes normal. Operating the machine without warming up operation may cause the engine to be seizure or damaged and hydraulic system to be damaged. Be sure to perform warm up operation also to ensure safe operation such as protecting any accidents caused by unstable motion of hydraulic system.

1. Run the engine at low idle speed for more than 5 minutes.

2. Run the engine at medium speed for 5 minutes.

IMPORTANT:

Do not run the engine at fast speed at this time.

3. Fully extend the bucket cylinder.

IMPORTANT:

Do not continuously operate the loader control lever in tilt position for more than 10 seconds at this time.

4. Fully retract extend the bucket cylinder.

IMPORTANT:

Do not continuously operate the loader control lever in tilt position for more than 10 seconds at this time.

5. Repeat steps 2 to 4 above until the loader front operating speed becomes normal. When the atmospheric temperature is lower than 0 °C (32 °F), extend the warming up operation time by running the engine at middle speed.

3-11

OPERATING ENGINE Stopping Engine Stop the engine in the following procedures.

1. Lower the bucket before stopping the engine.

IMPORTANT:

If the engine equipped with a turbocharger is stopped without first performing the cool down operation, the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present inside the turbocharger, possibly causing damage to the turbocharger.

1 M4EJ-01-025

LOCK

2. Run the engine at low idle speed for 5 minutes to cool the engine.

UNLOCK

2

3. Turn key switch (1) to OFF position to stop the engine.

4. Be sure to move loader control lever lock (2) in forward and place it in the LOCK position.

1

M4FG-01-015

3-12

DRIVING MACHINE Driving Machine Correct operation will result in extending the service life of each part and component as well as saving fuel and oil. Always be sure to safely and efficiently operate the machine while paying attention to the following points.

Precautions for Starting to Move 1. While checking the tires for abnormal air pressure and any obvious damage, make sure that there is no hazardous and/or obstacles in and around the vicinity of the machine.

2. After raising the lift arm set the machine to the driving position, ground, fully tilt the bucket backward.

3. Before driving on public roads, set the machine to the driving position as illustrated to the right. Be sure to place loader control lever lock (1) in the LOCK position so that the machine will not move even if the control levers are accidentally operated.

A

Driving Position A: 300 to 400 mm (12 to 15 in)

LOCK

M4FG-04-001

UNLOCK

1

M4FG-01-015

4-1

DRIVING MACHINE 1

Starting to Move

2 3

WARNING: Start to move the machine only after d checking that no personnel and/or obstacles are present around the machine.

Never turn ride control switch (4) (Optional) to ON position while traveling the machine or raising the front attachment. Before turning the ride control switch ON, stop the machine and confirm the safety around the bucket. If ride control switch (4) (Optional) is turned ON while traveling the machine, the lift arm will move upward or downward, possibly creating a dangerous situation.

M4FG-01-011

4

Refer to page 1-35 for ride control switch (4) (Optional).

3

5

1. Check that none of the warning indicators except service indicator (2) and parking brake indicator (3) on the monitor panel (1) are ON. 2. Set the front attachment in the driving position by operating loader control lever (5).

3. Press neutral lever lock (6) to the UNLOCK position.

M4FG-01-015

A

Driving Position A: 300 to 400 mm (12 to 15 in)

M4FG-04-001

LOCK UNLOCK 6

4-2

M4FG-01-014

DRIVING MACHINE 2

4. Step on brake pedal (9) and depress parking brake switch (7) to the OFF position to release the parking brake. Check that at this time service indicator (2) and parking brake indicator (3) go OFF.

3

5. Move F-N-R lever (10) to either forward (F) or reverse (R) position.

6. Shift the travel speed stage by using Hi-Lo selector switch (11) to match the desired travel/work mode.

Hi-Lo Selector Switch

M4FG-01-011

Switch (11) is used to shift the travel speed stage. Auto shift 2-Speed mode or 1-Speed mode is selected.

7

Lo : To be used for excavation and loading work Hi : To be used for traveling the machine CAUTION: When traveling on rough terrain, slopes, d mud or snow, select the travel mode switch in Lo

8 10

position and drive the machine at slow speed.

7. Release brake pedal (9) and step on accelerator pedal (8).

9

9

M4FG-01-006

11

M4FG-01-014

4-3

DRIVING MACHINE Parking Brake Switch WARNING: To prevent the occurrence of accidents d due to running away of the machine, be sure to apply

ON OFF

the parking brake when parking the machine and before leaving the machine.

Never apply the parking brake by operating parking brake switch (1) while traveling the machine except in an emergency. Premature wear and/or damage to the parking brake may result. If the parking brake was applied while traveling the machine because of an emergency, have the parking brake inspected by your nearest TCM dealer.

• Press the OFF side of parking brake switch (1) to release the parking brake. Check that parking brake indicator (5) and service indicator (4) go OFF by pressing the switch twice with clicks.

Press the ON side of parking brake switch (1) to apply the parking brake.

Operate the parking brake after parking the machine on level ground.

1

M4FG-01-020

2

fNOTE: While running the engine, when the parking brake is applied with F-N-R lever (2) in neutral, parking brake indicator (5) and service indicator (4) come ON.

• While running the engine, when the parking brake is applied with F-N-R lever (2) in either the forward (F) or reverse (R) position, parking brake indicator (5) and service indicator (4) come ON, and the alarm buzzer sounds. The monitor display indicates (3) “N” not “F” and “R”. The monitor display will not indicate “F” and “R” until the parking brake is released.

• In order to ensure safe operation, the parking brake is automatically applied when the engine is stopped even though parking brake switch (1) is OFF. In this case even after the engine is restated, the parking brake will not be released. After starting the engine, push OFF position of parking brake switch (1) to release the parking brake.

4-4

M4FG-01-014

3

4

5

M4FG-01-011

DRIVING MACHINE Drive Speed Change Travel speed of this machine is automatically shifted.

Auto shift 2-Speed mode or 1-Speed mode is selected by using Hi-Lo selector switch (1).

Lo : 1-Speed mode. To be used for excavation and loading work Hi : Auto shift 2-Speed mode. To be used for traveling the machine.

IMPORTANT:

1 Lo Hi

While traveling at high speed, avoid quick deceleration by operating Hi-Lo selector switch (1). Change the travel speed only after the machine decelerates by releasing the accelerator pedal.

M4FG-01-014

Changing Forward/Reverse Drive Direction

2

WARNING: Before changing the drive direction, d confirm that the drive direction is clear.

F

To ensure operator’s safety and ensure the longevity of the power train system, change the machine drive direction only after sufficiently reducing the drive speed.

N R

1. Pull neutral lever lock (3) to the UNLOCK position.

UNLOCK

2. Press the OFF position of parking brake switch (4).

3

3. Move F-N-R lever (2) to the desired position.

F: Forward Driving N: Neutral R: Reverse Driving

M4FG-01-014

4

M4FG-01-020

4-5

DRIVING MACHINE Steering WARNING: Avoid sudden steering changes while d driving at fast speed and driving on a slope.

Do not stop the engine while driving the machine.

If the engine is stopped, the steering becomes heavy.

Avoid sudden steering operation with the lift arm raised to a high enough position. Failure to do so may possibly cause the machine to turn over.

IMPORTANT:

When the steering wheel is fully turned, the front and the rear frames come in contact with the stoppers so that the steering wheel does not rotate further. If the steering wheel is forcibly turned moreover, the engine may stall or malfunction of the steering system may result.

Turn the steering wheel towards the direction you intend to steer the machine during drive operation.

fNOTE: The front and rear frames are coupled by a

connection pin (center pin) so that the rear wheels follow the tracks of the front wheels.

Turn the steering wheel smoothly so as to follow the motion of the machine.

4-6

M4FG-04-002

DRIVING MACHINE Provisional Stop and Restart of Driving Follow the tips described below when required to provisionally stop or restart driving.

1. Slowly release the accelerator pedal. Depress the brake pedal to stop the machine.

2. Slowly depress the accelerator pedal to move the machine again.

3. In case the machine is required to park for a long period of time, make it a rule to return the F-N-R lever to neutral, turn the brake switch ON, and apply the parking brake to ensure safety operation.

4. During drive operation, the machine drive position may be changed due to inner hydraulic oil leaks. When required to rectify the drive position, provisionally stop driving, return the F-N-R lever to neutral, apply the parking brake by turning the parking brake switch ON. Then, after rectifying the drive position, begin driving the machine again. Always allow the machine to maintain the correct drive position.

Precautions for Traveling During drive operation, observe the general operating manners beside the precautions described below to ensure safe and correct operation.

Use care to the following points: d •WARNING: In case a tire becomes punctured while driving, securely hold the steering wheel and slowly reduce the drive speed.

If the brake is suddenly applied by strongly depressing the brake pedal, the steering may become out of control, possibly creating a serious accident. Never apply the brake quickly if a tire becomes punctured.

• Never mount or dismount the moving machine.

Never allow any personnel other than the operator to ride on the machine when driving.

4-7

DRIVING MACHINE • Even after break-in operation is complete, avoid running the engine at fast speed under no load.

• If any abnormal condition such as an abnormal noise or smell is notified during drive operation, immediately stop the engine and inspect the machine for any trouble.

• Avoid using sudden steering or braking as much as possible because not only own machine but also other machines may become involved in a hazardous condition.

• Driving speeds of this machine are lower than most normal automobiles. Always give the right of way to automobiles.

• Make it a habit to periodically scan the gauges and instruments. If any abnormality is recognized, immediately stop the machine and check the machine for the cause of the trouble.

• When required to drive on the road shoulder or in tight spaces, use a signal person.

• Slowly drive in or turn a crossing while paying attention to the visibility ahead and in the opposite driving lane.

Driving in Water or on Soft Ground IMPORTANT:

When driving/operating on muddy ground, mud can easily accumulate on the frame even if the frame is not heavily submerged in mud, check regularly and clean as necessary. Contact your nearest TCM dealer.

• Do not submerge the front and rear axles, transmission, parking brake, or front and rear propeller shafts in water or mud. Avoid driving in water as much as possible.

• If driving in water or mud is unavoidable, do not allow the machine to be submerged deeper than allowable depth (A) (up to the bottom of the axle housing). Reduce the allowable depth in case the river bed is feared to be rugged or water is flowing fast.

• When driving/operating on muddy ground, mud can easily accumulate on the frame even if the frame is not heavily submerged in mud, Check regularly and clean as necessary.

fNOTE: After operation is complete, be sure to wash and lubricate all areas which were submerged.

4-8

A

M4EJ-04-004A

DRIVING MACHINE Precautions for Driving on Slopes WARNING: When descending a slope with placing the d F-N-R lever in neutral (N) position, the engine brake does not operate and malfunction or failure of the machine may result.

When descending a slope, use engine braking.

Apply the brakes only when absolutely required. If the brake is continuously used while descending a slope, the brake temperature will increase, possibly decreasing the braking performance.

If overheating of the brake system is recognized, immediately park the machine in a safe location.

Restart and drive the machine only after the brake system is sufficiently cooled.

When steering on a slope, lower the front attachment to increase the machine stability. Do not steer on a steep slope.

Failure to do so may possibly cause the machine to turn over.

When descending a slope, place the Hi-Lo selector switch in Lo and using sufficient engine braking.

Do not drive the machine faster than its maximum driving speed.

In case the engine stalls on a slope, immediately step on the brake pedal as strongly as possible, lower the front attachment to the ground and stop the machine. The parking brake is automatically applied when the engine stops regardless of the position of the parking brake switch. Before restarting the engine, turn F-N-R lever in neutral (N) and push the parking brake switch to ON position.

• Before descending a slope, confirm that the brake system works normally by operating the brake pedal.

• In case the hydraulic oil and lubricant temperatures are low, the machine grade ability may decrease. Before climbing a steep slope, sufficiently perform the warm up operation of the machine.

4-9

DRIVING MACHINE Precautions to Be Taken if Machine Failure Occurs • Keep your presence of mind. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible. Turn the parking brake switch ON to apply the parking brake. When any machine failure is recognized in a short tunnel, park the machine outside the tunnel as long as possible.

• Indicate using a sign that the vehicle is disabled. Unless a sign is used, collision with a following vehicle from behind may result. Be sure to indicate the sign of the disabled vehicle using one of the following methods.

• Use a parking signboard.

• Turn the hazard lights ON. • Use an emergency signal instrument (emergency signal light).

• Use a red flag or light.

• Check the failed section. If possible, repair the machine by yourself while ensuring safety and paying attention to the traffic conditions of other vehicles.

Do not spill oil on the road surface. Failure d toWARNING: do so may cause the following vehicle to slide, possibly creating a serious accident.

• In case the hydraulic oil leaks, immediately repair it. If the road surface is severely covered with oil, take the highest priority to notify the following vehicles of this danger. Then, recover the leaked oil as soon as possible.

• In case the repairing the machine by yourself is impossible, contact your nearest TCM dealer.

• Repair work in the tunnel is very dangerous. Avoid working outside the vehicle even simple tasks.

4-10

DRIVING MACHINE Precautions for Driving Speeds CAUTION: Descend the machine on a steep slope d with the Hi-Lo selector switch in Lo while applying engine brake sufficiently. Apply the normal brakes only when absolutely required.

Traveling for a long time without reducing the speed will create the causes of various machine troubles.

When the machine travels faster than the warning travel speed, the service indicator and the HST warning indicator flash, the buzzer sounds. When the indicator flashes and the buzzer sounds, release the accelerator pedal in order to reduce the speed.

Speed Control Function This controls the speed in order to prevent from overrunning (faster than the warning setting speed).

Warning Setting Speed HST Warning Indicator Service Indicator 42 km/h (26 mph)

Flashing

Buzzer

Flashing

Continuous

fNOTE: If the machine travel speed exceeds the maximum

speed (36 km/h (22mph)), the speed control system will activate.

4-11

DRIVING MACHINE Stop

1

1. Avoid sudden deceleration. Smoothly reduce the drive speed.

Release accelerator pedal (2) and step on brake pedal (3) to stop the machine.

2. Return F-N-R lever (5) to neutral (N).

Place neutral lever lock (4) to the LOCK position.

2

5

3. Turn parking brake switch (1) ON. 4. Level the bucket with the ground surface and lower the bucket to the ground by operating loader control lever (6).

5. Move the lock position of loader control lever lock (7).

IMPORTANT:

This machine is equipped with a turbocharged engine. Therefore if the engine is stopped without performing cooling down operation, the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present, possibly causing damage to the turbocharger.

3

4

3

M4FG-01-006

6 LOCK

UNLOCK 7

6. Run the engine at low idle speed to cool the engine for 5 minutes.

M4FG-01-015

Stop and Parking Position

4-12

M4FG-04-003

DRIVING MACHINE Parking IMPORTANT:

When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab door when parking the machine.

When parking the canopy vehicle, cover vinyl sheet on the electrical components and the operator’s seat to protect them from bad weather.

Stop and Parking Position

1. Stop and park the machine on level surface. Lower the bucket to the ground.

M4FG-04-003

1

2. Check that loader control lever (3) is in the neutral (N) position and that neutral lever lock (2) is in the lock position.

3. Turn parking brake switch (1) ON. 4. Level the bucket with the ground surface and lower the bucket to the ground by operating loader control lever (4).

LOCK

UNLOCK

5. Move the lock position of loader control lever lock (5).

IMPORTANT:

This machine is equipped with a turbocharged engine. Therefore if the engine is stopped without performing cooling down operation, the lubricant on the turbocharger bearing surfaces may desiccate due to the intense heat present, possibly causing damage to the turbocharger.

3 M4FG-01-007

2 4 LOCK

UNLOCK

5

6. Run the engine at low idle speed to cool the engine for 5 minutes.

M4FG-01-015

4-13

DRIVING MACHINE IMPORTANT:

If the key switch (6) is left in ON position, the batteries may become discharged.

Be sure to turn key switch to OFF position before leaving the machine.

7. Turn the key switch (6) to OFF position to stop the engine. Remove the key from the switch.

6

8. Before leaving the machine, close all access covers and lock them up.

If the machine is equipped with the cab, close and lock all the windows, cab doors, and access covers and lock them up before leaving the machine.

M4FG-01-015

6 M4EJ-01-025

4-14

DRIVING MACHINE Emergency Evacuation When the Engine Has Stalled During Driving The service brake applies by depressing the brake pedal and the pressurized oil in the master cylinder acts on the brake system.

If the machine does not stop even if the brake pedal stepped on, press the parking brake switch ON side to stop the machine.

As the hydraulic system becomes deactivated, the steering system becomes very difficult to operate.

In the event any symptom mentioned above occurs, immediately trace the cause of the problem.

In case a complicated failure has occurred, consult your nearest TCM dealer.

4-15

DRIVING MACHINE MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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4-16

OPERATING MACHINE C

Loader Control Lever

B

Mono-Lever Type Is used to operate the lift arm and/or bucket.

(C) Float

E 1

N

: The lift arm free falls and can be moved as loads are applied.

D G

A

(B) Lift arm Lower (N) Hold

: The lift arm and bucket are stopped and held in that position.

(A) Lift arm Raise (E) Bucket Dump : The bucket is tilted forward to dump the bucket load.

(D) Bucket Tilt

: The bucket is tilted back, taking the transportation position.

(G) Detent

: When the loader control lever is moved from the bucket dump position to the bucket tilt position, the loader control lever is maintained in this position.

M4FG-01-023

fNOTE: After dumping the bucket, when loader control lever

C

(1) is pulled further from the TILT position (D), the lever is held in that position (G). Then, as soon as the bucket is tilted up to the position set by the bucket auto-leveler, loader control lever (1) is automatically returned to the HOLD position (N).

B

D

E N A M4GB-01-074

M4EJ-01-031A

5-1

OPERATING MACHINE Lever Locks WARNING: When locking the loader control lever and d the auxiliary control lever (3) (optional), securely

1

shift lever locks (2), (4) to the LOCK position. Unless lever locks (2), (4) are fully moved to the LOCK position, the control levers are not locked, possibly creating a hazardous situation.

Before leaving the operator’s seat, be sure to stop the engine. Then, move lever locks (2), (4) to the LOCK position.

After completing operation of the machine or transporting the machine, be sure to move lever locks to the LOCK position.

Lever locks (2), (4) are provided to prevent the machine is unexpectedly operated even if the operator mistakenly comes in contact with loader control lever (1) or auxiliary control lever (3) (if equipped) when getting on or off the machine. When loader control lever (1) and auxiliary control lever (3) (optional) is placed to the UNLOCK position, the levers becomes operable.

LOCK

UNLOCK

2 M4FG-01-023

4

3

fNOTE: Auxiliary control lever (3) and lever lock (4) are

UNLOCK

optional.

Loader Control Lever Lock Operation

LOCK

• When leaving the operator’s seat: 1. Park the machine on solid level ground. Lower the bucket to the ground. Return all levers to neutral. Stop the engine.

2. Be sure to move lever lock (2) in the LOCK position.

Be sure to place lever lock (4) in the LOCK position when auxiliary control lever (3) is not in use.

• Before starting operation: Before starting operation, check that lever lock (2) is in the UNLOCK position.

Be sure to place lever lock (4) in the UNLOCK position when auxiliary control lever (3) is in use.

5-2

Auxiliary Control Lever (Optional)

M4FG-01-024

OPERATING MACHINE Adjustment of Bucket Auto Leveler Pay attention to safety to avoid personal dWARNING: injury and/or death when adjusting the bucket auto leveler.

Stop the engine. Lower the loader front attachment to the ground to release the remaining pressure in the hydraulic circuits.

Apply the parking brake to prevent the machine from moving unexpectedly. Wedge the wheels with blocks. Keep bystanders away from the vicinity of the machine.

The bucket auto leveler automatically stops the bucket movement at the preset digging angle. (When the machine is shipped from the factory, the bucket positioner is preset so that the bucket is stopped with the bucket bottom parallel with the road surface.)

For example, after discharging the handling materials onto a truck or into a hopper, when loader control lever (4) is placed to detent position (G), the lever is held in that position. Then, when the bucket is returned to the preset angle position, the bucket is automatically stopped and the lever is returned to neutral (N).

The bucket auto leveler is preset so that the bucket is stopped when the bucket bottom becomes parallel with the road surface. Nevertheless, when tilting the bucket forward or backward more than the preset level position is needed, adjust the mounting position of the auto leveler proximity switch.

M4FG-05-004

N 4

D G

M4FG-01-023

Adjustment Procedures IMPORTANT:

Do not operate the machine with the bucket dumped more than 10 degrees.

Avoid applying great towing force to the bucket cutting edge.

1. After moving the bucket to the desired digging angle, stop the engine.

3

5

1

2. Loosen lock nuts (2) (2 used) of proximity switch mounting bracket (1). Slide bracket (1) up to the end edge of leveler bar (3) moves to the center of the sensitive area (orange color) (5). Then, tighten lock nuts (2) (2 used).

3. After adjustment start the engine. Check that the bucket can be stopped at the preset angle position.

2

5-3

M4EJ-05-003

OPERATING MACHINE Before Operation WARNING: Be sure to install only authorized buckets d and other work tools on the front attachment.

Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights. Failure to do so may result in personal injury and/or machine trouble.

Precautions for Operation WARNING: Confirm work site safety before starting d any operations.

• Use the machine equipped with ROPS / FOPS cab if the machine is to be operated in the areas where the possibility of falling stones exists.

• If operation on soft ground is required, operate the machine only after reinforcing the ground.

• Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.

• Clear all persons and obstacles away from the area of operation and machine movement. Always be aware of the area around the machine while operating.

Ensure Safety When Operating on Road Shoulders CAUTION: Reinforce the ground before operating the d machine on soft road shoulders.

5-4

OPERATING MACHINE Avoid Overloading Do not penetrate the bucket into piles d ofWARNING: soil and/or gravel at fast travel speed to avoid personal accidents.

Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over.

Avoid Rapid Steering Changes and/or Sudden Braking WARNING: Always maintain a flat work site surface. d Avoid rapid steering changes and sudden braking while raising the lift arm with the bucket loaded to prevent the machine from turning over.

Avoid Operation with Biased Loads WARNING: Avoid abuse machine operation by d allowing the bucket to receive biased loads at only one side. Turning over of the machine or deformation of the working devices such as the lift arm may result.

5-5

OPERATING MACHINE Excavation Loading Accumulated Soil IMPORTANT:

Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the undercarriage.

Scoop load while driving the machine forward as described below. As load increases the wheels begin to slip, slightly raise the bucket to reduce the load.

M4EK-05-001

1. Level the bucket with the surface of the ground.

Penetrate the bucket into the accumulated soil while driving the machine forward.

2. After the bucket has sufficiently penetrated the soil, raise the lift arm while driving the machine forward further and occasionally tilt the bucket back to fill the bucket.

3. If it is difficult to penetrate the soil with the bucket, move the bucket back and forth and the bucket teeth up and down.

M4EK-05-002

4. Drive the machine with the bucket tilted backward fully and held at the lowest possible position.

M4EK-05-003

M4EK-05-004

5-6

OPERATING MACHINE Digging and Loading Level Ground IMPORTANT:

While excavating with the bucket or fork, never apply excessive traction force to the tooth tips with the bucket or fork tiled more than 10 degrees.

Failure to do so may result in cracking or damaging the work tools.

M4EK-05-005

Slightly position the bucket teeth downward (0 to 10 degrees) and dig the ground while driving the machine forward as described below. Always take care not to apply loads to only to one side of the bucket.

1. Position the bucket teeth slightly downward.

2. While driving the machine forward, tilt the bucket so that the ground surface is gradually separated.

3. Adjust the digging depth by operating the lift arm.

M4EK-05-006

4. Drive the machine with the bucket tilted backward fully and held at the lowest possible position.

M4EK-05-007

M4EK-05-008

5-7

OPERATING MACHINE Grading IMPORTANT: Be sure to perform grading work while driving the machine in reverse. If grading work is performed by driving the machine forward, severe loads are applied to the front attachment, possibly creating cracks or damage to the front attachment.

M4EK-05-009

1. After filling soil into the bucket, dump the bucket gradually to disperse soil while driving the machine in reverse.

2. Lower the bucket teeth tips onto the ground. Grade and level the ground surface while driving the machine in reverse with the bucket teeth tips dragging.

3. After filling the bucket with a load such as soil, position the bucket level with the ground surface. Finish the ground surface utilizing the bucket weight.

At this time, drive the machine in reverse with the lift arm held in the FLOAT position.

M4EK-05-010

M4EK-05-011

5-8

OPERATING MACHINE Loading IMPORTANT:

Always maintain the clean driving surface.

Cleaning of materials such as soil spilled on the driving surface will reduce wear and/or damage on tires.

IMPORTANT:

When carrying loads in the bucket, pay attention to the travel road surface conditions. Drive the machine at such speed so that the load will not spill out of the bucket, while positioning the bucket at the lowest possible height.

IMPORTANT:

Refrain from allowing the bucket to come in contact with the bucket stopper as much as possible when removing adhered material, like clay, from the bucket. Failure to do so may result in damage to the front attachment.

Remove material stuck to the bucket by washing with water.

Loading is dumping the handling material onto a truck or into a hopper.

Loading work is performed in either the load and carrying method or loader and dump truck method. Select either method depending on the work site conditions while taking the merits in cost and safety into account.

5-9

OPERATING MACHINE Load and Carrying Method Be sure to provide tire stopper (1) in front d ofWARNING: the dumping port.

WARNING: Before raising the lift arm, slightly tilt d the bucket back and forth to stabilize the load in the bucket to avoid personal injury or damage to the machine due to falling of the load.

Raising the lift arm on the slope possibly result in personal injury.

1 M4FG-05-001

WARNING: When approaching the machine to the d dumping port with the lift arm raised to a high enough position, slowly drive the machine. Never steer the machine to prevent turning over accident.

A wheel loader performs work process of loading, carrying, and dumping in sequence. Generally, when the carrying distance is 30 to 100 m (33 to 109 yd), this method is employed.

Make an upgrade slope of approx. 3 degrees around a hopper when dumping into the hopper. Be sure to provide a level area 10 m apart from the dumping port and tire stopper (1) at the dumping port edge. Automatic reduction in travel speed will assist operator’s braking operation effort.

5-10

OPERATING MACHINE Loader and Dump Track Combination Method Be aware of the following points: d •WARNING: Always maintain a flat work site surface. Avoid rapid swing and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over.

• Do not penetrate the bucket into a loading face at fast travel speeds, possibly resulting in personal accident.

A loader carries out loading, and carrying and dumping are carried out by a dump truck. Depending on the work site conditions encountered and matching with available trucks, select the most efficient method.

V-Shape Loading 1. Park a dump truck in a spot located at approx. 60 degrees angle toward the face of loading by the wheel loader. After loading material, travel the wheel loader in reverse and turn its direction so that the wheel loader faces the parked dump truck at a right angle. Then, travel forward to carry material onto the dump truck.

2. Position the wheel loader so that the material can be loaded around the center of the dump body. In case the dump body is longer than twice the bucket width, load from the front to rear position of the dump body in order.

3. When dumping sticky material such as clay, move the bucket lever back and forth to hit the bucket to the stoppers.

Take a steering angle as small as possible to operate the machine efficiently.

4. Before raising the lift arm to the maximum height with the bucket full, vibrate the bucket on the ground to stabilize the material in the bucket to prevent the material from spilling off the backside of the bucket.

5-11

M4EJ-05-016

OPERATING MACHINE I-Shape Loading Park a dump truck in a direction parallel to the loading face.

After loading material into the bucket, travel the wheel loader straight in reverse. Then, move a dump truck to a spot between the loading face and the wheel loader. Travel the wheel loader forward to load material onto the dump body.

Loading times become shorter using this loading method, reducing the total working cycle time and increasing work efficiency. Position the machine down the wind as much as possible. The engine will not only inhale as little dust as possible but also operator’s eyes will be protected from being contaminated.

5-12

M4EJ-05-017

OPERATING MACHINE Dozing IMPORTANT:

Never attempt to forcibly push piled material higher than the bucket capacity.

Premature wear of the tires due to slipping and/or waste of fuel may result.

IMPORTANT:

Do not perform dozing with the bucket dumped. Abnormal excessive stress will be reduced on the front attachment.

IMPORTANT:

M4EJ-05-018

Never apply great traction force to the cutting edge with the cutting edge tilted forward more than 10 degrees. Failure to do so may result in cracking or damaging the work tools.

Dozing stands for a working method performed by a wheel loader using the wheel loader bucket in place of the bulldozer blade. This operation method is employed when reclaiming land or dumping material into a hopper.

Set the bucket bottom parallel with the ground surface and drive the wheel loader forward.

Scooping WARNING: Do not allow the machine to engage in d piling up material on a soft ground. It is import to be aware that steering operation on a soft ground may easily cause tipping over of the machine.

WARNING: When piling up material with this d machine, do not operate the machine in so steep incline as the counterweight can come in contact with the ground. The machine may become unstable, possibly causing the machine to turnover.

In addition, impact loads to be applied to the counterweight may cause the mounting bolts to become loose and/or to break.

5-13

M4EJ-05-019

OPERATING MACHINE Removing Snow CAUTION: Snow removal is in the same method as d employed in general loading work. However, pay attention to slippage of tires and obstacles covered with snow.

Precautions for removing snow • Avoid sudden starting and stopping as well as rapid steering of the machine.

• Use tire chains on all four wheels.

• Pay attention to the presence of the utility facilities such a fire hydrant, a manhole, edge stones, roadside drains, etc.

M4EJ-05-020

Lifting Wheel Loader WARNING: Be sure to use lifting tools (optional) and d set the articulation lock bar in the LOCK position.

Never allow any person to ride on the machine to be lifted.

Never allow any person to enter below the lifted machine. Before fully lifting the machine above the ground, check that the hooks are securely attached to the machine and the machine is well balanced while lifting the machine slightly above the ground. Refer to the “Lifting Machine” in the “TRANSPORTING” chapter.

Lifting work of the machine will become necessary when loading the machine onto a ship or truck for repairing and/or transporting.

5-14

M4FG-05-002

OPERATING MACHINE Precautions for After Operations 1. After finishing the day’s operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods are present.

Park the machine referring to the “Parking” in the “DRIVING MACHINE” chapter.)

2. Refill the fuel tank.

CAUTION: Wash the machine immediately after d operation and then coat rust-preventive oil to protect the machine from rusting. If the machine continues to be used with rust developing, oil leaks may occur.

3. Clean the machine.

4. If anti-freeze or long life coolant is not used in cold weather, be sure to drain coolant from the radiator and the engine jacket.

Also, be sure to put a “No Water in Radiator” tag in a visible place after the coolant has been drained.

5. Maintenance for long term machine storage after engaging in snow removal Anti-freeze agents such as salt (sodium chloride or calcium chloride) are scattered on snow roads. When the machine is stored for a long time after engaging in snow removal work, perform the following maintenance to protect the machine from being corroded and/or damaged by salt.

IMPORTANT:

Take care not to spray water directly to electrical parts except for kinds of lights such as the headlights, work lights, and turn signal lights.

5.1 Clean and dry the machine thoroughly.

Clean each cylinder rod (plated areas) and the radiator with extra care.

5.2 After positioning the machine for storage, carefully coat each cylinder rod (plated areas) and the control valve spools with rust-preventive oil.

5.3 Lubricate all pins while referring to “A. Greasing” in the ”MAINTENANCE” chapter.

5-15

OPERATING MACHINE CAUTION: When removing the batteries, first d disconnect the ground cable from the battery terminal.

5.4 Remove the batteries and store them in a dry cool place. Do not put the batteries on the ground.

When the batteries are not removed, disconnect the ground terminal cable.

Positive Side (Red Vinyl Cap)

Ground Side M4FG-07-042

5-16

TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations.

1. For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded.

2. Investigate beforehand the conditions of the route to be traveled, such as dimensional limits, weight limits, and traffic regulations.

In some cases, getting approval from the authority concerned, disassembling the machine to bring it within dimensional limits or weight limits of local regulations may become necessary.

Transporting by Trailer Provide an appropriate trailer while referring to the weight and dimensions shown in the specifications. When transporting the machine within the weight and dimensions shown in the specifications by a trailer, it is possible to transport the machine without disassembling. If the machine width, height or weight is enlarged due to installing an attachment, consult your nearest TCM dealer.

6-1

TRANSPORTING Loading/Unloading on Trailer WARNING: Be sure to use a loading dock or a ramp d for loading/unloading.

Always load and unload the machine on a firm, level surface.

1

1

M4FG-06-001

Ramp/Loading Dock 1. Before loading, thoroughly clean the ramps, loading dock and flatbed. Dirty ramps, loading docks, and flatbeds with oil, mud, or ice on them are slippery and dangerous.

2. Place blocks (1) against the trailer wheels so that the trailer does not move while using a ramp or loading dock.

3. Ramps must be sufficient in width, length, and strength.

Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength to support the machine and have an incline of less than 15 degrees.

6-2

10 to 15 ° M4FG-06-002

TRANSPORTING Loading/Unloading Be aware of the following points: d •WARNING: NEVER steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover. If the travel direction must be changed on a slope, move back the machine to the flat ground of flatbed. Then, after changing the travel direction, begin to drive again.

Loading 1. Load the machine so that the machine width center aligns with the trailer deck width center.

2. Slowly drive the machine on the ramp.

3. Lower the bucket onto the trailer deck.

4. Stop the engine. Remove the key from the key switch.

5. Operate the loader control lever several strokes to relieve pressure in the cylinders.

6. Place the loader control lever lock in the LOCK position.

7. Cover vinyl sheet on the electrical components and the operator’s seat to protect them from bad weather. For the cab machine, close cab windows and door to prevent entry of wind and water.

8. Install the articulation lock bar (1) to the rear frame side to prevent the machine from articulating.

6-3

Rear Frame Side

1

M4FG-01-035

TRANSPORTING Transporting CAUTION: Securely fasten the machine to the trailer d flatbed with appropriate accessories (wire ropes/ chains, tighteners.)

The machine may move back and forth and/or laterally during transportation.

1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.

1

M4FG-06-003

2. Wedge wooden blocks (1) behind each tire to fasten the machine in position.

3. Securely fasten the base machine to the load carrying platform using appropriate accessories (wire ropes/ chains, tighteners.)

M4FG-06-008

6-4

TRANSPORTING Transporting Wheel Loader (Urgent Situation) When required to transport the wheel loader long distance, use a trailer.

Precautions for Towing WARNING: Never attempt to two the machine if the d brake system is in need of repair. Ask your nearest TCM dealer to repair the machine. Operate the machine only after repair is completed.

Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points.

IMPORTANT:

Do not tow the machine with the parking brake applied. Damage to the parking brake may result.

• When the engine is operable: Keep the engine running to maintain the steering and brake systems operable and then, release the parking brake.

• When the engine does not operate: • As it is impossible for the parking brake to be released, manually release the parking brake. (Refer to the “Releasing Parking Brake” on page 6-7.)

And then, relieve the HST hydraulic pressure. (Refer to the “Relieving HST Hydraulic Pressure” on page 6-8.)

6-5

TRANSPORTING • If the engine becomes inoperable, steering operation becomes impossible. Switch the hydraulic hose connections between the rod end side and the head end side on one of the steering cylinders. Articulation between the front frame and the rear frame will be easily performed during towing of the machine.

Steering Cylinder

fNOTE: Oil may pour out from the hose when disconnecting hoses.

Hose

M4GB-06-007

• In case the bucket is being rested on the ground, raise the bucket above the ground following the procedures below.

C

B

N LOCK

1. Place loader control lever (3) in FLOAT position (C).

UNLOCK

3

2. Using a jack or a crane, lift the bucket or the lift arm.

3. Move loader control lever (3) to neutral (N) position and loader control lever lock (4) to LOCK position to maintain the bucket in position above the ground.

4

M4FG-01-015

6-6

TRANSPORTING Releasing Parking Brake WARNING: Once the parking brake is released, the d machine becomes impossible to stop with the brake system, possibly resulting in personal injury or death.

Before releasing or connecting the parking brake, wedge the tire wheels.

CAUTION: As soon as towing operation is complete, d connect the parking brake.

Moving the machine by means of towing shall be made in a short distance until the machine reaches an appropriate location for inspection and/or maintenance. Do not tow the machine in a long distance.

Releasing the parking brake is made manually only when the parking brake switch becomes inoperable due to any abnormality or failure in the brake system such as a pump.

1

Procedures

d •WARNING: Once the parking brake is manually released, the machine braking system is completely deactivated.

• Before releasing the parking brake manually, wedge all tire wheels to prevent the machine from moving.

• Before operating the machine again after releasing the parking brake manually, have the parking brake readjusted by your nearest TCM dealer.

• Loosen plugs (1) (2 used) on the right side of the front axle center, remove the spacer, and then tighten plugs (1) (2 used) at the same time to release the parking brake.

6-7

1 M4FG-06-005

TRANSPORTING Relieving HST Hydraulic Pressure CAUTION: Do not tow the machine at travel speed d faster than 2 km/h (1.2 pmh) and in a distance longer than 1 km.

The HST hydraulic pressure must be reset to the original set pressure after towing is complete.

Contact your nearest TCM dealer for machine inspection:

1

Procedures

M4FG-06-007

The HST hydraulic pressure is manually relieved only when the machine must be towed with the engine inoperable.

d •WARNING: Before relieving the HST hydraulic pressure, wedge

3

4

2

the tire wheels to prevent the machine from moving.

Engine Side

• Before operating the machine again after resetting the HST hydraulic pressure, have the HST system readjusted by your nearest TCM dealer.

4

1. If required to tow the machine with the engine inoperable, the hydraulic pressure in the HST pump/ motor closed circuit must be relieved.

2. Remove the floor mat and the maintenance access cover from the foot of the operator’s seat. Wait for HST pump (1) to cool until it becomes touchable with a naked hand.

3. Remove caps from two high pressure relief valves on HST pump (1). Loosen lock nuts (2). Tighten adjust screws (hexagon socket head) (3) until the screw head becomes flush with the top surface of lock nuts (2).

4. Tighten lock nuts (2).

5. After towing is complete, return adjust screws (hexagon socket head) (3) to its original position and secure it with lock nuts (2).

6-8

1

M4EJ-06-008

TRANSPORTING Towing Method CAUTION: Use wire rope having the strength more d than approx. 150 % of the machine weight.

• Towing from the front side of the machine When using wire ropes, be sure to attach wire ropes to the front frame.

Always use soft material at the corners between the front frame and wire ropes to prevent damage to wire ropes.

• Towing from the rear side of the machine Be sure to attach wire ropes to the drawbar pin.

Always use the lock pin after completely inserting the drawbar pin to prevent the wire rope from coming off.

M4FG-07-015

Attach wire ropes to the machine as illustrated when the machine must be unavoidably towed, such cases when the machine can not be evacuated from soft ground by its own driving power.

M4FG-01-039

M4FG-01-036

6-9

TRANSPORTING Lifting Machine Be aware of the following points: d •WARNING: The lifting tools are optional. Install specific tools at your nearest TCM dealer.

• Use lifting cables and other lifting tools being free from any damage and/or aging, and having sufficient strength.

• Consult your nearest TCM dealer for correct lifting procedures, and the size and types of lifting cable and tools.

• Before lifting the machine, move the loader control lever lock to the LOCK position to prevent the machine from moving unexpectedly.

• Rigidly secure the front and rear frames using the articulation lock bar so that the machine front and rear frames are not articulated.

• If the machine is incorrectly lifted or if lifting wire ropes are incorrectly attached to the machine, the machine may be move when lifted, possibly resulting in personal accident and/or damage to the machine.

• Never apply impact loads to the lifting cables and tools.

• Do not allow anyone to enter the area under the lifted machine.

6-10

TRANSPORTING Lifting 1. Straighten the machine and horizontally resting the bucket on the ground.

2. Move the loader control lever lock to the LOCK position.

3. Rigidly secure the front and rear frames using the articulation lock bar.

4. Stop the engine. Remove the key from the key switch.

5. Use cables long enough so that the cables come in contact with the machine body when the machine is lifted.

Cover the cables with cloth as needed to protect the machine from being damaged. Be sure to use the specified lifting tools.

6. Set a crane in an appropriate position.

7. Attach the cable to the front attachment and the lifting tools.

6-11

M4FG-05-002a

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6-12

MAINTENANCE Correct Maintenance and Inspection Procedures Learn how to service your machine correctly. Follow the correct maintenance and inspection procedures shown in this manual.

Inspect machine daily before starting.

• Check controls and instruments.

• Check coolant, fuel and oil levels.

• Check for leaks, kinked, frayed or damaged hoses and lines.

• Walk around machine checking general appearance, noise, heat, etc.

• Check for loose or missing parts.

SA-005

If there is any problem with your machine, repair it before operating or contact your authorized dealer.

IMPORTANT: • Use only recommended fuel and lubricants.

• Be sure to use only genuine TCM parts.

Failure to do so may result in serious injury or death and/or machine breakdown.

• Failure to use recommended fuel, lubricants, and genuine TCM parts will result in loss of TCM product warranty.

• Never adjust engine governor or hydraulic system relief valve.

• Protect electrical parts from water and steam.

• Never disassemble electrical components such as main controller, sensors, etc.

7-1

MAINTENANCE Check the Hour Meter Regularly • Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in more adverse conditions, you should service it at SHORTER INTERVALS. • Lubricate, make service checks and adjustments at intervals shown on periodic maintenance guide table (see page 7-4).

Use Correct Fuels and Lubricants IMPORTANT:

Always use recommended fuels and lubricants.

Failure to do so will result in machine damage and loss of TCM product warranty.

7-2

MAINTENANCE Layout 3

4

5

6

7

8

9

10

11

12

13

14

15

16 17

2

1

29 28

18 27 19

26 30

25 24 23

22

21

20

1- Cutting Edge

16- Engine

2- Lift Arm Cylinder Pin

17- Radiator/Oil Cooler

3- Bucket

18- Backup Light

4- Bell Crank Pin

19- Battery

5- Bucket Cylinder Pin

20- Rear Combination Light

6- Bucket Auto-Leveler

21- Fuel Pre-Filter

7- Bucket Cylinder

22- Fuel Filter

8- Head Light/Front Combination Light

23- Air Cleaner

9- Lift Arm Pin

24- Rear Axle

10- Rear View Mirror

25- Transmission

11- ROPS Canopy

26- Front Propeller Shaft

12- HST Oil Filter

27- Fuel Tank

13- Return Filter

28- Steering Cylinder

14- Hydraulic Oil Tank/Suction Filter

29- Front Axle

15- Brake Oil Tank

30- Backup Buzzer

7-3

M4FGE-07-001

MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed on the under of the operator’s seat. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly.

M4FG-07-001_E

7-4

MAINTENANCE Preparations for Inspection and Maintenance

1

WARNING: The lift arm may move up while holding d ride control switch (1) in the ON position. Be sure

d

2

to turn the ride control switch OFF in order to avoid accidents due to unexpected movement of the lift arm.

CAUTION: If the machine is unexpectedly moved, serious accident may result. Be sure to apply the parking brake when parking the machine.

LOCK

UNLOCK

Unless especially specified, park the machine by following the procedures below before beginning the inspection and/or maintenance work.

M4FG-01-015

1

1. Park the machine on solid level surface.

ON

2. Lower the working tools such as the bucket to the ground.

3. Turn ride control switch (1) (optional) OFF. 4. Place F-N-R lever (3) in neutral (N) and place neutral lever lock (4) to LOCK position (3).

OFF

5. Apply the parking brake by turning parking brake switch (5) ON.

M4FG-01-025

6. Wedge the tires.

5

7. Run the engine for 5 minutes to cool the engine. Turn the key switch OFF and stop the engine. Remove the key from the switch. Fully move the loader control lever 3 to 4 strokes to release residual pressure in the hydraulic system. In case inspection and/or maintenance must be performed with the engine kept running, use a safety lookout.

LOCK

8. Be sure to place loader control lever lock (2) in the LOCK position.

9. Begin to work only after attaching a “Do Not Operate” tag in a highly visible place such as on the cab door or the loader control lever.

UNLOCK 3 M4FG-01-007

4

ON

OFF

5

7-5

M4EK-01-025A

MAINTENANCE Lock Frames Before beginning to work near the axle d ofWARNING: frames (3), (4), install articulation lock bar (1) to securely lock and prohibit movement between the front and rear frames (3) and (4). Avoid accidents due to unexpected movement of the machine.

3

1. Align the front and rear frames (3) and (4) centers with each other.

2

1

2. Remove lock pin (2) and remove articulation lock bar (1) from the front side pin hole on front frame (3).

M4FG-01-034

3. Install one end of articulation lock bar (1) to the mounting pin of rear frame (4). Secure articulation lock bar (1) in position with lock pin (2).

3

4

1

2 M4FG-01-035

7-6

MAINTENANCE Maintenance Side Cover WARNING: Open/close side cover (1) only after d stopping the engine. Failure to do so may create a very dangerous situation such as entanglement with the rotating parts.

Be sure to install side cover (1) before travelling or operating the machine.

1

2

Remove bolts (2) (4 used) to open side cover (1).

fNOTE: Side covers (1) are located at the left and right side of

M4FG-01-037

the base machine. Open left side cover (1) to check the engine oil level and to replace the engine oil filter.

M4FG-01-038

7-7

MAINTENANCE Engine Hood 1

WARNING: Open/close engine hood (1) only after d stopping the engine. Failure to do so may create a very dangerous situation such as entanglement with the engine hood.

Before travelling the machine, check that engine hood (1) does not open.

2

Opening Engine Hood Press lock key (2) of engine hood (1), engine hood (1) opens upward for daily check.

1

M4FG-01-039

Closing Engine Hood Pull band (3) down and slowly push engine hood (1) until a click sound is heard.

fNOTE: Engine hood (1) can be locked with a key.

3

7-8

M4FG-01-040

MAINTENANCE Periodic Replacement of Parts To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval.

Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.

Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary.

Consult your authorized dealer for correct replacement.

System/Equipment Engine Fuel Tank Brake valve Wet brake Brake system Brake piping Stop light Steering piping Steering Steering cylinder system Steering valve Pump Hydraulic System

Operator’s Seat

Working system

Seat belt

Replacement Part Hose Various seals (Rubber parts) Piston D-ring Hose Switch Hose Various seals (Rubber parts) Various seals (Rubber parts) Suction hose Delivery hose Bucket cylinder line hoses Lift arm cylinder line hose Hydraulic oil tank return hose Hydraulic oil cooler line hose Seat belt

Interval Every 2 years Every 1 year Every 4 years Every 2 years Every 2 years Every 2 years Every 4 years Every 2 years Every 4 years

Every 4 years

Every 4 years

fNOTE: When replacing hoses, replace O-rings, gaskets used for them at the same time.

7-9

MAINTENANCE Maintenance Guide Perform maintenance of items at the intervals shown by the shadowed areas in the table below.

A. Greasing (See Page 7-19)

Parts Bucket Pin Bucket Link Pin Bucket Cylinder Pin Bucket Cylinder Rod Pin Bell Crank Pin Lift Arm Cylinder Rod Pin Lift Arm Cylinder Lift Arm Pivot Pin Steering Cylinder Rod Pin Steering Cylinder Pin Frame Center Hinge Pin Rear Axle Pin Propeller Shaft Universal Propeller Shaft Spline

Quantity 2 2 1 1 1 2 2 2 2 2 2 2 2 1

10 Daily ★ ★ ★ ★ ★ ★ ★ ★ ★ ★

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★★ ★★★

★: Add grease daily during first 50 hours of operation.

In case the machine is engaged in excavation in mud, water or snow, add grease after each work shift. ★★: After 50 hours of operation, add grease every 250 or every 3 months of operation.

Shorten greasing intervals when the machine is operated under severe working conditions or when the machine is continuously operated for a long period of time. ★★★: Shorten greasing intervals when the machine is operated under severe working conditions or when the machine is continuously operated for a long period of time.

7-10

MAINTENANCE B. Engine (See Page 7-22) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extend, serious engine failure or damage may result.

Parts

Quantity

1. Engine Oil

Check Oil Level

2. Engine Oil

Change

3. Engine Oil Filter

Change

10 Daily

50 —

— 11.2 L (3 gal)

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★ ★

★★

★: Only first time at every 100 hours or 1 month. ★★: Replace the engine oil filter when changing engine oil at the same time.

C. Power Train (See Page 7-25) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious transmission and/or axle failure or damage may result.

Parts

Quantity

1. Transmission Oil

Change

2. Axle Oil

Change (Front) Change (Rear)

3. Clean Transmission Air Breather 4. Check Oil Leaks Around Axle and/or Cover 5. Clean Axle Housing Air Breather

1.0 L (0.3 gal) 6.2 L (1.6 gal) 6.4 L (1.7 gal) 1 — 1 each in front and rear

★: Only first time at every 250 hours or 3 month.

7-11

10 Daily

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★ ★ ★

MAINTENANCE D. Hydraulic System (See Page 7-30) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious hydraulic system failure or damage may result.

Parts

Quantity

1. Check Oil Level in Hydraulic Oil Tank 2. Change Hydraulic Oil/Clean Hydraulic Oil Tank 3. Clean Suction Filter 4. Replace HST Oil Filter Element 5. Replace Return Filter Check Hoses and Lines For Leaks and 6. Tightness Check Hoses and Lines for Cracks and Bends

10 Daily

— 73 L (19.3 gal) 1 1 1

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

When changing hydraulic oil ★ ★

— —

★: Only first time at every 100 hours or 1 month.

E. Fuel System (See Page 7-42) IMPORTANT:

Be sure to use the specified oil. Engine failure or damage may result.

Parts

Quantity

1. Check Fuel Level In Fuel Tank 2. Drain Water/Sediment from Fuel Tank 3. Check Fuel Pre-Filter and Drain Water 4. Clean Fuel Pre-Filter Element 5. Replace Fuel Filter Element Check Fuel Hoses for Leaks and Cracks 6.

Check Hoses for Cracks and Bends

10 Daily

50 —

— 1 1 1 1 — —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

★

★: Only first time at every 100 hours or 1 month.

F. Air Cleaner (See Page 7-48) Intervals (Hours) Parts

1. Air Cleaner Element

Quantity Clean Replace

1 1

7-12

10 Daily

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year When indicator comes ON After cleaning 6 times or once per year

MAINTENANCE G. Cooling System (See Page 7-49) IMPORTANT:

Be sure to use the specified LLC. Change LLC at the exact specified intervals. If unspecified LLC is used, or the LLC change intervals are arbitrarily extended, serious engine failure or damage may result.

Intervals (Hours) Parts

1. Check Coolant Level 2. Check Drive Belt 3. Check Drive Belt Tension 4. Adjust Drive Belt Tension 5. Change Coolant 6. Clean Radiator and Oil Cooler

Quantity

10

50

100

250

500

1000

Daily — 1 Month 3 Months 6 Months 1 Year — — — — 10 L (2.6 gal) — (Or when clogged)

H. Electrical System (See Page 7-55) Intervals (Hours) Parts 1. Check Monitor for Malfunction and All Instruments for Inoperativeness 2. Check All Lights for Abnormality in Lightning and/or Blinking 3. Check Horn, Backup Buzzer and Backup Light for Malfunction 4. Check Electrical Circuits and Fuses for Abnormality 5. Check Electrolyte Level 6. Check Electrolyte Specific Gravity

Quantity

10 Daily

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year

10 Daily

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year Indicator comes ON

— — — — 1 1

I. Brake System (See Page 7-65)

Parts

Quantity

1. Check Brake Oil Level 2. Check Right and Left Brake Interlock Control Performance 3. Check Parking Brake Force 4. Check Brake Discs (Service And Parking for Abnormality)

—

5. Change Brake Oil

— — — 0.35 L (0.1 gal)

7-13

MAINTENANCE J. Tire (See Page 7-68) Intervals (Hours) Parts

1. Adjust Tire Pressure 2. Check Tires for Damage 3. Check Wheel Nut Tightening Torque

Quantity Check Adjust Check Adjust

10 Daily

4 4 4 4

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year As needed

★

★: Only first 50 hours

K. Heater (Optional of Cab Vehicle) (See Page 7-74) Intervals (Hours) Parts 1. Heater Unit 2. Check Piping for Damage

Quantity — —

7-14

10 Daily

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year Every 6 months Every 6 months

MAINTENANCE L. Miscellaneous (See Page 7-75)

Parts 1. Check Bucket Bolt-on-cutting Edge for Tightness and/or Wear 2. Check and Replace Seat Belt 3. Check Canopy/Cab Damage and Bolt Tightness 4. Check Windshield Washer Fluid Level 5. Check Play Amount In Steering Wheel Stroke 6. Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise 7. Check Rear View Mirror and Inside Rear View Mirror for Damage and Tightness 8. Check Steps and Hand Rails for Damage and Tightness 9. Clean Engine Compartment and Hood 10. Check and Adjust Valve Clearance* 11. Check Sound Absorbing Mat Around Engine for Damage 12. Check Fuel Injection Timing* 13. Measure Engine Compression Pressure* 14. Check and Clean Starter and Alternator* 15. Retighten Front Axle and Rear Axle Support Mounting Nuts

Quantity

10 Daily

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

— 1

Every 4 years (Replace)

— — — — — — — — ★★ ★★

— — — ★

—

fNOTE: Contact your nearest TCM dealer for maintenance of items with mark (*). ★: Only first 50 hours ★★: Every 1000 hours or 1 year whichever comes first

7-15

MAINTENANCE Kind of Oils IMPORTANT:

Be sure to use the specified lubricants. Change/add lubricants at the exact specified intervals. If unspecified lubricant is used, or the lubricant change intervals are arbitrarily extended, serious machine failure or damage may result.

Grease Kind of Grease Application Air Temp.

Manufacturer SHELL Oil IDEMITSU Kosan JAPAN ENERGY COSMO Oil NIPPON Oil CALTEX Oil KIGNAS Oil MOBIL Oil GENERAL Oil

Grease (Lithium based) Front attachment joint pins, others -20 to 40 °C (-4 to 104 °F) * ALVANIA EP GREASE 2 DAPHNE EPONEX EP2 DAPHNE EPONEX No.2 JOMO LISONIC GREASE EP2 COSMO GREASE DYNAMAX EP2 EPINOC GREASE AP2 DIAMOND MULTIPURPOSE EP GREASE NO.2 MULTIFAX EP2 KIGNAS MPGREASE No.2 MOBILUX EP2 ZEMICO GREASE MP-2

fNOTE: Be sure to use a lithium-based grease. Use of other types of chassis grease may cause premature wear and/or noise emission. The machine shipped from the factory is filled with grease marked with *.

Engine Oil IMPORTANT:

Be sure to use the specified engine oil. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.

Be noted that all engine failures caused by using engine oil other than specified are excluded from TCM Warranty Policy. Consult your nearest TCM dealer for any unclear points.

Kind of Oil Application Air Temp.

Standard

Manufacturer IDEMITSU Kosan

Engine Oil Engine crank case -20 to 30 °C (-4 to 86 °F) SAE 10W-30 Class CF or CI-4 * Apolloil Motive CF-M (10W-30)

fNOTE: The machine shipped from the factory is filled with engine oil marked with *.

Be careful that oil change intervals will differ according to the standard employed.

7-16

MAINTENANCE Brake Oil Kind of Oil Application Manufacturer IDEMITSU Kosan

Torque Converter Oil SAE5W (Mineral Oil) Brake System (Brake oil tank) * DAPHNE TORQUE OIL B

fNOTE: The machine shipped from the factory is filled with the oil marked with *.

Use the same oil (mineral oil). Use of other oil (vegetable oil) may cause the failure and/or malfunction of the brake.

Transmission Oil, Axle Oil Kind of Fluid Application Standard Manufacturer IDEMITSU Kosan COSMO Oil MOBIL Oil SHELL Oil ELF

Gear Oil Transmission and Axle API GL5, LSA, MIL2105B * Apolloil Gear TH Multi 75W-80 COSMO HI-GEAR OIL SP90TS MOBIL LUBE SHCLS 75W90 (FULL SYNTHETIC) MOBIL 1 SAE 75W90 LS(E.P.) SHELL SL90, SHELL SPIRAX HD 85W90 * SF3

fNOTE: The machine shipped from the factory is filled with gear oil marked with *. Use the same oil.

Use of other types of gear oil may cause axle failure and/or noise emission.

Hydraulic Oil Kind of Oil Application Change Interval

Manufacturer NIPPON Oil

IDEMITSU Kosan

Hydraulic Oil (ISO VG 46) Hydraulic system (Hydraulic oil tank) Every 1000 hours or 1 year HYRAND WIDE 46 HYRAND KENKI HP46 SUPER-HYDRO LW46 SUPER-HYDRO 46X SUPER-HYDRO WR46 * SUPER-HYDRO HN46

fNOTE: Select hydraulic oil appropriate to the atmospheric temperature. When the machine is operated in a low

temperature district, oil viscosity may increase due to low temperature so that the lubrication performance of hydraulic oil will decrease, possibly resulting in insufficient lubrication in hydraulic components. Change hydraulic oil appropriated to machine operation under cold weather conditions. In case atmospheric temperature becomes lower than -20 °C (-4 °F), consult your nearest TCM dealer. The machine shipped from the factory is filled with the hydraulic oil marked with *.

7-17

MAINTENANCE Long-Life Coolant Kind of Fluid Application Standard Manufacturer TCM

LLC Mixing Ratio (%) 35

Long-Life Coolant (LLC) Radiator, Cooler JIS K 2234 (Class 2), SAE J814, SAE J 1034, ASTM D 3306 * TCM long-life coolant Total Capacity: 10 L (2.6 gal) LLC (L) Soft Water (L) 3.5 (0.9 gal) 6.5 (1.7 gal)

fNOTE: The machine shipped from the factory is filled with LLC marked with *.

The standard LLC mixing ratio is 35 %. When a machine is delivered to a cold weather district, the LLC mixing ratio is increased up to 50 %.

IMPORTANT:

If long life coolant (LLC) marked with * is unavailable, use LLC that meets following standards.

• JIS K-2234 • SAE J814 • SAE J1034 • ASTM D3306 Dilute LLC with soft water.

Never mix-up LLC with different brand.

7-18

MAINTENANCE A. Greasing WARNING: Apply the parking brake and hold the d front and rear frames rigidly with the articulation lock bar.

fNOTE: During break-in operation more than 50 hours until initial operational break-in is finished, grease the machine every day.

In case excavations are performed in mud, water or snow, grease the machine after operation is complete.

fNOTE: Sufficiently add high quality of grease through

the grease fittings. After removing contamination around the grease fitting, add grease. After greasing, thoroughly wipe off old grease that was pushed out from the seals.

2

Bucket Link Pin (1) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

Bucket Link (2) [2 point] --- every 250 hours or 3 months [Daily during first 50 hours]

Bucket Cylinder Pin (3) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours]

1

M4FG-07-003

3

Bucket Cylinder Rod Pin (4) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours]

4

Bell Crank Pin (5) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours] 5 M4FG-07-004

7-19

MAINTENANCE Lift Arm Cylinder Rod Pins (6) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

7

Lift Arm Cylinder Pins (7) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

6

Lift Arm Pivot Pins (8) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

8

M4FG-07-005

9, 10

M4FG-07-006

Steering Cylinder Rod Pin [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours] 12

9- Front-left 10- Front-right 11

Steering Cylinder Pin [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours] 11- Rear-left 12- Rear-right

Frame Center Hinge Pin [Each 1 point on the upper and lower sides] --- every 250 hours or 3 months 13

13- Upper side 14- Lower side

14 M4FG-07-006

7-20

MAINTENANCE Rear Axle Pins [Each 1 point on the front and rear pins] ---every 100 hours or 1 month 15- Front 15

16- Rear

16

M4FG-07-008

Propeller shaft universal (17) [2 points] ---every 500 hours or 6 months

fNOTE: When the machine is continuously operated under severe conditions for a long time, shorten the greasing intervals.

17

18

M4FG-07-009

17

Propeller Shaft Spline (18) [1 point] --- every 500 hours or 6 months

M4FG-07-010

7-21

MAINTENANCE B. Engine 1

Check Engine Oil Level --- every 10 hours (before starting the engine) Check the oil level before starting the engine. Remove dipstick (1). Check for mixing of foreign matter or contamination in the oil. Wipe oil off the dipstick with a clean cloth. Reinsert dipstick (1) and remove it again. Read level. Oil level must be within the specified range on dipstick (1).

If necessary, add the recommended engine oil via oil filler (2).

Recheck oil level after adding the oil.

2

M4FG-07-011

Specified Range M4EJ-07B-002

fNOTE: Before refilling oil or checking the oil level, level the

engine. When checking the oil level after operating the machine, first stop the engine.

Wait for more than 15 minutes. Then check the oil level.

(This means that the oil level has become stabilized after all oil was delivered to respective lubrication area returns to the oil pan.) In case the oil color change, severe contamination, and/or mixing of foreign matter is found, change the oil.

7-22

MAINTENANCE Change Engine Oil --- every 500 hours or 6 months (Only first time at 100 hours or 1 month) WARNING: Immediately after the machine was d operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.

Clean Cloth Container

IMPORTANT:

Consult a professional waste collector or your nearest TCM dealer about disposal of waste oil and filters.

Dispose waste oil and filters according to local regulations while giving consideration to earth’s ecology.

Be sure to replace the engine oil filter when changing engine oil at the same time.

M4GB-07-020

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Clean the areas around the drain plug and the oil filter.

3. Arrange 12 liter (3.2 gal)-capacity container to receive the drain oil.

4. Remove drain plug (3) provided in the rear frame opening located at rear side of the fuel tank (on the left side of the base machine) to allow oil to drain.

5. Drain oil from the oil filter cartridge.

6. Allow oil to drain through clean cloth to check if any foreign matters such as metal pieces are not included in the oil.

7. Install new oil filter.

8. Securely tighten drain plug (3).

9. Remove the oil filler cap. Supply the specified amount of engine oil.

Oil refill quantity: 11.2 L (3 gal) 10. Check that the oil level is between the minimum and maximum level scales on the dipstick. Then, start the engine.

11. After starting the engine, check the sealing surfaces for any oil leakage.

12. Allow the engine to run at low idle speed for 5 minutes and stop the engine. About 15 minutes after, check the oil level. If necessary, add oil.

7-23

3 M4FG-07-012

MAINTENANCE Replace Engine Oil Filter --- every 500 hours or 6 months (Only first time at 100 hours or 1 month) WARNING: Immediately after the machine was d operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.

fNOTE: Be sure to replace the engine oil filter when changing engine oil at the same time.

1

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

M4FG-01-038

2. Remove left side cover. Clean the area around the oil filter.

3. Before removing oil filter (1), loosen drain plug (2) to drain oil from the oil filter. The oil is drained through the drain hose. After draining the oil, tighten the drain plug.

4. Remove the cartridge type element from the filter head with a filter wrench.

IMPORTANT: • Take care not to allow foreign matter such as dirt to enter the oil filter.

• Be careful not to damage the oil filter when removing or installing the filter.

• Never reuse the cartridge type oil filter element.

5. Fill the oil filter with clean engine oil.

6. After coating new oil filter gasket with engine oil, tighten the oil filter until the gasket comes in contact with the sealing surface. Take care that if the oil filter is overly tightened, the oil filter may become deformed.

fNOTE: When installing the element, take care not to allow gasket (4) to break due to twisting.

Check for oil leaks around the mounting surface of cartridge type element (2).

7-24

2 M4FG-07-012

MAINTENANCE C. Power Train

3

Change Transmission Oil --- every 1000 hours or 1 year (Only first time at 250 hours or 3 months) WARNING: If the machine is unexpectedly moved, d serious accident may result. When parking the LOCK

machine, place F-N-R lever (1) in neutral and neutral lever lock (2) in the lock position. Then, apply parking brake (3) and stop the engine.

UNLOCK

Pay attention to the following points. d •WARNING: Immediately after the machine was operated, all

2

1

M4FG-01-007

engine parts are hot. Wait for the oil to cool before starting any maintenance work.

• Secure the front and rear frames with articulation lock bar (4).

IMPORTANT:

Do not use transmission oils other than those listed in the table for “Kinds of oils”.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

4

2. Install articulation lock bar (4) to the front and rear of the frames by following the procedures described on page 7-6.

M4FG-01-035

3. Turn the key switch OFF to stop the engine. Leave the machine untouched for 10 minutes.

4. Clean areas around drain plug (5) and oil level plugs (6) (2 places).

6

5. Prepare a container of approximately 2 liter (0.5 gal) capacity to receive the drain oil.

6

6. Remove drain plug (5) from the transmission bottom to drain the oil. Dispose of the drain oil in the proper way.

5

7. Securely tighten drain plug (5).

8. Refill the specified amount of oil through either one of oil level plug (6) holes (2 places). Oil refill quantity: 1.0 L (0.3 gal) 9. Check that the oil level is equal to the position of oil level plug (6) hole. Add oil as necessary.

fNOTE: Finally, check for any oil leakage around drain plug.

7-25

M4FG-07-013

MAINTENANCE Change Axle Oil --- every 1000 hours or 1 year (only first time at 250 hours or 3 months) Pay attention to the following points. d •WARNING: Immediately after the machine was operated, all engine parts are hot. Wait for the oil to cool before starting any maintenance work.

• Secure the front and rear frames with the articulation lock bar and pins.

IMPORTANT:

Do not use axle oils other than those listed in the table for “Kinds of transmission oil“.

M4FG-07-032A

1

Change Axle Oil 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

Park the machine so that each oil level plug (1) at left and right side of the axle is level off.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Clean the areas around drain plug (2) and oil level plugs (1) (2 places) and oil level plug (3) mounting area.

4. Arrange a container of approximately 10 liter (2.6 gal) capacity to receive the drain oil.

5. Remove drain plug (2) from axle bottom to drain the oil.

Dispose of the drain oil in the proper way.

IMPORTANT:

Do not wrap the drain plug with any seal tape. Failure to do so may damage the case or may cause oil leakage.

6. After coating drain plug (2) with LOCTITE #572 or equivalent, securely retighten the drain plug.

IMPORTANT:

It takes time for oil to fully lubricate the overall front axle.

After installing the plug, allow the machine to drive for several minutes. Then, stop the engine and check the axle for any oil leaks.

7. Refill the specified amount of oil through oil level plugs (1) (2 places) and oil level plug (3).

Front Axle 6.2 L (1.6 gal)

Rear Axle 6.4 L (1.7 gal)

7-26

2

3

M4FG-07-015

MAINTENANCE Check Oil Level 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

Park the machine so that each oil level plug (1) at left and right side of the axle is level off.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Clean the area around oil level plugs (1) (2 places) and oil level plug (3) mounting area.

M4FG-07-032A

1

4. Remove oil level pugs (1) (2 places) and oil level plug (3).

Check that the oil level is equal to the position of oil level plug holes.

Add oil as necessary.

3

7-27

M4FG-07-015

MAINTENANCE Clean Transmission Air Breather --- every 500 hours or 6 months

1

CAUTION: Be sure to wear safety glasses or goggles d when cleaning the air breather with compressed air.

1. Clean the vicinity around air breather (1) before removing the air breather.

2. Put a cover on the air breather port to prevent foreign matter from entering.

3. Clean air breather (1) using compressed air. If completely contaminated, wash the air breather with a cleaning solvent and reinstall it.

4. Take care not to allow foreign matter to enter into the transmission when reinstalling the air breather.

7-28

M4FG-07-016

MAINTENANCE Check Surrounding Areas Around Axles and Covers for Oil Leaks --- every 1000 hours or 1 year Check the surrounding areas around the axles and covers for oil leaks. If any oil leaks are found, check the bolts in the oil leaking area for tightness. Retighten as needed.

Clean Axle Housing Air Breather --- every 500 hours or 6 months

1

CAUTION: Be sure to wear safety glasses or goggles d when cleaning the air breather with compressed air.

1. Clean the vicinity around air breather (1) before removing the air breather.

2. Put a cover on the air breather port to prevent foreign matter from entering.

3. Clean air breather (1) using compressed air. If completely contaminated, wash the air breather with a cleaning solvent and reinstall it.

Front Axle

M4FG-07-017

1

4. Take care not to allow foreign matter to enter into the transmission when reinstalling the air breather.

Rear Axle

7-29

M4FG-07-018

MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment WARNING: Always follow the following precautions d for checking and maintaining the hydraulic system.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Begin servicing hydraulic components only after components, hydraulic oil and lubricants have completely cooled, and only after releasing residual pressure.

2.1 Operate all control levers several strokes to bleed residual air pressure.

2.2 Immediately after operation, all hydraulic components and hydraulic oil or lubricants are hot and highly pressurized. Begin inspection and/or maintenance work only after the machine has cooled down.

Servicing heated and pressurized hydraulic components may cause plugs, screws and/or oil to fly off or escape suddenly, possibly resulting in personal injury. Hydraulic components may be pressurized even when cooled.

Keep body parts and face away from the front of plugs or screws when removing them.

IMPORTANT: • When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them.

• Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them.

• Only use O-rings that are free of damage or defects. Be careful not to damage them during reassembly. Do not allow high pressure hoses to twist when connecting them. The life of twisted hoses will be shortened considerably.

• Do not use hydraulic oils other than listed in the “Brand Names of recommended Hydraulic Oil”.

• Never start the engine without first supplying hydraulic oil.

7-30

MAINTENANCE Check Hydraulic Oil Level --- every 10 hours (daily) IMPORTANT:

If the oil level is not viewed in the level gauge, immediately refill hydraulic oil up to the appropriate level. Failure to do so may result in serious failure in the hydraulic system.

If the oil level is higher than the level gauge, remove oil down to the appropriate level using a pump.

1 M4FG-07-021

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

1

2. Check oil level with level gauge (1) at the side of the hydraulic oil tank. Oil must be within the gauge.

fNOTE: During cold weather season, check the oil level after warming up the hydraulic oil by referring to the instructions described in the “Warm Up Operation” section.

M4EJ-07D-002

7-31

MAINTENANCE Change Hydraulic Oil/Clean Hydraulic Oil Tank --- every 1000 hours or 1 year Change/Cleaning WARNING: Hydraulic oil becomes hot and d pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

IMPORTANT:

1

Do not use hydraulic oils other than listed in the “Brand Names of recommended Hydraulic Oil”.

M4FG-01-035

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Install articulation lock bar (1) to the front and rear of the frames by following the procedures described on page 7-6.

2

3. Slowly loosen oil filler port plug (2) to relieve the air pressure from the hydraulic oil tank.

IMPORTANT:

When changing hydraulic oil, take care not to allow foreign matter such as dirt, water or soil to enter the hydraulic oil tank.

M4FG-07-021

4. Clean the vicinity of drain plug (4) on the bottom of hydraulic oil tank (3).

5. Arrange container of approx. 80 liters (21.1 gal) to receive the drain oil.

3

6. Remove drain plug (4) to drain hydraulic oil.

7. Remove cleaning cover (5) on the bottom of hydraulic oil tank (3). Clean the tank bottom with cleaning oil. Install cleaning cover (6) in its original position after cleaning.

4

8. Securely tighten drain plug (4).

7-32

5

M4FG-07-022

MAINTENANCE 9. Remove oil filler port plug (2). Refill hydraulic oil while checking oil level with level gauge (6).

Specified Oil Amount: Hydraulic Oil Tank 50 L (13.2 gal)

Hydraulic System 73 L (19.3 gal)

2

10. Install oil filler port plug (2).

11. Start the engine. Slowly raise or lower the arm and tilt the bucket forward and backward. Stop the engine.

Check for any oil leaks. Check the oil level using level gauge (6).

6 M4FG-07-021

6

Bleed Air from the Hydraulic System After changing hydraulic oil or replacing the return filter, HST oil filter and/or suction filter, bleed air from the hydraulic system following the procedures below.

Procedures 1. After supplying oil, start the engine. Move the bucket and lift arm cylinders several times to bleed air mixed in the hydraulic circuit.

2. Rest the bucket on the ground to resume the hydraulic oil level check position.

3. Stop the engine. Check the oil level. Add oil as needed.

7-33

M4EJ-07D-002

MAINTENANCE Clean Suction Filter --- each time when hydraulic oil is changed

1

A suction filter is located on the bottom of the hydraulic oil tank. Clean the suction filter when changing hydraulic oil.

1. After draining the hydraulic oil, remove cleaning cover (3) on the bottom of hydraulic oil tank (1). Slowly remove suction filter (2) from the opening. Trapped dust will fall.

4

2. Clean suction filter (2) and inside of the hydraulic oil tank with cleaning oil.

3

3. Install suction filter (2) in the hydraulic oil tank. Inspect O-ring seal for wear or for damage. Install cleaning cover (3) with bolts (6 used).

2

M4FG-07-023

5

4. Refill hydraulic oil by the specified volume through the oil filler port while checking the oil level with oil gauge (5).

5. Start the engine. Slowly raise and lower the lift arm and tilt the bucket forward and backward to confirm that no abnormality is present. Stop the engine. Recheck the oil level with oil gauge (5).

M4EJ-07D-002

7-34

MAINTENANCE Replace HST Oil Filter Element --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) WARNING: Hydraulic oil becomes hot and d pressurized during operation. Severe burns may 1

result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

Apply the parking brake and wedge the tires before starting any maintenance work.

M4FG-07-021

The HST oil filter is located at the front-left side of the HST pump.

Replace the element when changing hydraulic oil.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Before removing the filter element, arrange a container and workshop towel to receive the drain oil and the element.

M4FG-07-025

3

4. Slowly loosen oil filler port plug (1) to relieve the air pressure from the hydraulic oil tank.

IMPORTANT: • Do not allow foreign matter such as dirt to enter cartridge type element (2).

• When installing or removing cartridge type element (2), be careful not to damage cartridge type element (2).

• Do not reuse cartridge type element (2).

5. Rotate the hexagonal section on the bottom of cartridge type element (2) counterclockwise with a spanner to remove the filter from filter head (3).

4

2

M4FG-07-029

7-35

MAINTENANCE 6. Pour new hydraulic oil into cartridge type element (2).

7. Coat O-ring (4) on new cartridge type element (2) with hydraulic oil. Install cartridge type element (2) to filter head (3) by turning the hexagonal section on the bottom of cartridge type element (2) with a spanner. After gasket (4) comes in contact with the seal surface on filter head (3), further tighten the element by 3/4 turns.

3

4

fNOTE: When installing the element, take care not to allow O-ring (4) to break due to twisting.

Check for oil leaks around the mounting surface of cartridge type element (2).

8. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.

(Refer to the descriptions for “Bleed Air from the Hydraulic System”. ) If the machine is operated without bleeding air mixed in the hydraulic circuit, damage to the hydraulic pump may result.

fNOTE: Replace the element at the regular intervals. The element keeps hydraulic oil clean and to extend hydraulic components service life.

7-36

2

M4FG-07-029

MAINTENANCE Replace Return Filter --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) Replacement WARNING: Hydraulic oil becomes hot and d pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

Apply the parking brake and wedge the tires before starting any maintenance work.

M4FG-07-026

The return filter is located at the front-right side of the HST pump.

Replace the element when changing hydraulic oil.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

1

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Before removing the filter element, arrange a container and workshop towel to receive the drain oil and the element.

M4FG-07-021

3

4. Slowly loosen oil filler port plug (1) to relieve the air pressure from the hydraulic oil tank.

IMPORTANT: • Do not allow foreign matter such as dirt to enter cartridge type element (2).

• When installing or removing cartridge type element (2), be careful not to damage cartridge type element (2).

• Do not reuse cartridge type element (2).

2

5. Rotate the cartridge type element (2) counterclockwise with a filter wrench to remove cartridge type element (2) from filter head (3).

M4FG-07-030

7-37

MAINTENANCE 6. Pour new hydraulic oil into cartridge type element (2).

7. Coat O-ring (4) on new cartridge type element (2) with hydraulic oil. Install cartridge type element (2) to filter head (3) by turning the hexagonal section on the bottom of cartridge type element (2) with a spanner. After Oring (4) comes in contact with the seal surface on filter head (3), further tighten the element by 3/4 turns. Take care not to damage cartridge type element (2) as it may become deformed if overly tightened.

fNOTE: When installing the element, take care not to allow

3

4

2

O-ring (4) to break due to twisting.

Check for oil leaks around the mounting surface of cartridge type element (2).

8. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.

(Refer to the descriptions for “Bleed Air from the Hydraulic System”. ) If the machine is operated without bleeding air mixed in the hydraulic circuit, damage to the hydraulic pump may result.

fNOTE: Replace the element at the regular intervals. The element keeps hydraulic oil clean and to extend hydraulic components service life.

7-38

M4FG-07-030

MAINTENANCE Check Hoses and Lines --- every 10 hours (daily)/every 250 hours or 3 months WARNING: Escaping combustible fluid can cause d fires.

Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, and any oil leaks.

Escaping oil under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for oil leaks with a piece of cardboard. Take care to protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Tighten, repair or replace any missing, loose or damaged clamps, hoses, lines.

Do not bend or strike high-pressure lines.

Never reinstall bent or damaged hoses or lines.

SA-031

According to the check points shown below, check hoses and lines for oil leaks and damage.

If any abnormality is found, replace or retighten as instructed in the table.

SA-292

SA-044

Hose Interval Check Points (hours) Every 10 hours Hose covers Hose ends Fittings

3

Abnormalities Leak (1) Leak (2) Leak (3)

Remedies

2

Replace Replace Retighten or replace hose or O-ring

1 2 3 M4GB-07-053

3

2 1 2 3 M4GB-07-054

7-39

MAINTENANCE Interval (hours) Every 250 hours

4

Check Points

Abnormalities

Remedies

Hose covers Hose ends

Leak (4) Leak (5)

Replace Replace

Hose covers Hose covers

Exposed reinforcement (6) Blister (7)

Replace Replace

Hose

Bend (8), Collapse (9)

Replace

Hose ends and Fittings Deformation or corrosion (10)

5

M4GB-07-055

7 6

Replace

Lines Interval (hours) Daily

Every 250 hours

M4GB-07-056

Check Points

Abnormalities

Contact surfaces of flange joints Leak (11) Bolts Loose or leak (11) Welded surfaces on flange joints Leak (12) Flange joint neck Crack (13) Welded surfaces on flange joints Crack (12) Clamps Missing or deformation Loose bolts

8

Remedies Replace Retighten or replace O-ring Replace Replace Replace Replace or retighten

M4GB-07-057

9

10 M4GB-07-058

13

12 11 M4GB-07-059

13

12

M4GB-07-060

7-40

MAINTENANCE Kinds of Hose/Line Fittings Following joint is used for hose fittings.

1

2

3

4

5

1. Metal Face Seal Fittings Tight contact between metal flares on adaptor (1) and connector (3) of hose (5) prevents pressure oil leakage.

This type of fittings is used on smaller diameter joint.

M4GB-07-062

Precautions for Use Connect or disconnect fittings with care not to damage seat surfaces (2 and 4).

Tightening Torque Tighten fittings to the torque values shown below.

Wrench size (mm) (in) 19 (0.75) 22 (0.87) 27 (1.06) N·m 29 39 93 Tightening Torque (kgf·m) (3.0) (4.0) (9.5) (ft·lb) (22) (29) (69)

7-41

MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) DANGER: Beware of fire. d Fuel is flammable. Keep fuel away from fire hazards.

IMPORTANT:

Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and may also make the engine difficult to start.

Do not allow any fluid other than fuel to enter the fuel tank. Especially if alcoholic based additive is mixed, the filter may crack.

1

M4GB-01-030

2 3

Recommended Fuel Use high quality DIESEL FUEL only (JIS K-2204) (ASTM D-975) (GOST-R 52368) (GB252). Kerosene must NOT be used.

(Sulfur content: Less than 500 ppm)

Refueling

M4FG-07-027

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Check the fuel level with gauge (1). Remove cap (2) on the fuel tank to add fuel as necessary.

3. Fill the tank at the end of operation in each day.

Fuel Tank Capacity : 82 L (21.7 gal) Add fuel while checking that fuel is not filled more than the specified amount.

4. Immediately after fueling, install and lock fill cap (2) to prevent vandalism and loss.

fNOTE: When fueling, do not remove strainer (3) from the

filler port. Take care not to allow dirt and/or water to enter the fuel tank.

7-42

MAINTENANCE Water and Sediment from Fuel Tank 困 Drain --- every 1000 hours or 1 year Before starting to operate the machine, remove drain plug (1) on the fuel tank bottom to drain water and/or sediment from the fuel tank.

1

7-43

M4FG-07-028

MAINTENANCE Check and Drain Water from Fuel Pre-Filter --- every 10 hours (daily) Check before starting operation.

Fuel pre-filter (1) functions to separate water mixed in fuel.

There is float (9) inside filter cup (10). When water accumulates, float (9) buoys up.

Before float (9) buoy rises up to the drain level (3) of filter cup (10), drain water.

Open the engine hood. Fuel pre-filter (1) is located on the left side of the radiator.

1

M4FG-07-031

Fuel Pre-Filter Drain Procedures 1. Turn cock (2) on fuel pre-filter (1) counterclockwise 90 ° to the close position.

2

2. Loosen retaining ring (4). Remove filter cup (10) from filter head (5). Get out float (9) and spring (8) from filter cup (10). Drain water.

Close

Receive water to protect the environment from being polluted.

Open

If any stain and/or affixes are found inside filter cup (10), clean the cup.

3

IMPORTANT:

Tighten retaining ring (4) by hands. If tightened with a tool, filter cup (10) may become damaged.

3. After draining, install filter cup (10) to filter head (5).

Tighten retaining ring (4).

M4FG-07-065

5 6

4. Turn cock (2) to OPEN position.

7

8 9

10

4 M4FG-07-066

7-44

MAINTENANCE Clean Fuel Pre-Filter Element --- every 500 hours or 6 months DANGER: Beware of fire. Fuel is flammable. Keep d fuel away from fire hazards.

CAUTION: Wear goggles or safety glasses when using d compressed air [less than 0.2 MPa (2 kgf/cm2)

3 1

(29.1 PSI)].

IMPORTANT:

When cleaning/replacing the filter, take care not to allow foreign matter such as dirt to enter the filter. Engine failure or damage may result.

Remove fuel pre-filter element (1) following the same procedure as described in “ Check and Drain Water from Fuel Pre-Filter”.

Clean element (1) with light oil. Blow compressed air [less than 0.2 MPa (2 kgf/cm2) (29.1 PSI)] from the inner side of the filter element. If any stain and/or affixes are found inside filter cup (2), clean the cup. If element (1) is damaged, use new parts for replacement. Use new O-ring (3) when replacing element (1).

After element (1) is cleaned, install it. Bleed air from the fuel system.

2

M4FG-07-066

Bleed Air from the Fuel System IMPORTANT:

Mixing of air in the fuel system may cause the engine to become difficult to start or engine trouble.

In case the machine runs out of fuel in the fuel tank, after the fuel filter or fuel prefilter is drained, or the element is replaced, bleed air from the fuel system.

When fuel with much water content is used, shorten check intervals and drain water as soon as possible.

1. Turn key switch (4) to ON position. The electric fuel pump is driven by which air is bled.

2. Start the engine. Check the fuel system for any fuel leaks.

7-45

4 M4EJ-01-025

MAINTENANCE Replace Fuel Filter Element --- every 500 hours or 6 months (Only first time at 100 hours or 1 month)

1

DANGER: Beware of fire. Fuel is flammable. Keep fuel d away from fire hazards.

IMPORTANT:

Consult a professional waste collector or your nearest TCM dealer about disposal of waste oil and filters.

Dispose waste oil and filters according to local regulations while giving consideration to earth’s ecology.

When replacing the filter, take care not to allow foreign matter such as dirt to enter the filter. Engine failure or damage may result.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

M4FG-07-031

2

2. Remove cartridge filter (2) from fuel filter (1) by using the filter wrench.

Receive fuel to protect the environment from being polluted.

M4GB-07-066

3. Put a thin film of fuel on the gasket of new cartridge filter element (2).

4. Tighten cartridge filter element (2) by hand until the gasket contacts the seal face.

5. Tighten the filter element 2/3 turn more using the filter wrench.

Take care that if the cartridge filter (2) is overly tightened, the filter may become deformed.

6. Bleed Air from the Fuel System After replacing the fuel filter element, bleed mixed air from the fuel system.

(Refer to “Bleed Air from the Fuel System”.)

7-46

MAINTENANCE Check Fuel Hose --- every 10 hours (daily)/250 hours or 3 months Fuel leaks can lead to fires that may result d inWARNING: serious injury.

Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that rub against each other, and any fuel leaks.

Repair or replace any loose or damaged hoses.

Never reinstall bent or damaged hoses.

According to the check points shown below, check hoses and lines for oil leaks and damage.

If any abnormality is found, replace or retighten as instructed in the table.

1

Hose Interval (hours) Every 10 hours Every 250 hours

Check Points

Abnormalities

Remedies

Hose ends

Leak (1)

Retighten or replace

Hose ends Hose Hose fittings

Crack (4) Bend (5), Collapse (6) Corrosion (7)

Replace Replace Replace

1 M4GB-07-071

4 M4GB-07-072

5

M4GB-07-073

6

7 M4GB-07-074

7-47

MAINTENANCE F. Air Cleaner

1

2

Clean and Replace Air Cleaner Element Cleaning --- when indicator comes ON Replacement --- after cleaning 6 times (or every 1 year) Clean and Replace Air Cleaner Element 3

CAUTION: Wear goggles or safety glasses when using d compressed air [less than 0.2 MPa (2 kgf/cm2) (29.1 PSI)].

IMPORTANT:

M4FG-07-033

To clean the element, avoid giving shocks or striking element with other objects.

When cleaning/replacing the element, take care not to allow foreign matter such as dirt to enter the engine.

Air cleaner (2) is comprised of double elements, outer element (5) and inner element (6). Normally, clean outer element (5). In case severely contaminated, remove inner element (6) and clean it in the same cleaning method as the outer element.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

4

4

M4FC-07-037

5

6

2. Loosen clip band (3) and remove dust cup (1). Clean off dust inside the cup.

3. Clean outer element (5) by blowing compressed air [less than 0.2 MPa (2 kgf/cm2) (29.1 PSI)] from the inner side of the filter element. After cleaning is complete, be sure to check outer element (5) for any damage. If any damage is found, replace the element with new one.

4. In case the air cleaner restriction indicator lights soon after cleaning outer element (5) even if the cleaning times are less than 6 times, replace both outer and inner elements with new ones.

5. Install dust cup (1) in the original position so that arrow marks (4) (↑ TOP ↑) point upward.

6. After cleaning the element, run the engine at low idle speed. Check that the indicator on the monitor does not come ON.

7-48

M4FG-07-034

MAINTENANCE G. Cooling System IMPORTANT:

Cylinder Liner

Use fresh water or normal tap water as a coolant. Do not use river-water, well-water or fountain–water which would have an adverse effect to the engine and radiator so that the cylinder liner would become corroded.

Soft water makes a lot of bubbles.

Use only long life coolant (LLC) described in the “Brand Names of recommended LLC” .

fNOTE: The machine shipped from the factory is filled with

coolant mixed with LLC. In this case, the coolant is usable through the year. Change the coolant at the earliest specified interval.

Normal

Long Life Coolant (LLC)

Corrosion/Rust M4GB-07-156

Dilute LLC with coolant. LLC mixing ratio is 35 %.

When refilling long life coolant (LLC), use the same brand product and the same mixture ratio as already used in the machine.

Change long life coolant (LLC) every 1000 hours or 1 year whichever comes first.

Change coolant only after cleaning the cooling system.

7-49

MAINTENANCE Precautions for Handling Long Life Coolant (LLC) Long life coolant (LLC) is poisonous. d •WARNING: If ingested by mistake, induce vomiting and get emergency medical attention immediately.

• If antifreeze is accidentally splashed into eyes, flush with water sufficiently and get emergency medical attention.

• When storing LLC, be sure to keep it in a clearly marked container with a tight lid. Always keep LLC out of the reach of children.

• Use attention to fire hazards. LLC is specified as a dangerous substance in the fire protection law.

• When disposing of LLC, be sure to comply with all local regulations.

Air tempera ture (°C)

Long-Life Coolant (LLC) Mixture ratio (%)

Long-Life Coolant (LLC) (L) (gal)

Soft Water (L) (gal)

-15 °C or higher (5 °F)

30

3.0 (0.8)

7.0 (1.8)

-20 °C or higher (-4 °F)

35*

3.5 (0.9)

6.5 (1.7)

-25 °C or higher (-13 °F)

40

4.0 (1.1)

6.0 (1.6)

-35 °C or higher (-31 °F)

50

5.0 (1.3)

5.0 (1.3)

Total Capacity: 10 L (2.6 gal)

fNOTE: *The LLC mixture ratio filled for the machines shipped from the factory is 35 %.

In case a machine destination is nominated as a cold weather district, the mixture ratio is increased to 50 %.

7-50

MAINTENANCE Check Coolant Level --- every 10 hours (daily)

1

WARNING: Do not remove radiator cap (1) until the d coolant temperature in the radiator become cool.

Hot steam may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen cap (1) to release the inside air pressure before removing cap (4).

Check the coolant level at reservoir tank (2).

The normal coolant level is between FULL and LOW marks on the side surface of reservoir tank (2).

M4FG-07-035

In case no coolant is present in reservoir tank (2), supply the coolant via the cap hole on reservoir tank (2).

2

• When refilling long life coolant (LLC), use the same brand product and the same mixture ratio as already used in the machine. (35 % Concentration) • If only water is refilled, the mixture ratio in the long life coolant (LLC) is diluted so that anti-rust and antifreeze effect in the coolant will become deteriorated.

FULL

LOW M4FG-07-036a

7-51

MAINTENANCE Check Fan Belt --- every 10 hours (daily) Check the fan belt for any abnormality. If any cracks are found, replace the belt with a new one.

Check Fan Belt Tension --- every 250 hours or 3 months IMPORTANT: Loose fan belt may result in insufficient battery charging, engine overheating, as well as premature belt wear. An excessively tight belt, however, can damage both water pump and alternator bearings and fan belts.

2 1

Check fan belt (1) tension by depressing the midpoint between alternator pulley (2) and crank pulley (3) with the thumb. Normal deflection must be 7 to 9 mm (0.3 to 0.35 in) with a depression force of approximately 98 N (10 kgf ) (22 lbf ).

Adjust Fan Belt Tension --- every 500 hours or 6 months (or whenever slack is found) 1. Loosen alternator (4) mounting bolts (5) (2 used).

3

M4FG-07-038

4

5

2. Adjust belt tension by moving alternator (4) forward or backward.

3. Tighten mounting bolts (5) (2 used).

fNOTE: When a new belt is installed, be sure to readjust the

belt tension after operating the machine for 3 to 5 minutes at low idle speed to be sure that the new belt is correctly seated.

7-52

5

M4FG-07-037

MAINTENANCE Change Coolant --- every 1000 hours or 1 year

1

WARNING: Do not remove radiator cap (1) until the d coolant temperature in the radiator become cool.

Hot steam may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen cap (1) to release the inside air pressure before removing cap (4).

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Install the articulation lock bar to the front and rear of the frames following the procedures described on page 7-5.

M4FG-07-035

2

3. Remove radiator cap (1). Loosen the radiator drain cock (2). Open the drain hole located at the left bottom of the rear frame and drain plug (3) at the engine water jacket to drain coolant. Remove impurities such as scale at the same time.

M4FG-07-042

M4FG-07-039

3 M4FG-07-040

7-53

MAINTENANCE Clean Radiator and Oil Cooler --- every 100 hours or 1 month or if the core becomes clogged CAUTION: When using compressed air pressure [less d than 0.2 MPa (2 kgf/cm2) (29.1 PSI)], wear safety glasses or goggles.

IMPORTANT:

IMPORTANT:

If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm2) (29.1 PSI) or with high delivery pressurized tap water is used for cleaning, damage to the radiator/oil cooler fins may result.

Keep the nozzle away from the core surface more than 500 mm.

If the machine is operated with radiator/oil cooler are clogged, damage to the engine or radiator may result.

In case dirt and/or dust is adhered to the radiator (1) and oil cooler (2) cores, clean them with compressed air [less than 0.2 MPa (2 kgf/cm2) (29.1 PSI)] or tap water to prevent a reduction in cooling system performance.

7-54

2

1

M4FG-07-041

MAINTENANCE H. Electrical System IMPORTANT: • Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment may effect the machine’s electronic parts, causing involuntary movement of the machine.

Also, improper installation of electrical equipment may cause unexpected machine failure and/or fire on the machine.

Be sure to consult your nearest TCM dealer when installing radio communication equipment or additional electrical parts.

• Never attempt to disassemble or modify the electrical/electronic components.

If replacement or modification of such components is required, contact your nearest TCM dealer.

Check Monitor Function and All Other Instrument Operation --- every 10 hours (daily) Run the engine at low idle speed when checking the instruments.

The monitor indicates alarm, caution and confirmation status in red, orange, and normal operative condition in blue or green respectively.

Check the needle movement of each gauge and meter with the key switch ON. The needle shall be moved to the blue range when normal and to the red range when abnormal.

Refer to the “Operator’s Station” for more information.

7-55

M4FG-01-011

MAINTENANCE Check Work Lights --- every 10 hours (daily) CAUTION: If any burned-out lights are found, d immediately replace it with a new one.

Visually check that all work lights normally light and/or blink from the front and rear sides of the machine.

M4FGE-01-021

M4FGE-01-019

Check Horn, Backup Buzzer and Backup Light --- every 10 hours (daily) WARNING: Before checking the horn and/or the d backup buzzer, always apply the parking brake and clear all personnel from the machine’s vicinity.

The horn switch button is located at the steering wheel center.

Horns (1) are located at the left and right side of the front work light bracket.

Check that the backup buzzer (2) sound and backup light (3) ON when moving the FNR lever to reverse (R) position.

Backup light (3) is located at the right side of the weight center. Backup buzzer (2) is located of the weight center.

1

1

M4FGE-01-021

2

3

M4FGE-01-019

7-56

MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours CAUTION: If dirt or dust is adhered to the wirings and d relays, it possibly results in fire.

Check the electrical harness and terminals of the batteries, battery relays, starter motor and alternator for loose connections and/or short circuit (broken shield). Clean any dirt and dust.

If any burned mark or an abnormal smell is noticed on a harness, consult your nearest TCM dealer.

1

M4FG-01-029

Check and Replace Fuse 1. If any electrical equipment becomes inoperable, first check the fuses in base machine fuse box (1) located on the behind the operator’s seat.

2. One each spare fuse for respective fuse capacities is provided in the fuse box.

3. Finally, check slow blow fuses (2) (2 used) located in the left front of the engine room.

2

Slow blow fuses (2): 100 A (2 used) M4FG-01-048

7-57

MAINTENANCE Fuse Box No. 1 2 3 4 5

Ampere 10 10 15 5 5

6

15

7 8 9 10 11 12 13 14 15 16 17 18 19 20

15 10 10 10 10 30 15 10 − − − − 15

Corresponding Circuit HEAD LIGHT (LEFT) HEAD LIGHT (RIGHT) HEAD LIGHT (HI BEAM) CLEARANCE LIGHT (LEFT), TAIL LIGHT (RIGHT) CLEARANCE LIGHT (RIGHT), TAIL LIGHT (LEFT) HST [F], [R] SOLENOID, PARKING BRAKE SOLENOID, BACKUP LIGHT, BACKUP BUZZER, RELAY [1], RELAY [2] HORN, BRAKE LAMP ENGINE STOP SOLENOID, FUEL PUMP SAFETY RELAY, ALTERNATOR, ENGINE SPEED SENSOR, RELAY [3] BUCKET AUTO LEVELER PROXIMITY SWITCH, CONTROL VALVE DETENT (TILT) MONITOR HEAD LIGHT, CLEARANCE LIGHT, TAIL LIGHT HST CONTROLLER MONITOR BACKUP POWER SUPPLY OPTIONAL POWER OPTIONAL POWER OPTIONAL POWER NOT USED OPTIONAL POWER HAZARD LIGHT, FLASHER UNIT

M4FG-07-047

7-58

MAINTENANCE Battery WARNING: Explosive gas is generated during use d and/or charging of batteries. Keep sparks and Open flames away from batteries.

Do not continue to use or charge the battery when electrolyte is lower than the specified level.

Explosion of the battery may result.

Charge the batteries in a well ventilated location.

Dilute sulfuric acid used for electrolyte is strong enough to burn skin and eats holes in clothing and metal. Always be careful when handling the batteries.

IMPORTANT:

If the battery is used with the electrolyte level lower than the specified lower level, the battery may deteriorate quickly.

IMPORTANT:

Do not refill electrolyte more than the specified upper level. Electrolyte may spill, damaging the painted surfaces and/or corroding other machine parts.

SA-032

fNOTE: In case electrolyte is refilled more than the specified

upper level line or beyond the bottom end of the sleeve, remove the excess electrolyte until the electrolyte level is down to the bottom end of the sleeve using a pipette. After neutralizing the removed electrolyte with sodium bicarbonate, flush it with plenty of water, otherwise, consult the battery manufacturer.

SA-036

Precautions for Handling Batteries

fNOTE: A battery terminal (with a black cap) located on the center of the counterweight is the ground terminal.

• If electrolyte spills on your skin and/or clothes, immediately flush the skin and/or clothes with water and then wash further with soap.

If splashed in eyes, flush with water for approximately 15 minutes and seek immediate medical attention.

M4FG-07-042

7-59

MAINTENANCE • Avoid using fire hazards such as matches lighters and tobacco near the batteries. Do not allow sparks to fly.

• Check and service the batteries only after stopping the engine, turning the key switch OFF and removing the battery caps.

• Contact of the battery immediately after operation may cause personal injury.

Wait for the battery to cool.

• When the battery is recharged, inflammable hydrogen gas is created. Remove the battery from the base machine. Recharge the battery after removing the caps in a well ventilated area.

• When disconnecting the battery terminals, first disconnect the ground line [minus (-)] side terminal.

When connecting the battery terminals, connect the ground line [minus (-)] side terminal last. If a piece of metal, such as a tool comes in contact with the battery plus (+) side terminal and the vehicle frame when both terminals are connected, the electrical system may shortcircuit, possibly creating a dangerous situation.

• Loose terminal may allow sparks to fly. Securely tighten the terminals.

7-60

MAINTENANCE In Case the Batteries Were Discharged

d •WARNING: Hydrogen gas is generated from batteries.

Inappropriate handling of the batteries may cause fires and/or explosion. Keep tobacco and/or open flame away from the batteries.

• If a metal tool is placed across the battery terminal and a vehicle component such as the engine block, sparks may be created, possibly resulting in fire and/or explosion.

• If electrolyte spills on your skin, scalding and/or blindness may be caused. Wear safety glasses, rubber gloves and a rubber apron whenever handling a battery.

• If electrolyte spills on your skin, immediately flush the skin with plenty of water and then seek immediate medical attention.

• Before checking the batteries, turn the key switch OFF to stop the engine and turn all switches OFF or neutral.

CAUTION: When the batteries are removed, d horizontally rest the bucket on the ground. Apply the parking brake. Turn the key switch OFF to stop the engine.

Be careful not to place a metal tool on the batteries.

To prevent sparks from flying, first disconnect the negative side (ground line) terminal. When connecting the batteries, connect the negative side terminal last.

CAUTION: When disposing the batteries, consult d the shop where you purchased the batteries or professional disposer. Do not irregularly dispose the battery.

7-61

MAINTENANCE Method to Recharge the Removed Battery • Thoroughly read and understand the operation manual for the battery charger and follow the manual instructions.

• When charging the battery indoors, sufficiently ventilate the area. Remove the battery caps to allow the developed gas to be released.

• During charging the battery, keep fire hazards away from the battery. Do not allow a metal piece to come in contact with the battery terminals.

• After the battery is charged, clean the battery terminals and coat the terminals with grease before installing the battery on the base machine.

Method to Replace with Charged Auxiliary Batteries • Once the battery has been fully discharged, the service life of the battery is shortened. Replace such batteries with new ones at the earliest opportunity.

• Correctly and securely connect battery plus (+) terminal to cable plus (+) terminal and battery minus (-) terminal to cable minus (-) terminal respectively.

7-62

MAINTENANCE Check Electrolyte Level --- every 100 hours or 1 month Check the electrolyte level at least once a month.

U.L

1. Park the machine on a level ground and stop the engine.

2. Check the electrolyte level.

2.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.

Do not use a dry towel. Static electricity may be developed, causing the battery gas to explode.

Check if the electrolyte level is between U.L (Upper Level) and L.L (Low level). In case the electrolyte level is lower than the middle level between the U.L and L.L, immediately refill with distilled water or commercial battery fluid.

M4FGE-07-067

L.L Filler Port

Sleeve

After refilling, securely tighten the filler plug.

Be sure to refill with distilled water before recharging (operating the machine).

2.2 When impossible to check the level from the battery side or no level check mark is indicated on the side: After removing the filler plug from the top of the battery, check the electrolyte level by viewing through the filler port. It is difficult to judge the accurate electrolyte level in this case. Therefore, when the electrolyte level is flush with the U.L, the level is judged to be proper. Then, referring to the right illustrations, check the level. When the electrolyte level is lower than the bottom end of the sleeve, refill with distilled water or commercial battery fluid up to the bottom end of the sleeve.

Separator Top

U.L L.L M4GB-07-093

Proper Since the electrolyte surface touches the bottom end of the sleeve, the electrolyte surface is raised due to surface tension so that the electrode ends are seen curved.

M4GB-07-094 Lower When the electrolyte surface is lower than the bottom end of the sleeve, the electrode ends are seen straight.

M4GB-07-095

After refilling, securely tighten the filler plug.

Be sure to refill with distilled water before recharging (operating the machine).

2.3 When an indicator is available to check the level, follow the checking results.

3. Always keep the area around the battery terminals clean to prevent battery from discharging. Check terminals for loose and/or rust.

Check terminals for loose and/or rust. Coat the terminals with grease or petroleum jelly to prevent corrosion build up.

7-63

M4GB-07-096

MAINTENANCE Check Electrolyte Specific Gravity --- every 250 hours or 3 months The electrolyte specific gravity varies depending on the electrolyte temperature. The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit.

Recommended range of specific gravity by electrolyte temperature 40 °C (104 °F) 20 °C (68 °F)

Fluid temp.

Working Range

0 °C (32 °F) –20 °C (–4 °F) –40 °C (–40 °F)

1.21

1.22

1.23

1.24

1.25

1.26

1.27

Specific gravity of battery fluid

fNOTE: Measure the electrolyte specific gravity when the

electrolyte temperature is equal to the atmospheric temperature. Do not check the electrolyte specific gravity immediately after operation as the correct value can not be obtained.

7-64

1.28

1.29

1.30

1.31

1.32

1.33 M104-07-054

MAINTENANCE I. Brake System Check Brake Oil Level --- every 10 hours (daily) or when the brake oil indicator comes ON WARNING: If brake oil low level indicator (1) on d the monitor comes ON, immediately stop machine 1

operation, check brake oil tank (2) level and the brake system. Do not continue to operate the machine with the brake oil level reduced, possibly resulting in personal injury or death.

M4FG-01-011

2

IMPORTANT:

When the oil level in brake oil tank (2) becomes lower than [MIN] level, brake oil low level indicator (1) on the monitor comes ON. Immediately stop the machine.

Check the brake system for any leaks, and then refill the specified brake oil up to the appropriate level.

IMPORTANT:

Refill brake oil with the same brand of oil as described in the “kind of oils”.

If oil other than those described in the “kind of oils” is used, malfunction or failure of the brake may result.

M4FG-01-030

2

3

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Brake oil tank (2) is located at the left front of the engine room. When the brake oil level is correct, it should be between MAX and MIN marks on brake oil tank (2).

3. If the oil level is lower than MIN mark on brake oil tank (2), open cap (3) of brake oil tank (2) and refill specified brake oil up to the appropriate level.

After refilling, securely tighten the filler plug.

4. Check that brake oil low level indicator (1) on the monitor does not come ON before operating the machine.

7-65

MAX MIN

M4EK-07I-002

MAINTENANCE Check Right and Left Brake Interlocking Performance --- every 10 hours (daily)

1

1

WARNING: Put up a No Entrance notice 100 m d (109 yd) ahead of the machine forward travel direction. Arrange a safety monitor person.

WARNING: Do not allow dust and/or soil to d accumulate in vicinity (3) of the brake pedal. The brake may become inoperable.

While stepping on brake pedal (1), check the pedal movement, the brake performance and the play in the pedal stroke for any abnormality.

If dust and/or soil accumulate in vicinity of the brake pedal, remove the accumulated dust and/or soil.

3

3

M4FG-07-045

Check Brake Performance The machine must be stopped within 5 m (16’ 5” ft·in) range after the brake is applied while driving at the speed of 15 km/h (9.3 mph) on a flat dry paved surface road.

2

Check Play in Brake Pedal Stroke Measure the pedal stroke at pedal tip by pressing the pedal with hand until the hand feels an intermittent repulsion from the pedal.

Correct play (2): Approx. 10 mm (0.4 in) If the play is outside the specified range, or abnormal pedal operation and/or performance is noticed, consult your nearest TCM dealer.

Get the machine checked and repaired.

M4FG-07-046

7-66

MAINTENANCE Check Parking Brake Force --- every 10 hours (daily) WARNING: Check the machine in a place where d no person is present around or ahead the driving

1

direction.

Keep bystanders away from the machine.

Park the machine with no load applied on a 15 ° inclined dry surface slope. The machine must not move with the parking brake switch (1) ON. Should the machine move during inspection, consult your nearest TCM dealer. Get the brake system checked and repaired.

M4FG-01-008

Check Brake Disc (Service and Parking) --- every 1000 hours or 1 year Wet disc type service brake and parking brake are mounted on the front axle.

Consult your nearest TCM dealer for checking.

M4FG-06-005

Change Brake Oil --- every 1000 hours or 1 year Consult your nearest TCM dealer for changing brake oil.

M4FG-01-030

7-67

MAINTENANCE J. Tire Check and Adjust Tire Pressure Check --- every 10 hours (daily) Adjust --- as necessary WARNING: Secure the front and rear frames with the d articulation lock bar and ring pins.

When inflating tires, stand behind the tire tread and use the self-attaching chuck.

Avoid welding near tires, which could potentially cause the tires to explode.

If the machine catches fire, tires may explode due to emission of heat if any sign of abnormality such as tire smoking, abnormal increase in tire temperature, or the air smells of rubber or tire bead burning is found.

SA-249

IMPORTANT:

Always maintain the correct tire pressure.

Even if only one tread pattern has worn out, replace the tire with a new one. Before operating the machine, check the tires for any breaks, damage or foreign matter.

When replacing one tire, use a new tire having the same tread pattern and specification as the other tires.

Check Tire Pressure WARNING: Pay attention not to allow tires to be d used with excessively high or low pressure, possibly causing abnormal vibration of the machine during traveling. In addition, cracks of the tires and premature cracks of the wheels may result.

1. Measure air pressure when the tires are cool before operating the machine.

Standard Tire Size

Standard Air Pressure

17.5/65-20-10PR

240 kPa (2.4 kgf/cm2) (34 PSI)

2. Check tires for any damage and/or excessive wear.

7-68

MAINTENANCE Check Tire for Damage --- every 10 hours (daily) WARNING: If tire has external damaged such as a d score, an accident due to puncture or burst of the tire may occur, possibly resulting in personal injury or death.

Check the external appearance of tires for any damage.

Check Wheel Bolt Torque --- every 500 hours or 6 months (Only first time at 50 hours) Be sure to check the wheel bolt torque by turning the bolt in the tightening direction.

Tightening Torque: 494 to 604 N·m (50.4 to 61.6 kgf·m) (364 to 445 ft·lb) Replace Tire WARNING: Secure the front and rear frames with the d articulation lock bar and pins.

IMPORTANT:

Allover height of the machine may change according to the type of tires installed.

Do not change the specifications of the registered machine.

1. Lower the bucket and lift arm to the ground. Apply the parking brake.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Loosen all wheel nuts one turn.

Note which way the tread pattern is facing.

4. After jacking up the machine, securely support the machine with blocks.

5. Remove the wheel nuts. Replace the tire.

1

6. With the tire raised off the ground, lightly tighten the wheel nuts in the order as illustrated to the right.

7. Lower the machine to the ground. Retighten the wheel bolts to specification in the order as illustrated to the right.

6

7

4

3

8

5 2

7-69

M4FG-07-032

MAINTENANCE Tire Sizes to Be Used

fNOTE: Consult with your nearest TCM dealer about the

optional tire patterns.

The machine may vibrate depending on tire pattern to be employed during traveling. This is caused by resonance of the machine with the tire pattern not by failure.

TIRE Standard Size Standard Tire Standard Air Pressure Optional

Bias

17.5/65-20-10PR

Bias

17.5/65-20-10PR L2

Bias Bias (Snow)

17.5/65-20-10PR L2 240 kPa (2.4 kgf/cm2) (34 PSI) 17.5/65-20-10PR 240 kPa (2.4 kgf/cm2) (34 PSI)

fNOTE: Regardless of tire patterns to be used, inflate the tire with the same air pressure shown above.

Adjust tire pressure conforming with the work mode the machine is engaged in.

Consult your nearest TCM dealer for more detailed information.

• Driving on public roads: Standard pressure • Loading/excavation on normal ground surface: Standard or slightly higher than standard pressure • Heavy-duty excavation: Higher pressure in the standard pressure range • Operation on soft terrain or sandy territory: Slightly lower than standard pressure Tire Pressure Adjustment Range: 240 to 260 kPa (2.4 to 2.6 kgf/cm2) (34 to 37 PSI)

7-70

MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tire. Tire rotation is recommended to achieve uniformity of wear on tires or equalization of tire service life.

Rotation Method

Correct

Incorrect

Install tire with no external damage such d asWARNING: score and abnormal wear.

Failure to do so may cause the puncture or the tire to blowout, possibly resulting in personal injury or death since tire load is increased when the machine is loaded or braked during operation.

• Switch tires only between the front and rear positions. Do not switch the tires between diagonal positions.

• Align the tire rotation direction with the tire tread design pattern. Especially traction read design pattern (optional) will affect not only economy of the tire but also safety in operation.

Front

M4EJ-07J-001

How to Check Wear Amount (Tread Design Groove Depth) IMPORTANT:

If the machine is operated with tires at either rear or front being extremely worn or different in type, construction, or size, the travel driving system such as axles or transmission will be adversely affected in their performance and/or endurance.

Avoid operating the machine under such conditions.

When replacing tires, be sure to use the same tires in type, construction and size on all four wheels. It is recommended to replace all four tires at the same time.

Measure the groove depth at position of 1/4 tread width [shown with X mark (1) in the figure].

Use limit of the groove depth shall be approx. 85 % of the new tire groove depth. In case extreme uneven wear or exposed rubbing strips are found, replace the tire even before reaching 85 %.

7-71

Tread Width

1

1/2

× ×

1/4

× × Groove Depth

× × 1/4 1/2 Tread Width M4EJ-07J-002

MAINTENANCE Removal and Installation of Tire WARNING: Wheel with tire is a very heavy part so d that removal and installation of tire is hazardous and difficult work. In addition, a crane to lift the tire is required when removing or installing the tire to the wheel. Consult your nearest TCM dealer or professional tire sales shop for tire removal and installation work.

In case jacking up the machine is required, be sure to observe the following points.

• Select dry, solid and level ground for work site.

• Work in groups of more than two personnel. One person shall mainly engage in the repair work and others shall work as assistants and/or to ensure safety.

• Do not use the bucket to raise the front wheels.

• Do not raise the machine off the ground more than necessary.

• When the front (or rear) wheels are raised off the ground, wedge wheel stoppers under the rear (or front) wheels.

• After the machine is raised off ground, be sure to block the machine using rigid supports. Never leave the machine supported only by jacks.

• The rear wheels oscillate. Insert wooden blocks between the axle and the frame to stop oscillation.

• When removing the wheel nuts, lift the wheel with a crane so that the wheel nut remaining at the top position is finally removed.

• Refer to Check Wheel Bolt Torque for the wheel bolt tightening torque value.

7-72

MAINTENANCE Tire Wheel WARNING: When a tire wheel must be removed, ask a d professional person to do so.

Allow only an authorized person to inflate a tire after the tire was installed onto the wheel.

Sufficiently remove rust from the wheel. Severe rust may be caused by cracks, possibly resulting in the machine and/or personal accident.

7-73

MAINTENANCE K. Heater (Optional of Cab Vehicle) Check Heater for Any Damage --- every 6 months Check the heater mounting and hoses for any damage.

fNOTE: Heater is an optional of the cab vehicle.

When the cold season approaching, check the heater before it is actually required to be sure it is operable at any time.

When the heater is not used for a long period of time, perform heating operation once a week to prevent oil from running dry.

M4FG-01-049

Check Heater Piping --- every 6 months CAUTION: If any water leak is found, repair or replace d the corresponding parts.

Check the heater piping for any abnormal deformation and/or damage.

If a pipe joint become contaminated, check the joint for water leaks.

M4FG-07-072

7-74

MAINTENANCE L. Miscellaneous Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear --- every 10 hours (daily) Check the bucket cutting edge for wear and tightness.

1

Replacement WARNING: Guard against injury from flying pieces of d metal.

3

Wear protection such as safety glasses and a hard hat when servicing the machine.

2

1. Raise the bucket to an appropriate height with the bucket bottom supported with blocks.

fNOTE: Raise the bucket so that the bucket bottom is horizontally maintained.

2. Remove bolts (2) and nuts (1). Remove cutting edge (3).

3. Install new cutting edge (3). If the reverse side of cutting edge is not worn much, use it again with the face reversed. If both sides are worn out, replace with a new one.

Tighten nuts (1) to specified torque.

Tightening torque: 245 to 300 N·m (24.9 to 30.6 kgf·m) (180 to 221 ft·lb) 4. Retighten the mounting nuts after several hours of operation.

7-75

M4FG-07-062

MAINTENANCE Check and Replace Seat Belt Check --- every 10 hours (daily) Replace --- every 4 years Examine seat belt tongue (1), buckle (2) and seat belt. Replace the damaged or worn parts. Check if the seat belt is correctly reeled in.

Replace the seat belt every 4 years, regardless of appearance.

1 2

M4FG-07-068

Check Canopy/Cab for Damage and Mounting Bolts for Tightness --- every 10 hours (daily) Check the appearance of the canopy resin roof and cab for any abnormal damage or deformation. Check mounting bolts (3) for tightness.

3

M4FG-07-063

Check Windshield Washer Fluid Level (Cab Vehicle) --- every 10 hours (daily) IMPORTANT: Keep all dirt, dust and other foreign materials out of the tank.

Use antifreeze washer fluid in cold weather district.

Check the fluid level. If necessary, add the fluid.

M4FG-07-069

7-76

MAINTENANCE Check Play in Steering Wheel Stroke --- every 10 hours (daily) WARNING: When the steering wheel is turned, d clearance between the front and rear frames becomes narrower, possibly creating hazardous situation such as entanglement of limbs. Keep all personnel away from the frame articulation joint during inspection.

Check that play (1) in steering wheel stroke is correct.

In addition, check that the steering wheel column normally comes in contact with the stopper when the steering wheel is fully turned and that the steering cylinder operates normally.

1. Start the engine.

Turn the parking brake switch ON. 2. Slightly lift the bucket above the ground.

Place the loader control lever lock in the LOCK position.

3. While running the engine at slow speed, slightly rotate the steering wheel knob in both clockwise and counterclockwise. Measure the moving distance along the steering wheel circumference until both right and left steering cylinders start moving (check the movement of the bucket and/or tires).

Correct play (1): 20 to 40 mm (0.8 to 1.6 in)

fNOTE: If steering wheel play is excessively large or if steering wheel does not smoothly move, consult your nearest TCM dealer for inspection.

7-77

1

M4EJ-07L-004

MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise --- every 10 hours (daily)

d

1

WARNING: Move the F-N-R lever to neutral. Apply the parking brake. After horizontally resting the bucket on the ground, set the wheel stoppers.

While slowly stepping on accelerator pedal (1), check if the engine speed smoothly increases. Then, while slowly returning accelerator pedal (1), check if the engine speed smoothly decreases.

If dust and/or soil accumulate in vicinity of accelerator pedal (1), remove the accumulated dust and/or soil.

Exhaust Gas Color and Noise Check exhaust gas color and noise.

DANGER: Sufficiently ventilate when carrying out d warming up operation indoors. Failure to do so may cause inhalation of the exhaust gas, possibly resulting in personal death accident.

IMPORTANT:

The engine mounted on this machine meets Tier 3 emission requirements. Modification of the engine inlet and exhaust system is prohibited by low.

Exhaust gas color is normally transparent or light blue.

Although exhaust gas becomes a light black color immediately after the engine is started or quickly accelerated, this symptom is not abnormal.

If the exhaust gas color becomes black, white, blown, or gray, check the engine oil level and the fuel supply system for any abnormality. In addition, check that no abnormal noise is heard coming from the engine or the muffler.

7-78

M4FG-07-045

MAINTENANCE Check Rearview Mirror and Inside Rearview Mirror --- every 10 hours (daily) Check that inside rearview mirror (1) and rearview mirror (2) (on the cab vehicle) are facing correct direction and check for dirt or damage.

2

1

1

Cab Vehicle

Canopy Vehicle M4FGE-01-033

Check Steps and Handrails for Damage and Tightness --- every 10 hours (daily) Check steps (3) and handrails (4) for any damage, tightness and contamination. If any slippery matter such as machine lubricants or mud becomes adhered to the steps and/or handrails, remove such contaminants. If the steps and/or handrails become damaged or loosened so that getting on and off the machine is difficult, immediately repair or replace.

4

4

3

M4FGE-01-052

Clean Engine Compartment and Hood --- every 10 hours (daily) CAUTION: Dust or chips accumulated in the engine d compartment or around the hood may come in contact with high temperature sections near the engine or hood, possibly causing fires.

Remove the accumulated dust and chips from the hood.

Open the hood and check if dust and/or chips are accumulated in the engine compartment and/or the areas above the engine. Remove the accumulated chips and/or dust if any.

7-79

M4FG-01-040

MAINTENANCE Check and Adjust Valve Clearance --- every 1000 hours or 1 year Consult your nearest TCM dealer for inspection and repair.

Check Sound Absorbing Mat Around Engine --- every 1000 hours or 1 year CAUTION: If the sound absorbing mat in the engine d compartment becomes unglued, the mat may come in contact with the high temperature sections of the engine, possibly resulting in fires.

Check if the sound absorbing mat around the engine has become unglued. If any part of the mat is found unglued, immediately contact your nearest TCM dealer for repair.

M4EK-01-056

Check Fuel Injection Timing --- every 1000 hours (or 1 year whichever comes first) Consult your nearest TCM dealer for inspection and repair.

7-80

MAINTENANCE Check Engine Compression Pressure --- every 1000 hours (or 1 year whichever comes first) Consult your nearest TCM dealer for inspection and repair.

Check and Clean Starter and Alternator --- every 1000 hours or 1 year Consult your nearest TCM dealer for inspection and repair.

Retighten Front Axle, Rear Axle and Transmission Mounting Nuts --- every 1000 hours (Only first time at 50 hours) Check the front/rear axle and the transmission support mounting nuts for tightness.

Tightening torques of the front/rear axle and the transmission support mounting nuts Front axle mounting nuts (1), (2) (1) 207 to 253 N·m (21.1 to 25.8 kgf·m) (153 to 187 ft·lb) (2) 259 to 316 N·m (26.4 to 32.2 kgf·m) (191 to 233 ft·lb)

Rear Axle and Transmission mounting nuts 491 to 600 N·m (50.0 to 61.2 kgf·m) (362 to 443 ft·lb)

fNOTE: The front axle is mounted with double nuts such as lock nut (1) and nut (2).

7-81

MAINTENANCE Tightening and Retightening Torque of Nuts and Bolts Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Check nuts and bolts for tightness and missing daily before and after operation. If any loose or missing nuts and/or bolts are found, retighten or supply replacement parts. The nuts and bolts other than those shown in the table below shall be tightened in accordance with the torque values shown in the table on page 7-83.

Use LOCTITE #262 to the torque values shown with mark *.

Bolt Wrench Size Torque Quantity diameter mm (in) N·m (kgf·m) (ft·lb) Front axle mounting Lock nut 8 207 to 253 (21.1 to 25.8) (153 to 187) 1 18 27 (1.06) Nut 8 * 259 to 316 (26.4 to 32.2) (191 to 233) nut 2 Rear axle and transmission mounting nuts 20 4 30 (1.18) * 491 to 600 (50.0 to 61.2) (362 to 443) 3 Wheel rim mounting nuts 22 32 32 (1.26) 494 to 604 (50.4 to 61.6) (364 to 445) 4 Propeller shaft mounting bolt 10 16 17 (0.67) * 58 to 71 (5.9 to 7.2) (43 to 52) 5 HST motor mounting bolt 16 4 24 (0.94) 186 to 227 (19 to 23) (137 to 166) 6 HST Pump mounting bolt 18 4 27 (1.06) 265 to 314 (27 to 32) (195 to 231) Front side 12 8 19 (0.75) * 83 to 93 (8.5 to 9.5) (61 to 69) Engine mounting 7 bolt, Bracket Rear side 14 8 22 (0.87) * 122 to 149 (12.4 to 15.2) (90 to 110) 8 Engine mounting bolt, Rubber cushion 18 4 27 (1.06) 343 to 412 (34.9 to 42.0 ) (252 to 304) Muffler mounting Lock nut 4 20 to 24 (2.0 to 2.4) (14 to 17) 9 10 17 (0.67) Nut 4 44 to 54 (4.5 to 5.5) (33 to 40) nuts 10 Counterweight mounting bolt 20 4 30 (1.18) 423 to 460 (43.1 to 46.9) (312 to 339) Mounting nuts 24 1 36 (1.42) * 255 to 314 (26.0 to 32.0) (188 to 231) Retainer fixing nuts 12 4 19 (0.75) * 77 to 94 (7.9 to 9.6) (57 to 69) 11 Upper center pin Lock nuts 12 1 19 (0.75) * 77 to 94 (7.9 to 9.6) (57 to 69) 12 Lower center pin locking 12 1 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 13 Loader front pin locking 12 13 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 14 Steering cylinder pin locking 12 4 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 19/17 77 to 94 (7.9 to 9.6) (57 to 69)/ 15 Radiator frame mounting bolt 12/10 4/8 (0.75/0.67) 44 to 54 (4.5 to 5.5) (33 to 40) 16 Cutting edge mounting nut 16 7 24 (0.94) 245 to 300 (24.9 to 30.6) (180 to 221) 17 Canopy mounting bolt 16 6 24 (0.94) 188 to 229 (19.2 to 23.4) (139 to 169) 18 Cab rubber cushion 16 10 24 (0.94) 188 to 229 (19.2 to 23.4) (139 to 169) Tightening location

7-82

MAINTENANCE Nuts and Bolts Tightening Torque IMPORTANT: • Remove soil, dust, and/or dirt from the nut and bolt thread surfaces before tightening.

• Tighten nuts and bolts to specifications.

If tightened with excessively low or high torque, missing or breakage of nuts and/or bolts may result.

When checking the machine parts, if loose nuts and bolts are found, retighten them to the torque values shown in the table below.

Tightening Torque Hexagon head bolt Bolt M4FG-07-073 M4GB-07-122 M4GB-07-123 Wrench Dia. Standard size Standard Standard mm torque Allowable torque range torque Allowable torque range torque Allowable torque range mm (in) kgf·m kgf·m kgf·m N·m N·m kgf·m N·m N·m kgf·m N·m N·m kgf·m (ft·lb) (ft·lb) (ft·lb) 4

1.27

5

2.55

6

4.31

8

10.2

10

19.7

12

34.5

14

54.3

16

83.9

18

116

20

168

22

221

24

280

27

346

30

475

0.13 (1) 0.26 (2) 0.44 (3) 1.04 (8) 2.01 (15) 3.52 (25) 5.54 (40) 8.56 (62) 11.8 (85) 17.1 (124) 22.5 (163) 28.6 (207) 35.3 (255) 48.4 (350)

0.43 0.33 3.82 to 4.61 0.39 to 0.47 2.94 to 3.53 0.30 to 0.36 4.22 (3) (2) 0.84 0.64 7.45 to 9.02 0.76 to 0.92 5.69 to 6.86 0.58 to 0.70 8.24 0.23 to 0.29 6.28 (6) (5) 1.45 1.11 12.8 to 15.7 1.31 to 1.60 9.80 to 12.0 1.00 to 1.22 1.45 0.40 to 0.48 10.9 (10) (8) 3.38 2.59 29.8 to 36.5 3.04 to 3.72 22.8 to 27.9 2.33 to 2.85 33.1 0.94 to 1.14 25.4 (24) (19) 6.55 5.01 57.9 to 70.7 5.90 to 7.21 44.2 to 54.0 4.51 to 5.51 64.2 1.81 to 2.21 49.1 (47) (36) 11.4 8.75 101 to 123 10.3 to 12.5 77.2 to 94.4 7.88 to 9.63 112 3.17 to 3.87 85.8 (82) (63) 18.0 13.8 159 to 194 16.2 to 19.8 122 to 149 12.4 to 15.2 177 4.99 to 6.09 135 (130) (100) 27.8 21.3 245 to 300 25.0 to 30.6 188 to 229 19.2 to 23.4 273 7.70 to 9.42 209 (201) (154) 38.3 29.3 338 to 413 34.5 to 42.1 259 to 316 26.4 to 32.2 376 10.6 to 13.0 287 (277) (212) 55.6 42.6 490 to 600 50.0 to 61.2 376 to 460 38.3 to 46.9 545 15.4 to 18.8 418 (402) (308) 73.2 56.0 646 to 789 65.9 to 80.5 494 to 604 50.4 to 61.6 718 20.3 to 24.8 549 (529) (405) 93.0 71.3 821 to 1000 83.7 to 102 630 to 769 64.2 to 78.4 912 25.7 to 31.5 699 (673) (516) 115 87.9 1020 to 1245 104 to 127 775 to 948 79.0 to 96.7 1128 31.8 to 38.8 862 (832) (636) 157 121 1383 to 1697 141 to 173 1069 to 1304 109 to 133 1540 43.6 to 53.2 1187 (1135) (875)

1.18 to 1.37 0.12 to 0.14 3.24 2.26 to 2.84 3.92 to 4.71 9.22 to 11.2 17.8 to 21.7 31.1 to 38.0 48.9 to 59.7 75.5 to 92.4 104 to 127 151 to 184 199 to 243 252 to 309 312 to 380 428 to 522

* Tightening torque of strength criteria 10.9 is used for socket bolts.

7-83

7 (0.28) 8 (0.31) 10 (0.39) 13 (0.51) 17 (0.67) 19 (0.75) 22 (0.87) 24 (0.94 ) 27 (1.06) 30 (1.18) 32 (1.26) 36 (1.42) 41 (1.61) 46 (1.81)

MAINTENANCE 1. Front axle mounting nut Bolt diameter Quantity

18 16

M4FG-07-050

2. Rear Axle and Transmission mounting nuts Bolt diameter Quantity

16 4

M4FG-07-051

3. Wheel rim mounting nuts Bolt diameter Quantity

18 32

M4FG-07-032

7-84

MAINTENANCE 4. Propeller shaft mounting bolt Bolt diameter Quantity

12 16

M4FG-07-052

M4FG-07-070

5. HST motor mounting bolt Bolt diameter Quantity

16 4

M4FG-07-053

6. HST Pump mounting bolt Bolt diameter Quantity

18 4

M4FG-07-054

7-85

MAINTENANCE 7. Engine mounting bolt, Bracket Bolt diameter Quantity

Front side 12 8

Rear side 14 8

M4FG-07-071

8. Engine mounting bolt, Rubber cushion Bolt diameter Quantity

18 4

M4FG-07-071

9. Muffler mounting nuts Bolt diameter Quantity

10 8

M4FG-07-056

7-86

MAINTENANCE 10. Counterweight mounting bolt Bolt diameter Quantity

20 4

11. Upper center pin

M4FGE-01-019

Bolt diameter Quantity

Mounting nuts 24 1

Bolt diameter Quantity

Lock nuts 12 1

Retainer fixing nuts 12 4

M4FG-07-057

12. Lower center pin locking Bolt diameter Quantity

M4FG-07-058

12 1

M4FG-07-057

7-87

MAINTENANCE 13. Loader front pin locking Bolt diameter Quantity

12 13

M4FG-07-059

14. Steering cylinder pin locking Bolt diameter Quantity

10 4

15. Radiator frame mounting bolt Bolt diameter Quantity

M4FG-07-060

10 4

M4FG-07-061

7-88

MAINTENANCE 16. Cutting edge mounting nut Bolt diameter Quantity

16 7

M4FG-07-062

17. Canopy mounting bolt Bolt diameter Quantity

16 6

M4FG-07-063

18. Cab rubber cushion Bolt diameter Quantity

16 6

M4FG-07-064

7-89

MAINTENANCE MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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7-90

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions

d •WARNING: Before operating the machine in a river, check the riverbed conditions in advance.

• Avoid driving the machine into a river where the riverbed is steep and deep or the stream is rapid.

Operating Conditions Muddy Soil, Rainy or Before Operation Snowy Weather After Operation

Near the Ocean

Dusty Atmosphere

Rocky Ground

Precautions for Maintenance : Check tightness of plug and all drain cocks. : Clean the machine and check for cracks and damage. Check for loose or missing bolts and nuts. Lubricate all necessary parts without delay.

If the machine should be submerged in water, water may get into the brake device (like the parking brake), resulting in poor braking performance.

Watch out when starting/stopping the machine.

Before Operation : Check tightness of plugs and all drain cocks.

After Operation : Thoroughly clean the machine with fresh water to wash off salt. Service electrical equipment often to prevent corrosion.

Air Cleaner : Clean the element regularly at shorter service intervals.

Radiator : Clean the oil cooler screen to prevent clogging of the radiator Fuel System : Clean the filter element and strainer regularly at shorter service intervals.

Electrical : Clean them regularly, in particular, the commutator surface of the alternator Equipment and starter.

Chassis : Check for damage on tires, for loose, cracked, worn, and damaged bolts and nuts.

Front Attachment : Standard attachment may be damaged when digging rocky ground.

Reinforce the bucket before using it, or use a heavy duty bucket.

9-1

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature becomes down below -0 °C (32 °F), practice the following points.

• Water and oil in the machine will freeze.

• Road surfaces will freeze so that tires may slip.

Keeping the above points in mind, follow the advices below: 1. Refill fluids such as water and lubricants prior to operation. Avoid practices after operation (except fuel).

2. Mix LLC in the radiator (coolant). When this machine is shipped from the factory, LLC (long life coolant) is supplied. Therefore, this machine can operate normally without any problem.

3. Change the engine oil in the engine crankcase for a cold weather type oil.

4. Use fuel (diesel oil) of an antifreeze type. To prevent condensation of air into dew on the wall in the fuel tank, fully refill the fuel tank with an antifreeze type diesel fuel.

5. If the electrolyte in the battery case freezes, damage to the battery case may result. Maintain the batteries at fully charged condition. After completing work, turn all lights OFF. Perform cooling operation for five minutes.

Or by other way, dismount the batteries and store them in a warm indoor place. When it is possible to measure and adjust the specific gravity of the electrolyte, increase the specific gravity of the electrolyte up to 1.280. Do not increase more than 1.280.

6. Use anti-freeze type washer fluid.

After taking the measures as recommended above, start operation of the machine.

Sufficiently ventilate when carrying out dWARNING: warming up operation indoor. Failure to do so may cause intoxication by exhaust gas, possibly resulting in personal death accident.

7. After preheating the engine, start the engine. Sufficiently perform warm-up operation.

9-2

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 8. After warming up the engine, warm up the front attachment system. Slowly operate the loader control lever to move the cylinders full stroke several times.

9. Road surfaces covered with snow, especially when snow has been compacted, will become frozen. Use tire chains on four wheels.

10. Take anti-freeze measures after completing operation.

• Cover the keyhole by sticking a tape on.

• Rubber parts such as wiper may freeze. Keep other parts away from the rubber parts.

• Remove packed snow from around the undercarriage and inside the machine with a bar or brush.

• In case it is impossible to store the machine indoor, park the machine on a level dry surface and cover overall the machine with a large vinyl sheet.

9-3

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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9-4

STORAGE Storing Machine WARNING: In case lubrication operation is d unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation.

Apply the parking brake while storing.

If the machine is to be stored for more than one month, observe the following precautions so that its function will not be impaired during storage.

Precaution Items for Long-Time Storage

Wash Machine Supply Oil and Grease

Battery Coolant

Prevention of Dust and Moisture Tools Lubrication Operation No-load Operation at a Slow Speed for Several Minutes IMPORTANT:

Contents of Work Sufficiently wash the machine and dry to remove stuck mud and/or dust.

Check for low level/contamination of lubricating oil.

Supply grease to greased parts.

Apply a thin coat of oil to parts susceptible to rust (i.e. cylinder rods etc.)

Remove and fully recharge the battery, then store it.

Supply a rust preventive agent without fail. If there is a possibility of freezing, also supply an antifreeze solution or fully drain the coolant. In this case, be sure to attach a “No Water in Radiator” sign in the operator’s cab.

Also, clean and dry the radiator thoroughly.

Store the machine in a relatively dry garage and cover it.

Inspect and repair, then store.

If the oil films of the parts are broken and parts are rusted, they will be worn abnormally when operated the next time. To prevent this, operate the machine at least once a month to lubricate the parts. At this time, check the coolant and lubrication oil levels.

Operating the machine without lubrication operation may cause the engine to be seizure or damaged and hydraulic system to be damaged.

fNOTE Lubrication operation means that a series of

operations such as drive, and loader front operation are repeated a few times after performing the warm-up operation. Before operating the loader front attachment and steering wheel, remove rust prevention oil coated on the hydraulic cylinder rods.

10-1

STORAGE Removing Machine from Storage WARNING: In case lubrication operation is d unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after bring stored. Apply the parking brake while storing.

IMPORTANT:

Lubricants will deteriorate during storage of the machine. Thoroughly check lubricants and adequately perform lubrication operation before resuming operation of the machine. Avoid quick operation. Failure to do so may cause damage to the engine, hydraulic equipment, transmission, axle, etc. due to insufficient lubrication.

1. Remove grease from the cylinder rods if coated.

2. Adjust alternator and fan belt tension.

3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels.

4. Start the engine.

Run the engine at half speed for several minutes before full load operation.

5. Cycle all hydraulic functions several times.

6. Carefully check all systems before operating the machine at full load.

fNOTE: When the machine has been stored for a long time,

be sure to perform the following steps as well: (a) Check condition of all hoses and connections. (b) Warm up the engine. (c) Stop the engine. (d) Install new fuel filters. Replace the engine oil filter and fill the engine with oil.

Before starting operation, sufficiently check the machine in accordance with the descriptions on “Check Before Starting” on page 3-1 and perform warm-up operation.

10-2

TROUBLESHOOTING Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest TCM dealer. Never attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components.

Engine Consult the nearest TCM dealer for the engine troubleshooting.

Engine Auxiliaries Problem Batteries will not be charged.

Batteries discharges quickly after being charged.

Coolant temperature is too high.

Cause Broken battery separator Faulty regulator Faulty ground line Faulty alternator Shorted cable Shorted battery separator Increased sediment in battery Low coolant level Loose engine fan V-belt Damaged rubber hose Faulty thermostat Faulty coolant temperature gauge Cooling system passages dirty Radiator core or oil cooler core plugged Radiator screen plugged

Items with * mark: Consult your nearest TCM dealer.

11-1

Solution Replace * Adjust or replace * Repair * Repair or replace * Repair or replace * Replace * Replace Add * Adjust * Replace * Replace * Replace Flush cooling system Clean radiator and oil cooler Clean screen

TROUBLESHOOTING Engine does not Start Symptom The starter does not rotate.

Cause Reduced battery voltage Increased resistance in the starter circuit

Faulty key switch Damaged wire harness Faulty battery relay Blown slow blow fuse link The F-N-R lever is in either the forward or reverse position.

Faulty starter Although the starter rotates, the Use of poor quality fuel, insufficient fuel, lack engine does not start. of fuel Faulty glow plug Air mixed in the fuel supply line Faulty injection pump or nozzle Reduced compression pressure Engine speed does not increase.

The accelerator pedal function is abnormal.

Although the engine cranks, running Deteriorated engine oil speed is low and easy to stall.

Contaminated injection nozzle Clogged fuel filter Clogged fuel pre-filter Air mixed in the fuel supply line

Solution Charge the batteries. Replace * Clean and/or retighten the battery terminals and starter terminals * Replace * Repair or replace * Replace * Replace Return to neutral. * Repair or replace Change fuel. Refill * Replace glow plug Bleed air * Repair or replace * Adjust Replace the accelerator pedal.

Change engine oil. * Replace Replace Replace Bleed air

Items with * mark: Consult your nearest TCM dealer.

Control Lever Symptom Hard to move Does not move smoothly Does not return to neutral The lever is tilted in the neutral position due to increase in play.

The lever is not held with magnetic detent.

Cause Rusted joint Worn pusher Worn pusher Faulty control valve Faulty control valve Worn joint Faulty control valve Faulty magnetic solenoid Faulty sensor

Items with * mark: Consult your nearest TCM dealer.

11-2

Solution * Lubricate or repair * Replace * Repair or replace * Replace * Replace * Repair or replace * Replace * Replace * Replace

TROUBLESHOOTING Hydraulic System After the machine has been kept stowed for a long time, air in the oil may be separated and accumulate in the upper section in the cylinder, causing slow response time in operation or reducing cylinder power. In case these symptoms appear, repeatedly operate all actuators several times.

Problem Front attachment is inoperable (Hydraulic pump noise level increases).

All actuators have no power.

Only one actuator is inoperable.

Only one cylinder is inoperable or has no power.

Oil overheats Oil leak from low pressure hose

Cause Faulty hydraulic pump Lack of hydraulic oil Broken suction pipe and/or hose Malfunction due to worn hydraulic pump Decrease in set pressure of main relief valve in control valve Lack of hydraulic oil Trapped foreign matter in hydraulic oil tank suction filter Aeration in suction side Broken control valve spool Trapped foreign matter in valve spool Broken pipe and/or hose Loose pipe line joint Broken O-ring at pipe line joint Broken actuator Broken oil seal in cylinder Oil leak due to damage to cylinder rod Stained oil cooler Weak tension of engine fan V-belt Loose clamp Faulty suction manifold

Items with * mark: Consult your nearest TCM dealer.

11-3

Solution * Repair, Replace Refill * Repair, Replace * Replace * Adjust Refill Clean Retighten * Replace * Repair, Replace * Repair, Replace Retighten * Replace * Repair, Replace * Repair, Replace * Repair, Replace Clean Adjust Retighten * Repair, Replace

TROUBLESHOOTING Drive Function Steering Wheel Problem Steering wheel is heavy to operate.

Steering wheel is rotated in unexpected direction.

Cause Faulty hydraulic pump Faulty steering device Relief valve set pressure reduction Faulty steering column Low tire air pressure Faulty steering device

Solution * Repair, Replace * Repair, Replace * Adjust * Repair, Replace * Inflate * Repair, Replace

Items with * mark: Consult your nearest TCM dealer.

Accelerator Pedal Problem Accelerator pedal is heavy to operate.

Accelerator pedal play is large.

Cause Rusted joint

Solution * Lubricate, Repair

Worn joint

* Replace, Repair

Items with * mark: Consult your nearest TCM dealer.

Parking Brake Problem Parking brake The brake is not released (sticking, dragging).

Parking brake Does not work properly.

Cause Oil leak due to failure of D-ring on the parking brake piston Faulty brake disk Damaged disk brake spring Faulty disk brake Scored or seized piston or worn disk

Solution * Repair or replace * Repair or replace * Replace * Replace * Repair or replace

Items with * mark: Consult your nearest TCM dealer.

Service Brake Problem Service brake does not work properly.

Service brake is dragged.

Service brake fluid decreases.

Cause Solution Malfunction of brake master cylinder * Repair or replace Oil leak from brake line, Air mixing * Repair. Bleed air Malfunction of brake master cylinder * Repair or replace Faulty brake pedal * Repair or replace Oil leak from brake line and/or hose connector * Retighten or repair Oil leak due to brake piston seal (Inside of * Retighten or repair front axle)

Items with * mark: Consult your nearest TCM dealer.

11-4

TROUBLESHOOTING Transmission Problem Transmission is noisy.

Cause Lack or deterioration of gear oil Worn out transmission part Broken gear or bearing

Solution Refill, replace * Repair, Replace * Repair, Replace

Items with * mark: Consult your nearest TCM dealer.

Propeller Shaft Problem Propeller shaft vibrates.

Propeller shaft is noisy.

Cause Bent propeller shaft Loosen parts, Loss of balance Excessively worn spline Worn or seized spider bearing Loosen parts Insufficient greasing

Solution * Repair, Replace * Retighten, Adjust * Replace * Replace * Retighten Grease

Items with * mark: Consult your nearest TCM dealer.

Front and/or Rear Axle Problem Front and/or rear axle is noisy.

Front and/or rear axle does not transmit power.

Cause Worn or broken gears Lack or deterioration of gear oil Worn bearings, Expanded play Expanded play on shaft spline Broken axle Broken gears

Items with * mark: Consult your nearest TCM dealer.

Others The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs. Always beware of the machine conditions during operation.

11-5

Solution * Replace Refill, Replace * Replace * Repair, Replace * Repair * Repair

TROUBLESHOOTING MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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11-6

SPECIFICATIONS Specifications

M4FGE-12-001

Model Bucket Type Bucket Capacity (heaped) Operating Weight (Canopy/Cab) Static Tipping Load Straight Full 40 degree turn Engine A: Overall Length B: Overall Width (Bucket) C: Overall Height (Canopy/Cab) D: Wheel Base E: Tread F: Ground Clearance G: Bucket Hinge Height H: Dumping Clearance (45 °) I: Dumping Reach (45 °) R1: Minimum Rotation Radius Outer Ring Center R2: Minimum Rotation Radius End of Bucket Travel Speed Forward/Reverse Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size

—

E820-3 Pin Type

m3 (yd3) kg (lb) kgf kgf

Coupler Type

mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in)

0.9 (1.17) 5245/5405 (11570/11920) 5380/5540 (11860/12220) 3650 3350 3110 2840 Kubota V3307-DI-T 45.6 kW/2200 rpm (62 PS/2200 rpm) 5220 (17’ 2”) 5380 (17’ 8”) 2860 (6’ 3”) 2790/2850 (9’ 2”/9’ 4”) 2200 (7’ 3”) 1470 (4’ 10”) 340 (1’ 1”) 3160 (10’ 4”) 2500 (8’ 2”) 2390 (7’ 10”) 880 (2’ 11”) 990 (3’ 3”)

mm (ft·in)

3795 (12’ 5”)

—

mm (ft·in)

4475 (14’ 8”)

km/h (mph) — (°) —

4540 (14’ 11”) 34/34 (21/21) 2/2 40 17.5/65-20-10PR

fNOTE: The specifications can change at any time.

12-1

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12-2

OPTIONAL ATTACHMENTS Handling Quick Coupler (Mechanical Type) WARNING: During work, keep other persons away d from the machine.

The quick coupler is a system with which a front attachment work tool such as a bucket can be easily replaced with other work tool.

When installing an additionally purchased bucket or your own bucket with the quick coupler, the bucket may not be fit on due to misaligned stopper. Contact your nearest TCM dealer for adjustment.

M4EK-13-001 Install Remove

Removal

d

20 cm

2

1

WARNING: Apply the parking brake before leaving the machine.

Disconnect all hydraulic hoses routed to the attachment cylinders except for the bucket and lift arm cylinders. (Refer to page 13-6 for “Disconnection/Connection Hydraulic Hoses”.)

If possible, place the bucket (attachment) to be removed on a pallet.

1. Raise the bucket (attachment) about 20 cm (8 in) above the pallet with horizontal posture.

4

3

3

M4EK-13-002

3

2. Remove quick coupler lock pin (1). Pull up lever (2) to the removal position and remove coupler pins (3) (right and left).

3. Check that coupler pins (3) (right and left) are removed.

Install lock pin (1) in hole (4) to fix lock lever (2) in position.

4. Place the bucket (attachment) to as close rear end of the pallet as possible so that the quick coupler can be easily removed.

5. While tilting the bucket forward, slightly lower the arm.

The bucket (attachment) is removed from the quick coupler. Take your time and proceed with care.

13-1

M4EK-13-003

OPTIONAL ATTACHMENTS Installation WARNING: Be sure to complete installation work only d after checking that coupler pins (5) (both right and left) have been installed.

WARNING: Apply the parking brake before leaving d the machine.

IMPORTANT:

5

5

6

6

Apply grease onto coupler pin (5) to prevent seizing and rust before installing the attachment.

M4EJ-13-004

1. After checking that coupler pins (5) have been removed.

Slowly approach the machine to the bucket (attachment) hooks (6) until the hooks are inserted into the quick coupler.

7

2. Slightly raise lift arm (7) to slowly allow the bucket (attachment) to tilt backward until stopper (8) on the bucket comes in contact with quick coupler stopper (9).

8

3. Remove lock pin (9). Turn lever (10) to the installation position and install coupler pins (5) (right and left).

M4EK-13-004

4. After checking that coupler pins (5) (right and left) have been securely installed, set lock pin (9) in the original position.

If installed attachment uses additional hydraulic cylinder other than the bucket or the lift arm, connect the hydraulic hoses to the attachment cylinder.

M4EK-13-005 Install Remove

10

9 6

5

5

M4EK-13-002

13-2

OPTIONAL ATTACHMENTS Handling Quick Coupler (Hydraulic Type) WARNING: During work, keep other persons away d from the machine.

The quick coupler is a system with which a front attachment work tool such as a bucket can be easily replaced with other work tool.

When installing an additionally purchased bucket or your own bucket with the quick coupler, the bucket may not be fit on due to misaligned stopper. Contact your nearest TCM dealer for adjustment.

Removal WARNING: Apply the parking brake before leaving d the machine.

Disconnect all hydraulic hoses routed to the attachment cylinders except for the bucket and lift arm cylinders.

Connect the removed hydraulic hoses to the coupler cylinder of the quick coupler. (Refer to page 13-6 for “Disconnection/Connection Hydraulic Hoses”.)

If possible, place the bucket (attachment) to be removed on a pallet.

20 cm (8 in)

M4EK-13-001

1. Raise the bucket (attachment) about 20 cm (8 in) above the pallet with horizontal posture.

1

2

3

2. Check that the hydraulic hoses (2, 3) from the machine body are connected to coupler cylinder (1) of the quick coupler.

fNOTE: Connecting hydraulic hoses (2, 3) from the machine

body with coupler cylinder (1) of the quick coupler allows operator to install/remove the attachment by controlling auxiliary control lever (5).

4

4

M4EK-PLOW-065

Remove

5

Install

M4EK-PLOW-063

13-3

OPTIONAL ATTACHMENTS 3. Move auxiliary control lever (5) forward (Remove) to remove coupler cylinder pins (4) (left and right).

Remove

4. Slightly lower the arm and tilt the bucket forward, the bucket (attachment) is removed from the quick coupler.

Take your time and proceed with care.

5

Install

M4EK-PLOW-063

4

M4EK-13-003

13-4

OPTIONAL ATTACHMENTS Installation WARNING: Be sure to complete installation work only d after checking that coupler pins (6) (both right and

d

6

6

left) have been installed.

WARNING: Apply the parking brake before leaving the machine.

IMPORTANT:

Apply grease onto coupler pin (6) to prevent seizing and rust before installing the attachment.

M4EK-PLOW-066

1. After checking that coupler pins (6) have been removed.

Slowly approach the machine to the bucket (attachment) hooks until the hooks are inserted into the quick coupler.

IMPORTANT:

Take care not to pinch hydraulic hoses between the quick coupler and the attachment.

7

2. Slightly raise lift arm (7) to slowly allow the bucket (attachment) to tilt backward until stopper (8) on the bucket comes in contact with quick coupler stopper (8).

8

M4EK-13-004

3. Move auxiliary control lever (9) reverse (Install) to install coupler cylinder pins (6) (left and right).

fNOTE: Disconnect hydraulic hoses from the coupler cylinder

of the quick coupler, connect them to the attachment cylinder.

M4EK-13-005

Remove

9

Install

M4EK-PLOW-063

13-5

OPTIONAL ATTACHMENTS Disconnecting/Connecting Hydraulic Hose When activating an attachment with a hydraulic cylinder other than the lift arm cylinder or bucket cylinder using the machine hydraulic pressure oil, hydraulic hoses must be connected or disconnected. At this time, connect or disconnect the hydraulic hoses following the procedures below.

Procedures CAUTION: Before starting to work, apply the parking d brake and stop the engine. Operate the attachment

Plug (Male)

When connecting hoses, insert the plug while pulling the sleeve. When the sleeve is returned, the hose connectors are automatically locked and connected.

control lever several strokes to release any hydraulic oil pressure remaining in the circuits.

IMPORTANT:

Sleeve (Female)

M4GB-13-007

Thoroughly remove dirt or stains from the hydraulic hose connectors.

• Connect the attachment hydraulic hoses to the machine

hydraulic pipe lines.

• After connecting the hydraulic hoses, start the engine.

While operating the attachment control lever, slowly move the attachment. Check that no oil leaks from the hydraulic hose connectors.

• When the attachment is removed, joint the attachment hose female end to the male end. Put dust caps to the machine hydraulic pipe line female and male ends to prevent the pipe line ends from becoming contaminated.

When disconnecting the hoses, pull the sleeve.

The connectors are instantaneously separated.

M4GB-13-008

Dust cap

Sleeve (Female)

When installing the dust cap to or removing the dust cap from the female type hose end, pull on the sleeve.

M4GB-13-009

When installing the dust cap to the male type hose end, just connect it to the hose end.

M4GB-13-010

13-6

INDEX A Accelerator Pedal ......................................................................... 1-29 Adjust Fan Belt Tension ............................................................. 7-52 Adjust Operator’s Seat ..................................................................S-6 Adjusting Operator’s Seat (Standard Type) ........................ 1-37 Adjusting Operator’s Seat (Suspension Type) ................... 1-38 Adjustment of Bucket Auto Leveler .........................................5-3 Air Cleaner ........................................................................... 7-12, 7-48 Air Filter Restriction Indicator (Red) .........................................1-9 Alarm Setting Procedure .......................................................... 1-49 Armrest Angle Adjustment ....................................................... 1-39 Articulation Lock Bar .................................................................. 1-54 Auto Station Presetting Procedure ....................................... 1-49 Avoid Accidents from Backing Up and Turning ............... S-16 Avoid Applying Heat to Lines Containing Flammable Fluids ................................................................... S-31 Avoid Heating Near Pressurized Fluid Lines ...................... S-31 Avoid High-Pressure Fluids ...................................................... S-28 Avoid Injury from Rollaway Accidents ................................. S-15 Avoid Operation with Biased Loads ........................................5-5 Avoid Overloading .........................................................................5-5 Avoid Positioning Bucket or Attachment Over Anyone S-17 Avoid Power Lines ....................................................................... S-19 Avoid Rapid Steering Changes and/or Sudden Braking .........................................................................5-5 Avoid Tipping ................................................................................ S-17 B Battery ............................................................................................. 7-59 Before Operation ............................................................................5-4 Beware of Asbestos and Silicon Dust and Other Contamination ............................................................ S-32 Beware of Exhaust Fumes ......................................................... S-30 Bleed Air from the Fuel System .............................................. 7-45 Bleed Air from the Hydraulic System ................................... 7-33 Brake Oil .......................................................................................... 7-17 Brake Oil Low Level Indicator (Red) .........................................1-8 Brake System ....................................................................... 7-13, 7-65 Brake/inching Pedal ................................................................... 1-29 BREAK-IN ............................................................................................2-1 C Cab Door ......................................................................................... 1-51 Cab Features .....................................................................................1-3 Cab Vehicle (Optional) ..................................................................1-2 Canopy Vehicle ................................................................................1-1 Change Axle Oil............................................................................. 7-26 Change Coolant ........................................................................... 7-53 Change Engine Oil ...................................................................... 7-23 Change Hydraulic Oil/Clean Hydraulic Oil Tank ............... 7-32 Change Transmission Oil .......................................................... 7-25 Change/Cleaning ........................................................................ 7-32 Changing Forward/Reverse Drive Direction .........................4-5

Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise .................................... 7-78 Check After Starting ......................................................................3-7 Check and Adjust Tire Pressure .............................................. 7-68 Check and Adjust Valve Clearance ........................................ 7-80 Check and Clean Starter and Alternator ............................. 7-81 Check and Drain Water from Fuel Pre-Filter ....................... 7-44 Check and Replace Fuse ........................................................... 7-57 Check and Replace Seat Belt ................................................... 7-76 Check Before Starting ...................................................................3-3 Check Brake Disc (Service and Parking) .............................. 7-67 Check Brake Oil Level ................................................................. 7-65 Check Brake Performance ........................................................ 7-66 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear ......................................................... 7-75 Check Canopy/Cab for Damage and Mounting Bolts for Tightness ............................................ 7-76 Check Coolant Level ................................................................... 7-51 Check Electrical Harnesses and Fuses .................................. 7-57 Check Electrolyte Level ............................................................. 7-63 Check Electrolyte Specific Gravity ......................................... 7-64 Check Engine Compression Pressure ................................... 7-81 Check Engine Oil Level .............................................................. 7-22 Check Fan Belt .............................................................................. 7-52 Check Fan Belt Tension .............................................................. 7-52 Check Fuel Hose ........................................................................... 7-47 Check Fuel Injection Timing .................................................... 7-80 Check Fuel Level .......................................................................... 7-42 Check Heater for Any Damage ............................................... 7-74 Check Heater Piping ................................................................... 7-74 Check Horn, Backup Buzzer and Backup Light ................. 7-56 Check Hoses and Lines .............................................................. 7-39 Check Hydraulic Oil Level ......................................................... 7-31 Check Monitor Function and All Other Instrument Operation ....................................... 7-55 Check Oil Level ............................................................................. 7-27 Check Parking Brake Force ....................................................... 7-67 Check Play in Brake Pedal Stroke ........................................... 7-66 Check Play in Steering Wheel Stroke .................................... 7-77 Check Rearview Mirror and Inside Rearview Mirror ....... 7-79 Check Right and Left Brake Interlocking Performance ............................................................................ 7-66 Check Sound Absorbing Mat Around Engine ................... 7-80 Check Steps and Handrails for Damage and Tightness ........................................................ 7-79 Check Surrounding Areas Around Axles and Covers for Oil Leaks ............................................................... 7-29 Check the Hour Meter Regularly ...............................................7-2 Check Tire for Damage .............................................................. 7-69 Check Tire Pressure ..................................................................... 7-68 Check Wheel Bolt Torque .......................................................... 7-69 Check Windshield Washer Fluid Level (Cab Vehicle) ....... 7-76 Check Work Lights ....................................................................... 7-56 Clean and Replace Air Cleaner Element .............................. 7-48

14-1

INDEX Clean Axle Housing Air Breather ............................................ 7-29 Clean Engine Compartment and Hood ............................... 7-79 Clean Fuel Pre-Filter Element .................................................. 7-45 Clean Radiator and Oil Cooler ................................................. 7-54 Clean Suction Filter ..................................................................... 7-34 Clean Transmission Air Breather ............................................ 7-28 Clearance Light Indicator (Green) ......................................... 1-11 Closing Engine Hood ....................................................................7-8 Coat Hook ...................................................................................... 1-46 COMPONENTS NAME ..............................................1-1, 1-37, 1-38 Control Lever ................................................................................. 11-2 Controls on the Radio ................................................................ 1-47 Cooling System .................................................................. 7-13, 7-49 Correct Maintenance and Inspection Procedures ..............7-1

F Fasten Your Seat Belt .....................................................................S-7 FM/AM Radio (Optional) Operation ...................................... 1-47 F-N-R (Forward/Reverse) Position Indicator ...................... 1-13 F-N-R Lever .................................................................................... 1-20 Follow Safety Instructions ...........................................................S-2 Fore-Aft Position Adjustment ....................................... 1-37, 1-39 Forward/Reverse and Shift Position Indicator .................. 1-13 Front Console ...................................................................................1-4 Front Window Wiper Switch (Cab Vehicle) ......................... 1-28 Fuel Gauge ...................................................................................... 1-10 Fuel Pre-Filter Drain Procedures ............................................. 7-44 Fuel System.......................................................................... 7-12, 7-42 Fuse Box ............................................................................... 1-41, 7-58

D Damper Adjustment.................................................................... 1-37 Dig with Caution .......................................................................... S-18 Digital Clock Setting Procedure ............................................. 1-49 Dimmer Switch ............................................................................. 1-21 Discharge Warning Indicator (Red) ..........................................1-8 Dispose of Waste Properly ........................................................ S-34 Door Lock Disengage Lever ..................................................... 1-53 Door Lock Knob ........................................................................... 1-52 Door Open/Close Lever ............................................................. 1-52 Dozing ............................................................................................. 5-13 Drain Water and Sediment from Fuel Tank ........................ 7-43 Drink Holder .................................................................................. 1-45 Drive Function .............................................................................. 11-4 Drive Machine Safely (Work Site) ........................................... S-13 Drive on Snow Safely .................................................................. S-14 Drive Safely .................................................................................... S-12 Drive Safely with Bucket Loaded ........................................... S-14 Drive Speed Change ......................................................................4-5 DRIVING MACHINE .........................................................................4-1

G General Precautions for Cab .......................................................S-5 Grading ..............................................................................................5-8 Grease .............................................................................................. 7-16 Greasing ................................................................................ 7-19, 7-10

E eco Mode Switch ......................................................................... 1-34 Electrical System ................................................................ 7-13, 7-55 Emergency Evacuation .............................................................. 4-15 Engine......................................................................... 7-11, 7-22, 11-1 Engine Coolant Temperature Gauge .................................... 1-10 ENGINE EMISSION CONTROL LABEL ............................................1 Engine Hood .........................................................................1-55, 7-8 Engine Oil ....................................................................................... 7-16 Engine Oil Low Pressure Indicator (Red) ................................1-9 Ensure Safety Before Rising from or Leaving Operator’s Seat ..........................................................S-7 Ensure Safety When Operating on Road Shoulders ..........5-4 Equipment of Head Guard, ROPS, FOPS .............................. S-11 Error Code ...................................................................................... 1-18 Evacuating in Case of Fire ......................................................... S-30 Excavation .........................................................................................5-6 Exhaust Gas Color and Noise .................................................. 7-78

H Handle Chemical Products Safely .......................................... S-33 Handle Fluids Safely−Avoid Fires ........................................... S-23 Handle Starting Aids Safely ........................................................S-8 Handling Quick Coupler (Hydraulic Type) .......................... 13-3 Handling Quick Coupler (Mechanical Type) ...................... 13-1 Hazard Switch ............................................................................... 1-23 Heater (Optional of Cab Vehicle) ................................. 7-14, 7-74 Heater (Optional) Operation ................................................... 1-36 Heater Switch ................................................................................ 1-36 High Beam Indicator (Blue) ...................................................... 1-11 Hi-Lo Selector Switch ................................................................. 1-25 Horn Switch ................................................................................... 1-21 Hour Meter ..................................................................................... 1-16 How to Check Wear Amount (Tread Design Groove Depth) ........................................... 7-71 HST Error Code Readout Switch ............................................. 1-17 HST Warning Indicator (Red) ......................................................1-9 Hydraulic Oil .................................................................................. 7-17 Hydraulic System .................................................... 7-12, 7-30, 11-3 I In Case the Batteries Were Discharged ................................ 7-61 Inspect Machine .............................................................................S-4 Inspect Machine Daily Before Starting ...................................3-1 Inspection and Maintenance of Hydraulic Equipment ............................................................ 7-30 Investigate Job Site Beforehand ............................................ S-10 J Jump Starting ..................................................................................S-9

14-2

INDEX K Keep Riders Off Machine .......................................................... S-12 Key Switch ...................................................................................... 1-34 Kind of Oils ..................................................................................... 7-16 Kinds of Hose/Line Fittings ...................................................... 7-41 L Layout .................................................................................................7-3 Lever Locks ............................................................................1-32, 5-2 Lifting Machine ............................................................................ 6-10 Lifting Wheel Loader .................................................................. 5-14 Light Switch ................................................................................... 1-22 Loader Control Lever ..........................................................1-31, 5-1 Loading ..............................................................................................5-9 Loading/Unloading on Trailer ....................................................6-2 Lock Frames ......................................................................................7-6 Long Life Coolant (LLC) ............................................................. 7-49 Long-Life Coolant ........................................................................ 7-18 M Machine Information Display .................................................. 1-15 MACHINE NUMBERS ..........................................................................3 MAINTENANCE ................................................................................7-1 Maintenance Guide .................................................................... 7-10 Maintenance Guide Table ............................................................7-4 Maintenance Side Cover ...................................................1-55, 7-7 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ...........................................9-1 Method to Recharge the Removed Battery ....................... 7-62 Method to Replace with Charged Auxiliary Batteries .... 7-62 Miscellaneous ..................................................................... 7-15, 7-75 Monitor Display ............................................................................ 1-12 Monitor Panel ..................................................................................1-6 Move and Operate Machine Safely ..........................................S-8 N Neutral Lever Lock (F-N-R Lever) ............................................ 1-20 Never Ride Attachment .................................................................S-6 Never Undercut a High Bank ................................................... S-18 Nuts and Bolts Tightening Torque ......................................... 7-83 O Object Handling .......................................................................... S-20 Observe Engine Operation Closely ..........................................2-1 Odometer ....................................................................................... 1-16 Opening Engine Hood ..................................................................7-8 Operate Only from Operator’s Seat .........................................S-9 OPERATING ENGINE .......................................................................3-1 OPERATING MACHINE ...................................................................5-1 OPERATOR’S STATION ...................................................................1-3 OPTIONAL ATTACHMENTS ....................................................... 13-1 Others .............................................................................................. 11-5 Overheat Indicator (Red) .............................................................1-9

P Park Machine Safely .................................................................... S-21 Parking ............................................................................................ 4-13 Parking Brake Indicator (Red) .....................................................1-8 Parking Brake Switch ..........................................................1-26, 4-4 Perform Truck Loading Safely ................................................. S-18 Periodic Replacement of Parts ...................................................7-9 Power Train .......................................................................... 7-11, 7-25 Practice Safe Maintenance ....................................................... S-24 Precautions for After Operations ........................................... 5-15 Precautions for Driving on Slopes ............................................4-9 Precautions for Driving Speeds .............................................. 4-11 Precautions for Handling Batteries ....................................... 7-59 Precautions for Handling Long Life Coolant (LLC) .......... 7-50 Precautions for Lightning ......................................................... S-19 Precautions for Maintenance During Cold Weather Season ...............................................................9-2 Precautions for Operation ................................................S-19, 5-4 Precautions for Use ..................................................................... 7-41 Precautions for Welding and Grinding ................................ S-30 Precautions to Be Taken if Machine Failure Occurs ......... 4-10 Preheat Indicator (Yellow) ........................................................ 1-11 Preparations for Inspection and Maintenance ....................7-5 Prepare for Emergencies ..............................................................S-3 Prevent Battery Explosions ...................................................... S-32 Prevent Burns ................................................................................ S-27 Prevent Fires .................................................................................. S-29 Prevent Parts from Flying ......................................................... S-27 Procedures ..................................................................................... 7-33 Protect Against Flying Debris ................................................. S-20 Protect Against Noise ...................................................................S-4 Provide Signals for Jobs Involving Multiple Machines ... S-11 Provisional Stop and Restart of Driving .................................4-7 R Rear View Mirror ........................................................................... 1-46 Rear Window Wiper Switch (Cab Vehicle) ........................... 1-28 Reclining Angle Adjustment .................................................... 1-39 Recognize Safety Information ...................................................S-1 Recommended Fuel ................................................................... 7-42 Refueling ........................................................................................ 7-42 Removal and Installation of Tire.............................................. 7-72 Remove Paint Before Welding or Heating .......................... S-31 Removing Machine from Storage ......................................... 10-2 Removing Snow ........................................................................... 5-14 Replace Engine Oil Filter ........................................................... 7-24 Replace Fuel Filter Element ...................................................... 7-46 Replace HST Oil Filter Element ............................................... 7-35 Replace Return Filter .................................................................. 7-37 Replace Rubber Hoses Periodically ....................................... S-28 Replace Tire ................................................................................... 7-69 Replacement ....................................................................... 7-75, 7-37 Retighten Front Axle, Rear Axle and Transmission Mounting Nuts ............................................. 7-81

14-3

INDEX Ride Control Indicator (Optional) .......................................... 1-14 Ride Control Operation ............................................................. 1-35 Ride Control Switch (Optional) ............................................... 1-35 Right Console ...................................................................................1-5 Right Console (Front Attachment) ........................................ 1-30 Right Console/Switch Panel .................................................... 1-33 Room Light .................................................................................... 1-45 Room Rear View Mirror .............................................................. 1-46 ROPS Cab (Optional) .................................................................. 1-43 Rotary Beacon Switch (Optional) ........................................... 1-50 Rotation Method ......................................................................... 7-71 S SAFETY ...............................................................................................S-1 SAFETY SIGNS ............................................................................... S-35 Scooping ........................................................................................ 5-13 Seat Belt .......................................................................................... 1-40 Seat Pocket (Suspension Seat)................................................. 1-40 Service Air Conditioning System Safely .............................. S-33 Service Indicator (Yellow) ............................................................1-7 Shift Position Indicator .............................................................. 1-13 Shifting Item to Be Indicated on Machine Information Display ............................................ 1-16 SPECIFICATIONS ........................................................................... 12-1 Speedometer ................................................................................ 1-14 Starting Engine ...............................................................................3-5 Starting to Move .............................................................................4-2 Station Presetting Procedure .................................................. 1-48 Stay Clear of Moving Parts ....................................................... S-26 Steering ...................................................................................1-21, 4-6 Steps ................................................................................................. 1-56 Stop .................................................................................................. 4-12 Stop Indicator (Red) .......................................................................1-7 Stopping Engine .......................................................................... 3-12 STORAGE ......................................................................................... 10-1 Store Attachments Safely ......................................................... S-21 Storing Machine .......................................................................... 10-1 Sun Visor (Optional) .................................................................... 1-45 Support Machine Properly ....................................................... S-25 Support Maintenance Properly .............................................. S-26 Suspension adjustment ............................................................. 1-38 Switches, Steering Wheel and Pedals ................................... 1-19

Transport Safely ........................................................................... S-22 TRANSPORTING ...............................................................................6-1 Transporting by Road ...................................................................6-1 Transporting by Trailer .................................................................6-1 Transporting Wheel Loader (Urgent Situation) ...................6-5 Travel on Public Roads Safely .................................................. S-15 TROUBLESHOOTING ................................................................... 11-1 Tuning Procedures ...................................................................... 1-48 Turn Signal Indicator (Green) .................................................. 1-11 Turn Signal Lever ......................................................................... 1-21 U Understand Signal Words ............................................................S-1 Upper Switch Panel (Optional) ............................................... 1-50 Use Correct Fuels and Lubricants .............................................7-2 Use Handrails and Steps ..............................................................S-6 Using Booster Batteries ................................................................3-8 V Vandal-Proof Devices ................................................................. 1-56 Vent .................................................................................................. 1-36 W Warming Up Operation ............................................................. 3-10 Warming Up Operation in Cold Weather ............................. 3-11 Warn Others of Service Work .................................................. S-25 Wear Protective Clothing .............................................................S-3 When Fully Opening the Door ................................................ 1-53 Window Open/Close Levers .................................................... 1-52 Wiper Operation .......................................................................... 1-27 Work Light Indicator (Yellow) .................................................. 1-11 Work Light Switch (Cab Vehicle) ............................................ 1-24

T Tightening and Retightening Torque of Nuts and Bolts ......................................................................... 7-82 Tightening Torque ....................................................................... 7-83 Tire .......................................................................................... 7-14, 7-68 Tire Rotation .................................................................................. 7-71 Tire Sizes to Be Used ................................................................... 7-70 Tire Wheel ....................................................................................... 7-73 Towing Method ...............................................................................6-9 Towing Pin ..................................................................................... 1-54 Transmission Oil, Axle Oil ......................................................... 7-17

14-4

Write Down Your Loader Data Here Write Down Your Loader Data Here LOADER MODEL LOADER SERIAL NO. ENGINE SERIAL NO. SUPERVISER’S NAME

DATE OF PURCHASE DEALER’S NAME

WORKSHOP’S NAME

PHONE

Memo

(Page 1/4)

Maintenance Log Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

(Page 2/4)

Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

(Page 3/4)

Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

(Page 4/4)

Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

(Page 1/4)

Notes

(Page 2/4)

Notes

(Page 3/4)

Notes

(Page 4/4)

Notes

Memo

No. OW-62M-MAE ISSUED: FEBRUARY, 2010

MARKETING GROUP:

All rights reserved

‘10.2~

1-15-5, Nishi-shimbashi, Minato-ku, Tokyo 105-0003, Japan FAX: Japan +81-3-35918154 I-1002005(TA) Printed in Japan

CALIFORNIA Proposition65Warning D i e s e le n g i n ee x h a u s tandsomeo fi t sc o n s t i t u e n t sa r eknown t ot h eS t a t eo fC a l i f o r n i at oc a u s ec a n c e r ，birthdefects，and o t h e rr e p r o d u c t i v eharm.

TCA 縄∞

RPO臥 T酬