PRIMARY COURSE FOR
OPERATION OF
CONSTRUCTION EQUIPMENT
Media # KLMS Course #
MENU
1. SAFETY
2. STARTUP INSPECTION
3. BASIC OPERATION OF HYDRAULIC
EXCAVATOR
4. PROHIBITION AND PRECAUTION DURING
OPERATION OF HYDRAULIC EXCAVATOR
5. BASIC OPERATION OF WHEEL LOADER
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
Media # KLMS Course #
MENU
7. BASIC OPERATION OF DUMP TRUCK
8. PRECAUTION DURING OPERATION OF
DUMP TRUCK
9. BASIC OPERATION OF BULLDOZER
10. PRECAUTIONS FOR BULLDOZER WORK
11. FINISH INSPECTION
Media # KLMS Course #
1. SAFETY
1-1.
1-2.
1-3.
1-4.
Working Clothes for Equipment Operation
Climbing up and down Equipment
Engine Startup
Equipment Startup
Media # KLMS Course #
1. SAFETY
1-1.
Working Clothes for Equipment Operation
• Be sure to properly wear designated working clothes, hard
hat, safety shoes and other protective tools.
• Button up the working clothes.
• Do not hang a wash cloth around the waist or wind it
around the neck loosely.
1-2.
Climbing up and down Equipment
• When climbing up the equipment, use a provided step and
handrail.
• When climbing down the equipment, take the same
posture as when climbing up. Never try to jump off the
equipment.
Media # KLMS Course #
Page 5
1. SAFETY
1-3.
Engine Startup
• Before starting up the engine, make sure that there is
nobody around the equipment. It is recommended to blow
a horn then.
1-4.
Equipment Startup
• Before starting up the equipment, make sure that there is
nobody around the equipment and blow a horn.
Media # KLMS Course #
Page 6
2. STARTUP INSPECTION
2-1. Walk-around Check
2-2. Oil and Coolant Level Check
Media # KLMS Course #
2. STARTUP INSPECTION
2-1.
Walk-around Check
• Inspection for oil leakage
• Inspection for track tension
• Inspection for cracks on undercarriage (upper and lower
carrier rollers and shoe plates)
• Inspection for cracks on work equipment and loosening of
bolts
• Inspection for cracks on hoses
• Inspection for damage on lights and mirrors
• Inspection for electric wirings and horn
Media # KLMS Course #
Page 8
2. STARTUP INSPECTION
2-2.
Oil and Coolant Level Check
•
•
•
•
Checking engine cooling water level and refilling
Checking engine oil level in oil pan and refilling
Checking fuel level and refilling
Checking water separator and draining water and
sediments
• Checking oil level in hydraulic tank and refilling
 When carrying out those checking listed above, you are
required to refer to the section of CHECK BEFORE
STARTING in the relative operation and maintenance
manual.
Media # KLMS Course #
Page 9
3. BASIC OPERATION OF
HYDRAULIC EXCAVATOR
3-1. Level Ground Excavation
Work
3-1-1. Effective Excavation Work
3-1-2. Excavation of soft earth
3-1-3. Excavation of relatively hard
earth
3-1-4. Excavation of hard earth
3-2. Face Down Excavation Work
3-2-1. Face Down Excavation
3-3. Face Up Excavation Work
3-5. Slope Finishing Work
3-5-1. Slope lower portion finishing
work
3-5-2. Slope upper portion finishing
work
3-6. Dump Truck Loading Work
3-6-1. Comparison of loading
methods
3-6-2. Backhoe loading
3-6-3. Swing loading
3-3-1. Face Up Excavation
3-4. Ditch Excavation Work
3-4-1. Basics of ditch excavation
3-4-2. Excavation of ditch as wide
as bucket width
3-4-3. Excavation of ditch 1.5 times
as wide as bucket width
Media # KLMS Course #
Page 10
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-1. Level Ground Excavation Work
3-1-1. Effective Excavation Work
Arm Cylinder
Arm
When the arm and arm cylinder,
likewise the bucket cylinder and
link, is set at a right angle, each
cylinder has the maximum digging
force.
Digging should take place within a
range of 45 to the front and 30
to the rear of the upright arm.
Media # KLMS Course #
Page 11
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-1. Level Ground Excavation Work
3-1-2.
Excavation of soft earth
(1)
(2)
Approx.
60
Set the bucket bottom plate at an angle of
approx. 60.
(3)
Pull back the arm while lowering the boom, and
let the bucket dig in the earth to as much as
2/3 of its height.
Scoop earth at one go using the bucket
force.
Media # KLMS Course #
Page 12
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-1. Level Ground Excavation Work
3-1-3.
Excavation of relatively hard earth
(1)
(2)
Pull back
the arm.
Set the bucket bottom plate at an angle of
approx. 30.
(3)
Pull back the arm to allow the
bucket teeth to dig in the earth to
as much as 1/3 of its height.
(4)
Raise the
boom.
Keep the bucket bottom plate at angle of 30
through a fine control of BOOM RAISE, pull
back the bucket horizontally.
Continue to scoop earth while watching the
increasing earth volume.
Media # KLMS Course #
Page 13
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-1. Level Ground Excavation Work
3-1-4.
Excavation of hard earth
(1)
Pull back the arm while raising the boom to
lessen load applied to the bucket as it
increases, and dig the earth as if thinly
scraping off the surface.
(2)
Less than
30
Set the bucket bottom plate at an angle of
less than 30(10 to 30).
(3)
Control the boom so that the front portion of
the track shoes will not be lifted.
(4)
If the bucket teeth hit a hard rock and will not
move any farther, then tilt the bucket back to
approx. 60 once.
Tilt back the bucket slowly while keeping the
bucket dug in, and try to scoop the earth and
rock as if prying off.
Media # KLMS Course #
Page 14
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-2. Face Down Excavation Work
3-2-1. Face Down Excavation
(1)
(2)
Raise the boom.
Less than
30
Set the bucket bottom plate at an angle of
less than 30.
(3)
Pull up the boom along the slope and pull
the arm to dig as if scraping off the slope
surface.
(4)
Raise the boom.
If the bucket teeth hit a hard rock and will not
move any farther, tilt the bucket angle back
to approx. 60.
While keeping the arm as it is, tilt the bucket
slowly and dig as if prying off the rock.
Media # KLMS Course #
Page 15
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-3. FACE UP EXCAVATION WORK
3-3-1. Face Up Excavation
(1)
(2)
Lower the
boom.
Pull back the arm
while maintaining the
set angle of the bucket to do digging.
(4)
Set the bucket teeth
perpendicular to the ground.
(3)
If the bucket teeth
hit a hard rock and
will not move any farther, press the bucket
against the rock with boom operation and
dig it out as if prying off.
Basically digging should take place in the order
of  through  as illustrated above.
Media # KLMS Course #
Page 16
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-4. Ditch Excavation Work
3-4-1.
Basics of ditch excavation
(1)
At the beginning of digging, do not hold
the arm at the maximum reach but at
approx. 80% of the whole reach.
(2)
When digging a ditch whose width is
larger than the bucket width, swing the
bucket and press it against a ditch
sidewall. And then start digging.
Media # KLMS Course #
Page 17
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-4. Ditch Excavation Work
3-4-2.
Excavation of ditch as wide as bucket width
Start digging in the order illustrated
below.
Earth Dumping
(to one side of a ditch)
Back up the equipment and reset the
bucket position.
Dumped
Earth
Media # KLMS Course #
Page 18
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-4. Ditch Excavation Work
3-4-3.
Excavation of ditch 1.5 times as wide as bucket width
Digging in this case should take place in the order illustrated below.
Media # KLMS Course #
Page 19
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-5. Slope Finishing Work
3-5-1.
Slope lower portion finishing work
(1) Embankment Slope
(2) Natural ground slope
Finish a slope by slightly pressing the
surface with the bottom of a bucket.
Finish a slope by thinly scraping off the
surface with bucket teeth.
Media # KLMS Course #
Page 20
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-5. Slope Finishing Work
3-5-2.
Slope upper portion finishing work
(3) Upper Portion of Slope
Finish an upper portion of slope as if
scraping off the surface with bucket
teeth.
Media # KLMS Course #
Page 21
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-1.
Comparison of loading methods (1/2)
(1) Backhoe Loading Method
(2) Swing Loading Method
This type of loading method assures
higher working efficiency, as loading
work is easy thanks to a better
visibility to an operator of a
hydraulic excavator.
This type of loading method is used
primarily in a jobsite having
restrictions, as working efficiency is
not so high.
Media # KLMS Course #
Page 22
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-1.
Comparison of loading methods (2/2)
Comparison of Cycle Time (0.7m3 class)
Cycle Time (sec.)
Backhoe loading
Swing loading
Media # KLMS Course #
Page 23
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-2.
Backhoe loading (1/2)
(1) Matching height of work bench and dump truck
Arm angle  is such that the bucket can
reach out to the front end of a dump truck's
vessel when a hydraulic excavator dumps
earth on a dump truck.
As a loading machine, a hydraulic excavator
should position itself on the same level or
slightly higher than a dump truck as a hauler.
(2) Digging and scooping
(Soft Embankment)
Media # KLMS Course #
(Natural Ground)
Page 24
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-2.
Backhoe loading (2/2)
(3) Boom Raise + Swing
Swing to the left assures a better visibility
and facility in loading.
(4) Dumping Earth
(5) Boom Lower + Swing (Return)
A combination of three operations, swing + boom lower + bucket, which helps an
operator return to the digging spot in a short time.
Media # KLMS Course #
Page 25
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-3.
Swing loading (1/2)
Load on a dump truck, beginning with the
vessel's front end. That ensures a good
visibility all the time and promises easy
loading work.
(1) Setting dumping reach
At the initial setting, dumping reach of a
hydraulic excavator should not be set at
the maximum but there should be some
allowance left.
(2) Digging and Scooping
Start digging a portion of earth before the arm's max reach.
Media # KLMS Course #
Page 26
3. BASIC OPERATION OF HYDRAULIC EXCAVATOR
3-6. Dump Truck Loading Work
3-6-3.
Swing loading (2/2)
(3) Boom Raise + Swing + Dumping
The moment the bucket crosses over the
truck's sideboard, start the operation of
bucket dumping to dump earth in the middle
of the vessel.
(4) Boom Lower + Swing (Return)
Get back to the digging spot swiftly through a three complex operation of swing +
boom lower + bucket.
Media # KLMS Course #
Page 27
4. PROHIBITION AND PRECAUTION DURING
OPERATION OF HYDRAULIC EXCAVATOR
4-1. Prohibition
4-1-1.
4-1-2.
4-1-3.
4-1-4.
4-1-5.
4-1-6.
4-1-7.
4-1-8.
Prohibition of work using bucket swing force
Prohibition of work using travel force
Precaution for work using hydraulic cylinder at its stroke end
Prohibition of work using bucket falling force
Prohibition of work using equipment falling force
Prohibition of excavating bedrock
Prohibition of hoisting work
Prohibition of sudden operation of control lever while running at a high speed
4-2. Precautions
4-2-1.
4-2-2.
4-2-3.
4-2-4.
Precautions while traveling
Precautions while traveling at a high speed
Precautions for work on a slope
Precautions when climbing up and down a slope
Media # KLMS Course #
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-1. Prohibition
4-1-1.
Prohibition of work using bucket swing force
This practice of work can
drastically reduce machine life
and cause danger.
4-1-2.
Prohibition of work using travel force
This practice of work can cause
damage to machines and work
equipment.
Media # KLMS Course #
Page 29
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-1. Prohibition
4-1-3.
Precaution for work using hydraulic cylinder at its stroke end
In this practice of work, a
hydraulic cylinder will break down,
when external force is applied to
the machine's work equipment,
and may cause a bodily injury.
4-1-4.
Prohibition of work using bucket falling force
Any such work that uses bucket
falling force can drastically reduce
machine's life.
Media # KLMS Course #
Page 30
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-1. Prohibition
4-1-5.
Prohibition of work using equipment falling force
This practice of work can
drastically reduce the life of
equipment.
4-1-6.
Prohibition of excavating bedrock
Try to break bedrock into pieces in other adequate methods when the
bucket stumbles on it during the work.
Media # KLMS Course #
Page 31
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-1. Prohibition
4-1-7.
Prohibition of hoisting work
It is prohibited to use your
hydraulic excavator as a hoist.
4-1-8.
Prohibition of sudden operation of control lever while running at a
high speed
It can not only invite danger but
also shorten the life of your
hydraulic excavator to operate the
control lever all of sudden while it
is traveling at a high speed.
Media # KLMS Course #
Page 32
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-2. Precautions
4-2-1.
Precautions while traveling
Avoid climbing over an obstacle
lying on the path as far as
possible. Either go around or
remove it.
4-2-2.
Precautions while traveling at a high speed
When traveling equipment on a
rough terrain, rocky or strewn with
loose stones, keep the travel
speed at Lo.
Media # KLMS Course #
Page 33
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-2. Precautions
4-2-3.
Precautions for work on a slope
Work on a slope should be avoided as far as possible because
equipment can tip over.
Never attempt to make a turn on a
slope or travel across a slope.
Where work on a slope cannot be
avoided, build a bench on the
slope to keep equipment as level
as possible.
Media # KLMS Course #
Page 34
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-2. Precautions
4-2-4.
Precautions when climbing up and down a slope (1/2)
Climbing up and down a slope with gradient of 15 or less
For climbing down, keep a posture
as illustrated at right and travel at
a low speed.
For climbing up, keep a posture as
illustrated at right and travel at a
low speed.
Media # KLMS Course #
Page 35
4. PROHIBITION AND PRECAUTION DURING OPERATION OF HYDRAULIC
EXCAVATOR
4-2. Precautions
4-2-4.
Precautions when climbing up and down a slope (2/2)
Climbing up a steep slope
Keep a posture illustrated at aright
and travel at a low speed.
Media # KLMS Course #
Page 36
5. BASIC OPERATION OF WHEEL
LOADER
5-1.
5-2.
5-3.
5-4.
5-5.
Digging Work
Loading Work
V-shape Loading
Cross Loading
Load and Carry Work
Media # KLMS Course #
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (1/12)
1. Run Forward
• Run the equipment straight to a mound at a right angle.
• Select the 2nd gear speed in running straight.
• Lower the bucket almost to the ground level right before the mound.
(The bucket should be as low as its teeth lightly touch the ground.
Adjust the bucket height while running.)
• Right after the bucket teeth have dug in the mound, press the
kickdown switch to FI to slow down.
The equipment to be positioned perpendicular to
the mound
+ Run straight forward.
+ Hold the bucket slightly off the ground.
+ Four-wheel driving (do not allow the tires to slip)

Media # KLMS Course #
Run the equipment and dig
the bucket in the mound,
keeping the equipment in
these conditions.
Page 38
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (2/12)
One Point Lesson
 Do not dig the bucket in the mound, keeping the bucket bottom hard pressed
against the ground.
• This practice of work tends to reduce the bucket digging force while
accelerating wear on the bucket.
• Load on the front wheels will lessen, which tends to lift them off the ground.
 Do not dig the bucket in the mound while the equipment is in an articulated
posture.
• Digging force is reduced.
 Do not dig the bucket in the mound the way digging load is applied only to one
side of the bucket.
• Traction force (pressing force) will lessen, taking a longer time for excavation.
• The work equipment and arm will likely be twisted, shortening the equipment
life as a result.
Media # KLMS Course #
Page 39
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (3/12)
2. Thrusting Direction
• Aim an obtrusion (soft spot) in the mound with the bucket center, and
run the equipment straight forward.
• An obtrusion is invariably a thrusting point, and do not try to dig the
same spot again and again.
• Aim the nearest obtrusion in a place easy to swing and load on a dump
truck.
Media # KLMS Course #
Page 40
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (4/12)
One Point Lesson
• If you continue to dig a hollowed spot or the same spot again and again, both
side of the bucket are rubbed against earth, which produces more and more
resistance to the bucket. As a result, earth scooping becomes less and less
efficient.
• If you continue to dig the same spot, the wheels are rubbed against earth and
rocks spilt from the bucket or climb over them. In either case there is a
possibility that tires are damaged.
Media # KLMS Course #
Page 41
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (5/12)
3. Digging (Scooping)
• Dig the bucket in earth at the 1st forward gear speed, raise the bucket
gradually by 10 to 20cm and thrust the bucket further in.
• Dig the bucket up to the bottom so that it will fully scoop earth.
• While still going forward, pull back the bucket gradually by tilting it
back 2 to 3 times.
• Do not allow the equipment wheels to slip.
Run the equipment perpendicular to the mound.
+ Run the equipment straight forward.
+ Hold the bucket slightly above the ground surface.
+ Drive four wheels (that the tires do not slip).
Media # KLMS Course #

Higher pressing force
and better bucket
scooping
Page 42
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (6/12)
One Point Lesson
• The equipment can exert the biggest traction force right before its wheels begin
to slip.
• When the wheels threatens to slip, release the accelerator pedal slightly, depress
the pedal gradually again to increase the engine speed, and then dig the bucket
into earth to scoop.
• If the wheels begin to slip, release the accelerator pedal once, depress the pedal
gradually again and dig the bucket in to scoop.
Media # KLMS Course #
Page 43
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (7/12)
4. Timing for pressing kickdown switch
(1) In case of earth:
• Press the switch right after the bucket is dug into earth.
• Retard this timing when earth is soft. (Dig the bucket at the 2nd gear speed
and press the switch when the equipment begins to slow down.)
(2) In case of soft rock and hard rock:
• Press the switch to slow down sufficiently right before the bucket teeth hit a
rock, and then dig the bucket at the 1st forward gear speed. (Do not try to
dig the bucket the way it causes a shock.)
One Point Lesson
• If you try to push the switch after the equipment comes to a halt, the switch does
not respond.
• If you try to continue digging at the 2nd forward gear speed, the equipment stops
and as a result, the torque converter may overheat.
Media # KLMS Course #
Page 44
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (8/12)
5. Timing for raising (pulling back) the boom
• Slightly raise the boom gradually while digging the bucket at the 1st
forward gear.
• When the digging speed is too fast, the bucket cannot scoop enough
earth.
• When the digging speed is too slow, the wheels are likely to slip.
One Point Lesson
• When the boom lever is raised, more load is applied to the front wheels, which
prevents them from slipping and allows the equipment to still go forward.
• If the boom is raised after the bucket is overloaded, the rear wheels may lift off
the ground.
Media # KLMS Course #
Page 45
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (9/12)
6. Timing for Boom Raise + Bucket Tilt
 In case of heavy sand and earth (the same procedure as "Pumping
Action")
• Press the kickdown switch to reduce the travel speed to the 1st
forward gear right after digging the bucket at the 2nd forward gear.
 Lock the boom lever at the RAISE position.

• Alternate between Bucket Tilt and Dump operations several times (3
to 4 times) quickly while digging the bucket at the 1st forward gear
in order to force the bucket deep in earth.

• When the bucket is completely filled with earth (the earth rises
above the bucket spill guard), tilt back the bucket to its stroke end.
Media # KLMS Course #
Page 46
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (10/12)
One Point Lesson
• When tilting the bucket back and forth, do so quickly to keep a small tilting angle.
• When this action is slow and as a result, the bucket tilting angle is large, the
front wheels are likely to lift off the ground and slip.
• There is an alternative operation method that instead of locking the boom lever
at the RAISE position, the operation of tilting the bucket back and forth, as earth
is scooped, and the operation of boom raise are repeated separately.
Media # KLMS Course #
Page 47
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (11/12)
7. Excavation of the natural ground
(1) Digging order
• Start digging with a lower part of the ground.
• When a cutting face is formed, dig the ground beginning with its upper part.
One Point Lesson
• When a cutting face is formed, do not dig only the base of the ground. Otherwise
there is the danger that the ground will collapse because of a hollow created at
the bottom.
Media # KLMS Course #
Page 48
5. BASIC OPERATION OF WHEEL LOADER
5-1.
Digging Work (12/12)
7. Excavation of the natural ground
(2) How to use work equipment control lever
• When digging a portion of the ground that is lower than the level boom (at
the max. reach), take a larger "Pumping Action", i.e. increasing the
frequency and amount of tilting the bucket back and forth.
• To dig the bucket, tilt the bucket forth slowly and raise the boom slightly.
• When digging a higher portion of the ground, take a smaller "Pumping
Action", and increase the frequency and amount of boom RAISE operation.
One Point Lesson
• If you attempt to forcibly repeat the bucket TILT and DUMP operations by
increasing the engine speed, the wheels will likely start to slip.
• If the wheels threaten to slip, either lower the engine speed, or control the
equipment movement, using the cutoff brakes.
Media # KLMS Course #
Page 49
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (1/8)
1. Outline of equipment operation
(1) While running forward, steer the equipment smoothly so that the bucket will face a dump
truck at a right angle.
(2) When the equipment reaches a predetermined loading spot, step on the left brake pedal
to bring the equipment to a gentle halt.
(3) Raise the bucket high enough to load, still running forward, and dump earth in the middle
of the dump truck's vessel.
(4) Carry out the whole steps smoothly. Avoid abrupt operation of the equipment like sudden
braking, steering and work equipment operation. Otherwise there is the danger that the
equipment tips over.
(5) Do not operate the equipment with the engine running at a high speed all the while. A
jerky movement ( of gearshift, work equipment and steering ) and a shock can result
more easily, endangering the equipment operation.
(6) It is recommended to increase and decrease the engine speed at a regular interval during
in operation, because such a practice helps the equipment work smoothly and alleviates
a shock to the equipment. All these contribute to safe operation and longer life of the
equipment.

Media # KLMS Course #
Page 50
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (2/8)
2. Approach to dump truck
(1) Reduce the running speed to the F2 gear  Pull back the lift arm lever fully
(ready for kickout)  Depress the accelerator pedal to increase the speed 
Put a foot on the left brake pedal lightly in preparation for braking
(2) Steer the equipment smoothly to face the dump truck at a right angle and run
up to the truck.
(3) Get close to the dump truck, raising the bucket at same time  Lower the
engine speed slightly right before the loading point and then release kickout
(4) As the equipment gets nearer the dump truck, bring it to a gentle halt.
(Control the approach speed with an amount of the brake pedal as it is
depressed.)
(5) If it is anticipated that the bucket will not reach the necessary dumping height
in time while in approach to the truck, decelerate the equipment speed
smoothly by stepping on the left brake pedal timely so that the bucket rising
speed will increase.
Media # KLMS Course #
Page 51
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (3/8)
2. Approach to dump truck
Steering Wheel
: Steer the equipment to face the dump truck at a right angle.
Gearshift
: F1 or F2
Accelerator Pedal : F acceleration  Fully depress the accelerator pedal to
increase the speed.
Boom Lever
: Kickout action  Release at the dumping height.
Left Brake Pedal : Slow down the equipment, allowing the bucket to fully rise.
(Match the equipment approach speed with the bucket rising
speed.)
Media # KLMS Course #
Page 52
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (4/8)
One Point Lesson
What is the dumping height?
It is a height of the bucket at which it can easily dump earth on a waiting dump
truck when loading equipment gets closer to the truck. The height is regarded as
adequate if the tip of bucket teeth do not touch the bottom of the dump truck's
vessel when the vessel is still empty and the surface of earth when the vessel is
loaded with some earth.
Media # KLMS Course #
Page 53
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (5/8)
One Point Lesson
-Function of Transmission Cutoff SwitchWhen the switch is:
ON : The brakes are actuated and the transmission is brought to the neutral
position, when the left brake pedal is stepped on.
OFF : The left brake pedal works the same way as the right brake pedal does,
when it is stepped on. (This function is used when the equipment is running on
an upslope and downslope.)
Left Brake Pedal
Area A
Point at which
the detection
switch begins
to work
Condition of T/M
Cutoff Switch
Position of
Brake Pedal
Condition of Equipment
Switch ON
(Where the brakes
are equipped with a
clutch.)
In Area A
(at the beginning
of depressing)
(1) T/M is connected.
(2) The brakes are lightly applied.
In Area B
(1) T/M is in the neutral position (not
connected).
(2) The brakes are applied. They are in the
same condition as a clutch and brake of a
direct clutch type car as they are depressed.
Switch OFF
(Serves as an
ordinary brake and
works the same
way as the right
brake pedal does.)
In Area A
(at the beginning
of depressing)
(1) T/M is connected.
(2) The brakes are lightly applied.
In Area B
(1) T/M is connected.
(2) The brakes are applied.
Area B
Media # KLMS Course #
Page 54
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (6/8)
One Point Lesson
• Do not make an abrupt turn or stop while in
approach to a waiting dump truck. By the same
token, do not lower or swing the bucket abruptly
even when the equipment is standing. All these
abrupt actions can cause the equipment to tip over
due to resultant reaction force.
Ensure smooth seamless operation in steering and
braking in order to avoid a shock to the equipment.
One Point Lesson
• Dry sand, earth and rocks are likely to spill from the
front side or the right and left sides of the bucket due
to a running vibration and shock to the work
equipment while they are dumped. When loading
with the bucket raised high, try to dump them in the
inner part of the vessel, avoiding damage to the truck,
and also provide some space between piles.
Media # KLMS Course #
Page 55
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (7/8)
3. Loading on dump truck
(1) In the first dumping, aim at center or inner space of the truck's vessel, and dump gently,
holding the bucket at a lower height.
(2) Dump slowly at the beginning, quicken the dumping speed in the middle and finish
slowly again so that little shock is given to the dump truck.
(3) While in dumping, take care so that the tip of the bucket teeth do not strike the bottom of
the vessel or loaded earth. (A complex operation of DUMP + BOOM RAISE is required.)
(4) In the second dumping and thereafter, make sure that falling sand and earth will land on
top of the loaded sand and earth without fail. (An almost simultaneous operation of
dumping + boom raising + traveling forward + applying the left brake is required.)
(5) When traveling the equipment forward, be careful of the distance between the
approaching equipment and standing dump truck so that the front wheels will not bump
the side of the dump truck, using the brakes adequately.
Media # KLMS Course #
Page 56
5. BASIC OPERATION OF WHEEL LOADER
5-2.
Loading Work (8/8)
Steering
Gear Speed
Accelerator Pedal
Lift Arm Lever
Bucket Lever
Left Brake Pedal
:
:
:
:
Fix the equipment heading at a right angle to the dump truck.
F2 or F1, or N
Depress the pedal by 50% to 80% of its stroke.
Pull back the lever (raise the bucket) slowly so that the tip of
the bucket teeth does not strike the loaded sand and earth.
: Operate the lever to dump in the order of slowly, quickly and
slowly again.
: Bring the equipment to a gentle halt. Do not release the pedal
in the middle.
Media # KLMS Course #
Page 57
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (1/9)
1. Summary of Work
(1) This is a loading method that a dump truck driver is instructed or
guided to park his/her dump truck at an angle of approx. 60 to a
travel path of loading equipment and the equipment travels between
an earth pile and the dump truck, drawing a track of a "V" shape.
(2) V- shape loading consists of the following six steps (one cycle).
Travel forward  Digging
 Travel backward + Turn
 Travel forward + Turn (dumping approach)
Dumping  Travel backward + Turn
Travel Distance
L = Vehicle Length
Media # KLMS Course #
Page 58
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (2/9)
2. Summary of Equipment Operation
(1) It is recommended to increase or decrease the engine speed during the work depending
on jobsite conditions or in a shift from one step to another as explained below. This
practice smoothes the equipment operation away, alleviating a shock at a gearshift or a
shock caused by the work equipment. As a result, the equipment life can be prolonged.
(2) Do not operate the equipment with the engine running at a high speed all the time. Such a
practice can cause an abrupt movement or shock (at the time of steering, gearshift and
operating the work equipment). Moreover, the tires will likely slip. Thus the equipment
operation is exposed to danger.
(3) Abrupt operation of the equipment such as abrupt braking, steering and stopping the
work equipment can cause the equipment to tip over. Try the best to smooth out the
equipment operation.
Abrupt braking can cause the tires to slip.
Media # KLMS Course #
Page 59
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (3/9)
3. Approach to Dump Truck
(1) Steps after digging:
Gearshift to R2  Acceleration by depressing the accelerator pedal + Turn  Slow down
by releasing the accelerator pedal (the equipment may also be stopped)  Gearshift from
R2 to F2 (if the equipment cannot slow down timely, use the brakes)
(2) After gearshift to F2:
Pull back the lift arm lever fully (the same as the kickout condition)  Turn + Acceleration
by depressing the accelerator pedal  Put a foot on the left brake lightly in preparations
for braking
(3) Steer the equipment smoothly so that it will face the dump truck at a right angle.
(4) Run up to the dump truck, raising the bucket at the same time.  Lower the engine speed
slightly right before the bucket reaches a dumping height, and then release the kickout
function.
(5) If it is anticipated that the bucket will fail to reach the necessary dumping height in time,
apply the left brake to reduce the equipment travel speed so that the bucket can increase
its rising speed.
(6) Bring the equipment to a gentle halt as it gets close to the dump truck. (Adjust the
amount of brake pedal depressing as adequate depending on the equipment travel
speed.)
60
Media # KLMS Course #
Page 60
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (4/9)
60
Steering
: Steer the equipment smoothly to face the dump truck at a right angle.
Gearshift Speed : F2 or F1
Accelerator Pedal : R (acceleration)  Release the pedal for slow down  Gearshift to F  F
(acceleration)
Boom Lever
: Move the lever to the kickout position  Release the kickout function at
the dumping height
Left Brake Pedal : Reduce the equipment travel speed to allow the bucket to rise quickly and
high enough.
(Match both speeds of the equipment travel and bucket rising.)
Distance of Travel Back and Forth
: 1.0 to 1.5 L (L = Vehicle Length)
Angle (between digging and dumping spots) : Approx. 60
Media # KLMS Course #
Page 61
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (5/9)
One Point Lesson
• When the angle of dumping on the dump truck (V- shape angle) is thought to be
wider than approx. 60, begin to steer the equipment rather late to restore a V
shape while traveling backward. In the opposite case (i.e. the dump truck and the
equipment are nearly in parallel to each other), begin to steer the equipment
rather early.
One Point Lesson
• Do not try to load when the equipment is in an articulated posture, as such a
practice can shorten the equipment life (tires, undercarriage, frame, etc.).
Moreover, there is the danger that the equipment tips over in such an unstable
posture. In the loading work, keep the equipment straight and hold it at a right
angle to the dump truck.
Media # KLMS Course #
Page 62
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (6/9)
5. Loading on dump truck
• In the first dumping, aim at center or inner space of the truck's vessel, and
dump gently, holding the bucket at a lower height.
• Dump slowly at the beginning, quicken the dumping speed in the middle and
finish slowly again so that little shock is given to the dump truck.
• While in dumping, take care so that the tip of the bucket teeth do not strike the
bottom of the vessel or loaded earth. (A complex operation of DUMP + BOOM
RAISE is required.)
• In the second dumping and thereafter, make sure that falling sand and earth will
land on top of the loaded sand and earth without fail. (A four complex operation
of dumping + boom raising + traveling forward + applying the left brake is
required.)
• When traveling the equipment forward, be careful of the distance between the
approaching equipment and standing dump truck so that the front wheels will
not bump the side of the dump truck, using the brakes adequately.
Media # KLMS Course #
Page 63
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (7/9)
Steering
Gear Speed
Accelerator Pedal
Lift Arm Lever
Bucket Lever
Left Brake Pedal
:
:
:
:
Fix the equipment heading at a right angle to the dump truck.
F2 or F1, or N
Depress the pedal by 50% to 80% of its stroke.
Pull back the lever (raise the bucket) slowly so that the tip of
the bucket teeth does not strike the loaded sand and earth.
: Operate the lever to dump in the order of slowly, quickly and
slowly again.
: Bring the equipment to a gentle halt. While the equipment is
standing, keep the pedal fully depressed to ensure that it does
not start up.
Media # KLMS Course #
Page 64
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (8/9)
5. Travel backward after dumping
(1) Gearshift to R2  Depress the accelerator pedal + Lower the lift arm,
simultaneously turning the steering wheel  Travel backward until the bucket
comes to squarely face the digging spot.  Release the accelerator pedal to
slow down.
(2) When the bucket comes to squarely face the digging spot, shift the gear
speed from R2 to F2, depress the accelerator pedal to travel forward, and
straighten out the equipment by turning the steering wheel.
Media # KLMS Course #
Page 65
5. BASIC OPERATION OF WHEEL LOADER
5-3.
V-Shape Loading (9/9)
Steering
: While in traveling backward, steer the equipment smoothly
until the bucket comes to squarely face the digging spot.
Gearshift Speed : From R2 to F2
Accelerator Pedal : R2 acceleration  Slow down  R
 Gearshift to F  Acceleration at F2
Lift Arm Lever
: R2 + BOOM LOWER (smoothly)
Bucket Lever
: Pull the lever as far back as the bucket positioner begins to
work (to the level position).
Left Brake Pedal : Slow down smoothly from R to acceleration at F2.
Media # KLMS Course #
Page 66
5. BASIC OPERATION OF WHEEL LOADER
5-4.
Cross Loading (1/4)
1. Summary of Work
• This is a loading method that while loading equipment travels back and
forth in the vertical direction between digging and loading spots, a
dump truck moves back and forth in the horizontal direction to come in
front of the equipment for each loading, thus forming a cross shape.
(In this loading method, the dump truck comes to a loading spot
backward.)
• This method promises a shorter cycle time per loading to the loading
equipment, as it does not have to make a turn. Moreover, it ensures
less wear on the tires and less spill of sand and earth. Thus it is
deemed the most effective loading method.
• It works well where the loading frequency is rather limited and where
the ground is flat and hard enough to facilitate the travel of a dump
truck.
Media # KLMS Course #
Page 67
5. BASIC OPERATION OF WHEEL LOADER
5-4.
Cross Loading (2/4)
2. Procedures for Equipment Operation
(1) Steps after digging:
Gearshift to R2  Acceleration by depressing the accelerator pedal  Slow down by
releasing the accelerator pedal (if the equipment cannot slow down timely, use the brakes,
or the equipment may also be stopped).
(2) Back up the loading equipment and stay well clear of the dump truck, when it comes up
for loading, so that the bucket does not contact the dump truck. (Only when the loading
equipment reaches this point, the dump truck should begin to back up.)
(3) After gearshift to F2:
Pull back the lift arm lever fully (the same as the kickout condition)  Accelerate the
bucket rising speed by depressing the accelerator pedal
(4) When the dump truck reaches the loading spot, sound a horn to signal the truck driver to
stop.
(5) Run up to the dump truck, raising the bucket at the same time.  Lower the engine speed
slightly right before the bucket reaches a dumping height, and then release the kickout
function.
(6) If it is anticipated that the bucket will fail to reach the necessary dumping height in time,
apply the left brake to reduce the equipment travel speed so that the bucket can increase
its rising speed.
(7) Steer the equipment to squarely face the dump truck.
(8) Bring the equipment to a gentle halt as it gets close to the dump truck. (Adjust the
amount of brake pedal depressing as adequate depending on the equipment travel
speed.)
(9) For the subsequent steps, see the loading section.
Media # KLMS Course #
Page 68
5. BASIC OPERATION OF WHEEL LOADER
5-4.
Cross Loading (3/4)
Steering
: Steer the equipment smoothly to face the dump truck at a right angle.
Gearshift Speed : F2 or F1
Accelerator Pedal : Shift to R (acceleration) after digging  Release the pedal for slow down
 Gearshift to F  F (acceleration)  Release the pedal slightly (for
loading)  Shift to R  Accelerate at R Release the pedal slightly
Boom Lever
: Move the lever to the kickout position  Release the kickout function at
the dumping height
Left Brake Pedal : Reduce the equipment travel speed to allow the bucket to rise quickly and
high enough. (Match both speeds of the equipment travel and bucket
rising.)
Distance of Travel Back and Forth : A distance that ensures a point well clear of the dump
truck where the tip of the bucket teeth does not contact any part of the
dump truck when it comes up to the loading point.
Angle (between digging and dumping spots) : Straight
Media # KLMS Course #
Page 69
5. BASIC OPERATION OF WHEEL LOADER
5-4.
Cross Loading (4/4)
One Point Lesson
• When guiding a dump truck driver to drive up to a spot in front of the loading
equipment, make sure that the dump truck does not come direct under the
bucket. (If the truck positions itself under the bucket, loading work becomes
difficult.)
• Bring the dump truck as close to the cutting face as possible, and start dumping
while the equipment is still going forward.
Media # KLMS Course #
Page 70
5. BASIC OPERATION OF WHEEL LOADER
5-5.
Load and Carry (1/4)
Summary of Work
This is a kind of earth transportation method using only a wheel loader that
handles scooping, transport and dumping in a seamless way. It is best suited to
transport of a short distance that does not require a dump truck.
The application range is determined by a wheel loader in use, but generally
speaking it is good for the transport of earth for a distance of 30 to 100 meters.
Media # KLMS Course #
Page 71
5. BASIC OPERATION OF WHEEL LOADER
5-5.
Load and Carry (2/4)
Summary of Equipment Operation
While in transport, operate the equipment in the shock-minimum way. In addition,
for the fuel economy, use a higher gear speed and lower engine rpm, and make the
most of travel speed.
While in transport, pay attention to the following points.
(1) Abrupt operation of the equipment is likely to invite a shock, which in turn can
reduce the equipment life and also cause the equipment to tip over. The abrupt
operation of the equipment here means:
• Shift-down or forward-reverse directional change in high speed running +
high engine rpm
• Steering in a high speed
• Jamming on the brakes (Never do this while running in a high speed.)
• Jerky operation of the work equipment
(2) Acceleration / deceleration that takes into account ground conditions, gear
speed and load in the bucket
• Release the acceleration pedal before riding on the irregular ground, and run
through it at a lower speed to alleviate a shock to the equipment.
• On the other hand, use as high a gear speed and engine rpm as possible
where the ground surface is good and load in the bucket is stable and secure.
Media # KLMS Course #
Page 72
5. BASIC OPERATION OF WHEEL LOADER
5-5.
Load and Carry (3/4)
(1) Scooping Work
• After scooping and before starting with transport, shake the bucket several times to throw
off loose sand and earth to secure them in the bucket. Then the load in the bucket remains
steady and does not spill off during the transportation.
• Spill from the bucket during the transportation varies depending on soil conditions,
scooped amount, transportation speed, ground surface conditions, etc. Generally a struck
amount is the standard for loading.
(2) Travel Posture
• While in travel, hold the bucket as low as it does
not block the front visibility. If it is held too low, the
equipment will likely bounce due to a running
vibration and let the bucket bottom interfere with
the ground. For this reason, se the bucket height
at 50 to 80cm above the ground, measure at the
bucket hinge pin.
Media # KLMS Course #
Page 73
5. BASIC OPERATION OF WHEEL LOADER
5-5.
Load and Carry (4/4)
(3) Transportation Work
• Gear speeds in each of scooping, transport and dumping work vary depending
on various factors like ground conditions. Meanwhile, make a turn near the
scooping and dumping spots.
Steering
: Steer the equipment the way it does not cause a shock. (Abrupt operation can cause a
shock to the equipment.)
Gear Speed
: Make a directional change only after lowering the engine speed to slow down. And
select an optimum gear speed taking the ground condition into account.
Accelerator Pedal : To minimize vibrations of the equipment, control the travel speed (with an amount of
accelerator pedal depressing), taking into account ground conditions, gear speed and
bucket loading conditions. (Startup: F2 at the full throttle, good ground surface
condition: at the full speed, irregular ground surface condition: slow down)
Work Equipment Lever : Do not operate the lever abruptly. Operate it the way no shock is caused.
Left Brake Pedal
: Do not jam on the brakes, but slow down gradually to prevent a shock to the equipment.
Media # KLMS Course #
Page 74
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-1. Prohibited Operations
6-2. Prohibited Work
Media # KLMS Course #
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-1.
Prohibited Operations (1/4)
(1) Don’t make shift down with high speed running or high engine speed
(2) Don’t make direction change (F <-> R) with high speed running or high
engine speed
(3) Don’t make sudden stop when driving with high speed (except
emergency)
(4) Don’t make sudden steering operation with high speed running
(5) Don’t make sudden operation of work equipment with high speed
running
(6) Don’t slump down the bucket
(7) Don’t make sudden motion of bucket
(8) Don’t steer the machine without traveling
Media # KLMS Course #
Page 76
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-1.
Prohibited Operations (2/4)
(1) Don’t make shift down with high speed running or high
engine speed
Shift changes with high speed driving or high engine speed
makes drive train (*) suffer large shock and load. It causes
shorten the machine life.
(*) Engine, Torque converter, Transmission, Axle, Final
gears) ++ Release the acceleration pedal and make brake
before the shift change. (reduce engine speed and machine
traveling speed)
(2) Don’t make direction change (F <-> R) with high speed
running or high engine speed
Direction changes with high speed driving or high engine
speed makes torque converter and transmission suffer large
shock and load. It causes shorten the machine life.
++ Release the acceleration pedal and make brake before
the direction change.
(3) Don’t make sudden stop when driving with high speed
(except emergency)
Sudden stop makes drive train and brake system suffer a
large load and shock. It causes shorten the machine life.
Furthermore there is a risk to tumble the machine with
sudden brake while loading to the dump truck
++ Stop smoothly after decreasing the speed with braking
Media # KLMS Course #
Page 77
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-1.
Prohibited Operations (3/4)
(4) Don’t make sudden steering operation with high speed
running
There is a risk of tumbling with losing balance. Sudden
steer is especially dangerous with carrying load or
approaching for dumping operation
++ Turn the steering wheel smoothly without shock
(5) Don’t make sudden operation of work equipment with
high speed running
Moving work equipment suddenly while high speed driving
may cause the risk of tumbling. (You may encounter the
shock and losing balance)
It is especially dangerous with carrying load or approaching
for dumping operation.
++ Avoid unnecessary motion of work equipment. And
make smooth operation when move the work equipment
avoiding shock.
(6) Don’t slump down the bucket
If you slump down the bucket while dashing against the
face, bucket, work equipment pins, machine body suffers
too much load. It causes damages and clacks and then
shorten the machine life.
++ Decrease descent speed and use minute lever operation
near the ground.
Media # KLMS Course #
Page 78
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-1.
Prohibited Operations (4/4)
(7) Don’t make sudden motion of bucket
Sudden bucket motion while engine is running in high
speed causes shock over the whole machine body. And
the shock makes work equipment, frame, pins, and etc.
suffer a large load, and then shorten the machine life.
You may have shorter machine life if you hit the stopper
of bucket.
++ Move the bucket with decelerating the engine speed
a little. Avoid unnecessary bucket motion
(8) Don’t steer the machine without traveling
Making steer with machine stopped causes cutting tires
or wear of tires. Furthermore large load applied on the
frame and underbody shorten the machine life.
++ Steering should be made smoothly while traveling.
Don’t make steer when machine stops.
Media # KLMS Course #
Page 79
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-2.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Prohibited Work (1/5)
Don’t run in with the machine articulated
Don’t excavate with the machine articulated
Don’t run in with a load on one side of the bucket
Don’t excavate with a load on one side of the bucket
Don’t excavate with F2 machine speed
Don’t run in with high speed against waste or blasted rocks
Don’t work with putting front tires on waste or face
Don’t dump the bucket more than 8deg when excavating ground
Don’t excavate the foot of face
Don’t excavate the cliff
Don’t excavate unstable rock
Don’t move the bucket above the cab of dump truck
Media # KLMS Course #
Page 80
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-2.
Prohibited Work (2/5)
(1) Don’t run in with the machine articulated
Running in with the machine articulated causes twisted force
on the center pin etc. and then shorten the machine life.
++ Run in with the machine body straight and aiming at the
concaved portion of mound with center of bucket.,

(2) Don’t excavate with the machine articulated
Excavating with the machine articulated causes unstable
situation and risk of tumbling. Furthermore, since uneven
load are applied on the front tire, tire life will be shorter. Also
durability of center pin become worse.
++ Excavate with the machine perpendicular to the mound
(3) Don’t run in with a load on one side of the bucket
Running in with a load on one side of the bucket causes
twisted force on work equipment, frame and etc. and then
shorten the machine life.
++ Run in with the machine body straight and aiming at the
convex portion of mound with center of bucket
Media # KLMS Course #
Page 81
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-2.
Prohibited Work (3/5)
(4) Don’t excavate with a load on one side of the bucket
Causes twisted force on work equipment, frame and etc.
and then shorten the machine life.
++ Run in with the machine body straight and aiming at the
convex portion of mound with center of bucket
(5) Don’t excavate with F2 machine speed
Since the pushing force of F2 is not enough, takes longer
digging time and longer stalling (*) time of torque converter.
Continuous situation of this causes overheat and then
shorten the life of torque converter.
* : The situation that the machine stops and engine is keep
on running.
++ Excavating must be done with F1 speed.
(6) Don’t run in with high speed against waste or blasted
rocks
Running in with high speed causes shocks on the whole
machine, and then shorten the life of work equipment,
frame, drive train, under body, and etc. Large shock may
break up the machine instantly.
++ Decelerate the machine before the contact of rocks and
dig in slowly with F1 speed.
Media # KLMS Course #
Page 82
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-2.
Prohibited Work (4/5)
(7) Don’t work with putting front tires on waste or face
Causes tire cut. Furthermore it is unstable while excavating
and there may be a risk of tumbling.
(8) Don’t dump the bucket more than 8deg when
excavating ground
It may suffer large damage on work equipment by traction
force.
++ Excavating must be done with less than 8deg of bucket
dump angle. In the beginning, excavate with low engine
speed and raise the engine speed gradually.
(9) Don’t excavate the foot of face
Encounters the excess load and there may be a risk of
breaking work equipment or frame.
++ When you do this work by necessity, keep the bucket
dump angle less than 8deg, and excavate with low engine
speed in the beginning then raise the engine speed
gradually.
Media # KLMS Course #
Page 83
6. PROHIBITION AND PRECAUTION DURING
OPERATION OF WHEEL LOADER
6-2.
Prohibited Work (5/5)
(10)
Don’t excavate the cliff
Encounters the excess load and there may be a risk of
breaking work equipment or frame.
Especially, avoid the excavating the place higher than
running position of bucket.
(11)
Don’t excavate unstable rock
Fallen rocks may hit the cab. It has even risk of killing
operator. Catching the fallen rocks by the bucket may cause
the large damage on the cylinder of work equipment.
(12)
Don’t move the bucket above the cab of dump truck
Fallen rocks may hit the cab. It has even risk of killing
operator.
Media # KLMS Course #
Page 84
7. BASIC OPERATION OF DUMP
TRUCK
7-1. Travel
7-1-1. Precautions and instructions for travel
7-1-2. Travel on uphill
7-1-3. Travel on downhill with load
(Prohibitions in braking action)
7-2. Dozing Work
7-2-1.
Dumping
Media # KLMS Course #
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-1.
Precautions and instructions for travel
PRECAUTION AT STARTUP TIME
The dumping lever has to be in the "PLAY"
condition, and the vessel pilot lamp has to
be off.
AK626770
• If you try to start up the dump truck when
the dumping lever is in any other position
than PLAY, or when the vessel is raised,
a centralized warning lamp begins to
flash and an alarm buzzer sounds.
9JR01438
Media # KLMS Course #
Page 86
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-1.
Precautions and instructions for travel (continued)
Position D
• Used when running on a flat ground
with a loaded vessel, or when running
on a not necessarily flat ground with
an empty vessel
Position L to 6
Used at or on:
• A jobsite where running at a high speed is difficult
• Soft ground
• The pretty irregular ground (with a loaded vessel)
• Startup on an uphill
• A downhill which requires engine braking
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Page 87
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-1.
Precautions and instructions for travel (continued)
POSITION OF GEARSHIFT LEVER AND SPEED
(in case of HD465-7)
Position
6
5
4
3
2
L
Gearshift Range
1st T/C – 6th D/D
1st T/C – 5th D/D
1st T/C – 4th D/D
1st T/C – 3rd D/D
1st T/C – 2nd D/D
1st T/C – 1st D/D
Max. Speed
52.5 km / h
39.0 km / h
29.5 km / h
21.5 km / h
16.0 km / h
11.5 km / h
(Note)
T/C stands for a torque converter type and D/D for a direct drive type.
Media # KLMS Course #
Page 88
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-2.
Travel on uphill
AVOID OVERHEATING.
RUN AT POSITION 6.
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Page 89
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-3.
Travel on downhill with load
When running down on a long stretch of downhill, slow
down to a set max. downhill speed before the downhill
begins.
Slow down
Speed
Actual
running speed
Set max. downhill speed
0
Media # KLMS Course #
Page 90
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-3.
Travel on downhill with load
Having started to run down on a long stretch of downhill,
keep running at a constant speed.
Slow down
Speed
Actual
running speed
Set max. downhill speed
0
Media # KLMS Course #
Page 91
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PRECAUTIONS
In climbing down a long haul of slope, keep a close
watch on the retarder brake oil temperature gauge,
engine rpm and the gear speed all the time.
A display in the retarder brake oil
temperature gauge should be in the range
of green.
(C)
130
120
110
90
70
50
The engine rpm should be kept
somewhere between 1800 rpm and 200
rpm.
The gear speed should be monitored on
the instrument panel.
Media # KLMS Course #
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-3.
Travel on downhill with load (continued)
-When a slope gradient changes midway-
How to negotiate an increased gradient
Case A:
An inclination returns to the previous less steep gradient after a distance of less
than 30 meters.
 Slow down for the portion of a steeper inclination, using the retarder brake.
Slow down
for this
portion with
the retarder
brake lever.
Less than 30 m
Case B:
A steeper inclination stretches over 30 meters.
 Set a new downhill speed that is commensurate with that specific inclination.
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
7-1-3.
Travel on downhill with load (continued)
-When a slope gradient changes midway-
How to negotiate a decreased gradient
Case A:
An inclination returns to the previous steeper gradient after a distance of less than
30 meters.
 Release the retarder brake lever and adjust the travel speed with the accelerator
pedal for the portion of a less steep inclination.
}
Adjust the travel
speed with the
accelerator
pedal.
Less than 30 m
Case B:
A less steep inclination stretches over 30 meters.
 Set a new appropriate downhill speed that is commensurate with that specific
inclination.
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Page 94
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION
1. Never pump the retarder brake.
Media # KLMS Course #
Page 95
7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
2. Do not use the service brake (foot brake) too often.
Media # KLMS Course #
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
3. Do not operate the retarder brake lever abruptly.
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
4. Do not use the retarder brake as a parking brake.
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
5. Do not attempt to shift up unnecessarily by
acceleration.
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
6. Do not run down on a slope with the gearshift lever
left in the "N" position.
Gearshift lever not to be in
"N" (neutral) position in
downhill running
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7. BASIC OPERATION OF DUMP TRUCK
7-1. Travel
PROHIBITIONS IN BRAKING ACTION (continued)
-SUPPLEMENT-
<Reason for Prohibition Items 5 and 6>
• A lowered engine speed makes it difficult to thoroughly cool
down the retarder brake oil, which in turn causes the brake
to overheat.
Low rate of oil flow to oil cooler
Brake
Oil
Cooler
Oil Tank
Media # KLMS Course #
Page 101
7. BASIC OPERATION OF DUMP TRUCK
7-2. Dozing Work
7-2-1. Dumping
Move the gearshift lever to the "N" (neutral)
position and the parking brake to the
"PARK" position.
Move the dumping lever to the
"RAISE" position and then depress
the accelerator pedal.
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7. BASIC OPERATION OF DUMP TRUCK
7-2. Dozing Work
7-2-1. Dumping (continued)
When lifting the vessel of a dump truck, release the acceleration pedal at
about the max. tilting angle (otherwise called a dumping end).
When dumping work is finished, move
the dumping lever to the "LOWER"
position.
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Page 103
8. PRECAUTION DURING
OPERATION OF DUMP TRUCK
● A turn in a high speed poses danger.
● A turn on a steep slope poses danger.
● An attempt to further turn a steering wheel is
prohibited when it is at the extreme end.
● Lower the dumping speed when dumping a big
rock on a vessel.
● Do not load on a vessel when it is raised.
● Keep a vessel lowered to the bottom while in
running.
● Keep the dumping lever in "PLAY" position while
in running.
Media # KLMS Course #
9. BASIC OPERATION OF
BULLDOZER
9-1.
9-2.
9-3.
9-4.
9-5.
Basics of Dozing Work
Excavating & Dozing Work
Ripping Work
Ground Leveling Work
Ground Compacting Work
Media # KLMS Course #
9. BASIC OPERATION OF BULLDOZER
9-1.
Basics of Dozing Work (1/2)
Working Distance
Economical distance for dozing work in general
• Excavating and dozing work --- Less than 80 m
• Finishing work ---- Less than 100 m
Travel
• Do not raise the blade up to the max. height while in travel.
• Take extra care when traveling on a steep slope.
Dozing work on the soft ground
•
•
•
•
Avoid a track shoe slip as far as possible.
Do not make a meaningless sharp turn.
Do not travel on the previous ruts.
Stop the engine when parking the bulldozer.
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9. BASIC OPERATION OF BULLDOZER
9-1.
Basics of Dozing Work (2/2)
Travel Speed by Kind of Work
In general, the following travel speeds promise easy work and fine finishing.
Kind of Work
Excavating
Dozing
Leveling
Backing up
Speed Range
Optimum Gear Speed Range
T/C: F1 & F2
2 – 3km/h
D/D: F1
T/C: F2 or F3
3 – 6km/h
D/D: F3
T/C: F3
4 – 7km/h
D/D: F4
Select the highest gear speed as far as a comfortable
ride is assured.
(Note)
T/C stands for a torque converter type, and D/D a direct drive type.
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9. BASIC OPERATION OF BULLDOZER
9-2.
Excavating & Dozing Work (1/4)
For this kind of work, make use of a
downslope.
Relationship among Relative Three Factors
(Distance, Slope Gradient and Earthmoving
Amount)
Less than 1/5 gradient
Relationship among distance, slope gradient and earthmoving
amount
Dozing
Distance
1.0 (Flatland)
(Close
Range)
20m
40m
60m
Flatland
1.00
0.96
0.88
0.80
Downslope
1.28
1.23
1.13
1.02
Upslope
0.80
0.77
0.70
0.64
Gradient
Media # KLMS Course #
Assuming that a
working amount on a
flatland is 1.0, that on a
downslope of 1/10 gradient is approx.
1.3 times as large as the former.
Page 108
9. BASIC OPERATION OF BULLDOZER
9-2.
Excavating & Dozing Work (2/4)
Let the bulldozer build its own travel path
while in dozing.
Do not press the blade against the ground
forcibly.
Do not let the bulldozer's track shoes make
a slip.
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9. BASIC OPERATION OF BULLDOZER
9-2.
Excavating & Dozing Work (3/4)
Keep the machine horizontal sideways while
in operation.
Start excavation with a flatland and then
scrape off a ridge astride it.
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9. BASIC OPERATION OF BULLDOZER
9-2.
Excavating & Dozing Work (4/4)
Optimum Dozing Distance
If the dozing work stretches over a long
distance, stop the first dozing midways,
leaving earth there, and put them together
with the earth of the 2nd dozing and haul.
2nd Dozing
Large-sized Bulldozer
Medium-sized Bulldozer
Small-sized Bulldozer
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9. BASIC OPERATION OF BULLDOZER
9-3.
Ripping Work
- Basics-
Do not attempt to steer the bulldozer while
in ripping work.
Make sure that the track shoes are fully
engaged with the ground.
Keep the bulldozer horizontal sideways (in
the right and left direction).
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9. BASIC OPERATION OF BULLDOZER
9-3.
Ripping Work (continued)
-Working Steps-
Lower the shanks to the ground as they are
tilted back.
Shift the ripper control lever to the "LOWER"
position to raise the rear of the bulldozer.
Shift the ripper control lever slowly to the
"TILT" position to dig the ripper point into
the bedrock.
Travel the bulldozer straight forward for
ripping, keeping the fixed travel direction.
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9. BASIC OPERATION OF BULLDOZER
9-3.
Ripping Work (continued)
-Handling Rocks-
(1) Lower the engine speed to the extent
that the track shoes will not make a
slip.
(2) Tilt the shanks.
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9. BASIC OPERATION OF BULLDOZER
9-3.
Ripping Work (continued)
-Handling Rocks-
(3) When bedrock or a boulder cannot be (4) If it still cannot be broken or dug out,
broken or dug out, repeat the same
go around it and resume ripping work.
process all again.
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9. BASIC OPERATION OF BULLDOZER
9-4.
Ground Leveling Work (1/3)
Bulldozers are used for rough leveling
(grading).
For finishing 2 to 3- centimeter irregularity,
use a motor grader.
A blade full of earth can make leveling work
easier.
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9. BASIC OPERATION OF BULLDOZER
9-4.
Ground Leveling Work (2/3)
Lower the blade on the ground where
the bulldozer is horizontal to the
finished surface.
Lower the blade to
the ground where
the bulldozer
becomes horizontal.
To finish the surface, operate the blade
vertically by a margin of 2 to 5
centimeters.
Operate the blade
vertically by a
margin of 2 to 5
centimeters.
First cleanly finish a band of the ground
as wide as the bulldozer, and use this
bandt as a datum (guide) for the
subsequent finishing work.
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9. BASIC OPERATION OF BULLDOZER
9-4.
Ground Leveling Work (3/3)
It is recommended to first
finish a band of the ground
as wide as the bulldozer
cleanly and use this band
as a datum (guide) for the
subsequent finishing work.
Tilt the blade slightly in the last round of
finishing work.
Overlap the present blade track with the
immediately preceding one by as much
as 1/4 of the blade length.
Tilt the blade slightly and
deal with the windrow in
the last round of finishing
work.
The ruts that the track shoes have left
behind are to be smoothed out when
backing up the bulldozer to the original
starting point.
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9. BASIC OPERATION OF BULLDOZER
9-5.
Ground Compacting Work (1/2)
In general, a soil compacting method by a
bulldozer is used in a case where a lift
thickness is 20 to 30cm and the compaction
frequency is 3 to 5 times.
3 to 5
Times
Round
Trip
This portion can be compacted.
This portion cannot be compacted
Filling work always requires compaction
work. Every time piled earth reaches 20 to
30cm in thickness, the soils have to be
compacted 3 to 5 times.
Filled
Portion
Cut
Portion
Road
Centerline
When lift thickness reaches 20 to
30cm, compact the soils 3 to 5 times.
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9. BASIC OPERATION OF BULLDOZER
9-5.
Ground Compacting Work (2/2)
O: GOOD
It is good to compact piled earth in between
fillings, relying on a bulldozer for its weight
and vibration.
X: NO GOOD
Soil compaction cannot take place
afterwards.
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10. PRECAUTIONS FOR
BULLDOZER WORK
10-1.
10-2.
10-3.
10-4.
Precautions during Operation
Precautions for Work on Slope
Prohibition of Dangerous Work Practice
How to Use Brakes
Media # KLMS Course #
10. PRECAUTIONS FOR BULLDOZER WORK
10-1. Precautions during Operation
• When traveling on the flat ground, pull
back the work equipment and hold it 40 to
50cm above the ground.
• Do not attempt to climb over an obstacle.
If there is no way to avoid climbing over an
obstacle, do so holding the work equipment
near the ground surface and travel at a low
speed.
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10. PRECAUTIONS FOR BULLDOZER WORK
10-2. Precautions for Work on Slope
• Travel straight forward along a slope.
It is very dangerous to try to cross a slope
or cross at an angle.
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10. PRECAUTIONS FOR BULLDOZER WORK
10-3. Prohibition of Dangerous Work Practice
• When operating the equipment on a precipice or road shoulder, position the
equipment at a right angle to the precipice or road shoulder with the
sprocket facing in the opposite direction to the precipice or road shoulder.
10-4. How to Use Brakes
• Do not rest a foot on the brake if not necessary.
• Do not apply the brakes repeatedly more often than necessary.
• Be sure to use engine brake mainly and the foot brake as auxiliary means
on a downhill.
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11. FINISH INSPECTION
11-1.
11-2.
11-3.
Mud Removing (Equipment Washing)
Walk-around Check
Refueling
Media # KLMS Course #
11. FINISH INSPECTION
11-1. Mud Removing (Equipment Washing)
When mud has got stuck to the work equipment and undercarriage, remove it.
(Be careful of mud on the carrier rollers in particular, because it can cause
them to partially wear, if not removed.)
11-2. Walk-around Check
Walk around the equipment to check the following points.
• Oil leak and damage to hoses
• Damage and deformation of exterior parts
• Crack on work equipment, and wear and slip-off of teeth and cutting edges
• Crack on undercarriage parts and loosened nuts and bolts
 A walk-around check should be made in accordance with the walk-around check
items provided in the relative operation and maintenance manual for the model.
11-3. Refueling
Check the fuel level for the remaining amount. If short, refill the fuel tank fully.
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