Morooka MST-800VD Manual

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
willcome intocontact with it.

A-1
CONTENTS
ITEM
Page
FOREWORD
0-1
1.Foreword
0-2
2.Introduction
0-3
3.Safetyinformation
0-4
4. Locationof serialnumber
0-5
SAFETY
1-1
1.General precautions
1-2
2.Precautions duringinspectionandmaintenance
1-4
3.Precautions before starting engine
1-9
4.Precautions when startingengine
1-11
5.Precautions when traveling
1-12
6.Precautions for operation
1-15
7.Precautions for transportation
1-17
8.Position forattaching safetylabels
1-18
OPERATION
2-1
1.General view
2-2
1.1General view ofmachine
2-2
1.2General view ofoperator’s compartment
2-4
1.3 General viewof control panel box
2-5
1.4General viewof monitorpanel
2-5
2.Explanation of components
2-6
2.1 Meters andlamps on control panel box
2-6
2.2Meters andlamps on monitorpanel
2-8
2.3 Switches and levers on controlpanelbox
2-11
2.4Warningdevices
2-13
2.5Travel lever
2-14
2.6Dumpcontrol lever
2-16
2.7Dumpbody safetybar
2-16
2.8Fuse boxincontrolpanel box
2-17
2.9 Fuses and fusiblelink inside wiring harness
2-18
2.10 Operator’seat ApplicabletoCabSpecifications
2-19
2.10 Operator’seat ApplicabletoCanopySpecifications
2-21
2.11 Seat belt
2-22
2.12 Cabdoor lock releasing lever Applicable to Cab Specifications
2-23
2.13 Openingand closingcab frontdoor Applicable to Cab Specifications
2-23
2.14 Engineinspection cover
2-24
2.15 Batteryinspection cover
2-24
2.16Front grill
2-24
2.17Undercover
2-25

A-2
ITEM
Page
3.Operation
2-26
3.1 Check before starting engine
2-26
3.2 Operationsandchecksbefore starting engine
2-31
3.3Startingengine
2-32
3.4Movingmachine off
2-35
3.5Shiftingspeed range,changingbetweenFORWARDandREVERSE
2-36
3.6Steeringmachine
2-38
3.7Stoppingmachine
2-40
3.8 Emergencystoppingmachine
2-40
3.9Parkingmachine
2-41
3.10 Stopping engine
2-41
3.11 Checks afterstoppingengine
2-42
3.12 Locking
2-42
3.13 Precautionswhentraveling
2-43
4.Handlingdumpbody
2-44
4.1 Dumping operation of dumpbody
2-44
4.2Lockingdumpcontrol lever
2-44
4.3Operating safetybar
2-45
4.4 Precautionsduring operation
2-46
5.Manual releaseparking brake
2-47
5.1Outline of parkingbrake
2-47
5.2 Method for manual release of parking brake
2-47
6.Handling rubbercrawler
2-49
6.1Features ofrubbercrawler
2-49
6.2 Prohibited operationsfor rubber crawler
2-49
6.3 Precautions when using rubbercrawler
2-50
7.Transportation
2-51
7.1Loading,unloadingwork
2-51
7.2 Precautionsforloading
2-51
7.3 Precautionsfortransportation
2-51
8.Coldweather operation
2-52
8.1 Precautionsforlow temperature
2-52
8.2Aftercompletion of work
2-53
8.3 Aftercold weather
2-53
9. Long-term storage
2-54
9.1 Before storage
2-54
9.2 Precautionsduring storage
2-54
9.3Precautionsafterstorage
2-54

A-3
ITEM
Page
10. Handling battery
2-55
10.1 Precautionswhenhandling battery
2-55
10.2 Removal andinstallation of battery
2-56
10.3 Precautionswhencharging battery
2-56
10.4 Startingengine with booster cable
2-57
11. Troubleshooting
2-58
11.1 Problems with engine related parts
2-58
11.2 Problems with chassisrelated parts
2-59
11.3 Problems with electric relatedparts
2-60
MAINTENANCE
3-1
1.Basic outlineofmaintenance
3-2
2.Precautions for maintenance
3-4
3.Use of fuel andlubricantsaccordingto ambienttemperature
3-6
3.1 Fuel, coolant, andlubricant table
3-6
4.Tools and tighteningtorques
3-8
4.1Introduction ofnecessarytools
3-8
4.2 Torque listfor bolts andnuts
3-9
5.Periodic replacement of critical parts
3-10
5.1 Periodic replacement interval (every 2 years)
3-10
5.2 Periodicinspection
3-10
5.3 Specifiedperiodic replacement parts
3-11
6.Maintenance schedule chart
3-12
7.Serviceprocedure
3-13
7.1 Outline of inspectionand maintenanceprocedures
3-13
7.2 Initial 100 hoursservice
3-13
7.3 Initial 500 hoursservice
3-13
7.4Whenrequired
3-14
7.5 Check before starting
3-26
7.6 Every50hours service
3-31
7.7Every250 hoursservice
3-31
7.8Every500 hoursservice
3-32
7.9Every1500hours service
3-36
SPECIFICATIONS
4-1
1.Dimensiondrawing
4-2
2. Specifications table
4-3

A-4

0-1
FOREWORD
1. FOREWORD
0- 2
2. INTRODUCTION
0- 3
3. SAFETY INFORMATION
0- 4
4. LOCATION OF SERIAL NUMBER
0- 5

0-2
1. FOREWORD
Thank you for purchasing this Morooka Rubber Crawler Carrier.
This manual describes procedures for operation, handling, testing, and maintenance.
It will help the operator realize many years of faithful service from the machine.
Please read this manual carefully BEFORE operating the machine. This will enable
you to realize the peak performance of the machine.
For details of handling the engine, please see the separate engine operation manual
for any item not given in this manual.
•Improper operation and maintenance of this machine can be hazardous and
could result in serious injury or death.
•Operators and maintenance personnel should read this manual thoroughly
before beginning operation or maintenance.
Always keep this manual on the machine and be sure to read and understand
it thoroughly before performing operation and maintenance.
•Some actions involved in operation and maintenance of the machine can
cause a serious accident if they are not done in the manner described in this
manual.
•Keep this manual handy and have all personnel read it periodically.
•If this manual has been lost or has become dirty and cannot be read, request
a replacement manual from Morooka or your Morooka distributor.
•If you lend this machine to another person, always have that person read the
operation manual and make sure that they understand the content of the
manual before starting operation.Be particularly careful to ensure that they
follow the safety regulations when operating.
•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.
•The description of safety is given in SAFETY INFORMATION on page 0-3 and
in SAFETY from page 1-1.

0-3
2. INTRODUCTION
1. FEATURES OF THE MACHINE
•Low-ground-pressure rubber crawler type that can travel easily on uneven ground, soft ground,
or snow.
•Long, wide rubber crawler to provide powerful and stable drawbar pull.
•Hydraulic drive (HST) to allow travel operations to be carried out with a single lever to give
forward and reverse with stepless gear shifting, as well as turning and stopping.
2. BREAKING IN THE MACHINE
Your Morooka machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect
the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the hourmeter). Proper
breaking in will allow the machine to give you many years of service.
During breaking in, pay particular attention to the following points.
•After starting the engine, idle it for 5 minutes to carry out the warming-up operation.
•Avoid operation with heavy loads or at high speeds.
•Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases
of emergency.
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 hours on the hourmeter, whichever comes sooner,
repairs will be carried out free of charge in accordance with the warranty.

0-4
3. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines.
To avoid accidents, read, understand and follow all precautions and warnings in this manual and
on the machine before performing operation and maintenance.
Do not operate or carry out maintenance of this machine unless you are sure that you
understand the explanations and procedures completely.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
This word is used on safety messages and safety labels where there
is a high probability of serious injury or death if the hazard is not
avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid
this hazard may also result in serious damage to the machine.
This word is used on safety messages and safety labels where there
is a potentially dangerous situation which could result in serious
injury or death if the hazard is not avoided. These safety messages
or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious
damage to the machine
This word is used on safety messages and safety labels for hazards which could
result in minor or moderateinjuryif the hazard is not avoided. This word might also
be word forhazardswhere the onlyresult could be damage to the machine.
This word is used for precautions that must be taken to avoid actions which could
shorten thelifeof themachine.
Safety precautions are described in SAFETYfrom page 1-1.
Morooka cannot predictevery circumstance thatmightinvolve apotential hazard inoperation andmaintenance.
Thereforethesafetymessagesinthismanualandonthemachinemaynotincludeallpossiblesafetyprecautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibilitytobesurethatyouandotherscandosuchproceduresandactionssafelyandwithoutdamagingthe
machine. If youareunsureabout thesafetyofsome procedures,contactyour Morookadistributor.
NOTICE

0-5
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
insidetheoperator’scompartmentinthepositioninthediagramonthe
right.
For the position of the engineserial number,please seethe separateengineoperationmanual.
Wheninquiringabout serviceorordering parts,please quote themachine serial number, engine serialnumber,
and hour-meter reading.

0-6

1-1
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. Position for attaching safety labels
1-18
Read and follow all safety precautions. Failure to do so may result
in serious injury or death.
This safety section also contains precautions for optional
equipment and attachments.

1-2
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.
•Operating the machine when you are not in good physical condition
reduces the power of judgment needed to avoid danger and leads to
accidents.
People in the following conditions should not operate the machine.
•People who cannot operate normally because they are tired, ill, or
suffering from the effects of medication.
•People who have been drinking.
•Pregnant women
SAFETY FEATURES
•Be sure that all guards and covers are in their proper position. Have guards and covers repaired if
damaged.
•Use safety features such as safety lock levers and seat belts properly.
•Improper use of safety features could result in serious bodily injury or death.
Parking brake switch : See “OPERATION 3.7 PARKING MACHINE”.
Dump control lever lock : See “OPERATION 4.2 LOOCKING DUMP CONTROL LEVER”.
Seat belt : See “OPERATION 2.11 SEAT BELT”.
WEAR SUITABLE CLOTHING
•Always wear properly fitting clothes which allow ease of movement.
If there are buttons, always button the cuffs.
•Avoid loose clothing, towels, jewelry, and loose long hair. They can
catch on controls or in moving parts and cause serious injury or
death.
•Also, do not wear oily clothes, they can easily catch fire.
•Wear a hard hat, safety glasses, non-slip safety shoes, and gloves
when operating or maintaining the machine.
FIRE EXTINGUISHER AND FIRST AID KIT
•Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them.
•Provide a first aid kit at the storage point.
•Know what to do in the event of a fire.
•Be sure that you know the phone numbers of persons you should
contact in case of an emergency.

1-3
UNAUTHORIZED MODIFICATION
•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.
FIRE PREVENTION FOR FUEL, OIL, AND ANTIFREEZE
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly
flammable and can be hazardous.
•Use well-ventilated areas for adding or storing oil and fuel.
•Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
•Tighten all fuel and oil caps securely.
•Keep any flame away from flammable fluids.
•Do not leave any cloths or rags soaked in oil or fuel lying in the fuel
or oil storage area. Clean such materials up immediately.
•Stop the engine and do not bring lighted cigarettes or cigarette
lighters close when refueling.
USE HANDRAILS AND STEPS FOR GET ON OR OFF
Get on or off the machine as follows.
•Never jump on or off the machine. Never get on or off a moving
machine.
•When getting on or off the machine, always face the machine and
use the handrails and steps.
•If there is any oil, grease, or mud on the handrails or steps, wipe it
off immediately. Always keep these parts clean.

1-4
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.
USE SUITABLE TOOLS
Always use tools that are designed for the purpose. Do not use
broken or deteriorated tools, or tools that are designed for other
purposes.
STOP ENGINE WHEN INSPECTION AND MAINTENANCE
When carrying out inspection and maintenance, always follow the
precautions below.
•Select firm, level ground to park the machine.
•Lower the dump body, apply the parking brake, then stop the
engine.
•Check that the travel lever is at the N position.
•If the engine must be started to carry out inspection or maintenance,
take steps to ensure that the engine can be stopped at any moment.
•When carrying out the operation with two or more workers,
determine the order of operation and fix signals, and follow the
instructions of the person in charge.
ALWAYS KEEP MACHINE CLEAN
Always do the following to keep the machine clean.
•Always keep the floor, steps, and handrails free of oil, grease, mud,
or water. There is danger that you may slip and be injured.
Always wipe off any oil, grease, mud or water.
•Do not leave tools or parts lying around on the floor or steps. There
is danger that you may trip over them. Always clear up tools and
parts immediately.
•Dry wood chips, leaves, grass, paper, oil, and other flammable
materials around the engine, muffler, battery, or hydraulic tank may
cause fire. Always remove any flammable objects and wipe off any
oil.
•Always remove any mud accumulated around the undercarriage.
There is danger that you may slip and fall when stepping on to the
rubber crawler.

1-5
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
•Do not go close to the fan when it is rotating. Do not bring anything
that can be caught up in the fan close to the fan.
•Do not come close to the dump body when it is moving. There is
danger of getting caught or crushed.
KEEP AWAY FROM FLAME WHEN ADDING FUEL
When filling the fuel tank with fuel, or when draining the water, always
follow the precautions below.
•Stop the engine.
•Do notbring anylighted cigarette orcigarette lighter close to thefuel
tank.
•After adding fuel, tighten the cap securely and wipe up any spilled
fuel.
•Do not bend the fuel hose or hit it with any sharp object.
•If any hose is loose or damaged, always repair or replace it.

1-6
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.
•Radiator and radiator cap
•Hydraulic tank and hydraulic hoses
•Muffler and all parts of engine.
WAIT FOR ENGINE TO COOL BEFORE CHANGING ENGINE OIL
When changing the engine oil, always follow the precautions below.
•Stop the engine and wait for the engine and oil temperature to go
down before changing the oil.
•After adding oil, tighten the cap and drain valve securely and wipe
up any oil that was spilled.
WAIT FOR WATER TEMPERATURE TO GO DOWN BEFORE ADDING COOLANT
Do not add water to the radiator.
Always follow the precautions below.
•Stop the engine and wait for the water temperature to go down.
•Raise the lever attached to the radiator cap to release the internal
pressure before removing the cap.
•After adding water, tighten the cap securely and wipe up any water
that was spilled.
WAIT FOR PRESSURE TO GO DOWN BEFORE ADDING HYDRAULIC OIL
When adding oil to the hydraulic tank or when changing the oil,
always follow the precautions below.
•Lower the dump body and stop the engine.
•Loosen the hydraulic tank cap slowly to release the internal
pressure completely, then remove the cap.
•After adding oil, tighten the cap and drain plug securely and wipe up
any oil that was spilled.

1-7
TAKE CARE WHEN HANDLING HIGH PRESSURE HOSES
Remember that oil is always flowing under high pressure in the
hydraulic hoses. Do not remove the hoses before the internal
pressure has been released.
When handling the high-pressure hoses, always follow the
precautions below.
•Do not bend the high-pressure hoses or hit them with any sharp
object.
•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. The grease
is kept under high pressure by the recoil spring inside the tension
adjuster.
Always follow the precautions below when adjusting the tension. If
these precautions are not followed, the valve may fly out and cause
serious injury.
•Do not loosen the tension adjustment valve more than one turn.
There is danger that the valve may fly out.
•When adjusting the tension, do not stand directly in front of the
valve; stand to the side to avoid danger.
USE SAFETY BAR UNDER DUMP BODY
When going under the dump body to carry out operations, always
follow the precautions below.
•Hang a "DO NOT OPERATE !" sign (Part No.: 1-41010-1210) in the
operator’s compartment to prevent any one else from operating the
machine.
•Apply the lock of the dump control lever to prevent the truck box
from lowering when the lever is touched inadvertently by an
unauthorized person.
Dump control lever lock: See “OPERATION 4.2LOCKING DUMP
CONTROL LEVER OPERATING”.
•Always use the safety bar when going under the dump body.
Safety bar: See “OPERATION 4.3 OPERATING SAFETY BAR”.
BE CAREFUL WHEN HANDLING BATTERY
•When checking or repairing the electrical system, always remove
the negative (-) terminal from the battery to stop the flow of
electricity.
Failure to do this may cause fire or short circuit.
•Be careful not to get battery electrolyte on your skinor clothes. If the
battery electrolyte gets on you, wash it off immediately with water.

1-8
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.
•Instrument panel and control panel, switches, sensors, connectors
•Starting motor, alternator, sensors, connectors around the engine
•Battery, relay, connectors at front right of machine
DISPOSE OF WASTE MATERIAL CORRECTLY
•When draining and changing the oil, always put a container under
the engine and tank to catch the oil.
•Do not drain the oil directly into the ground or throw it into rivers or
the sewage system.
•When disposing of oil, fuel, coolant, solvent, filters, batteries, and
other harmful objects, always use a suitable method or procedure.