I. Purpose & Scope

To safely and effectively provide instruction on the inspection and proper use of dump trucks.

II. Definitions

Standard PPE – High Viz Garment, Hard Hat, Z-87.1 Safety Glasses, Gloves, Pants, Work Boots

III. Process

NOTE: Work instruction does not supplement the manual. For specific instructions for the exact model please refer to the owner’s manual.

A. Potential Hazards

• Moving Parts Hazard
• Fire and Explosion Hazard
• Burn Hazard
• High Pressure Fluid Hazard
• Electric Shock Hazard
• Crush Hazard
• Slip and Fall Hazard
• Tip Over Hazard
• Dust Hazard
• Toxic fumes hazard

B. PPE

• Standard PPE
• Respiratory Protection (recommended)
• Safety Goggles or Face Shield (recommended)
• Hearing Protection

C. Inspection

Before Operation

1. Check bolts and nuts for loose connections.
2. Check the fuel, oil and water for leaks.
3. Check the implement and the hydraulic system to see that they are operating properly.
4. Check the electrical wiring for loose connections and for dust deposits in the heat build-up areas.
5. Check the implement, hydraulic cylinders, linkages, and hoses for damage, wear and loose connections. If any abnormality is found, take corrective action.
6. Check that there are no dust deposits around the engine or on the radiator, and that there are no combustibles (dead leaves, twigs, etc.) in the heat build-up areas, such as the engine muffler, or around the battery. If there are any, remove them.
7. Check the engine for oil leakage and the cooling water system for water leakage. If oil or water leakage is found, take correct action.
8. Check for oil leakage. If oil leakage is found, take corrective action.
9. Check for grease leakage or ooze. If grease leakage or ooze is found, take corrective action.
10. Check the undercarriage (tracks, sprockets, and idlers) for breakage, wear, loose bolts, and oil leakage around the rollers. If any breakage or wear is found, correct it. Retighten the bolts if necessary. If oil leakage is found, take corrective action.
11. Check the handrails and steps for breakage and loose bolts. If any breakage is found, take corrective action. Retighten bolts if necessary.
12. Check the gauges and the monitor for breakage and loose bolts. If any abnormality is found replace the gauge or the monitor with a new one, or retighten the bolts if necessary. Clean the surfaces of the gauges and monitor.
13. Check and replenish the cooling water.
    NOTE: Do not remove the fill cap from the radiator unless refilling the coolant. Check the coolant water level in the sub-tank when the engine is cool.
    • Open the engine hood rear cover. Then check that the cooling water level in the sub-tank between the Full and Low marks. If the water level is below the Low mark, refill the sub-tank up to the Full mark through the water supply port of the sub-tank.
    • After replenishing, securely tighten the radiator cap.
    • If the sub-tank is empty, check it for water leakage, and then, check the water level in the radiator. If the water level is low, refill the radiator first, then refill  the sub-tank.
    • If the cooling level is appropriate, close the engine hood rear cover.
14. Check and drain the water separator.
    NOTE: Keep sparks, flames, and lit cigarettes away. Drain and replace the water separator element after the engine has cooled down. Fuel leaked or spilled onto hot surface or electrical components could cause a fire.
    • Prepare a container for fuel waste.
    • Check the water separator to see whether the float (red ring) has sunk down to the cup bottom and a contamination has not mixed into the oil.
      • If the float has sunk down to the cup bottom, no water has mixed into the oil.
      • If the float is floating in the cup, water is mixed into the oil under the float. If the water or the contamination is found in the cup remove it as per the procedure below.
        • Take the drain hose out from the inside of the engine room and place the container for fuel waste under the drain hose.
        • Turn the fuel cock to the off position.
        • Loose the drain cock about 4 turns, and drain the water and contamination.
          • If no water drips when the water separator drain cock is opened, loosen the air bleeder bolt on the top of the water separator by using a screwdriver to turn it counter clockwise 2 to 3 turns. After draining the water separator, be sure to tighten the air bleeder bolt.
        • Hand-tighten the drain cock (tightening torque 0.73 to 1.48ft•lbf.
        • Wipe off the water and fuel adhered to the drain hose.
        • Turn the fuel cock to the on position.
        • After draining, release the air.
        • Check the fuel leak.
        • Close the engine hood.
15. Check and replenish the engine oil.
    • Open the engine hood rear cover and securely lock it with the stopper.
    • Pick up the dipstick and wipe it with a rag to remove oil deposits.
      NOTE: At operating temperature, oil and dipstick areas are hot. Do not allow hot oil or components to contact skin to prevent bodily injury. Check oil level and refill oil after engine has cooled down.
    • Insert the dipstick into the dipstick tube fully, then draw it out.
      • If the dipstick is wet above the midpoint between the H and L marks, the engine oil level is appropriate.
      • If the oil level is below the midpoint between the H and L marks, supply engine oil through the oil supply port.
      • If the engine oil is above the H mark, remove the cover under the drain plug. Remove the excessive amount of oil through the drain plug then recheck the engine oil level.
    • After verifying that the amount of engine oil is appropriate, securely retighten the oil supply port cap and close the engine hood rear cover.
      • If cover was removed for draining engine oil, reinstall the cover.
        NOTE: When checking engine oil level after starting up the engine, stop the engine and allow more than 15 minutes for the engine to cool down. If the machine is slanted, reposition the machine to ensure it is level before checking the engine oil level. Keep in mind that the excess engine oil must not be disposed of on the ground or the road.
16. Check and replenish the fuel in the fuel tank.
    • Turn the starter switch to the on position, and check the fuel level with the fuel meter.
    • Open the bonnet and supply fuel from the fuel supply port which checking the level gauge.
      NOTE: Be careful not to overfill the fuel tank because it could cause a fire. If the tank is overfilled, completely wipe off the spilled fuel. Do not remove the strainer from the fuel supply port of the fuel tank to refill the tank. Be careful not to allow water settled at the bottom of the fuel container or dirt on refueling equipment to enter into the fuel tank.
    • After refueling, securely retighten the fuel supply port cap, and close the engine hood.
      NOTE: If the breather hole in the cap is clogged, the pressure in the tank may decrease and the fuel may not be supplied adequately to the engine. Clean the engine breather hole from time to time.
17. Check and replenish the hydraulic oil tank.
    • Park the machine on firm, level ground, start the engine, retract the bucket and arm cylinders to their stroke ends at low speed, lower the boom until the bucket teeth are place on the ground, then lower the blade to the ground and stop the engine.
    • Check the oil level with the oil level gauge on the right side of the machine. The oil level must be between the upper and lower limit marks on the gauge.
      NOTE: Before start up, the oil level gauge should read the level around the midpoint of the gauge scale. During normal operation, the oil level gauge should read the level around the upper limit mark of the gauge scale.
    • Open the bonnet and lock it with the stopper. Replenish oil from the oil supply port if the oil level is below the lower limit.
      NOTE: When removing the plug of the oil supply port, slowly loosen it to release the pressure in the tank to prevent a dangerous high-pressure leak. Do not replenish hydraulic oil above the upper limit mark on the oil level gauge. An excessive amount of hydraulic oil may damage the hydraulic system by placing stress on its components, causing a dangerous high-pressure leak.
    • Disengage the stopper and close the bonnet.
18. Check and adjust the fan belt tension
    • Open the engine hood rear cover fully to be locked with the stopper.
    • Press down fan belt between the fan pulley and the generator pulley with a finger to check the generator belt tension.
      • Pressing load: Approximately 22.1lbs
      • Adequate slack: 0.39 to 0.59in
        NOTE: Stop the engine, take out the starter switch key, and attach LOTO device to a control lever. The fan belt is hot immediately after the engine is stopped. Do not adjust the fan belt tension immediately after stopping the engine. Adjust the fan belt tension after all parts of the engine have fully cooled down.
    • Adjust the tension if necessary.
      • Open the cover of the seat mount, remove bolts and the cover.
      • Loosen mounting bolts of the generator.
      • Loosen the lock nut of the adjuster.
      • Turn the adjuster bolt clockwise and move the generator so that the fan belt tension will be slackened approximately 0.4 to 0.6 inch 72.3ft-lbf.
      • Retighten the mounting bolts to secure the generator.
      • Retighten the lock nut to secure the adjuster bolt.
      • Check the pulleys, the V-groove, and the fan belt for damage, and check to see that the fan belt does not touch the bottom of the V-groove.
      • If the fan belt cannot be adjusted since it has lost its elasticity or if it is damaged or cracked, replace the fan belt with a new one.
    • When the tension is proper close the engine hood rear cover.
19. Check and replenish the battery electrolyte.
    • Open the bonnet and lock it with the stopper.
    • Check the electrolyte level of the batter. The level must be between the upper and lower limit marks.
      NOTE: The battery generates flammable gas and can cause a fire and an explosion. Keep sparks, flames, and lit cigarettes away from the battery. Battery electrolyte is strong acid. To avoid serious injury, do not allow the electrolyte to contact your skin or splash into your eyes. Do not use the machine with the battery which is short of battery electrolyte. The shortage of battery electrolyte not only will reduce the life of the battery but also could cause an explosion.
      • If the level is lower than the lower limit mark, loosen the bolt.
      • Open the cover and fix it with the stopper.
      • Replenish the electrolyte.
      • Disengage the stopper and close the bonnet.
20. Grease the fittings thoroughly after washing the machine or after operation in rain, on soft ground or in muddy water. Be sure to perform the greasing daily before startup.
    • Put the bucket and the blade on the ground and stop the engine.
    • Clean the grease nipples using a grease gun.
    • After greasing, wipe off the excessive grease with waste cloth or the like.
21. Check fuses for damage, wiring for poor connections or short circuits, and batter terminals for corrosion or loose fits. Take corrective action as necessary.
22. Check the following items after the start switch is turned to the “On” position.
    • Check the functions of LCD monitor (hour meter, water temp. meter and fuel meter).
    • Check LED lamps on the LCD monitor.
    • Check the work lights.
    • Check the horn.
    • Check the auto deceleration function.
    • Check the eco mode function.
    • Check the wiper function (cabin type)
    • Check the room lamp for lighting (cabin type)
    • Check the heater function (cabin type)
    • Check the air conditioner function (option).
    • Check the travel alarm function, push or pull the travel levers after the lock levers are unlocked.

After Operation

1. Check the water temp meter and LED lamps on the LCD monitor, and also check the residual quantity of fuel with the fuel meter.
2. Check oil and water for leaks, and visually inspect the implement, the machine, and the undercarriage by walking around them. If there are any leaks of oil or water, or any observed abnormality, take corrective action.
3. Completely fill the fuel oil tank.
4. Confirm that the engine room compartment is free of any foreign matter.
   NOTE: Paper or dust in the engine room may cause fire. Remove them if any.
5. Remove mud adhering to the undercarriage of the machine.
6. Make sure to lock up the following parts:
   • Bonnet
   • Engine hood rear cover
   • Side door (cabin type)
   • Cabin rear cover (cabin type)
     NOTE: The starter switch key is used to lock all of the parts mentioned above.

D. Use

Loading and Unloading the Machine

1. Firmly brake the truck and apply wheel stoppers to the tires. Securely install the ramp plates on the bed of the truck in a position where the center of the truck aligns with the center of the machine. Make sure that the left and right ramp plates are at the same level.
   NOTE: The ramp plates should be set at an angle of less than 15 degrees. Determine the span between the ramp plates on the basis of the centers of the track shoes. Do not operate the high-speed switch.
2. Turn the engine control dial to “idling” direction.
3. Travel toward the ramp plates at a low speed, and load or unload the machine with the implement lowered as close as possible to the deck of the truck. Do not operate any levers other than the travel levers while driving on the ramp plates.
4. Load the machine in a safe position on the truck.
5. Place the blade down on the ground.
6. Extend the bucket and arm cylinders to the maximum limit, and slowly lower the boom down on a block of wood.
7. Stop the engine to take the key out of the starter switch.
   NOTE: The brake works to lock the swing motor.
8. Be sure to lock the control levers with the lock levers.
9. Lock the bonnet, covers and cabin door with the starter switch key to prevent them from opening during transportation.
10. Provide wood blocks in the front and back of the track and secure the machine with a chain or a wire rope so that the machine will not move during shipping. In particular, be sure to secure it to prevent skidding.

Suspending the Machine

1. Swing the upper structure so that the blade is behind the operator’s seat.
2. Raise the blade to the highest limit.
3. Extend the hydraulic cylinders of the front implement (except for the swing cylinder) to the maximum.
4. Stop the engine, and make sure that nothing is around the operator’s seat before leaving the machine.
5. Fit the shackles to the suspending hooks on the front side (one point) and the rear side (two points), and securely fasten a sling belt (or a wire rope) to the shackles.
6. Suspend the machine above the ground, wait until the machine is stable and then suspend it slowly.

Leaving Operator’s Seat

NOTE: When leaving the operator’s seat, be sure to place the lock lever in the lock position, to prevent accidental machine movement which could result in bodily injury.

1. Lower the bucket to the ground.
2. Place the lock lever in the lock position.
3. Stop the engine.
4.  Set all the locks in to the lock position.
5. Be sure to take the key out of the starter switch.

Using Handrails and Steps

1. Do not jump on or off the machine. Never get on or off a machine in motion as it may result in bodily injury.
2. When getting on and off the machine, face the machine and use the handrails and steps.
3. Do not grab the control levers or the front windshield opening and closing knobs when getting on and off the machine.
4. Make sure that you maintain three point contact with the handrails or the steps.
5. If the handrails and steps are soiled with oil or dirt, clean them off immediately. Repair any damaged parts and retighten any loose bolts.
6. When opening or closing the cabin side door from the outside, do not do so standing on the part of the machine; for example, on the crawler or the step. Be sure to open or close the door standing on the ground.

Before Starting Engine

1. Check that the lock lever are in the lock position.
   NOTE: When both the lock lever are in the unlock position, the engine cannot be started. Pull either lock lever up to start the engine.
2. Check that all other levers are in their appropriate positions
   NOTE: Accidentally operating a control lever can cause the machine to move suddenly, possibly causing a serious accident.
3. Fasten the seatbelt snugly.
4. Insert the key into the starter switch and set it to the On position. Then check the following points:
   • The buzzer will sound, and LED lamps on the LCD monitor will go on.
   • After 2 seconds, the buzzer and LED lamps except for the following lamps will turn off.
     • Engine oil pressure lamp
     • Battery charge lamp
   • If any of the alarm lamps do not go on or the buzzer does not sound, it may mean that the alarm lamp has blown out or the wire is broken.
   • Position the light switch to On whether the work lights will go on.
     • If they do not go on, the lamp might have blown out or the wire might be broken.

Starting up the Engine

1. First check that there are no people or obstacles around the machine. Then sound the horn and start the engine. Be sure that you are seated in the operator’s seat when starting the engine.
2. Turn the engine control dial to the “run” direction.
3. Set the key in the starter switch to the “start” position. The engine will start.
   NOTE: Do not keep the key in the “start” position for more than 10 seconds. If the engine fails to start, do not attempt to start the engine immediately again, but set the switch to the “off” position and wait for approximately 30 seconds, then start the engine again.
4. After the engine has started, release the starter switch key. The starter switch key will return to the “on” position by itself.
   NOTE: When the engine is warm, the engine can start up even if the accelerator lever is left in the “idling” position.

Engine Warm Up

1. Idle the engine to check that LED lamps on the LCD monitor is off.
2. Turn the engine control idle to the midpoint between the “idling” and “run” positions, and run the engine with no load at a medium speed for approximately five (5) minutes.
3. Unlock the lock lever and lift the bucket from the ground.
4. Operate the bucket and arm control levers slowly to move the bucket and arm cylinders to their stroke ends. Operate the bucket for thirty seconds and the arm for thirty seconds alternately for approximately five minutes to increase the hydraulic oil temperature to 70°F or more.
5. After warming up the engine, check that the LED lamps on the LCD monitor have turned off and no errors are displayed on the LCD screen. If there are any problems, take the necessary corrective action.
6. Check the exhaust gas color, the machine noise, and the vibration level for abnormality. If something is abnormal, take corrective action.
7. Set the lock lever to the “lock” position to check that the implement cannot be operated and the upper structure cannot be swung with the left and right control levers.
8. Unlock the lock lever and operate the control levers to check that the implement can be operated and the upper structure can be swung normally with the control levers. If something is abnormal, take corrective action.
9. Check that the swing brake valve operates normally. If something is abnormal, take corrective action.
10. Check that no abnormal noise is heard from the hydraulic system. If any abnormal noise is heard, take corrective action.

Traveling Forward

1. Turn the engine control dial to the “run” position to increase the engine speed.
2. Sound the horn before beginning travel to alert the people near the machine.
3. Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
4. Unlock the lock lever and retract the implement to lift it 16 to 20in. above the ground.
5. Pull back the blade lever to lift the blade.
6. Operate the left and right travel levers or pedals as follows:
   • When the blade is in the front of the machine, slowly push the travel levers forward or step on the front of the pedals to move the machine forward.
   • When the blade is in the rear of the machine, slowly push the travel levers back or step on the rear of the pedals in order to move the machine forward.

Traveling in Reverse

1. Turn the engine control dial to the “run” position to increase the engine speed.
2. Sound the horn before beginning travel to alert the people near the machine.
3. Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
4. Unlock the lock lever and retract the implement to lift it 16 to 20in. above the ground.
5. Pull back the blade lever to lift the blade.
6. Operate the left and right travel levers or pedals as follows:
   • When the blade is in the front of the machine, slowly pull the travel levers back or step on the rear of the pedals in order to move the machine backward.
   • When the blade is in the rear of the machine, slowly pull the travel levers forward or step on the front of the pedals to move the machine backward.

Steering (Turning the Machine)

1. When not traveling, to turn left, push the right travel lever forward and start traveling forward on the left. Pull the right travel lever back and start traveling in reverse on the left.
   NOTE: To turn right, operate the left travel lever in the same manner as above.
2. When traveling, to turn left, return the left travel lever to the neutral position.
   NOTE: To turn right, operate the right travel lever in the same manner as above.
3. To spin-turn the machine when it is not traveling, push the right travel lever forward while pulling the left travel lever back.
   NOTE: To spin-turn right, push the left travel lever forward while pulling the right travel lever back.

Parking

1. Set the right and left travel levers or pedals to the neutral position to stop the machine.
2. Turn the engine control dial to the “idling” direction.
3. Place the bucket on the ground with its bottom surface in contact with the ground.
4. Place the blade on the ground.
5. Set the lock lever to the “lock” position.

Stopping the Engine

1. Idle the engine for approximately five minutes with no load.
2. To stop the engine, turn the starter switch key to the “off” position.
3. Take the key out of the starter switch.
   NOTE: As long as the starter switch key in in the “on” position and the lock lever(s) is (are) in unlock position, each implement can be moved by its own weight when the respective control levers are operated soon after the engine is stopped.

Replacing the bucket without the quick coupler

1. Park the machine on level, flat ground and lower the bucket onto the ground.
2. Stop the engine.
3. Clean around the bucket pin to prevent foreign material from entering the pin holes.
   NOTE: Keep the pins away from dirt or mud. The machines have dust seals on either end of the bushing. Be careful not to damage them.
4. Remove pins.
5. Clean the bucket boss section and install the O-ring.
   NOTE: Check that the O-ring is not damaged. If it is damaged, replace it. It is recommended to replace the O-ring when the bucket is replaced.
6. Connect the arm to hole, and then connect link to hole.
7. Install the O-ring in position.
   NOTE: Before mounting the bucket, clean the arm pin hole and grease it.
8. Install the bolt into the bucket pins.
9. Grease the connecting parts.

Reversing Bucket Without Quick Coupler

1. Park the machine on level, flat ground, and lower the bucket onto the ground.
   NOTE: TO remove the pins, place the bucket on the ground in such a way that it touches the ground lightly. Lowering the bucket down on the ground by its full weight will increase stresses on the pins and make the pins difficult to remove. Keep the pins away from dirt or mud.
2. Stop the engine.
3. Clean the area around the bucket pins to prevent foreign material from entering the pin holes.
4. Remove pins.
5. Reverse the bucket.
6. Clean the bucket boss section and install the O-ring.
   NOTE: Check that the O-ring is not damaged. If it is damaged, replace it. It is recommended to replace the O-ring when the bucket is replaced.
7. Connect the arm to hole, and then connect link to hole.
8. Install the O-ring in position.
   NOTE: Before mounting the bucket, clean the arm pin hole and grease it.
9. Connect the arm to hole, and then link to arm hole.
10. Install the bolt into the bucket pins.
11. Grease the connecting parts.
    NOTE: When using a revers bucket, the bucket and the boom cylinder can contact each other when the arm is curled or the boom is lowered. Never curl the bucket too much, and never allow it to contact the boom cylinder.

Dismounting Attachment

1. Park the machine on stable level ground.
2. Lower the attachment onto the ground.
3. Set up the handle of the lock pin.
4. Turn the arrow on the head of the pin from the lock position to the unlock position, and then pull it up.
   NOTE: The lock pin cannot be removed from the body.
5. Open the switch box cover.
6. Press the power supply switch. Then, beeps sound and the power supply switch blinks.
7. Turn the control switch to the dismounting position on the left side, and the attachment is dismounted.
8. Remove the quick coupler from the attachment.

Mounting Attachment

1. Place the attachment on stable level ground. Be sure to install the pins into the attachment.
2. Close the moveable hook.
3. Put the fixed hook onto the pin of the attachment on the arm side and set the quick hitch level with the ground.
4. Lift the attachment up in that state.
5. Curl the attachment so that it is level.
6. Turn the control switch to the mounting position on the right side, and the attachment is mounted.
7. Only one of the bores allows the whole lock pin. Install the lock pin to that bore.
8. Turn the arrow on the lock pin to the lock side.
9. Put the handle of the lock pin down to the arrowed side.
10. Make sure the attachment is securely mounted in the quick coupler before pressing the power supply switch on. The beeps stop sounding and the red lamp goes off.
11. Close the switch box cover.

E. Maintenance

1. Check there are no cracks and plays.
2. Check the bolts and nuts for looseness.
3. Check the hydraulic piping for oil leak.
4. Removed any damaged lock pins and clean the bore of the lock plate.
   NOTE: Replace the lock plate with a new one if it is damaged.
   • Put a new lock pin into the bore of the lock plate.
   • Install the washer and nut onto the lock pin from the back side of the lock plate.
     NOTE: Apply a lock agent ThreeBond 1324 on the thread.
   • Tighten the nut (M6, Hex 10mm) to 7.5 to 8.5ft•lb.
   • Confirm if the new lock pin can smoothly move to the lock and unlock positions.
5. Grease the fittings thoroughly after washing the machine or after operation in rain, on soft ground, or in muddy water.
   • Put the bucket and the blade on the ground and stop the engine.
   • Clean the grease nipples and grease them using a grease gun.
   • After greasing, wipe off the excessive grease with waste cloth or the like.
6. If working in mud, rain, snow, or on a beach, clean the amchine and check plugs, and cocks for cracks or damage, and check for loose or missing bolts and nuts. Apply grease earlier than usual. Particularly apply grease every day to the pins on the implement which are submerged in mud.
7. If working in a dusty place check the following:
   • Check the air cleaner for clogging.
   • Clean the air cleaner element earlier than scheduled.
   • Clean the radiator fin earlier to prevent it from clogging.
   • Clean or replace the fuel filter element earlier than scheduled.
   • Clean the electric equipment, especially the starter motor and the generator, to avoid dust deposits.

F. Live Line Contact

1. Immediately stop work.
2. Treat equipment, attachments and ground as energized.
3. Warn people nearby that an electric strike has occurred.
4. DO NOT exit equipment and stay inside cab while contact or arcing is occurring.
5. Ensure equipment is barricaded.
6. If there is an immediate hazard (i.e. fire hazard) that requires the exiting of equipment employee shall jump out of equipment with both feet together, landing on the ground.
7. Employee shall than shuffle away from equipment, not walk or run, taking small steps and feet together to minimize voltage difference in the ground until they reach a safe location.