Page 1 AE10800VD2-01 ＭＳＴ-800ＶＤ Serial No. 4001 and up Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel will come into contact with it.
Page 3: Table Of Contents
CONTENTS ITEM Page FOREWORD 0- 1 1. Foreword 0- 2 2. Introduction 0- 3 3. Safety information 0- 4 4. Location of serial number 0- 5 SAFETY 1- 1 1. General precautions 1- 2 2. Precautions during inspection and maintenance 1- 4 3.
Page 4 ITEM Page 3. Operation 2-26 3.1 Check before starting engine 2-26 3.2 Operations and checks before starting engine 2-31 3.3 Starting engine 2-32 3.4 Moving machine off 2-35 3.5 Shifting speed range, changing between FORWARD and REVERSE 2-36 3.6 Steering machine 2-38 3.7 Stopping machine 2-40...
Page 5 ITEM Page 10. Handling battery 2-55 10.1 Precautions when handling battery 2-55 10.2 Removal and installation of battery 2-56 10.3 Precautions when charging battery 2-56 10.4 Starting engine with booster cable 2-57 11. Troubleshooting 2-58 11.1 Problems with engine related parts 2-58 11.2 Problems with chassis related parts 2-59...
Page 7 FOREWORD 1. FOREWORD 0- 2 2. INTRODUCTION 0- 3 3. SAFETY INFORMATION 0- 4 4. LOCATION OF SERIAL NUMBER 0- 5...
Page 8: Foreword
• Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Morooka or your Morooka distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 9: Introduction
3. WARRANTY If any failure that is considered to be the responsibility of Morooka should occur within 6 months of delivery of the new machine or within 600 ho urs on the hourmeter, whichever comes sooner, repairs will be carried out free of charge in accordance with the warranty.
Page 10: Safety Information
Safety precautions are described in SAFETY from page 1-1. Morooka cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 11: Location Of Serial Number
4. LOCATION OF SERIAL NUMBER On this machine, there is plate with the machine serial number stamped on it stuck to the left side surface of the travel lever stand inside the operator’s compartment in the position in the diagram on the right.
Page 13: Safety
SAFETY 1. General precautions 1- 2 2. Precautions during inspection and maintenance 1- 4 3. Precautions before starting engine 1- 9 4. Precautions when starting engine 1-11 5. Precautions when traveling 1-12 6. Precautions during operation 1-15 7. Precautions for transportation 1-17 8.
Page 14: General Precautions
1. GENERAL PRECAUTIONS SAFETY RULES • Only trained and qualified personnel, or personnel authorized by the company (or superior) can operate and maintain the machine. • Follow all safety rules, prohibitions, precautions, procedures, and instructions when operating or performing maintenance on the machine, and pay careful attention to safety.
Page 15 • Any modification made without authorization from Morooka can adversely affect the performance of the machine, and may also create hazards. • Before making a modification, consult your Morooka distributor. Morooka will not be responsible for any injury or damage caused by any unauthorized modification.
Page 16: Precautions During Inspection And Maintenance
2. PRECAUTIONS DURING INSPECTION AND MAINTENANCE NO UNAUTHORIZED PERSONS Never allow unauthorized persons into the area when carrying out inspection and maintenance. When leaving the operator’s seat to carry out operations, hang a “DO NOT OPERATE ! ” sign (Part No.: 1-41010-1210) on the control lever to prevent any other person from operating the machine.
Page 17 VENTILATION FOR ENCLOSED AREAS Exhaust fumes from the engine can kill. • If it is necessary to start the engine within an enclosed area, open the doors and windows to provide adequate ventilation. KEEP AWAY FROM ROTATING AND MOVING PARTS •...
Page 18 DO NOT TOUCH HIGH-TEMPERATURE, HIGH-PRESSURE PARTS IMMEDIATELY AFTER STOPPING ENGINE Immediately after stopping the engine, many parts are at high temperature or under high pressure. If parts are removed or touched carelessly, there is danger of burns or other injury. For the following parts particularly, always wait for the machine to cool down before inspecting.
Page 19 • If any hose is loose or damaged, repair or replace it. • It is extremely dangerous if oil is leaking from even small holes in the hoses or hydraulic equipment. If such a problem occurs, please contact your Morooka distributor. BE CAREFUL OF HIGH-PRESSURE GREASE WHEN ADJUSTING RUBBER CRAWLER ATTENTION The rubber crawler tension adjuster is filled with grease.
Page 20 DO NOT SPRAY WATER ON ELECTRICAL COMPONENTS When washing the machine, do not spray water on the electrical components. If water gets into the electrical system, it will cause defective operations which may lead to malfunctions. Cover the following parts with a sheet to prevent water from getting on them.
Page 21: Precautions Before Starting Engine
• If any abnormalities are found during the check, carry out simple repairs. If the repairs are difficult, please contact your Morooka distributor. The machine must not be used before repairs are carried out. CHECK SAFETY PARTS AND LIGHTING...
Page 22 VENTILATION FOR ENCLOSED AREAS Exhaust fumes from the engine can kill. • If it is necessary to start the engine within an enclosed area, open the doors and windows to provide adequate ventilation. SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Page 23: Precautions When Starting Engine
4. PRECAUTIONS WHEN STARTING ENGINE PLACE LEVERS AT NEUTRAL Cab specifications Always place the levers at the following positions. • Place the travel lever at the N position. • Place the dump control lever at the HOLD position. • Set the parking brake switch to the STOP position. •...
Page 24: Precautions When Traveling
5. PRECAUTIONS WHEN TRAVELING CHECK FOR SAFETY IN SURROUNDING AREA Always check that there are no people in the surrounding area. Be particularly careful to check behind the machine. • If the dump body is raised, always lower it. • Sound the horn to warn people in the area that you are about to start the machine. AVOID SUDDEN OPERATIONS EXCEPT IN EMERGENCIES Do not suddenly start, suddenly stop, or suddenly turn the machine or carry out any other operation suddenly.
Page 25 AVOID OBSTACLES Avoid traveling over obstacles or earth embankments as far as possible. If the machine has to travel over an obstacle, do as follows. Never travel over large boulders, breakable objects, pieces of concrete, or other sharp objects. • Reduce the travel speed and travel carefully. •...
Page 26 OPERATE CAREFULLY ON SNOW • When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning. • When there has been heavy snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen, so always carry out operations carefully.
Page 27: Precautions For Operation
6. PRECAUTIONS FOR OPERATION USE SIGNALS When carrying out work with one or more workers, or when using a signalman, determine the signals and the person in charge before starting work, and always follow the agreed procedure. Even when using a signalman, always pay careful attention to the following.
Page 28 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE When carrying out operations on jobsites where there are power cables, use a signalman and take steps to protect the electric cables. Check with the electricity company before starting operations. • Going close to high-voltage cables can cause electric shock, even if the machine does not touch the cables.
Page 29: Precautions For Transportation
7. PRECAUTIONS FOR TRANSPORTATION USE SAFE RAMPS Always use ramps which fulfill the following conditions. • Strong ramps which can fully support the weight of the machine. • Ramps with a width greater than the width of the crawlers. • Ramps of a length which will not form a steep angle when placed against the platform of the truck or trailer to be used for transportation.
Page 30: Position For Attaching Safety Labels
8. POSITION FOR ATTACHING SAFETY LABELS Always keep these labels clean. If they are lost or damaged, always attach them again or replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way. •...
Page 31 8. POSITION FOR ATTACHING SAFETY LABELS Always keep these labels clean. If they are lost or damaged, always attach them again or replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way. •...
Page 32 (1) Precautions when operation (1-41010-1330) (2) machine Precautions when travelling downhill (1-41010-1290) (3) Precaution for starting engine and leaving (4) Caution for periodic replacement parts (1-41010-1320) (1-12020-1210) (5) Precautions for warming-up operation (6) Precautions when fitting seat belt (1-41010-1230) (1-41010-1310) 1-20...
Page 33 (7) Precautions for slope alarm (1-41010-1360) (8) Precautions when adding fuel (1-41010-1280) (9) Precautions for oil inside hydraulic tank (10) Beware of rotating fan and pulley (1-41010-1250) (1-41010-1260) (11) Beware of high-temperature coolant (12) Beware of rotating crawler (1-41010-1240) (1-41010-1300) (13) Precautions for crawler adjustment valve (14) Warning tag to prevent operation during maintenance (1-41010-1270) (1-41010-1210)
Page 34 1-22...
Page 35: Operation
OPERATION 1. General view 2- 2 2. Explanation of components 2- 6 3. Operation 2-26 4. Handling dump body 2-44 5. Manual release of parking brake 2-47 6. Handling rubber crawler 2-49 7. Transportation 2-51 8. Cold weather operation 2-52 9.
Page 36: General View
1. GENERAL VIEW 1.1 GENERAL VIEW OF MACHINE Cab Specifications (1) Battery box (7) Dump body (13) Travel motor, sprocket (2) Rear view mirror (8) Safety bar (14) Rubber crawler (3) Fuel tank (9) Rear idler (15) Turn signal lamp (4) Hydraulic tank (10) Carrier roller (16) Head lamp...
Page 37 1. GENERAL VIEW 1.1 GENERAL VIEW OF MACHINE Canopy Specifications (1) Battery box (7) Dump body (13) Dump control lever (2) Rear view mirror (8) Safety bar (14) Travel motor, sprocket (3) Fuel tank (9) Rear idler (15) Rubber crawler (4) Hydraulic tank (10) Air cleaner (16) Turn signal lamp...
Page 38: General View Of Operator's Compartment
1.2 GENERAL VIEW OF OPERATOR’S COMPARTMENT Cab Specifications (1) Travel lever (2) Control box (3) Operator’s seat (4) Dump control lever Canopy Specifications (1) Travel lever (2) Control box (3) Operator’s seat (4) Dump control lever...
Page 39: General View Of Control Panel Box
1.3 GENERAL VIEW OF CONTROL PANEL BOX (1) Turn signal pilot lamp (Right) (2) Combination switch (3) Head lamp high beam pilot lamp (4) Monitor panel (5) Hi-Lo speed range selector switch (6) Engine throttle lever (7) Heater switch (8) Wiper switch (9) Fuse box cover (10) Slope caution lamp (11) Tachometer...
Page 40: Explanation Of Components
2. EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. 2.1 METERS AND LAMPS ON CONTROL PANEL BOX [1] TACHOMETR When traveling uphill or downhill, be sure to regularly check the tachometer to ensure the engine is running at an...
Page 41 [4] PREHEATING INDICATOR LAMP This informs the operator of the actuation condition of the preheating. When the starting switch is turned to HEAT, it lights up and then goes out to inform the operator that the preheating of the engine is completed. Use the HEAT position of the starting switch when starting in cold weather on when it is difficult to start the engine.
Page 42: Meters And Lamps On Monitor Panel
2.2 METERS AND LAMPS ON MONITOR PANEL [1] ENGINE WATER TEMPERATURE GAUGE This indicates the temperature of the engine cooling water. During operation, the indicator point s should be in the green range. If the indicator point s is red range, run the engine at low speed and wait for the indicator point s to go down to the green range.
Page 43 [6] ENGINE OIL PRESSURE LAMP This warns the operator that the engine oil pressure has dropped. It should be out during operations. If it lights up during operations, the engine oil pressure has dropped. Stop operations immediately and check for the cause. Check the engine oil level.
Page 44 [9] HST OIL PRESSURE LAMP This warns the operator that the HST oil pressure has dropped. It should be out during operations. If it lights up during operations, the HST oil pressure has dropped. Stop operations immediately and check for the cause. Check the line filter and strainer for clogging, check for oil leakage from the hydraulic piping, and check the oil level in the hydraulic tank.
Page 45: Switches And Levers On Control Panel Box
2.3 SWITCHES AND LEVERS ON CONTROL PANEL BOX [1] STARTING SWITCH This switch is used to start and stop the engine. • OFF: The starting key can be inserted and removed at this position. When the key is turned to this position, all the switches for the electric circuits are turned off, and the engine stops.
Page 46 [4] PARKING BRAKE SWITCH NOTICE Before starting the engine, always press the parking brake switch to set it to the STOP (parking) position. If it is not in this position, the engine cannot be started. This switch is used to operate the parking brake inside the travel motor. •...
Page 47: Warning Devices
2.4 WARNING DEVICES [1] HORN Horn (1) is installed inside the front grill to the frame on the left side of the Applicable to Cab Specifications radiator. When the starting switch is turned ON and the horn switch is pressed, horn (1) will sound continuously.
Page 48: Travel Lever
2.5 TRAVEL LEVER • Always stop the machine before switching the travel levers between FORWARD and REVERSE. If the direction of travel is suddenly changed, it may cause damage to the machine. • Do not operate the travel levers by a large amount suddenly. Always operate them slowly. If they are suddenly operated, the machine and the operate will suffer a large shock.
Page 49 [4] PIVOT TURN There are the following two types of pivot turn. • Pivot turn: Return one travel lever fully to the N position and operate the other travel lever in the direction of FORWARD or REVERSE. • Spin turn (counter rotation turn): Operate the left and right travel levers in opposite directions.
Page 50: Dump Control Lever
2.6 DUMP CONTROL LEVER • Always stop the machine before operating the dump body to the dump position. • Position a signalman to ensure safety in the surrounding area, and follow his signals when carrying out the dumping operation. • Always operate the dump control lever slowly. If the dump body is suddenly stopped or it is allowed to hit the frame when it is lowered, it will cause failures and will also cause problems of safety in the surrounding area.
Page 51: Fuse Box In Control Panel Box
2.8 FUSE BOX IN CONTROL PANEL BOX • Always turn the starting switch to the OFF position before replacing the fuse. • If the fuse is blown, always check for the cause in that circuit and carry out repairs before replacing the fuse. •...
Page 52: Fuses And Fusible Link Inside Wiring Harness
2.9 FUSES AND FUSIBLE LINK INSIDE WIRING HARNESS • Always turn the starting switch to the OFF position before replacing the fuse. • If the fuse has melted, always check the circuit to find the cause, and carry out repairs before replacing the fuse. •...
Page 53 2.10 OPERATOR’S SEAT Applicable to Cab Specifications • Adjust the operator’s seat before operations. Always adjust the operator’s seat after it has been used by another operator. • Adjust the operator’s seat so that you can operate the travel lever easily with your back against the seat backrest. •...
Page 54 [2] ADJUSTMENT OF RECLINING ANGLE Sit in the seat, use reclining adjustment lever (2) at the seat left back side to adjust the reclining angle. 1. While pulling lever (2) up, sit up straight to move your back away from the backrest.
Page 55: Operator' Seat Applicable To Canopy Specifications
2.10 OPERATOR’S SEAT Applicable to Canopy Specifications • Adjust the operator’s seat before operations. Always adjust the operator’s seat after it has been used by another operator. • Adjust the operator’s seat so that you can operate the travel lever easily with your back against the seat backrest.
Page 56: Seat Belt
2.11 SEAT BELT • Before fastening seat belt, always check that there is no abnormality in the belt mount or seat belt clamps. If there is any wear or damage, always replace the seat belt. • Always adjust the seat belt and fasten it before starting operations. The seat belt is installed to prevent the danger of the operator falling from the operator’s seat if the machine tips at an angle when traveling.
Page 57: Cab Door Lock Releasing Lever Applicable To Cab Specifications
2.12 CAB DOOR LOCK RELEASING LEVER Applicable to Cab Specifications When keeping the door open, open the door until it is locked securely in the latch on the cab. Cab door lock releasing lever use • Push door latch release lever (1) down. The door latch is released and it is possible to close the door.
Page 58: Engine Inspection Cover
2.14 ENGINE INSPECTION COVER When carrying out inspection and maintenance of the engine, do as follows to Applicable to Cab Specifications open the inspection cover. 1. Release 2 catches (2) at the front and rear of inspection cover (1), then pull handle (3) up.
Page 59: Undercover
2.17 UNDERCOVER When changing the coolant, do as follows to remove the undercover. 1. Set a garage jack under the center of undercover (1). Applicable to Cab Specifications Set a wooden block between the jack and the undercover to prevent damage to the undercover.
Page 60: Operation
3. OPERATION 3.1 CHECK BEFORE STARTING ENGINE [1] WALK-AROUND CHECK Applicable to Cab Specifications • Check carefully that there are no dead leaves, waste paper, oil, grease, or other flammable materials around the battery or the muffler, or other parts of the engine which reach high temperatures. These flammable materials can cause fire.
Page 61 (1) Check around engine Check for dead leaves, waste paper, dust, oil, grease, or other flammable materials, and check for leakage of fuel, oil, or coolant from the engine. Remove any flammable materials, and repair any abnormalities. Check for hanging electrical wires, loose connections, or signs of burns around the starting motor, alternator, battery, or battery relay.
Page 62 [1] WALK-AROUND CHECK Applicable to Canopy Specifications • Check carefully that there are no dead leaves, waste paper, oil, grease, or other flammable materials around the battery or the muffler, or other parts of the engine which reach high temperatures. These flammable materials can cause fire.
Page 63 (1) Check around engine Check for dead leaves, waste paper, dust, oil, grease, or other flammable materials, and check for leakage of fuel, oil, or coolant from the engine. Remove any flammable materials, and repair any abnormalities. Check for hanging electrical wires, loose connections, or signs of burns around the starting motor, alternator, battery, or battery relay.
Page 64 [2] CHECKS BEFORE STARTING Before starting the engine at the beginning of the day’s work, carry out the following checks before starting and checks when required. For details of the checks before starting, checks when required, and other maintenance, see “MAINTENANCE”. 1.
Page 65: Operations And Checks Before Starting Engine
3.2 OPERATIONS AND CHECKS BEFORE STARTING ENGINE 1. Check that the left and right travel levers are at the N position. 2. Check that the parking brake switch is at the ON (STOP) position. 3. Check that the dump body is completely lowered and that dump control lever (1) is at the HOLD position.
Page 66: Starting Engine
3.3 STARTING ENGINE Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE • When starting the engine, be sure to press the parking brake switch to set it to the ON (STOP) position. The engine cannot be started without setting the parking brake switch to this ON (STOP) position.
Page 67 [2] STARTING ENGINE IN COLD WEATHER When starting the engine in cold temperatures, do as follows. 1. Pull the throttle lever fully to the back and set to the high speed position. 2. Insert the key in the starting switch, turn it to the PREHEAT position and hold it in position until the preheating indicator lamp on the control panel box lights up.
Page 68 [3] AFTER STARTING (warming-up operation) NOTICE Run the engine under light load until the engine coolant temperature is within a green range. Do not suddenly accelerate the engine. After the engine starts, carry out the warming-up operation as follows. 1. Push the throttle lever forward, set the engine to low speed, and run for approx.
Page 69: Moving Machine Off
3.4 MOVING MACHINE OFF • Check that there is no one in the area around the machine before starting. Check particularly carefully around the dump body at the rear of the machine. • When starting the machine off, check that the surrounding area is safe, and sound the horn to inform people that you are starting.
Page 70: Shifting Speed Range, Changing Between Forward And Reverse
3.5 SHIFTING SPEED RANGE, CHANGING BETWEEN FORWARD AND REVERSE • When traveling, select a travel speed to match the travel surface and ground condition. • When traveling on a slope, be sure to set the travel speed range to the low speed range. Also, when traveling on a slope, travel straight forward.
Page 71 [3] SWITCHING BETWEEN HIGH AND LOW SPEED RANGES The travel speed range is changed by operating the Hi-Lo speed range selector switch. • When the switch is pressed, the mechanism inside the travel motor is switched and the machine changes to the high speed range. At the same time, the high-speed lamp on the instrument panel lights up to show that the machine is traveling in the high speed range.
Page 72: Steering Machine
3.6 STEERING MACHINE • Do not turn the machine sharply at high speed; do not carry spin turns unless necessary. This will damage the crawler and hydraulic equipment, and there is also danger that the machine may hit other objects. •...
Page 73 [Turning while decreasing speed] • To make a gradual turn when traveling forward, pull the travel lever back a small amount in the direction of STOP on the same side as the direction of the turn. To make a rapid turn when traveling forward, pull the travel lever back a large amount on the same side as the direction of the turn.
Page 74: Stopping Machine
3.7 STOPPING MACHINE • Avoid stopping suddenly. Always leave room to spare when stopping. • Never use the parking brake to stop the machine. Using the parking brake will cause the machine to stop suddenly and will also damage the machine. •...
Page 75: Parking Machine
3.9 PARKING MACHINE Choose firm, level ground to park the machine. If the machine must be parked on the slope, apply the parking brake and block the tracks to prevent the machine from moving. Set the parking brake switch to the ON (STOP) position to apply the parking brake.
Page 76: Checks After Stopping Engine
3.11 CHECKS AFTER STOPPING ENGINE • Carry out a walk-around check and check the undercarriage, dump body, and bodywork; check also for leakage of oil and water. If any abnormality is found, repair it. • Fill the fuel tank with fuel. •...
Page 77: Precautions When Traveling
3.13 PRECAUTIONS WHEN TRAVELING Always follow these precautions when traveling. Failure to follow these precautions may lead to a serious injury or accident. [1] PERMISSIBLE WATER DEPTH When operating in water, do not let the bottom surface of the engine oil pan go below the water surface.
Page 78: Handling Dump Body
4. HANDLING DUMP BODY 4.1 OPERATING DUMP BODY • Always stop the machine before operating the dump body to the dump position. • Position a signalman to ensure safety in the surrounding area, and follow his signals when carrying out the dumping operation.
Page 79: Operating Safety Bar
4.3 OPERATING SAFETY BAR • If it is necessary to go under the dump body to carry out inspection and maintenance, always use the safety bar to prevent the dump body from coming down. • When using the safety bar, check that the bar is fitted securely to the dump body holder. •...
Page 80: Precautions During Operation
4.4 PRECAUTIONS DURING OPERATION Always follow these precautions when carrying out operations. Failure to follow these precautions may lead to a serious injury or accident. [1] PRECAUTIONS FOR JOBSITES • As far as possible, select firm, level ground. When working on slopes or extremely uneven ground, the change in the center of gravity when the dump is operated may cause the machine tip over.
Page 81: Manual Release Parking Brake
5. MANUAL RELEASE OF PARKING BRAKE 5.1 OUTLINE OF PARKING BRAKE The parking brake is built into the left and right travel motors. When the parking brake is released under normal conditions, the parking brake switch is operated and uses the hydraulic power generated when the engine is running.
Page 82 [2] PREPARATIONS FOR MOVING FAILED MACHINE NOTICE When moving a machine which has had its parking brake released manually, the distance of movement should be only the few meters needed to move it to a safe place. Moving the machine a long distance will cause failure of the HST. When moving a failed machine, carry out the following preparatory work.
Page 83: Handling Rubber Crawler
6. HANDLING RUBBER CRAWLER 6.1 FEATURES OF RUBBER CRAWLER The properties of the material used for the rubber crawlers gives it many advantages, such as low vibration, high drawbar pull, and ease of handling. Make sure that you fully understand the advantages of rubber crawlers, and follow the content of “6.2 PROHIBITED OPERATIONS FOR RUBBER CRAWLER”...
Page 84: Precautions When Using Rubber Crawler
6.3 PRECAUTIONS WHEN USING RUBBER CRAWLER Always follow these precautions when using rubber crawlers. Failure to follow these precautions may lead to a serious injury or accident. • Do not make sharp turns on concrete surfaces. • Do not operate the machine in such away that the rubber track scrapes against concrete walls.
Page 85: Transportation
7. TRANSPORTATION 7.1 LOADING, UNLOADING WORK • Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded. If the ramp sags appreciably, reinforce it with blocks, etc. • When loading and unloading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.
Page 86: Cold Weather Operation
8. COLD WEATHER OPERATION 8.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. [1] FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “MAINTENANCE 3.
Page 87: After Completion Of Work
[3] BATTERY • To avoid gas explosions, do not bring fire or sparks near the battery. • Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor. When the ambient temperature drops, the capacity of the battery will also drop.
Page 88: Long-Term Storage
9. LONG-TERM STORAGE 9.1 BEFORE STORAGE When putting the machine in storage for more than one month, do as follows. • After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors. In case it is indispensable to leave it outdoors, park the machine on the flat ground and cover it with canvas etc.
Page 89: Handling Battery
10. HANDLING BATTERY When handling batteries, always do as follows. • Before working with the battery, stop the engine and turn the key in the starting switch to the OFF position. • When working with the battery, always wear safety glasses. •...
Page 90: Removal And Installation Of Battery
10.2 REMOVAL AND INSTALLATION OF BATTERY The battery is installed in front of the fuel tank on the front right side of the machine. [1] REMOVAL 1. Open the inspection cover. For details, see “2.15 BATTERY INSPECTION COVER”. 2. Raise the rubber cover (1) on the battery and move it to inspection cover. 3.
Page 91: Starting Engine With Booster Cable
10.4 STARTING ENGINE WITH BOOSTER CABLE If the battery is discharged and booster cables are used to start the engine, do as follows • Be careful not to let the normal machine and problem machine contact each other. • When connecting the cables, never let the positive (+) and negative (-) terminals contact each other.
Page 92: Troubleshooting
11. TROUBLESHOOTING If it is felt that there is any abnormality, investigate the cause immediately and take the necessary action to prevent any serious failure. If the cause is unknown, please contact your distributor for repairs. When contacting your distributor, please give the machine serial number and engine number. 11.1 PROBLEMS WITH ENGINE RELATED PARTS Problem Main causes...
Page 93: Problems With Chassis Related Parts
Problem Main causes Remedy • Air in fuel line • Bleed air • Fuel filter clogged with dirt, water in • Check, replace new parts, or repair Engine does not run smoothly fuel filter • Leakage of fuel from fuel system •...
Page 94: Problems With Electric Related Parts
11.3 PROBLEMS WITH ELECTRIC RELATED PARTS Problem Main causes Remedy • Defective wiring • Check, repair • Blown fuse at rear of instrument • Check, replace Battery charge lamp on instrument panel panel lights up during operation • Loose fan belt •...
Page 95: Maintenance
MAINTENANCE 1. Basic outline of maintenance 3- 2 2. Precautions for maintenance 3- 4 3. Use of fuel and lubricants according to ambient temperature 3- 6 4. Tools and tightening torques 5. Periodic replacement of critical parts 3-10 6. Maintenance schedule chart 3-12 7.
Page 96: Basic Outline Of Maintenance
1. BASIC OUTLINE OF MAINTENANCE [1] OIL • Oil is used under extremely heavy-duty conditions (high temperature, high pressure) in the engine, hydraulic pump, motor, and work equipment. Therefore, it deteriorates as time passes. Always use the grade of oil and the oil which matches the ambient temperature listed in this operation manual. Even if the oil is not dirty, always change it at the specified interval.
Page 97 [5] FILTERS • Filters are used to prevent trouble caused when impurities in the oil, fuel, or air enter important equipment. When the replacement interval listed in this manual is reached, always replace or clean the filters. However, when using this machine under heavy-duty conditions, replace the filters before the specified replacement interval has passed.
Page 98: Precautions For Maintenance
• When replacing parts, always use the genuine parts specified in the parts list. [3] PRECAUTIONS WHEN ADDING OR CHANGING OIL OR GREASE • When adding or changing fuel, oil, or grease, always use the type specified by Morooka. Be sure to use the viscosity specified for the ambient temperature.
Page 99 [7] CHECKING DRAINED OIL, FILTER • When the oil has been changed or the filter replaced, always check the drained oil and removed filter to check for metal particles or other foreign materials. [8] SETTING UP WARNING SIGNS • When the oil or coolant has been drained, put warning signs (Part No.: 1-41010-1210) in the operator's compartment to prevent anyone from starting the engine by mistake.
Page 100: Use Of Fuel And Lubricants According To Ambient Temperature
3. USE OF FUEL AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 3.1 FUEL, COOLANT, AND LUBRICANT TABLE NOTICE • The quality of engine oil influences significantly on the engine performance and start ability. Always use the engine oil of CG-4 class or CAT diesel engine oil Cat DEO and of specified viscosity (refer to the table below) according to the ambient temperatures.
Page 101 REMARK • When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content Change interval of oil in engine oil pan 0.5 to 1.0% 1/2 of regular interval...
Page 102: Tools And Tightening Torques
4. TOOLS AND TIGHTENING TORQUES 4.1 INTRODUCTION OF NECESSARY TOOLS The following tools are needed when carrying out maintenance. If the tools are broken or worn, please order new tools from your distributor. Name of tool Part No. Remarks Wrench set 0-9100-00000 Width across flats (S1 x S2) 0-9100-00709...
Page 103: Torque List For Bolts And Nuts
4.2 TORQUE LIST FOR BOLTS AND NUTS Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below. The tightening torque is determined by the width across flats (b) of the nut and bolt. NOTICE When tightening panels or other parts with tightening fixtures made of plastic, be careful not to use excessive tightening torque.
Page 104: Periodic Replacement Of Critical Parts
5.1 PERIODIC REPLACEMENT INTERVAL (EVERY 2 YEARS) In order to further increase the safety of the machine Morooka recommends periodic inspection and replacement of critical parts (hydraulic hoses, fuel hoses, etc.) which are related to causes of fire and to efficiency in the raising and lowering of the dump body and traveling and stopping functions of the machine.
Page 105: Specified Periodic Replacement Parts
5.3 SPECIFIED PERIODIC REPLACEMENT PARTS • The list of periodic replacement parts specified by Morooka does not include the fuel hoses on the engine. Refer to the separate engine parts list (parts book) and carry out replacement in the same way as for the periodic replacement parts specified by Morooka.
Page 106: Maintenance Schedule Chart
6. MAINTENANCE SCHEDULE CHART Service item Page 7.2 INITIAL 100 HOURS SERVICE This is only after the first 100 hours for new machines 3-13 [1] Change engine lubricating oil, replace engine oil filter 3-33 [2] Replace hydraulic line filter 3-34 [3] Change oil in hydraulic tank 3-35 7.3 INITIAL 500 HOURS SERVICE This is only after the first 500 hours for new machines...
Page 107: Service Procedure
7. SERVICE PROCEDURE 7.1 OUTLINE OF INSPECTION AND MAINTENANCE PROCEDURES This section explains the methods for inspection and maintenance operations listed in “6. MAINTENANCE SCHEDULE CHART”. Always observe the precautions related to safety for each item, and carry out the operation safely. If the operation is difficult, do not try to carry it out;...
Page 108: When Required
7.4 WHEN REQUIRED [1] CHECK, ADJUST RUBBER CRAWLER TENSION The tension adjuster for the rubber crawler is charged with grease. The grease is kept under high pressure by the recoil spring inside the tension adjuster. Always follow the precautions given below. Failure to follow these precautions may cause the valve to fly out, resulting in serious injury or accident.
Page 109: Check Rubber Crawler For Damage, Wear
• ADJUSTING WHEN TENSION IS TIGHT (when measurement is above range for dimension A) 1. Remove 2 bolts, then remove grease valve cover (1). 2. Loosen valve (2) until dimension A is within the range given for “CHECKING TENSION”. If the grease comes out slowly, push the idler end of the rubber crawler strongly.
Page 110: Clean, Replace Air Cleaner Applicable To External Mounting Type
[3] CLEAN, REPLACE AIR CLEANER Applicable to external mounting type • Never clean, or replace the air cleaner when the engine is running. • When using compressed air to clean the element, there is danger that dirt and dust may fly and get into eyes. Always wear safety glasses.
Page 111 5. After cleaning, use a light bulb from inside the element to check if there are any small holes or thin places in the element. Replace the element if such places are found. 6. Remove the baffle (5) from the inside of the dust pan (2), then clean the inside of the dust pan.
Page 112 [3] CLEAN, REPLACE AIR CLEANER Applicable to operator’s cab rear mounting type (Cab Specifications) • Never clean, or replace the air cleaner when the engine is running. • When using compressed air to clean the element, there is danger that dirt and dust may fly and get into eyes. Always wear safety glasses.
Page 113 3. Remove the wing bolt (3) and take out the element (4). 4. Blow with dry compressed air (max. 0.68 MPa [7 kgf/cm ]) along the folds from the inside of element (4). Next, blow along the folds from the outside of the element, then blow from the inside of the element again.
Page 114: Clean, Replace Air Cleaner Applicable To Operator's Seat Rear Mounting Type (Canopy Specifications)
[3] CLEAN, REPLACE AIR CLEANER Applicable to operator’s seat rear mounting type (Canopy Specifications) • Never clean, or replace the air cleaner when the engine is running. • When using compressed air to clean the element, there is danger that dirt and dust may fly and get into eyes. Always wear safety glasses.
Page 115 4. Blow with dry compressed air (max. 0.68 MPa [7 kgf/cm ]) along the folds from the inside of element (4). Next, blow along the folds from the outside of the element, then blow from the inside of the element again. 5.
Page 116: Clean Inside Of Cooling System And Change Coolant
[4] CLEAN INSIDE OF COOLING SYSTEM AND CHANGE COOLANT • Immediately after the engine is stopped, the coolant is at high temperature, so there is danger of burns if you drain the coolant immediately. Wait for the engine to cool down before draining the coolant. •...
Page 117 8. After flushing the system, stop the engine, stop the water supply, then drain the water. 9. After draining the water, close the two drain valves in Step 5, then add cleaning agent through the water filler. For details of the method of cleaning, see the instructions on the cleaning agent. 10.
Page 118: Check Window Washer Fluid Level, Add Fluid Applicable To Cab Specifications
[5] CHECK, CLEAN RADIATOR, OIL COOLER, INTER COOLER, A/C CONDENSOR FINS • Never inspect or clean the fins when the engine is running. Always stop the engine before starting the operation. • When using compressed air to clean the fins, there is danger that dirt and dust may fly and get into eyes. Always wear safety glasses.
Page 119: Check Battery Electrolyte Level, Add Distilled Water
[7] CHECK BATTERY ELECTROLYTE LEVEL, ADD DISTILLED WATER • If any tool touches between the battery positive (+) terminal and the chassis, there is danger that sparks will be caused. Do not put tools and other metal objects in your breast pocket. They may fall out. •...
Page 120: Check Before Starting
7.5 CHECK BEFORE STARTING [1] CHECK COOLANT LEVEL, ADD WATER Do not suddenly remove the cap when the radiator water temperature is high. Boiling water will spurt out and cause burns. Wait for the water temperature to go down before removing the cap. When removing the cap, raise the lever attached to the cap to fully release the internal pressure, then remove the cap.
Page 121: Check Engine Lubricating Oil Level, Add Oil
[3] CHECK ENGINE LUBRICATING OIL LEVEL, ADD OIL • CHECKING OIL LEVEL 1. Open the engine inspection cover. 2. Pull out dipstick (1) and wipe the oil off with a cloth. 3. Insert dipstick (1) fully into the gauge guide, then pull it out again. 4.
Page 122: Check Dust Indicator
[5] CHECK DUST INDICATOR Applicable to external mounting type 1. Raise the dump body. For details, see “OPERATION 4. OPERATING DUMP BODY”. 2. Check if the he red piston has appeared in the transparent portion of the dust indicator (1). If the red piston has appeared, clean or replace the element immediately.
Page 123: Check, Adjust Fan Belt Tension
[5] CHECK DUST INDICATOR Applicable to operator’s seat rear mounting type (Canopy Specifications) 1. Raise the dump body. For details, see “OPERATION 4. OPERATING DUMP BODY”. 2. Open the inspection cover (2) at the rear side of the operator’s compartment, then check the air cleaner inside the cover.
Page 124: Check Electric Wiring
[7] CHECK ELECTRIC WIRING If any tool touches between the battery positive (+) terminal and the chassis, there is danger that sparks will be caused. Do not put tools and other metal objects in your breast pocket. They may fall out. •...
Page 125: Every 50 Hours Service
7.6 EVERY 50 HOURS SERVICE [1] DRAIN WATER, SEDIMENT FROM FUEL TANK Set a container under the fuel tank to catch the fuel. 1. Turn the plug (1) under the fuel tank to counterclockwise slightly. The water and sediment accumulated at the bottom of the tank will be drained together with the fuel.
Page 126: Every 500 Hours Service
7.8 EVERY 500 HOURS SERVICE Carry out “Every-50 hours, and Every-250 hours service” at the same time. [1] REPLACE FUEL FILTER • Stop the engine and wait for the engine to cool down. • Do not smoke or bring any flame close. NOTICE After replacing the fuel filter, always bleed the air from the fuel circuit.
Page 127: Change Engine Lubricating Oil, Replace Engine Oil Filter
[2] CHANGE ENGINE LUBRICATING OIL, REPLACE ENGINE OIL FILTER • Stop the engine and wait for the temperature to go down. • After adding oil, tighten the cap and drain plug securely, then wipe up any spilled oil. Set a container under the engine to catch the oil. Prepare a filter wrench.
Page 128: Replace Hydraulic Line Filter
[3] REPLACE HYDRAULIC LINE FILTER • Stop the engine and wait for the engine to cool down. • Loosen the cap of the hydraulic tank slowly to release the internal pressure completely, then remove the cap. • Operate the travel lever and dump control lever 2 or 3 times to the end of their stroke to completely release the remaining pressure in the hydraulic circuit.
Page 129: Change Oil In Hydraulic Tank
[4] CHANGE OIL IN HYDRAULIC TANK • Stop the engine and wait for the engine to cool down. • Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank, then remove the cap. • Make full stroke operations of the travel lever and the damp control lever to release the remaining pressure inside the hydraulic circuits totally.
Page 130: Every 1500 Hours Service
7.9 EVERY 1500 HOURS SERVICE Carry out “Every-50 hours, Every-250 hours and Every-500 hours service” at the same time. [1] CHANGE OIL INSIDE TRAVEL MOTOR REDUCTION GEAR CASE • Stop the engine and wait for the oil temperature to go down. •...
Page 131: Specifications
SPECIFICATIONS 1. DIMENSION DRAWING 2 .SPECIFICATIONS TABLE...
Page 132: Dimension Drawing
1. DIMENSION DRAWING Cab Specifications Canopy Specifications...
Page 133: Specifications Table
2 .SPECIFICATIONS TABLE MST-800VD Model name Cab Specifications Canopy Specifications Overall length (mm) 4,430 4,430 Overall width (mm) 2,425 2,300 Distance between center of idler and center of (mm) 3,130 3,130 sprocket Min. ground clearance (mm) Distance between front of machine and center...
Page 134 ＭＳＴ－８００ＶＤ RUBBER CRAWLER CARRIER OPERATION AND MAINTENANCE MANUAL Document No.AE10800VD2-01 First edition: January 15, 2011 Issued by Morooka Co., Ltd. 358 Shoubeisindencho, Ryugasaki, Ibaraki 301-0034, Japan No part of this manual can be reproduced in any from without permission...

Morooka MST-800VD Operation & Maintenance Manual

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