Cead 000300
Cead 000300
Cead 000300
Operation
& Maintenance
Manual
WA5004
WHEEL LOADER
SERIAL NUMBERS
VVA5004E - A61001 andup
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP
MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
SHOP MANUAL:
Engine:
Shop Manual .................. . . . . . . . . .. . . .. . . 3810487
Trouble Shooting & Repair ....... . . . . . .. . .. . . . . .. 3810456
Specifications Manual ........... . . . . . . .. . ... . .. .. . .. 3666090
Standard Man-Hour Guide ....... . . . ... . .. . ... . . .. . 3666031
SAFETY MANUAL. ....... .. .... . ... .. ... ... .... ... ... WLT70-1
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FORTECHNICAL PUBLICATIONS &SERVICE FORMS CAN BE USED. FORM KDC91 D IS SHOWN
ON THE REVERSE SIDE OF THIS PAGE.
COMPLETE FORM
AND RETURN TO - Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO a
A’lTN.
STREET ADDRESS
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ONLY l
CITY, STATE, ZIP CODE
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IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
This manual provides rules and guidelines, which will help you use this machine safely and effectively.
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not
be read, request a replacement manual from your local distributor if you are the owner or end user or from Komatsu
America International Company if you are a distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in
this manual. Consult your local distributor if you are the owner or end user or consult Komatsu America International
Company if you are a distributor for the latest available information on your machine or for questions regarding
information in this manual.
a WARNING! Improper operation and maintenance of this machine can be hazardous and could result
in serious injury or death. Operators and maintenance personnel must read this manual thoroughly
before operating or maintaining this machine. This manual should be kept near the machine for
reference and periodically reviewed by all personnel who come across it. Some actions involved in
operation and maintenance of the machine can cause a serious accident, if they are not performed
in the manner described in this manual. The precautions and procedures given in this manual apply
only to the intended uses of the machine. If you use the machine for any unintended uses that are not
specifically prohibited, you must be sure that it is safe for you and others. In no event should you or
others engage in prohibited uses or actions as described in this manual.
NOTICE: Komatsu America International Company delivers machines that comply with all applicable regulations and
standards of the country to which it has been shipped. If the machine has been purchased in another
country or purchased from someone in another country, it may lack certain safety features and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable regulations and standards of your country, consult your local distributor or
Komatsu America International Company before operating the machine.
NOTICE: For engine information not covered in this manual, refer to the Cummins Engine Operation and Maintenance
Manual.
O-l
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.
To identify safety messages in this manual and on machine product graphics, the following signal words are used.
A DANGER! - This word is used on safety messages and product graphics where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages and product graphics 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.
WARNING! - This word is used on safety messages and product graphics where there is a
A potentially dangerous situation, which could result in serious injury or death if the
hazard is not avoided. These safety messages and product graphics 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.
A CAUTION! - This word is used on safety messages and product graphics for hazards, which
could result in minor or moderate injury if the hazard is not avoided. These safety
messages and product graphics might also use this word for hazards where the
only result could be damage to the machine.
NOTICE - This word is used for precautions that must be taken to avoid actions, which could
shorten the life of the machine.
Komatsu America International Company cannot predict every circumstance that might involve a potential hazard in
operation and maintenance. Therefore the safety message in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are
used, you must be sure that you and others can do such procedures and actions safely and without damaging the
machine. If you are unsure about the safety of some procedures, contact your local distributor if you are the owner
or end user or or Komatsu America International Company if you are a distributor.
o-2
INTRODUCTION
If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will
prematurely deteriorate and the service life will be reduced. A new machine must be operated with care, particularly
with regard to the following items.
l After starting, let the engine idle for 3 to 5 minutes to allow proper engine warm-up prior to actual operation.
l Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of emergency.
0 At the first 250 hours of operation, the machine should be maintained in the manner described in Section 3
“MAINTENANCE”.
o-3
INTRODUCTION
* The engine data plate, shown below, shows specific information about your engine and provides the information
for ordering parts and service needs.
L02AD044
O-4
INTRODUCTION
MACHINE MODEL NAME & MACHINE SERIAL NO. ENGINE MODEL NAME & ENGINE SERIAL NO.
DISTRIBUTOR’S NAME:
NOTES OR REMARKS:
PERIODIC SERVICE
DELIVERY
PERIODIC
PERIODIC
PERIODIC
CONSUMABLE PARTS
O-5
CONTENTS
DESCRIPTION
SAFETY PRODUCT GRAPHICS AND LOCATIONS . ... .. .... ...... .... ... . .. ... 1-14
OPERATION -- SECTION 2
O-6
CONTENTS
Engine Coolant Level Monitor ...................... . . .
2-6
CAUTION MONITOR LAMP GROUP .................. .. . . . . ... ... ... . . .
2-6
Charge Monitor ................................. ... . . . . .. ... ... . . .
2-6
Fuel Level Monitor ............................... ... .. . . .. .. . . .. . . .
2-7
Transmission Oil Filter Monitor ..................... . . .. . . .. ... .. . . .
2-7
CAUTION MONITOR LAMP GROUP .................. ... . . . .. ... .. . . .
2-7
Brake Line Failure Monitor ......................... ... .. . . . .. ... .. . . .
2-7
Engine Oil Pressure Monitor ....................... ... . . . .. ... ... . , .
2-8
Engine Coolant Level Monitor ...................... ... . . . . .. . ... ... . . .
2-8
Air Pressure Monitor ............................. .. . . ... ... . ... .. . . .
2-8
Engine Coolant Temperature Monitor ................ .. . . ... ... ... .. . . 2-9
Torque Convertor Oil Temperature Monitor ............ ... .. . . .. . ... .. . .. 2-9
Ground Driven Steering Operation Monitor - If Equipped . . . . . . ... . ... ... . .. 2-9
METER AND PILOT LAMP GROUP ................... .. . . ... ... . ... .. . 2-10
Parking Brake Pilot Lamp ......................... ... .. . . . .. . ... ... . . 2-10
Working Lamp Pilot Lamp ......................... .. . . . . ... . ... .. . . 2-11
Transmission Cut-Off Selector Pilot Lamp ............. ... . . . . . ... .. . . 2-11
Air Pressure Gauge .............................. .. .. . . . .. . ... .. . . 2-l 1
Engine Coolant Temperature Gauge ................. ... .. . . . . ... ... . . 2-12
Torque Converter Oil Temperature Gauge ............ .. .. . . . . .. . ... .. . . 2-12
Fuel Level Gauge ................................ .. . ... ... . ... .. . . 2-12
Turn Signal Pilot Lamp ............................ .. . . . . .. . ... .. . . 2-13
High Beam Pilot Lamp ............................ ... . . . . . .. . ... .. . . 2-13
Speedometer ................................... ... .. . . ... .. . ... .. . . 2-13
Service Meter ................................... .. . . . . .. . ... .. . . 2-14
SWITCHES ......................................... ... . . . . .,. . .. ... . . 2-15
TRANSMISSION CUT-OFF SELECTOR SWITCH ....... ... . . .. .. . ... ... . . 2-15
ETHER START SWITCH ........................... ... .. . .. .. . ... .. . . 2-16
HORN BUTTON .................................. ... .. . .. .. . . .. . . 2-16
HAZARD LAMP SWITCH ........................... ... .. . . . ... . . . .. . 2-16
PARKING BRAKE SWITCH ......................... ... .. . . ... . . . .. 2-17
WORKING LAMP SWITCH .......................... ... . . . .. . . .. . 2-18
STARTING SWITCH ............................... ... . . . . ... . . . .. 2-l 8
LAMP SWITCHES. ................................ ... . . . ... . . . .. 2-l 8
Lampswitch .................................... ... . . . . ... . . .. . 2-18
Turn signal lever ................................ ... . . . . ... . . . .. . 2-19
Dimmer switch .................................. ... . . . . ... . ... ... . 2-19
CIGARETTE LIGHTER ............................. ... . . . . ... . ... .. . 2-20
TRANSMISSION KICKDOWN SWITCH ................ ... . . ... . ... .. . 2-20
FRONT WIPER SWITCH - IF EQUIPPED .............. ... . . . . ... . ... . . . 2-21
REAR WlPER SWITCH - IF EQUIPPED ............... . . . . . . .. . ... .. . . 2-21
CAB DOME LAMP SWITCH - IF EQUIPPED ............ ... . . . . .. . ... ... . . 2-22
LEVERS AND PEDALS ................................ ... . . . . .. . ... .. . . 2-23
DIRECTIONAL LEVER ............................. ... . . . . . ... .. . . 2-23
SPEED CONTROL LEVER .......................... ... .. . . . . ... .. . . 2-24
SPEED CONTROL LEVER STOPPER. ................ ... . . . . .. . ... ... . . 2-24
STEERING COLUMN TILT LEVER ................... ... . . . .. . ... ... . . 2-24
ACCELERATOR PEDAL. ........................... ... .. . . . .. . ... .. . 2-25
BRAKE PEDALS .................................. ... . . . . . ... .. . 2-25
Right brake pedal ................................ ... . . . . . . ... .. . 2-25
Leftbrakepedal ................................. ... . . . . . . . . ... . 2-25
LIFT ARM CONTROL LEVER ........................ ... . . ... ... . ... .. . 2-26
BUCKET CONTROL LEVER ........................ ... . . . .. . . 2-26
FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED .. . 2-27
WORK EQUIPMENT CONTROL LEVER LOCK. ......... .. . . 2-27
Q-7
CONTENTS
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED ............... . . . .. . . . . . . 2-27
AIR CLEANER SERVICE INDICATOR ....................... . . . .. . . . . . . . . 2-28
FRAME LOCKING BAR ................................... . . . .. . , . . . . . . 2-28
MAIN CIRCUIT BREAKER ................................ . . . . . . . . . . . 2-28
FUSE BOXES .......................................... . . .. .. . . . . . . . 2-29
OPERATOR’S SEAT ..................................... . . . .. . . . . . . 2-32
FORWARD-BACKWARD ADJUSTMENT. ................. . . . . . . . . . . . . 2-32
SEAT ANGLE ADJUSTMENT. .......................... . . . . .. . . . . . . . 2-32
WEIGHT ADJUSTMENT ............................... . . . . . . . . . . . 2-32
BACKREST TILT ADJUSTMENT ........................ . . . . . . . . . . . . 2-32
HEIGHT ADJUSTMENT ............................... . . . . . . . . . . . . . 2-32
RIGHT SIDE ARMREST .................................. . . .. .... . . . . . . 2-32
HEIGHT ADJUSTMENT ............................... . . . . . . . . . . . 2-32
ANGLE ADJUSTMENT ................................ . . . . . . . . . . . . 2-32
SEATBELT.. .......................................... . . . . . . . . . 2-33
O-8
CONTENTS
OPERATIONAL PRECAUTIONS ............... . . .... .. .. .. . .. . .... ... . 2-52
PERMISSIBLE WATER DEPTH ............. . .. .... .. . .. . .. . . . ... ... . 2-52
IF WHEEL BRAKES DO NOT WORK. ........ . .. .... . . .. . . .. . . .... .. 2-52
WHEN TRAVELING UP OR DOWN SLOPES . . . . . . . . . . . .. .. . . .. . . . .... .. . 2-52
Lower Center of Gravity When Turning ...... .... .... . .. .. . . .. . . .... ... . 2-52
Braking on Downhill Slopes ............... .... .... . .. .. . . .. . .. . .. ... . 2-52
If Engine Stops ......................... .. . .... .. .. .. . . .. . .. .... ... . 2-53
POSSIBLE WORK USING LOADER ............. .. . .. .. .. .. . . .. ... .... . . . 2-54
EXCAVATI 0 N ........................... . .. .. .. .. .. . . .. ... ... . . . 2-54
LEVELING .............................. . . .. .. .. .. . . .. ... .... . . 2-56
LOAD AND CARRY OPERATIONS .......... . .. ... . .. .. . . .. . ... .... . . . 2-57
LOADING .............................. . .. .. . . .. . . .. . . . . .. ... . 2-57
Cross Drive Loading .................... . .. ... .. .. .. . . .. . .. .... ... . 2-57
V-Shape Loading ....................... .... .... .. .. . . . .. . ... . .. . . . 2-58
PARKING MACHINE ......................... .... .... .. .. .. . . .. ... .... . . . 2-58
STOPPING ENGINE ......................... .. . . . .. .. .. . . .. ... .. . . . 2-59
OPERATIONS AFTER STOPPING ENGINE ...... . .. . .. .. .. .. . . .... 2-59
o-9
CONTENTS
BEFORE CONNECTING BOOSTER CABLES. .......................................... 2-72
CONNECTING BOOSTER CABLES .................................................. 2-72
STARTINGENGINE ............................................................... 2-72
DISCONNECTING BOOSTER CABLES ............................................... 2-73
MAINTENANCE -- SECTION 3
FILLER AND LEVEL GAUGE POSITIONS . ... ..... ..... . .. .... .. _ ...... . . . . . . . . . . 3-22
O-l0
CONTENTS
HYDRAULIC TANK OIL LEVEL. ......................................................... 3-46
LUBRICATION ....................................................................... 3-47
CAB AIR FILTER - IF EQUIPPED ........................................................ 3-47
O-l 2
CONTENTS
EVERY 6000 HOURS SERVICE ...... . . . .. .. ... . . . . . . .. . . . ....... 3-76
FUEL PUMP .................. .. . ... .. . . . . . . . . . . . ....... 3-76
FUEL INJECTORS ............. . . . . . . . . . . . . . ....... 3-76
ENGINE FAN HUB ............. . . . . . . . . ....... 3-76
ENGINE IDLER PULLEY ......... . . . . . . . . . . . ....... 3-76
TURBOCHARGER ............. . . . . . . . . . . . . ....... 3-76
AIR COMPRESSOR ............ . . . . . . . . . . . . ....... 3-76
ENGINE VIBRATION DAMPER ... . . . . . . . . . . . ....... 3-76
SPECIFICATIONS -- SECTION 4
DIMENSIONS............................................................................ 4-3
O-l 3
CONTENTS
MEMORANDA
o-14
SECTION 1
SAFETY PRECAUTIONS
A
WARNING ! REFER TO AND READ ALL
l-l
SAFETY PRECAUTIONS
AVOID ACCIDENTS
A
This symbol is used throughout this manual to call your attention to instructions
concerning personal safety. Observe and follow these instructions. Be certain anyone
operating or servicing this machine is aware of these rules. Failure to follow these rules
may result in injury or death.
GENERAL PRECAUTIONS
PERSONNEL PRECAUTIONS
Operating and servicing this machine can be hazardous if performed improperly. Personnel must have the necessary
skills, information and equipment and use safe and proper procedures. Study the Operation and Maintenance Manual
before operating or servicing this machine. Consult your Distributor for information and service.
Only trained and authorized personnel should be allowed to operate and service this machine.
Read all warning product graphics before starting, operating, maintaining or repairing this machine.
DO NOT wear jewelry or loose fitting or hanging clothing because they could catch on moving parts and cause injury
or death. Wear proper safety equipment, such as a hard hat, rough-soled work shoes or safety shoes, ear protectors,
reflective vests, respirators, safety glasses, goggles and heavy gloves. Consult your employer for specific
requirements.
DO NOT jump on or off the machine. Keep two hands and one foot, or two feet and one hand, in contact with the steps
and handholds at all times. Place objects on machine from ground level before climbing on. Always face the machine
when climbing on or off to reduce the chances of slipping and injury.
Think before you act. Careful operators and service personnel are the best insurance against accidents.
Do not rush. Hurrying can lead to accidents. Haste, carelessness and lack of training are the primary causes of
equipment-related injuries.
MACHINE PRECAUTIONS
Carefully evaluate your application’s particular safety needs. Each machine application can have unique requirements.
You may need such attachments as: rear windshield wipers, windshield washers, heater, defroster fan, warning lights,
air conditioning, ROPS, mirrors, backup alarm, fire extinguisher, spark arrestor, fire suppression system, cab screens,
sound suppression, rotating beacon, additional lights, anti-vandalism attachments, guards, tow hook, Lexann windows,
water glycol, communication radios, ground driven steering, turn signals, and slow moving vehicle sign. Consult your
Distributor for information.
Be sure the machine has the correct equipment required by local rules and regulations.
A rollover protective structure (ROPS) with a seat belt is required by OSHA in almost all applications. DO NOT operate
this machine without a ROPS.
l-2
SAFETY PRECAUTIONS
It is recommended that the machine be equipped with a fully charged fire extinguisherwith an Underwriter’s Laboratory
(UL) rating of 2A:IOB:C (or higher). Personnel should be instructed in proper usage. Recharge immediately after use.
If the machine will be used for tree removal or site clearing, install approved operator guards per S.A.E. or OSHA
requirements. Consult your Distributor for information.
If the machine will be working under conditions of flying combustible material, install screens and guards to reduce
the chance of fire.
If the machine is equipped with a suction fan (or a reversible fan in the suction position), check the engine exhaust
system periodically for leaks. Exhaust gases are dangerous to the operator. On machines equipped with a cab, keep
a vent open to outside air.
Keep shields and guard in place for your protection. Be sure to replace them after servicing the machine.
When transporting the machine, use caution when loading and unloading it. Load and unload the machine in a level
area which fully supports the machine and transport vehicle. Block the transport vehicle so it cannot move. Use loading
ramps of adequate strength, low angle and proper height. Keep the trailer bed and the machine’s tires clean of clay,
oil and other slippery materials. Lock the machine’s front and rear frames together with the frame locking bar and pins.
Apply the machine’s parking brake. Block the tires and securely tie down the machine and the machine tires, to the
trailer bed.
OPERATION
BEFORE STARTING
Before entering the operators compartment, walk completely around the machine and clear the area of personnel and
obstructions.
Perform a visual check of the machine before starting the engine. Look for such things as missing protective devices,
leaks, improper fluid levels, trash buildup and loose, damaged or missing parts. DO NOT start the engine until any
unsafe conditions are corrected.
Before operating the machine, check that the frame locking bar and pins are in the storage position on the rear frame.
A broken or lost frame locking bar or pins should be replaced immediately so that this device is always available for
use.
Be sure all filler caps, dipsticks, plugs, latches, service doors, etc., are secure before starting.
BE SURE the operator’s compartment, mounting steps and handholds are free of oil, grease, snow, ice, mud and
foreign objects to reduce the possibility of slipping and injury. Repair any damaged steps or handholds. Remove or
secure all maintenance and personal items which might interfere with the operator or jam the controls.
Do not use the machine’s controls or hoses as handholds when climbing on or off the machine. Controls and hoses
can move and do not provide solid support. Movement of the controls may cause unexpected machine movement and
injury.
Know the alternate exit routes from the operator’s compartment for use in an emergency.
l-3
SAFETY PRECAUTIONS
If the machine is equipped with a cab, the right hand side door of the cab serves as an emergency exit. Use only if
the left hand side door is blocked.
The operator must be alert, physically fit and free from the influences of alcohol, drugs and medications that might
affect his eyesight, hearing or reactions.
Safety must always be the operators most important concern. He must refuse to operate when he knows it is unsafe
and consult his supervisor when safety is in doubt.
START-UP
Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases. Once
the engine is running, move the machine outdoors as soon as possible. Exhaust gases are hazardous and can cause
unconsciousness and death.
Sit in the operator’s seat before operating any controls. Keep hands and footwear free of grease, water and mud to
insure positive control movement.
Before starting the engine, or when machine is standing with the engine running: place the transmission directional
lever in neutral (N), apply the parking brake and lower any raised equipment.
DO NOT SMOKE when using the ether start. Do not use the ether start when the air temperature is above freezing.
Follow the correct method for starting the engine. Refer to “STARTING ENGINE” in Section 2.
Before driving the machine, adjust the seat and fasten the seat belt. Adjust the seat for maximum comfort and control
of the machine. Adjust the seat belt to fit snugly and low around the hips to lessen the chance and severity of injury
in the event of an accident. Never wear the seat belt across the abdomen.
Use of the seat belt with the ROPS is strongly recommended. In the event of a rollover, stay with the machine.
Experience has shown this will reduce the chance and seriousness of injury.
Before moving the machine, check the brakes, steering, attachment controls and safety devices. DO NOT operate
the machine until any unsafe conditions have been corrected.
Before moving the machine, sound the horn to warn nearby personnel.
Release the parking brake before moving the machine. The brake could burn or be damaged if the machine is driven
with it applied.
NEVER HAUL PASSENGERS. Only the operator should be on the machine when it is moving.
Use caution and follow the manufacturer’s instructions when using external heaters to warm the power train in cold
weather.
Stay alert and aware of what you are doing. Use common sense. Do not operate when fatigued or ill. Know your
machine and its capabilities. Use the machine only for its intended purposes. For your safety, read the Operation and
Maintenance Manual carefully and follow all instructions and precautions.
1-4
SAFETY PRECAUTIONS
Provide proper ventilation when operating in a closed area to minimize the danger of exhaust gases. Exhaust gases
are hazardous and can cause unconsciousness and death.
Maintain clear vision of all work and travel areas. Keep windows and mirrors clean and repaired.
Look in the intended travel direction to be sure personnel and allied equipment do not interfere with the machine’s work
pattern. Do not operate if exposed personnel enter the immediate work area.
Turn on the machine’s lights at night and times of poor visibility to see and be seen.
DO NOT adjust the seat while the machine is moving because a loss of control may result. Stop the machine, apply
the parking brake and then adjust the seat.
Keep head, limbs and body inside the operators compartment at all times because of the chance of being injured by
hazards outside the operators compartment.
NEVER allow anyone near the center articulation pivot. If the machine turned, they could be crushed.
NEVER allow anyone to stand on the ladder when the bucket is raised or the machine is moving or turning to prevent
injury from falling, crushing or falling material.
NEVER get on or off the machine while it is moving because serious injury or death could result.
After starting and while operating, observe instruments and warning lights frequently. Investigate any unusual
indications or noises in the machine.
If the engine has a tendency to stall, investigate immediately. Do not operate the machine until the cause has been
corrected.
If noise exposure exceeds 90 dBA for eight hours, wear ear protective equipment.
DRIVINGTHEMACHINE
Carry the bucket low for maximum visibility and stability when traveling.
Before operating in areas with overhead obstructions, carefully check overhead clearance. Obstructions, such as guy
wires, power lines, tree branches, bridges and building doors could cause a rollover accident.
Drive slowly enough to insure complete control. Slow down when traveling in congested areas or on mud, ice or other
slippery surfaces. Keep a safe distance away from other vehicles, according to the load and ground conditions.
Avoid crossing obstacles, such as ridges, curbs, logs and rocks. If you cannot avoid them, reduce speed and cross
at an angle. Ease up to the breakover point, pass the balance point slowly and ease down on the other side.
Cross ditches and gullies slowly and at an angle after checking that the ground will safely support the machine.
Avoid sidehill travel whenever possible. Drive straight up and down the hill. If the machine starts slipping sideways,
turn downhill immediately.
When traveling on hills with a loaded bucket, travel forward up the hill and in reverse down the hill.
I-5
SAFETY PRECAUTIONS
Stop, look and listen before entering a highway. Stay on the right side of the road. Slow down and signal when turning
Off.
When roading the machine, engage the hydraulic control lever lock to guard against accidental actuation of the levers.
Personal injury could result if the bucket catches on a ledge in the road.
Do not use the transmission disconnect brake pedal when traveling fast or going downhill because this shifts the
transmission into neutral. Loss of control or damage to the power train could result when the pedal is released and
the transmission is re-engaged.
Never shift the transmission into neutral (N) when traveling downhill. The machine could go out of control or the power
train could be damaged when the transmission is shifted into gear again.
Do not overspeed the engine. Excessive speeds can be hazardous and harmful to the power train. Select the proper
gear before starting downhill. Control speed with the brakes.
Never use the bucket as a brake except in an emergency. It might catch on the ground and result in personal injury.
If the main steering light comes on, IMMEDIATELY stop the machine in a safe place. Shut off the engine and apply
the parking brake. Correct the cause before operating again.
If the brake system warning light or buzzer comes on during operation, IMMEDIATELY stop the machine in a safe
place. Apply the parking brake. Correct the cause before operating again.
Know the traffic flow pattern of the job site. Obey flagmen, signs and signals.
Give the right-of-way to loaded machines. On narrow or hilly roads, loaded machines should stay next to the high wall.
Keep the machine as close to the side of the road as safely as possible to leave room for oncoming and passing
vehicles.
Pass other vehicles only when the road is clear and the machine has enough distance and reserve power to pass.
Check the work area for hazardous conditions. Be alert for soft ground conditions, especially when working on slopes,
near dropoffs or excavations or on fill material, which could lead to sudden tipping of the machine.
Keep the work area free from obstructions and as smooth as possible.
Know the locations of underground cables, water mains, gas lines, etc. A broken gas line or electrical cable could
cause personal injury or death.
Avoid operating too close to an overhang, deep ditch or excavation because the machine’s weight and vibration may
cause the edge to collapse and result in personal injury. If this cannot be avoided, use extra caution and face the
machine toward the edge while operating.
Avoid undercutting high banks because the bank may cave in. Ramp up and remove the top layers first.
Trucks should be loaded from the drivers side whenever possible. When the truck is being loaded, be sure the driver
either stays in the cab (on cab-protected trucks) or away from the truck and loader.
When loading trucks, be careful not to hit the truck with the loader or its bucket.
l-6
SAFETY PRECAUTIONS
Use extra caution when moving with the bucket raised to minimize the chance of machine upset.
DO NOT swing a load over the heads of other workers or a truck cab.
If the loader begins to tip over because of an overload, IMMEDIATELY lower the bucket to regain stability.
There in no substitute for good judgment when working on a slope. Slope operation should be limited by ground and
traction conditions, the load being carried and the speed of the machine.
NEVER operate sideways on a steep slope because a rollover and serious injury could result.
Using the loader to carry large objects which do not fit into the bucket is NOT recommended. Handling large objects
can be extremely dangerous because the objects may roll or slide down the lift arms onto the operator. NEVER lift
large objects higher than the operator unless the machine has a device which prevents the objects from falling back
onto the operator.
When pushing over trees, the machine must have approved operator protection. Back away immediately when the
tree starts to fall. Use extreme care when pushing over trees with dead branches which may fall. To reduce the chance
of machine upset, never allow the machine to climb up the root structure.
PULLING/TOWING
For your safety, never push or tow a disabled machine farther than absolutely necessary to load it onto a truck.
When using a chain or cable, be sure it is strong enough for the expected load and properly secured to the drawbar
pin.
Hitch only to the drawbar pin. Machine upset can result if pulling from the wrong location.
When pulling, position the machine so that the chain or cable aligns with the long axis of the machine.
Inspect chains and cable for flaws before using. Avoid kinking. Do not pull with a kinked chain or cable because the
high stresses could cause a failure in the kinked area. Wear heavy gloves when handling chain or cable.
When pulling with a chain or cable, take up the slack slowly to avoid jerking. A chain or cable which fails under load
can whip and cause serious injury. STAND CLEAR. DO NOT PULL OR TOW UNLESS THE OPERATORS
COMPARTMENT IS GUARDED AGAINST OR OUT OF REACH OF A WHIPPING CHAIN OR CABLE.
SHUTDOWN
Never leave the machine with the engine running or the bucket raised. When parking the machine, shut off the engine,
lower the bucket to the ground, place the transmission directional lever in neutral (N), apply the parking brake, turn
off the electrical starting switch and remove the key.
Raised lift arms will drop when the control lever is moved to “LOWER’ or “FLOAT’ even with the engine off. ALWAYS
lower the lift arms when parking the machine.
If the machine is equipped with a multi-purpose bucket, close the clam before dismounting.
Park the machine in a non-traffic area. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers,
flares and warning signals. Also provide advance warning signals in the traffic lane for approaching traffic.
1-7
SAFETY PRECAUTIONS
Avoid parking on a slope because unexpected machine movement may occur. If necessary to park on a slope, park
at right angle to the slope and block the tires.
Always lock the machine, including any anti-vandalism attachments, when leaving it unattended.
MAINTENANCE
GENERAL MACHINE PRECAUTIONS
Constantly be aware of dangers involved in working on the machine and take proper precautions. It is not possible
to anticipate all conceivable ways or conditions under which this machine may be serviced or to provide precautions
for all the possible hazards that may result. Safety is always the most important rule. Standard and accepted safety
precautions and equipment should be used.
Do not attempt repairs you do not understand. Consult your Distributor for information and service.
NEVER run the engine when cleaning or lubricating the machine because serious injury could result from contacting
moving parts.
Before servicing the machine, BE SURE the engine is off, the bucket is lowered, the transmission directional lever is
in neutral (N), the parking brake is applied and the electrical starting switch is off and the key is removed. Tag the
machine.
Before working on the engine or electrical system, disconnect the negative (ground) battery cable. Tag the cable and
controls to warn against starting.
Before working under the machine, block the tires to prevent machine movement.
ALWAYS lock the front and rear frames together with the safety bar and pins before working near the center of the
machine. If the frames move, serious injury could result.
NEVER stand near the bucket or the tires while the engine is running.
During servicing, DO NOT allow anyone in the operator’s compartment who is not trained and assisting in the
servicing.
When it is necessary to make any checks or adjustments with the engine running, use two people. A trained operator
must be at the controls to safeguard the mechanic making the checks or adjustments. BE SURE the transmission
directional lever is in neutral (N), the parking brake is applied and the front and rear frames are locked together.
Be sure the engine hood or access door(s) is secure in the open position during service work in the engine
compartment. Unexpected closing could cause injury.
NEVER remove any guards or shields with the engine running because of the danger of contacting rotating parts.
When service requires access to areas that cannot be reached from the ground or a service platform on the machine,
use a ladder or platform of appropriate capacity.
Use only approved parts for repairs and maintenance. Failure to do so could compromise personal safety, machine
performance and reliability.
l-8
SAFETY PRECAUTIONS
This machine is assembled using high strength fasteners. Replacement fasteners must be of the same size and
strength as the originals. DO NOT SUBSTITUTE. Refer to the Parts Book for this machine. Tighten fasteners to the
proper torque. Refer to Section 4.
Replace any missing or defaced product graphics. When parts which have product graphics on them are replaced,
be sure to install new product graphics. New product graphics are available from your Distributor. For the proper
position of the product graphic, refer to “SAFETY PRODUCT GRAPHICS AND LOCATIONS’.
NEVER adjust relief valves higher than the specified pressure because this may damage the machine and lead to an
injury. When checking pressures, use the correct gauge for the expected pressure. Consult your Distributor for
information and service.
Keep work area clean and dry. Remove water and oil spills immediately to reduce the chance of slipping and injury.
Do not pile up oily or greasy rags; they are a fire hazard. Store them in an approved, closed metal container.
Use a non-toxic, non-flammable commercial solvent for cleaning parts, unless otherwise specified.
Avoid use of gasoline, diesel fuel, kerosene or other flammable solvents for cleaning parts. NEVER place these
solvents in an open drain.
Corrosion inhibitors are volatile and flammable. Use them only in a well ventilated area. Keep flames and sparks away.
Do not smoke. Store container in a cool, well ventilated place.
Avoid prolonged exposure to volatile corrosion inhibitors because eye and skin irritation may occur.
Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact, remove
sealant or solvent promptly by washing with soap and water. Follow the manufacturer’s advice whenever cleaning
agents or other chemicals are used.
Wear eye protection when using air or water under pressure to clean parts. Limit air pressure to 2.1 kg/cm* (30 psi
/ 200 kPa) and water pressure to 2.8 kg/cm* (40 psi I275 kPa).
When cutting, grinding, pounding, prying or whenever material could fly or fall, wear proper protective equipment such
as goggles, hard hat, safety shoes and heavy gloves. Many of the machine’s parts are hardened and can chip.
When welding, wear proper protective equipment, such as a helmet, dark safety glasses, protective clothing, gloves
and safety shoes. DO NOT LOOK AT THE ARC WITHOUT PROPER EYE PROTECTION.
If necessary to do welding on the machine, attach the ground cable close to the weld area. Do not attach the ground
cable where the current can flow through bearings or mounting pads because this will damage the parts.
Use extra caution when jacking up the machine. Jacking up the machine can be hazardous if performed improperly.
Use jacking equipment of sufficient capacity. Be sure the jacking points are strong enough to support the machine.
Be sure the jack is stable and well supported. Before jacking up the machine, block the tires which will not be lifted.
Lock the front and rear frames together with the locking bar and pins. If the rear tires are being lifted, block the rear
axle to prevent it from pivoting unexpectedly. DO NOT run the engine with the machine on jacks. For your safety,
transfer the weight of the machine to approved blocks, before servicing the machine.
l-9
SAFETY PRECAUTIONS
Use the proper tool for the job. Be sure all tools are in good condition. Do not use tools which are worn, bent or have
mushroomed heads because they can lead to injury.
Never align holes with fingers or hands. Use the proper aligning tool to avoid injury.
Do not carry loose objects in pockets because they might catch on the machine and result in a fall or injury.
Use only properly grounded auxiliary power sources for chargers, heaters, electrical drills and similar equipment to
reduce the chance of electrical shock.
Lift and handle all heavy parts with lifting devices of adequate capacity. Secure parts with proper slings and hooks.
Use lifting eyes provided. Warn nearby personnel to stand clear.
DO NOT use the bucket to lift personnel or as a work platform. Mechanical failure or human error could cause
unexpected movement of the attachment and serious injury or death.
ACCUMULATORS
l Never overhaul or dispose of an accumulator without first bleeding out all the nitrogen through the air bleeder
valve.
* Have your distributor check the gas pressure charge within the accumulator at the specified service interval as
listed in “MAINTENENCE”, Section 3.
ATTACHMENTS
For your protection, use EXTRA caution when adjusting the loader’s bucket positioner or boom positioner. Use two
trained people and guard against accidental movement of the machine or loader linkage.
For your protection, keep head, body, hands and fingers away from the bucket and linkage when they are in a raised
position, unless they are securely blocked.
I-IO
SAFETY PRECAUTIONS
When replacing cutting edges and teeth, securely block the bucket for your protection.
To install and remove bucket teeth, use a nonferrous hammer. It is hazardous to hammer on the teeth. Wear safety
glasses with side shields or goggles to reduce chances of injury.
BRAKES
Block the tires to prevent machine movement before servicing the brakes.
Test the parking brake periodically. If the parking brake does not hold the machine, correct the cause as soon as
possible. Until the cause is corrected, park the machine on level ground and block the tires to prevent it from moving.
When testing the parking brake, be sure the area near the machine is clear of personnel and obstructions because
the machine may move during the test.
CAB/ROPS
Do not attempt to repair a rollover protective structure (ROPS) after an accident. The ROPS is designed to bend during
a rollover to protect the operator from sudden impact loads. Repaired structures do not provide the original strength
and protection. O.S.H.A. regulations prohibit repair to damaged ROPS. Contact your Distributor for information on
ROPS replacement. Do not operate the machine again until the ROPS has been replaced.
Do not cut, grind, weld or drill holes in the ROPS because this could weaken the structure or affect its energy
absorption capability.
Periodically inspect the ROPS for fatigue cracks. Cracks indicate a weakened structure which should be replaced for
your protection.
Do not use bleach, dye or solvents on the seat belt because this may weaken the webbing and result in personal
injury. Clean the seat belt with warm water and a mild detergent. Replace belts with worn, frayed, torn, faded, stiff or
rotted webbing.
COOLING
Hot, scalding coolant can spray out if the radiator cap is removed suddenly. Relieve system pressure by slowly turning
cap to the first notch or lifting the safety lever (if equipped). Remove the cap ONLY after the pressure is relieved.
Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and goggles and keep
face away from the filler neck.
ELECTRICAL
Batteries give off a highly flammable gas. DO NOT SMOKE or allow sparks or open flame near the batteries because
a fire or explosion could result.
BE SURE the electrical starting switch is off when connecting or disconnecting batteries to minimize the chance of
sparks and explosion.
I-II
SAFETY PRECAUTIONS
DO NOT allow metal tools or a jumper cable clamp to contact the positive battery terminal and any other metal on the
machine. The resulting sparks could cause an explosion.
When using a booster battery and jumper cables, connect the negative (ground) cable to the machine frame, AWAY
FROM THE BATTERY. ALWAYS connect the ground cable last and disconnect it first to avoid sparks near the battery.
A spark could cause a battery explosion and injury.
NEVER check the battery charge by placing a metal object across the terminals. The sparks could cause a battery
explosion. Use a voltmeter or hydrometer to measure charge.
Battery acid causes severe burns. Avoid contact with eyes, skin or clothing. Wear goggles, rubber gloves and apron.
If skin contact occurs, flush with water. If eye contact occurs, flush with water for 15 minutes and get prompt medical
attention.
The engine can be started with the transmission in gear if the neutral start switch is bypassed. Do not connect across
the terminals on the starter motor. Attach booster batteries as directed in this manual.
DO NOT charge batteries in a closed area. Provide proper ventilation to guard against explosion of an accumulation
of the gas given off in the charging process.
ENGINE
Do not go into the engine compartment without securing the engine access panel door. Accidental closure of the door
could cause injury.
Do not rework or modify the engine flywheel because this could weaken it and lead to a failure.
Keep the engine exhaust manifold(s) and exhaust system clear of combustible material to reduce the chance of fire.
Ether starting fluid is highly flammable. Follow the precautions on the container. An explosion can result if sparks or
flame contact the ether in the container or if the container is stored where the temperature exceeds the temperature
listed on the container. Observe the following precautions:
Follow the correct method for starting the engine. Refer to “STARTING ENGINE” in Section 2.
Do not use the ether start when the air temperature is above freezing.
DO NOT store fluid containers in the operator’s compartment or in direct sunlight. Store containers in a cool,
well ventilated place.
9. Do not let ether contact your skin because it can cause frostbite.
h. NEVER puncture the fluid container or put it into a fire. Dispose of empty containers properly.
i. For your safety, remove the ether container when welding, grinding or using a torch on the machine.
l-12
SAFETY PRECAUTIONS
FUEL SYSTEM
NEVER remove the fuel filler cap or fill the fuel tank while the engine is running or when the machine is indoors. The
fumes are hazardous and a spark or flame could cause a fire or explosion.
DO NOT SMOKE while filling the fuel tank or servicing the fuel system because a fire or explosion could result.
When filling the fuel tank, place the fuel nozzle against the side of the filler neck to reduce the chances of static
electricity sparks.
NEVER mix gasoline, gasohol or alcohol with diesel fuel. This creates a fire or explosion hazard which could result
in personal injury or death.
HYDRAULICS
For your safety, lower the bucket before servicing the machine. Be sure no one is standing near the bucket when it
is being lowered.
Before working on the hydraulic system, be sure the system pressure is relieved by moving the control levers in all
directions with the engine off.
This machine has a pressurized hydraulic reservoir. Loosen the filler cap slowly to relieve the pressure before
disassembly of any hydraulic system components. DO NOT OVERFILL.
DO NOT use hands to search for hydraulic leaks. Hydraulic oil escaping under pressure from a very small hole can
be almost invisible, yet have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for
suspected leaks. If injured by escaping oil, see a doctor immediately because of the possibility of serious infection or
reaction to the oil.
Tire and rim repairs MUST be done by specially trained people using special safety tools. An improperly repaired tire
or rim can separate suddenly and cause serious injury.
NEVER inflate a flat tire without inspecting the tire, rim and wheel for damage. Be sure all components are properly
assembled. Unmounted tires being inflated or deflated should be placed in a tire safety cage. Inflate the tire to 0.3
kg/cm2 (5 psi / 35 kPa) and check that all components are properly seated. NEVER stand directly in front of a tire and
rim assembly while inflating. Use a clip-on chuck with a hose long enough to allow the person inflating the tire to stand
to the side. Serious injury could result if the tire and rim were to separate.
TURBOCHARGER
In certain types of engine service, the turbocharger air inlet hose must be removed so other parts are accessible for
service or repairs. When the air inlet hose is removed, THE TURBOCHARGER IMPELLER IS EXPOSED AND CAN
CAUSE SERIOUS PERSONAL INJURY AND/OR ENGINE DAMAGE. Engine operation creates a vacuum in the
compressor strong enough to suck objects into the impeller. It is imoerative to install a safetv shield on the
turbocharaer inlet ooenina whenever air inlet hoses are removed. Failure to follow this precaution could result in
serious injury.
1-13
SAFETY PRECAUTIONS
4
I
s
LOZAD221
1-14
SAFETY PRECAUTIONS
10
4
iki
)hzkY
1
13
VIEW A
+4 0
VIEW
0
.
B
!aI
I
15
-8 VIEW D
L02AD222
Always keep these product graphics clean. If they are missing or damaged, replace them with a new product graphic.
Replacement product graphics can be ordered from your distributor.
In addition to safety product graphics, the machine has instructional and identification product graphics, which should
be treated in the same manner as described above.
Safety product graphics may be available in languages other than English. To find out more information about foreign
language product graphics, contact your distributor.
I-15
SAFETY PRECAUTIONS
1. Cautions when starting the machine 3. Caution for engine fan and belts
L02AD046
1-16
SAFETY PRECAUTIONS
L02AD073
REMOVlNG CAP.
DO NOT LOOSEN CAP WHEN OIL
TEMPERATURE IS HIGH.
IF LOOSENED, OIL MAY GUSH OUT.
SLOWLY OPEN HYDRAULIC OIL
6. Warning for pressurized cooling system TANK CAP AND RELEASE INTER-
NAL PRESSURE COMPLETELY.
DO NOT OPEN DRAIN PLUG WHEN
OIL TEMPERATURE IS HIGH.
L02AD052
1-17
SAFETY PRECAUTIONS
9. Caution for brake oil 11. Caution for transmission oil level
L02AD055
I-18
SAFETY PRECAUTIONS
L.H. BATTERY /\
‘0 START%&)/
OOTOR THE BATTERY CABLE TO THE CHASSIS GROUND IS THE BLACK
CABLE (0) ON THE R.H. BATTERY.
THE ELECTRICAL SYSTEM OF THIS VEHICLE IS OPERATED UNDER
+24V APPLIED AT THE TERMINAL OF RED CABLE (0) ON THE
L.H. BATTERY. (SEE THE ILLUSTRATION AT THE ABOVE LEFT.]
WHEN CHARGING BATTERIES ON THISVEHICLE BYANOTHER
BATTERIES, CONNECT THE BOOSTER CABLE IN THE FOLLOWlNG
PROCEDURE.
1. FIRST CONNECT THE POSITIVEOTERMINAL OF THE BATTERY
OF THE OTHER VEHICLE TO POSITIVE 0 TERMINAL OF THE
RED CABLE ON THE L.H. BATTERY ON THIS VEHICLE.
2. THEN CONNECT THE NEGATIVEOTERMINAL OF THE BATTERY
OF THE OTHER VEHICLE TO THE FRAME OF THIS VEHICLE
TOGETHER WITH THE OTHER CABLE. (DO NOT CONNECT
THEM TO THE CAB OR TO ANY OTHER OUTER COMPONENT.)
3. TO PREVENT FIRE WHEN DISCONNECTING CABLES, FOLLOW
THE RMRSE ORDER OF THE ABOVE PROCEDURE.
WHEN CHARGING BATTERIES MOUNTED ON AVEHICLE. FIRST
DISCONNECT THE BLACKCABLE ON THE R.H. BATTERY,
THEN PROCEED TO THE CHARGING OPERATION.
CHARGE THE BATTERIES IN AN OPEN AREAOR IN A WELLVEN-
TILATED PLACE WITH THEIR COVERS KEPT RAISED, AND NEtVER
BRING FIRE NEAR THEM. EXPLOSIVE GASES ARE GENERATED
DURING CHARGING.
REFER TO THE OPERATION AND MAINTENANCE MANUAL FOR
L02AD057
CAUTION
. DON7PUT OIL INTO THIS CLEANER.
. USE ONLY GENUINE KOMATSU ELEMENT.
WHEN DUST lNDlCATOR TURNS TO RED (IF THERE IS NO
INDICATOR, EVERY 250 HOURS) CLEAN OUTER ELEMENT.
ONE YEAR AFTER EXCHANGE OR AFTER USING CLEANED
OUTER ELEMENT FOR SIX TIMES, RENEW lNNER AND OUTER
ELEMENT.
* IF DUST IDICATOR TURNS TO RED SOON OR COLOR OF EXHAUST
GAS IS NOT CLEAN AND ALSO IN CASE OF LACKING POWER AFTER
CLEANING OUTER ELEMENT. INNER AND OUTER ELEMENTS SHALL
BE REPLACED.
IN THIS CASE, HOWEVER. DO NOT CLEAN INNER ELEMENT.
. ELEMENT MUST BE KEPT FREE OF CRACKS AND OIL.
IF ELEMENT HAS A CRACK, IT MUST BE REPLACED.
. FOR CLEANING AND REPLACEMENT OF ELEMENTS, REFER TO
INSTRUCTION MANUAL.
L02AD058
I-19
SAFETY PRECAUTIONS
L02AD059
I-20
SECTION 2
OPERATION
A
WARNING! REFER TO AND READ ALL
2-l
OPERATION
GENERAL VIEW
6 LOlADOOC
2-2
OPERATION
MONITOR PANEL
This monitor panel consists of monitor lamp groups (A, B and C), meter group (D) and warning lamp (E).
If necessary, check for and correct the abnormality based on the particular monitor lamp(s) before starting the engine.
* When the engine is started, these monitor lamps will go off even if there are abnormalities.
If any abnormality occurs while the engine is running, the appropriate monitor lamp and warning lamp (E) will flash to
indicate the abnormality at the same time.
* Even if any monitor lamp flashes, the machine can operate, but it should be repaired as soon as possible.
2-3
OPERATION
If any abnormality occurs while the engine is running, the appropriate monitor lamp and warning lamp (E) will flash and
the alarm buzzer will sound intermittently at the same time.
* If any monitor lamp flashes, stop the engine and correct the problem immediately.
* However, if the machine is equipped with the ground driven steering feature and this steering system is being
operated, only the monitor lamp will flash.
This group consists of an air pressure gauge, engine coolant temperature gauge, torque converter oil temperature
gauge, fuel level gauge, speedometer, service meter and pilot lamp display.
E. WARNING LAMP
The warning lamp will flash when there is an abnormality in any item of group (B).
The warning lamp will flash and the alarm buzzer will sound when there is an abnormality in any item of group (C) or
when the parking brake is applied, but the directional lever is not in neutral.
* However, if the machine is equipped with the ground driven steering feature and this steering system is being
operated, the warning lamp will not light up and the alarm buzzer will not sound
SYSTEM CHECK
* When the starting switch is turned to ON, if the directional lever is not at neutral, the warning lamp will flash and
the alarm buzzer will continue to sound. If this happens, return the lever to neutral. The lamp will go out and the
buzzer will stop.
* To check the monitor immediately when the engine is stopped, wait for at least 30 seconds after the engine is
stopped.
2-4
OPERATION
* When the engine is started, these monitor lamps will go off even if there are abnormalities.
* Do not rely on the “CHECK MONITOR LAMP GROUP (Check items before starting)” only for the check before
starting. Always make the checks by referring to the section on “CHECKS BEFORE STARTING”.
B
\
‘3_ 2_ ‘_
6
Of‘,
- -&I, 7
_W, /
Ll lAH013
2-5
OPERATION
* Even if any monitor lamp flashes, the machine can operate, but it should be repaired as soon as possible.
1. Charge Monitor
2-6
OPERATION
*
monitor lamps.
* If any monitor lamp flashes, stop the engine and correct the problem immediately.
2-7
OPERATION
8
A
2-8
OPERATION
5. Engine Coolant Temperature Monitor
A
WARNING! If the monitor lamp flashes, move
the machine immediately to a safe place and
stop the machine.
* Park the machine on level ground and check the monitor lamps.
* Confirm that these monitor lamps light for about 3 seconds after turning the starting switch to ON. If any monitor
lamp does not light, ask your distributor to inspect that monitor lamp
2-9
OPERATION
When the starting switch is turned to ON, this lamp group lights up to indicate that the display items are working.
5
CHECK \ / / CAUTION
\
7
I \
8. 0 /’
CJ
I
‘u’
m h -2
q SERVICE
METER
ct
/ \
=
12
d Ll 1AH01 4
2-10
OPERATION
2-I 1
OPERATION
6. Engine Coolant Temperature Gauge
Red
This gauge indicates the temperature of the engine
coolant. If the temperature is normal during operation,
the green range will light. If the red range lights during
operation, stop the machine and run the engine with no
load at midrange speed until the green range lights.
Green
If the top lamp in the red range lights up, the alarm
buzzer will sound, the warning lamp will flash and the
coolant temperature monitor lamp will flash at the same
time. White
LllAHOlE
If the top lamp in the red range lights up, the alarm
buzzer will sound, the warning lamp will light up and the
torque converter oil temperature monitor lamp will flash
at the same time.
LllAHOl i
8. Fuel Level Gauge
Red
LllAHOlf
2-12
OPERATION
9. Turn Signal Pilot Lamp
f* .
When the turn signal lamp flashes, the pilot lamp also
flashes.
1 Ll 1AJOO6
11. Speedometer
k J/
Ll 1AZ003
2-13
OPERATION
12.Service Meter
l Record the readings of the start and the end of work, this is the work record of the machine.
l It also indicates the integrated working hours when machine problems are encountered.
2-14
OPERATION
SWITCHES
1. OFF POSITION:
Depressing the left brake pedal operates the wheel
brakes only, like the right brake pedal.
2. ON POSITION:
Depressing the left brake pedal operates the wheel
brakes and also returns the transmission to NEU-
TRAL. I \ LllAMOO!
A WARNING! If the machine has to be started on a slope, always turn the transmission cut-off selector
switch to OFF and depress the left brake pedal. Then depress the accelerator pedal while releasing
the left brake pedal to start the machine off slowly.
2-l 5
OPERATION
IA. ETHER START SWITCH
C. ON POSITION:
A fixed amount of ether (approx. 3 cc each time) is
injected into the engine air intake to make it easier to
start the engine in cold weather.
D. OFF POSITION:
When the switch is released, it automatically returns
LllAMOOZ
to the OFF position.
A
WARNING! Do not keep the switch at the ON position for more than 5 seconds.
2. HORN BUTTON
* All turn signal lamps and the pilot lamp on the steer-
ing column flash, when this switch is put in ON.
A
WARNING! Do not use this switch unless
abnormality has occured.
2-16
OPERATION
UlAM007A
ON POSITION:
The parking brake is applied, and the parking brake
pilot lamp lights up.
OFF POSITION:
The parking brake is released.
A
WARNING! Always apply the parking brake
when leaving the machine or parking it.
* If the directional lever is placed in F (FORWARD) or R (REVERSE) with the parking brake applied, the warning
lamp will flash and the alarm buzzer will sound.
* When the starting switch is turned to OFF, the parking brake is automatically applied.
Before starting the engine, turn the parking brake switch to ON, then turn it to OFF.
* The machine does not start when the directional lever is operated with the parking brake applied.
2-17
OPERATION
When the front and rear working lamps are turned ON,
the pilot lamp and illumination lamp for the monitor panel
will also light up.
LllAMOl(
7. STARTING SWITCH
OFF
This switch is used to start or stop the engine.
ON
,
OFF
Key insertion-withdrawal position. No electrical circuits
are activated.
The hazard lamp and the parking lamp will remain on,
START
however, when the switch is turned OFF.
ON
Charging and lamp circuits activate. Keep key at ON
after starting.
START
At this key position, the starting motor will crank the engine. Release the key immediately after starting, and the key
will return automatically to ON.
8. LAMP SWITCHES
For head lamps, turn signal lamps, dimmer switch
Lamp switch
Position 1
Parking lamps light up.
Position 2 OFF
Lamps go off.
Position 3
Ll 1 AM01
Clearance lamps, tail lamps and machine monitor
panel lighting light up.
Position 4
Head lamps light up in addition to the lamps in position 3.
* The lamp switch can be operated regardless of the position of the lever.
2-l 8
OPERATION
Dimmer switch
2-19
OPERATION
9. CIGARETTE LIGHTER
llAJOOl1
Z-20
OPERATION
LllAM117
Position 1
The wiper is actuated at low speed.
/( + -\
I 02
Position 2
0
1-\ 0
1
LllAMOla
2-21
OPERATION
When this switch is pushed in, the cab dome lamp should
light. When the switch is pushed in again, the cab dome
lamp should go out.
2-22
OPERATION
1. DIRECTIONAL LEVER
1 Forward
2 Reverse
N Neutral
2-23
OPERATION
2. SPEED CONTROL LEVER
Position 1
Stopper actuated.
Position 2
Stopper released.
I L07CH006
L05AMOOE
2-24
OPERATION
5.ACCELERATOR PEDAL
This pedal controls the engine speed and output. The engine speed can be freely controlled between low idle and full
speed.
6. BRAKE PEDALS
The right brake pedal operates the wheel brakes, and is used for normal braking.
A WARNING! When traveling downhill, use the engine as a brake, and always use the right brake pedal.
The left brake pedal operates the wheel brakes, and if the transmission cut-off selector switch is at ON, it also returns
the transmission to neutral.
If the transmission cut-off selector switch is at OFF, the left brake pedal acts in the same way as the right brake pedal.
A WARNING! Do not use the brake pedals as footrests. Use them only when applying the brakes.
* When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow or
stop the machine after putting the transmission cut-off selector switch in ON.
LlOAZ03C
2-25
OPERATION
1 Raise
2 Hold: The lift arm is kept in the same position.
3 Lower
4 Float: The lift arm moves freely under external force.
1 Tilt
2 Hold: The bucket is kept in the same position.
3 Dump
\ LlOAZ0321
2-26
OPERATION
When the bucket control lever is pulled further from 1 Tilt
position, the lever is stopped in this position until bucket
reaches the preset position of positioner, and the lever is
returned to the hold position.
Dump
This lever controls the operation of the optional front mounted work equipment.
This is used to lock the lift arm and bucket control levers.
A
WARNING! When parking or leaving the
machine, or when performing maintenance,
always lower the bucket to the ground, put
the work equipment control levers in the
hold position and place the lock lever in the
“lock” position.
Open the door so that tip (2) of the lever is aligned with
groove (1) for the lock, then pull down knob (3) as shown
in the diagram.
L13CMOl:!
2-27
OPERATION
AIR CLEANER SERVICE INDICATOR
L12AR074
A
WARNING! Always use the locking bar for
maintenance or when transporting the ma-
chine.
I/ \ LOSCHOW
2-28
OPERATION
FUSE BOXES
A
WARNING! Before replacing a fuse, be sure
to turn off the starting switch.
2-29
OPERATION
11 IOA Horn
12 1OA ---
2-30
OPERATION
0
II
-
ICI I- 10
L08CH012
Circuit
Working lamps
Parking brake
Monitor system
6 I IOA
Cigarette lighter
2-31
OPERATION
OPERATOR’S SEAT
A. FORWARD-BACKWARD ADJUSTMENT
Move adjustment lever (2) up, set the seat to the desired
angle, and release the lever. The seat can be tilted up or
down by about 3”.
C. WEIGHT ADJUSTMENT
HEIGHT ADJUSTMENT
ANGLE ADJUSTMENT
2
Loosen mounting bolts (2) to move the armrest to the
desired angle and tighten the bolts.
/:
1
I / L13BH018
2-32
OPERATION
SEAT BELT
A
WARNING! When operating a machine
equipped with a ROPS, be sure to use the
seat belt.
2. After positioning the seat, install the tether belt (1). With the seat unoccupied, tense the belt slightly across the seat
and install.
A
WARNING! Check that there are no kinks in the belt.
3. Sit in the seat. Hold buckle (2) and insert tang (3) into the buckle. Check that the belt has locked by pulling it.
4. When removing the belt, raise the tip of the buckle lever to release it.
* When leaving the operator’s seat, release the seat belt and hang it over the arm rest.
* Fasten the belt across your body without kinking it. Adjust the lengths of the belt on both the buckle and tang ends
so that the buckle is located at the mid-point of your body front.
. . . _.. I 1
Adjust the belt length In the tollowlng manner.
I I
1. To shorten the belt, pull the free end of the belt at
either the buckle or tang end or at both ends.
2-33
OPERATION
This switch controls the air flow when the cab heater is
used for heating.
Only air inside the compartment is used. This is mainly used for quick heating.
2-34
OPERATION
METHOD OF OPERATION
PURPOSE
SWITCH AND KNOB POSITIONS II
tGG+jG Temperature Control Knob (2) Air Intake Selector
Knob (3)
VENT POSITION
PURPOSE
Face (1) Foot (2) Defrost (3)
j, The effectiveness of the heating system can be increased by selecting the most suitable vent.
* Do not turn the fan speed switch on when all the vents are closed.
2-35
OPERATION
It is possible to use the cab heater and air conditioner to good effect in dusty jobsites. The outside air is passed
through the filter and is sent to the operators cab to increase the pressure inside the cab. In this way, dust is prevented
from entering, so comfortable operating conditions are always maintained for the operator.
This switch controls the air flow when the cab heater and
air conditioner is used for heating or cooling.
Only air inside the compartment is used. This is mainly used for quick heating or cooling.
2-36
OPERATION
OFF: If the system is ON and the switch is depressed again, the switch returns to the up position and the air
conditioner is switched off.
* Turn the air conditioner switch on after turning the fan speed switch on.
METHOD OF OPERATION
PURPOSE
r SWITCH AND KNOB POSITIONS
Fan Speed Air Conditioner Temperature Control Knob (2) Air Intake Se-
Switch (1) Switch (4) lector Knob (3)
VENT POSITION
PURPOSE
Face (1) Foot (2) Defrost (3)
* The effectiveness of the heating air conditioning system can be increased by selecting the most suitable vent.
2-37
OPERATION
* Do not turn the fan speed switch on when all the vents are closed.
0 Smoking in the air conditioned cab will cause your eyes to get sore. While smoking, open the window to let the
smoke out of the cab.
l While using the air conditioner, open the window once every hour.
0 The cab should feel cool when entering it from the outside (5°C lower than the outside temperature). It is not good
for the health to have the temperature in the cab too low. Always give careful consideration to temperature
regulation.
To use the air conditioner comfortably during its season, ask your distributor to check the air conditioner and add
refrigerant if necessary.
l The standard cleaning interval for the cab air filter is every 100 hours, but if it becomes clogged, it will be
impossible to pressurize the inside of the cab. In addition, it may cause failures, so check and clean the air filter
immediately. For details of cleaning the air filter, refer to “MAINTENANCE” in Section 3.
l If a large amount of dirt or dust collects on the condenser, the cooling capacity drops, so check and clean when
necessary. For details, of cleaning the air conditioner condenser, refer to “MAINTENANCE” in Section 3.
To lubricate each part of the compressor during the off-seasons, operate the air conditioner for a few minutes two or
three times a month.
2-38
OPERATION
A locking filler cap is located on the fuel tank filler opening. Open and close the locking cap as follows, using the
starting switch key:
Open
Shoulder
LO222054
2-39
OPERATION
A locking filler cap is located on the hydraulic tank filler opening. Open and close the locking cap as follows, using the
starting switch key:
Shoulder
LO222054
Aligning mark
2-40
OPERATION
Before starting the engine, check around and under the machine to check for loose nuts or bolts, collection of dirt, or
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for
loose electrical wiring, play, and collection of dirt at places that reach high temperatures.
In addition to the walk around check, the following checks should be performed before starting the engine.
* For the detailed procedures of the following checks, refer to “CHECKS BEFORE STARTING ENGINE’ in Section
3.
2-41
OPERATION
OPERATING MACHINE
OPERATIONS BEFORE STARTING ENGINE
L07CH008
2-42
OPERATION
2-43
OPERATION
STARTING ENGINE
NORMAL STARTING
Ll 1AJo
SPECIAL STARTING
OFF
When starting the engine after running out of fuel, first fill
the fuel tank and then, fill the fuel filter with fuel before
starting. Refer to “FUEL FILTERS’ in Section 3.
L11AJOll
l Disconnect the electrical wire from the fuel pump
solenoid valve.
l Using the starting switch, crank the engine by the cranking motor until the oil pressure monitor lamp goes out.
2-44
OPERATION
A
WARNING! Never operate ether start switch
(2) except when starting the engine.
,,%
2-45
OPERATION
OPERATIONS AFTER STARTING ENGINE
3. Check if the exhaust color is normal or whether there is any abnormal noise or vibration.
4. If the ambient temperature is less than 0°C (32°F) perform the “COLD WEATHER WARM-UP PROCEDURE”,
which follows.
* Do not run the engine at low idle continuously for more than 10 minutes.
When starting the engine in cold weather, do not start operations immediately. First, carry out the following.
1. Warm up the engine. Following is the guideline for warming-up time with the engine idling.
Ambient temperature -20°C (-4°F) -10°C (14°F) 0°C (32°F) and Above
* Avoid sudden acceleration of the engine before the warming-up operation is completed.
2. Warm up the work equipment circuits. After completing the warming-up operation for the engine, warm up the work
equipment circuit.
1) Move the lift arm control lever slowly to the RAISE position and raise the bucket slightly.
2) Move the lift arm control lever slowly to the LOWER position and lower the bucket slightly.
3) Repeat the above operation several times and gradually increase the amount you move the lift cylinders.
4) Repeat Steps 1) - 3) for the bucket control lever to warm up the work equipment circuit.
* Run the engine with the throttle at the l/3 position or below.
2-46
OPERATION
5) Raise the bucket 10 - 30 cm (3.7 - 11.8 in) from the ground, operate the bucket control lever to the tilt position,
relieve the circuit for approximately 5 seconds, then return the lever to the neutral position and hold it for
approximately 2 seconds. Repeat this operation to warm up the work equipment circuit.
A
WARNING! If the machine is operated suddenly before the warming-up operation is carried out, the
work equipment may be damaged. The warming-up operation is also mandatory for safety reasons.
A WARNING! If this operation is carried out when the oil temperature is still low, even when the steering
wheel is turned and stopped, there may be a time lag before the chassis turns or stops. In such cases,
carry out the warming-up operation in a large open area. In addition, use the safety bar to ensure
safety. In this case, do not relieve the circuit for more than 5 seconds.
4. Turn the steering wheel slowly to the left and right to warm up the oil inside the steering valve. Repeat this
operation about 10 times.
* Turn the steering wheel a short distance, then stop it, and check that the chassis stops according to the amount
the steering wheel is turned.
* The recommended oil for the work equipment hydraulic system depends on the ambient temperature. Select oil
according to the table under “LUBRICANTS, FUEL AND COOLANT” in Section 3.
2-47
OPERATION
UlAMOPf
A
WARNING! If the machine has to be started
on a slope, always turn the transmission
cut-off selector switch to OFF and depress
the left brake pedal. Then depress the accel-
erator pedal while releasing the left brake
pedal to start the machine off slowly.
L07CHOOg
2-48
OPERATION
SHIFTING GEAR
4th L07CH005
L07CH006
2-49
OPERATION
L07CHOi 2
STEERING IACHINE
A
WARNING! It is dangerous to turn the ma-
chine suddenly at high speed, or to turn on steep hills.
WARNING! If the engine stops when the machine is traveling, the steering cannot be used. This is
A particularly dangerous on hills, so never stop the engine when the machine is traveling.
WARNING! If the engine should stop, stop the machine immediately in a safe place.
A
Z-50
OPERATION
STOPPING MACHINE
1. Release accelerator pedal (l), and depress brake
pedal (2) to stop the machine.
I L07CH008
l
* When the parking brake is applied, the transmission
is automatically returned to neutral.
ON
/
/
LIlAMO2 ,2
2-51
OPERATION
A
WARNING! Stop the machine in a safe place
on firm level ground. If the machine has to be
stopped on a slope, put blocks under the
wheels. In addition, dig the bucket into the
ground to increase safety.
OPERATIONAL PRECAUTIONS
If the machine is not stopped by depressing brake pedal(s), use the parking brake to stop the machine.
When turning on slopes, lower the work equipment to lower the center of gravity before turning. It is dangerous to turn
the machine with the work equipment raised.
When driving down a slope, place the transmission speed control lever in a low speed range position to make full use
of the engine braking force. When applying the service brakes, depress the right brake pedal. If the service brakes
are used too frequently when traveling downhill, the brakes may overheat and damage may result.
If the speed control lever is not placed in a proper speed position, the torque converter oil may overheat. If it overheats,
place the speed control lever in the next lower gear speed to lower the oil temperature.
2-52
OPERATION
If the oil temperature gauge does not indicate the green range of the scale even with the lever in the 1st speed
position, stop the machine, place the lever in neutral, and run the engine at medium speed until the gauge indicates
the green range.
If Engine Stops
If the engine stops on a slope, depress the right brake pedal fully. Next, lower the work equipment to the ground and
apply the parking brake. Then put the directional and speed control levers in neutral, and start the engine again. If the
directional lever is not in neutral, the engine will not start.
2-53
OPERATION
Various types of attachments are available to extend the range of application beyond the applications
described below.
EXCAVATION
* If the bucket hits the ground, the front tires will come
off the ground, and the tires will slip.
2-54
OPERATION
2-55
OPERATION
0 When digging and loading on level ground, set the
bucket edge facing down slightly as follows and drive
the machine forward. Always be careful not to load
the bucket on one side and cause an unbalanced
load.
A
WARNING! Never dig or scoop when the
machine is articulated.
LEVELING
2-56
OPERATION
2. Go over the spread soil with the bucket teeth touching the ground and level the ground by back-dragging.
3. Scoop some more soil into the bucket, put the lift arm in float, level the bucket at ground level, and smooth the
ground by moving backward.
A WARNING! If leveling by forward travel can not be avoided, do not dump the bucket beyond 20”. This
will prevent quick wear and damage of the work equipment and frame.
A
WARNING! Lower the bucket to bring down
the center of gravity when carrying material.
LOADING
2-57
OPERATION
V-Shape Loading
Stop the truck with the angle of about 60” toward the
scooping direction of the wheel loader. After scooping the
soil, back the wheel loader in such a way that it makes a
right angle to the truck. The loading on the truck is made
by the wheel loader going forward.
PARKING MACHINE
A WARNING! Never leave the machine with the engine running or the bucket raised. When parking the
machine, stop the engine, lower the bucket to the ground, place the transmission in neutral (N), apply
the parking brake, turn off the electrical starting switch, and remove the key.
WARNING! Park the machine in a non-traffic area. If parking in traffic lanes cannot be avoided, provide
A appropriate flags, barriers, flares and warning signals. Also provide advance warning signals in the
traffic lane for approaching traffic.
WARNING! Avoid parking on a slop because unexpected machine movement may occur. If necessary
A to park on a slope, park at a right angle to the slope and block the tires.
WARNING! Before starting the engine or when the machine is standing with the engine running: Place
A the transmission in neutral (N), apply the parking brake, and lower all raised work equipment.
Park machine in an area free of grease and fuel puddles which cause tire deterioration.
Lower hydraulically supported equipment to the ground to avoid unexpected movement and damage possibilities.
Park on level ground to obtain accurate coolant, lubricant and fuel level checks.
A
WARNING! Always lock up the machine, including any anti-vandalism attachment, when leaving it
unattended.
2-58
OPERATION
STOPPING ENGINE
1. Walk around the machine and check the work equipment and tires, also check for oil or coolant leakage. If any
abnormalities are found, repair them.
3. Check the engine compartment for foreign matter and debris. If found, remove the matter and/or debris to avoid
a possible fire hazard.
2-59
OPERATION
2. Loosen two bolts (I), and adjust plate (2) so that the
bottom edge is in line with the center of the sensing
surface of the proximity switch under switch cover
(3). Then tighten the bolts to hold the plate in posi-
tion.
2-60
OPERATION
4. After adjusting, start the engine and raise the lift arm.
Operate the bucket control lever to the DUMP
position, then operate it to the TILT position and
check that the bucket control lever is automatically
returned to HOLD when the bucket reaches the
desired angle.
Surfaces (A) and (6) at the top rear of the bucket are the
level indicators, so the bucket angle can be checked
during operations.
2-61
OPERATION
HANDLING TIRES
PRECAUTIONS WHEN HANDLING TIRES
Beads L15AROlE
Tire layers are separated.
When the machine travels at high speed for a long distance, the tires become extremely hot. This causes early wear
of the tires, so it should be avoided as far as possible. If the machine must be driven for a long distance, take the
following precautions.
l The most suitable tire pressure, travel speed, or tire type differs according to the condition of the travel surface.
Contact your distributor or tire dealer for information.
l The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard
tires.
l Check the tire pressure before starting, when the tire is cool.
l After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage; also check the oil and
coolant levels.
l Never put calcium chloride or dry ballast in the tires when traveling.
2-62
OPERATION
Measure the tire pressure before starting operations, when the tires are cool.
If the inflation pressure is too low, it causes overload on the tires; if the inflation pressure is too high, the tire may be
cut or may burst under shock. Therefore adjust the inflation pressure to the values in the following table.
INFLATING TIRES
2-63
OPERATION
If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a
suitable deflection. See deflection ratio.
* Stockpile operations mean the loading of sand and other loose materials.
= H-h xl00
H
H: Free height
h: Height when loaded
* When checking the tire pressure, check also for small cracks and damage, and for wire or small pieces of metal
which may cause punctures. Check also for abnormal wear.
* Operating costs can be reduced and tire life increased by keeping the operating area in good condition and free
from fallen rocks.
2-64
OPERATION
Select the most suitable bucket and tires for the type of work and the ground conditions on the jobsite.
2-65
OPERATION
TOWING
TOWING THE MACHINE
This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
A
WARNING! If there is a failure in the brake line, the brakes cannot be used, so be extremely careful
when towing.
l Always keep the engine running when towing the machine, so that the steering and braking can be used.
l No lubrication oil flows in the transmission, so disconnect the front and rear drive shafts before moving the
machine.
l The steering cannot be used, so disconnect the steering cylinders and steering linkage.
* The machine should be towed only to the nearest place for inspection and maintenance. Do not tow the machine
for long distances.
* If leakage in the air circuit has caused the pressure inside the air tank to drop, the parking brake will be applied.
When towing the machine, release the parking brake.
3. Install the air charge hose for the tire to the air
supply coupling.
2-66
OPERATION
A
WARNING! If there is a failure in the air circuit, the brakes cannot be used. This is dangerous, so
always tow the machine at low speed. Keep the engine running so that the steering can be used.
4. Push the end of the hose on the tire valve, and air will be supplied to the brake spring cylinder to release the
brake.
5. When the parking brake is released, remove the air charge hose. Tow the machine immediately to a safe place.
A WARNING! Stop the machine on a flat surface when releasing the parking brake, and check that the
surroundings are safe. In emergencies or when the parking brake must be released on a hill, block
the tires carefully before releasing the brake.
TRANSPORTATION
When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle
limit ordinances, etc. It is a good idea to obtain a special platform for loading and unloading the machine.
When it is unavoidably necessary to use a gangplank, however, at the very least observe the following for the
sake of safety.
1. Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move. The
fix the gangplank in line with the centers of the trailer and the machine.
* Make sure the gangplank has sufficient width, length and thickness to enable the machine to be safely loaded and
unloaded.
2. Determine the direction of the gangplank, then slowly load or unload the machine.
* When transmission cut-off switch is put in OFF, the left brake pedal and accelerator pedal are operated at the
same time.
A
WARNING! Remove the mud from the undercarriage to prevent the machine from slipping to the side
on slopes.
A
WARNING! Do not on any account change the direction of the machine while it is on the gangplank.
To change the direction of the machine, first take it down from the gangplank.
3. Correctly load the machine onto the specified part of the trailer.
4. Lower the bucket and lock the work equipment control levers using the control lever lock.
5. Lock the front and rear frames with the frame locking bar.
6. When transporting the machine, place blocks against the front and rear tires to prevent the machine from moving
about. Also, hold it down with chains or wire ropes.
* Determine the route for transporting the machine by taking into account the width, height and weight of the
machine.
A
WARNING! When loading the machine, park the trailer on a flat, firm roadbed. Keep a fairly long
distance between the road shoulder and the machine.
2-67
OPERATION
COLD WEATHER OPERATION
PREPARATION FOR LOW TEMPERATURE
If the temperature becomes low, it may be difficult to start the engine, so do as follows.
Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “LUBRICANTS,
FUEL AND COOLANT” in Section 3.
COOLANT
l In climates where the temperature is above -37°C (-34°F) use a coolant mixture that contains 50 percent
antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the
coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture
unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition.
* Maintain the supplemental coolant additive concentration level between 1 and 2 units of DCA4 per 3.8 I?(1 US gal)
of coolant.
BATTERY
l As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge
is low. Maintain battery at a charge level of approximately 100% and insulate it against cold temperature so that
machine can be easily started.
* Measure specific gravity of fluid and obtain rate of charge from the following conversion table:
* When the electrolyte level is low, add distilled water in the morning before work instead of after the day’s work.
This is to prevent the fluid from freezing at night.
A WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.
2-68
OPERATION
A WARNING! If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.
1. Mud and water on the machine body should be completely removed. Park the machine on concrete or hard
ground. If this is impossible, park the machine on wooden boards. This will prevent the tires from freezing to the
ground thereby preventing machine movement the next morning. Particular attention should be given to water
drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be fully wiped off because
if water is frozen to the rod when the cylinder is utilized, the cylinder oil seals may be damaged.
2. Completely drain the air tanks and drain the water from the fuel system to prevent the possibilty of such water from
freezing at night.
3. As battery capacity drops at low ambient temperature, cover the battery or remove it from the machine to be kept
warm at night.
When the weather becomes warm, the following procedure must be performed:
l Replace the lubricating oils for the various units with the ones specified for warm weather use. For details, refer
to “LUBRICANTS, FUEL AND COOLANT” in Section 3.
2-69
OPERATION
BEFORE STORAGE
To place the machine in storage for an extended period of time, the following measures must be taken to insure that
it can be returned to operation with a minimum of service.
After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.
If it is unavoidable to leave it outdoors, park the machine on flat ground and cover it with canvas, etc.
Completely fill the fuel tank, lubricate and change oil before storage.
Apply a thin coat of grease to the metal surfaces of the hydraulic cylinder piston rods and splined shafts.
Disconnect the negative terminals of the batteries and cover the batteries or remove them from the machine and
store them separately.
Set each control lever to neutral or hold position, lock them and apply the parking brake.
Open the air tank drain valves to completely drain the tanks. After draining, close the drain valves.
If the engine will be out of service longer than six (6) months, take special precautions to prevent rust. Contact
the nearest Cummins Authorized Repair Location for information concerning engine storage procedures.
DURING STORAGE
A
WARNING! If it is unavoidably necessary to carry out rust-preventive operation while the machine is
indoors, open up doors and windows to improve ventilation and prevent the gas poisoning.
l Operate the engine and move the machine for a short distance once a month so the new oil film will be coated
over movable parts and component surfaces.
l Before operating the work equipment, wipe off the grease on the hydraulic cylinder piston rods.
AFTER STORAGE
NOTICE:lf the machine is stored without carrying out the monthly rust prevention operation, request your
distributor for service.
Carry out the following procedure when taking the machine out of long-term storage.
2-70
OPERATION
HANDLING OF BATTERY
1. Before charging, disconnect the cable from the negative (-) terminal of the battery. Otherwise, an unusually high
voltage will damage the alternator.
2. While charging the battery, remove all battery caps for satisfactory ventilation,
A WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.
3. If the electrolyte temperature exceeds 45°C (113°F) stop charging for a while.
5. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.
6. Do not mix up battery cables; positive (+) to negative (-) or negative (-) to positive (+), as this will damage the
alternator.
7. When inspecting or servicing a battery, be sure to stop the engine and turn the starting switch key to “OFF”
position.
8. When performing any service to battery besides checking the electrolyte level or measuring the specific gravity
or voltage reading, disconnect the cables from the battery.
l When removing the battery, first disconnect the cable from the ground; normally, from the negative (-) terminal.
A WARNING! If a tool touches a connected positive (+) cable terminal and the chassis, there is danger
that it will cause sparks.
l When installing the battery, connect the positive (+) cable first and connect the negative (-) or ground cable to the
ground terminal last.
l Batteries are mounted on both sides of the machine, just in front of the counterweight. The ground cable is
connected to the battery, located on the right side.
2-71
OPERATION
1. The size of the booster cable and clamp should be suitable for the battery size.
3. Make sure that the cables and clamps are firmly connected.
5. The battery of the normal machine must be the same capacity as that of the engine to be started.
A
WARNING! When connecting the cables, never contact the positive (+) and negative (-) terminals.
A
WARNING! Make sure that the booster cable connections are correct. Connect the booster cable to
the engine block as far as possible from the battery.
dl
2. Connect the opposite clamp of booster cable (A) to
0
the positive (+) battery terminal of the normal ma- 0 +
chine.
+
3. Connect one clamp of booster cable (B) to the nega-
tive (-) battery terminal of the normal machine. Batteries of
problem machine
4. Connect the other clamp of booster cable (B) to the
engine block of the problem machine. Engine block of problem machine
L08AH017
STARTING ENGINE
1. Start the engine of the normal machine and run the engine above low idle speed.
2. Start the engine of the problem machine as outlined under “STARTING ENGINE”.
2-72
OPERATION
DISCONNECTING BOOSTER CABLES
4. Disconnect the other clamp of booster cable (A) from the positive (+) battery terminal of the problem machine.
2-73
OPERATION
TROUBLESHOOTING
This guide is not intended to cover all conditions, however many of the more common possibilities are listed.
l In cases of abnormalities or causes which are not listed below, contact your distributor.
ELECTRICAL SYSTEM
Lamp does not glow brightly even when engine runs Cranking motor turns the engine sluggishly.
at high speed. l Charge the batteries.
l Replace the cranking motor.
Lamp flickers while engine runs.
l Check for loose terminals and open-circuit wiring. The cranking motor disengages before the engine
l Adjust belt tension. starts up
l Check and repair the wiring.
Charge monitor does not go out even when engine l Charge the batteries.
runs at high speed.
l Repair or place the alternator. The engine oil pressure monitor does not light up
l Inspect and repair wiring. when engine is stationary and when the starting
switch is in ON position.
Unusual noise is emitted from the alternator. l Replace the monitor.
l Repair or replace the alternator. l Replace the monitor sensor.
l Inspect and repair the wiring.
Cranking motor does not turn when starting switch
is turned on. Charge monitor does not light up when the engine is
l Inspect and repair the wiring. stationary and when the starting switch is in ON
l Charge the batteries. position.
l Replace the monitor.
The pinion of the cranking motor keeps going in and l Inspect and repair the wiring.
out.
l Charge the batteries.
ENGINE
The engine oil pressure monitor flashes when engine The engine does not start when the cranking motor
speed is raised after completion of warm-up. is turned over.
l Add the oil to the specified level. l Add fuel.
l Replace the oil filters. l Repair where air is leaking into fuel system.
l Check oil leakage from the pipe or the joint. l Replace the injection pump or the nozzle.
l Replace the monitor. l Check engine valve clearance.
l Check engine compression pressure.
Steam is emitted from the top of the radiator at the l Refer to section for ELECTRICAL SYSTEM.
pressure valve.
The engine coolant temperature monitor flashes. Exhaust gas is white or blue.
l Supply the coolant and check for leakage. l Adjust to specified oil quantity.
l Adjust fan belt tension. l Replace with specified fuel.
l Clean and flush inside of cooling system.
l Clean or repair radiator core fins. Exhaust gas occasionally turns black.
l Replace engine thermostat. Clean or replace the air cleaner element.
l Tighten the radiator cap firmly or replace the cap if it Replace the nozzle.
has a faulty gasket. Check engine compression pressure.
l Replace the monitor. Clean and replace turbocharger.
2-74
OPERATION
Combustion noise occasionally changes to breath- Unusual combustion noise or mechanical noise.
ing sound. l Replace with specified fuel.
l Replace the nozzle. l Check over-heating.
l Replace the muffler.
l Adjust valve clearance.
CHASSIS
Engine is running but machine will not move. Brake does not work properly.
l Release parking brake. l Adjust linkage.
l Put directional lever in position properly. l Clean brake pad.
l Add oil to transmission case to the specified level. l Replace spring in air cylinder.
l Adjust or replace brake pad.
Even at full throttle, machine moves slowly and lacks
power.
l Add oil to transmission case to the specified level. STEERING
l Disassemble transmission strainer and clean.
Steering wheel is heavy.
Oil overheats. l Adjust steering gear.
l Add oil to transmission case to the specified level or l Check linkage, replace parts.
drain oil.
l Use a suitable gear speed.
l Reduce time using torque converter at stall speed. EQUIPMENT HYDRAULIC SYSTEM
l Check engine.
Bucket lacks lifting power.
Abnormal noise is produced. Bucket lifting speed is slow.
l Add oil to transmission case to the specified level. l Add oil.
l Replace filter in hydraulic tank.
Brakes do not work when pedal is depressed. Cylinder vibrates when operating.
l Raise air pressure to specified level. l Add oil.
l Replace discs.
l Add brake oil to the specified level.
l Bleed air from brake system.
Brake slips.
l Replace discs.
2-75
OPERATION
MEMORANDA
2-76
SECTION 3
MAINTENANCE
A
WARNING ! REFER TO AND READ ALL
3-l
MAINTENANCE
PERIODIC MAINTENANCE
Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for
scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating
cost.
All hourly figures given in the following descriptions are based on service meter readings. In practice, however, it is
recommended to rearrange all of them into units of days, weeks and months, to make the maintenance schedule more
convenient. Under rough jobsite or operating conditions, it is necessary to somewhat shorten the maintenance intervals
stated in this manual.
MAINTENANCE GUIDELINES
Perform maintenance work on a hard, flat surface.
Use genuine oils and grease. Choose oils and grease with proper viscosities specified for the ambient temperature.
Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and
grease.
Always keep the machine clean. This makes is easier to find parts causing problems. Keep in particular grease fittings,
breathers and oil level gauges clean and avoid foreign matters from getting in them.
Fuel strainer:
Do not remove the fuel strainer while fueling.
Oil changes:
Check or change oils in the places where dust is scarce to keep foreign materials away from oils.
Warning tag:
Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of
the circumstances from starting the engine.
Obey precautions:
During operation, always obey the precautions on the safety product graphics located on the machine.
Welding instructions:
l Turn off the engine starting switch.
l Do not apply more than 200 V continuously.
l Connect grounding cable within 1 m (3.3 ft) from the area to be welded.
l Avoid seals or bearings from being between the area to be welded and the position of the grounding point.
3-2
MAINTENANCE
Fire prevention:
Use a nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from cleaning fluid
Clamping faces:
When O-rings or gaskets are removed, clean the clamping faces and replace the O-rings and gaskets with new ones.
Be sure to properly fit the O-rings and gaskets when assembling.
Cleaning machine:
l Do not direct a high-pressure jet directly at the radiator.
l Do not splash water on the electrical components.
Dusty worksites:
When working at dusty worksites, do as follows:
l Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than specified.
l Clean the radiator core frequently to avoid clogging.
l Replace the fuel filter(s) frequently.
l Clean electrical components, especially the cranking motor and alternator, to avoid accumulation of dust.
3-3
MAINTENANCE
OUTLINES OF SERVICE
LUBRICATION WHEN SHIPPED
l Use genuine oils and grease. Choose oils and grease with proper viscosities specified for the ambient
temperature.
l Unless otherwise specified, the oils, grease, fuel and coolant used at the time of shipment from the factory are as
shown in the table below.
COMPARTMENT LUBRICANT
Torque converter, Transmission, Transfer case & Oil Engine oil SAE 30W API classification CE
cooler
Fuel tank Diesel fuel ASTM D975 Grade No. 2-D or ASTM
D975 Grade No. 1 for winter season of October to
March
NOTE: For axle oil, one of the following oils was used:
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL AND SUPER UNIVERSAL
RELATING TO ENGINE
ENGINE OIL
l Engine oil is critical because it lubricates the engine, the heart of the machine.
o Main services relating to engine oil are: 1) daily check of oil level, 2) check for contamination and 3) periodic
replacement.
MAINTENANCE
COOLANT
l Coolant is used to cool the engine and to keep it in good working condition.
l Check coolant level in the radiator daily and maintain it at the proper level.
l For coolant recommendations/specifications, refer to “COOLANT” under “LUBRICANTS, FUEL AND COOLANT”.
DIESEL FUEL
Always use the fuel specified for the engine. Fuels other than the specifications can damage the engine or reduce
the engine output.
Always fill the fuel tank at the end of the day’s operation.
When adding fuel, be careful not to let any water on top of the drum or at the bottom of the drum get into the fuel.
After the machine has run out of fuel or after the fuel filter has been replaced, bleed the air from the fuel line.
Use extreme caution when servicing the hydraulic system, because oil in the system soon after the operation is
very hot. Also, high pressure is applied in the system not only during but also after the operation.
Services relating to the hydraulic system are: 1) weekly check of oil level, 2) periodic filter replacement and 3)
periodic oil replacement.
Always bleed the air from the circuit after replacing the filter or changing the hydraulic oil.
When a item, such as a hose, in the line is disconnected, check O-rings for damage and replace them if
necessary.
If a hydraulic component has been removed or any hydraulic line has been disconnected or removed, bleed the
air from the hydraulic tank and system after completion of assembly. Bleed the air from the tank and system as
described under “HYDRAULIC TANK” and/or “PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT” in the
section.
If the wiring gets wet or the insulation is damaged, the electrical system leaks and this could result in hazardous
malfunction of the machine.
Services relating to the electrical system are: 1) check fan belt tension, 2) check for damage or wear of the fan
belt and 3) check the battery electrolyte level.
Never install any electrical components other than those specified by Komatsu America International Company.
Be careful to keep the electrical system free of water when washing the machine or when it rains.
When working on the seashore, carefully clean the electrical system to prevent corrosion.
Never connect any optional power source to the fuse, starting switch, battery relay, etc.
3-5
MAINTENANCE
RELATING TO LUBRICATION
l Lubrication is to help smooth operation of the machine and work equipment. It prevents the machinery from being
subjected to excessive load and from getting caught or generating noise. There are two lubricating methods; using
oil and using grease.
l Services relating to lubrication are: 1) check of oil levels, 2) periodic changing of oil and 3) adding grease for
proper lubrication.
l The machine has grease fittings in various places. Some of the fittings may not be mentioned in this manual.
These fittings are equipped for the overhaul purpose, and no greasing is required for them.
l Always use only the lubricants specified under “LUBRICANTS, FUEL AND COOLANT”.
l After adding new grease, wipe off old grease that was forced out, especially on rotating parts that could be worn
by sand and dirt adhering to them.
l Maintain oil at the proper level. Both too high and too low oil levels are not good for the machine.
3-6
MAINTENANCE
The wear parts should be changed correctly in order to use the machine economically.
*
Machines with serial number A61017 and below have two (2) oil filter elements and machines with serial number
A6101 8 and up have one (1) oil filter element.
3-7
MAINTENANCE
These parts with the passage of time may have a tendency to deteriorate in quality and to wear or deform. These parts
must be replaced with new ones after a predetermined replacement interval even though there is no apparent
abnormality.
If any abnormality should be found, these parts must be replaced or repaired even before the predetermined period
expires.
Periodical part replacement cost does not imply reimbursement under the manufacture’s warranty policy. Refer to the
warranty manual for further details.
6 Rubber parts of wheel brake valves Every year Replace with repair
kit
7 Rubber parts of wheel brake slack adjusters Every year Replace with repair
kit
8 Rubber parts of parking brake cylinder Every year Replace with repair
3-8
MAINTENANCE
1 SAE 15W-40 1
Engine oil
Engine with filter See SAE IOW-30 42 e 364
I
NOTE 1 11 .O gal 9.5 gal
Synthetic SAE 5W-30
I
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
3-9
MAINTENANCE
NOTES:
1. ENGINE OIL
Normal Operation
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability.
SAE 15W-40 multi-viscosity heavy duty engine oil meeting the American Petroleum Institute (API) performance
classification of CF-4 or CG-4 is recommended.
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.
A sulfated ash content of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has
been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve
and/or piston damage and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate
oil categories; the lower half may contain words to describe oil energy conserving features. The center section
identifies the SAE oil viscosity grade.
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous table for
oil viscosity recommendations for extreme climates.
Limited use of low viscosity oils, such as SAE low-30 may be used for easier starting and providing sufficient oil
flow at ambient temperatures below -5°C (+23”F). However, continuous use of low viscosity oils can decrease
engine life due to wkar.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil
during the “break-in” as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A.
Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered
from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A.
60601. The telephone number is (312) 644-6610.
Arctic Operation
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep
the engine warm when it is not in operation, use a synthetic API performance classification CUSF engine oil with
adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the petformance service specifications.
3-10
MAINTENANCE
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
When using SAE 5W-20 engine oil in the work equipment hydraulic system in cold areas, return to SAE IOW when
the cold season ends.
3. AXLE OIL
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL AND SUPER UNIVERSAL
* It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise
may result, durability should not be affected.
4. GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
5. DIESEL FUEL
A WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept
clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and
nozzles.
For normal service above -12°C (+lO”F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number
of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating
conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient
temperatures to prevent misfires and excessive smoke.
At operating temperatures below -12°C (+lO”F), use ASTM Grade No. I-D diesel fuel. The use of lighter fuels can
reduce fuel economy.
Where a winterized blend of Grade No. 2-D and No. I-D fuels is available, it may be substituted for Grade No. I-D
fuel. However, it is the supplier’s responsibilty to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel
temperature. Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt at 100°C (212°F) to provide adequate fuel system lubrication.
3-11
MAINTENANCE
6. COOLANT
General
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled ‘Supplemental Coolant Additive”.
The coolant mixture must be drained and replaced at the specified service interval shown in the “SCHEDULED
MAINTENANCE GUIDE” or every two years of operation, whichever comes first.
Water
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited
water must meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount
will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits,
scale deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local
water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water
that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be
used.
NOTE: Never use water alone in the cooling system because corrosion will occur.
Antifreeze
In climates where the temperature is above -37°C (-34”F), use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing
point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze
protection is required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and
should not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous
alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel
formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or
supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to
maintain corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
3-12
MAINTENANCE
NOTE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer
or anti-leak additives will cause plugging problems in the cooling system.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient
protection against freezing.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Percentage of
Approximate Antifreeze Specific
Freezing Concentration Gravity at
Point by Volume 60°F (16°C)
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor SCA, to protect the engine
cooling system.
1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through
normal operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes
corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling
system conditioners which contain these additives must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer and allow
internal engine damage.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still
the best coolant.
4. SCA is recommended to inhibit corrosion in the cooling system for the following reasons:
l Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration
occurs.
3-13
MAINTENANCE
l Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion - Seal and gasket degradation
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and
corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in the
“SCHEDULED MAINTENANCE GUIDE” with a service DCA4 filter.
Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly
charged with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table
entitled, “DCA4 Unit Guide”.
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The
SCA concentration must not fall below 1.O unit per 3.8 P (1 US gal) or exceed 2 units per 3.8 P (1 US gal) of coolant.
The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a
laboratory analysis. For this reason, the coolant inhibitor should be maintained as shown in the “SCHEDULED
MAINTENANCE GUIDE”.
NOTE: Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to cooling
system components. Over concentration can cause formation of “gel” that can cause restriction, plugging of
passages and overheating.
Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs.
Install a service DCA4 filter as specified in the “SCHEDULED MAINTENANCE GUIDE”. When antifreeze is added,
add coolant conditioner equal to 1.O unit per 3.8 0 (1 US gal) of antifreeze.
NOTE: Mixing of DCA4 and other supplemental coo/ant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion.
Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion
protection must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S.
gallon] of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each
engine oil and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use
the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as
defined under “General”.
3-14
MAINTENANCE
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system
capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or
exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
Fleetguard DCA4
Part No. Units
DCA4 Liquid
DCAGOL 4 (1 Pint)
DCA80L 1760 (55 US gal)
DCA4 Powder
DCA95 20
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the SCA
concentration between 1 .O and 2.0 units per 3.8 e (1 US gal).
NOTE: When performing service which requires draining the cooling system, discard the coolant.
Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in
premature failure of cooling system components.
NOTE 2 - To precharge cooling systems larger than 114 r?(30 gal) do the following:
l Install appropriate service filter listed in the above table based on cooling system capacity.
3-15
MAINTENANCE
l The answer represents the additional units required to precharge the cooling system. Four bottles of
powder, part number DCA95, will provide a sufficient amount of SCA units (80) to precharge the example
cooling system.
l Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal SCA concentration of 1.0 unit per 3.8 Q(1 US gal) of coolant in the system. Less than 0.5 unit per
3.8 0 (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 Q(1 US gal) indicates
an over-concentrated coolant solution.
To check the SCA concentration level, use coolant test kit, CC-2606. Instructions are included with the test kit.
Over 55 Drops Extremely over-concentrated Drain 50% of the coolant and re-
place with water antifreeze mix-
ture. Retest the system for correct
SCA unit concentration.
3-16
MAINTENANCE
Normal 250 hour scheduled maintenance Refer to “EVERY 250 HOURS SERVICE”
WHEN REQUIRED
Lubrication
3-17
MAINTENANCE
Alternator Repair/replace 44
Additional checks
3-18
MAINTENANCE
Lubrication
3-19
MAINTENANCE
ITEM SERVICE
Lubrication
Lubrication
Lubrication
3-20
MAINTENANCE
Batteries Check 80
Hydraulic tank oil and filters Change oil and replace elements 83
Accumulator Check 87
3-21
MAINTENANCE
Turbocharger Check 89
3-22
MAINTENANCE
Y 3
t
L0222070
LO222060
3-23
MAINTENANCE
For details of the method of replacing or maintaining, see the section on “EVERY 500 HOURS SERVICE”.
WHEN REQUIRED
Check and supply. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
CHECKING
A
WARNING! Do not clean or replace the air
cleaner element with the engine running.
3-24
MAINTENANCE
6. Push the service indicator reset button to return the piston to the original position.
* Replace the outer element which has been cleaned six (6) times repeatedly or used throughout a year. Replace
the inner element at the same time.
* Replace both inner and outer elements when the service indicator piston appears soon after installing the cleaned
outer element even though it has not been cleaned six (6) times.
A
WARNING! Do not replace the air cleaner
element with the engine running.
1. First open the air cleaner access door, remove the outer element, and then remove the inner element.
2. Place a protective cover over the air intake opening to prevent dust from entering.
3. Clean the inside of the air cleaner body. Remove the protective cover from the air intake opening.
4. Install a new inner element and tighten it with the wing nut.
5. Reinstall the outer element and close the air cleaner access door. Push the service indicator reset button.
A
WARNING! When using compressed air,
wear safety glasses and other things re-
quired to maintain safety.
Using Water
3-25
MAINTENANCE
Wash the element with city water at less than 3 kg/cm2 (43 psi / 296 kPa) of pressure, from the inside along the folds,
then from the outside and again from the inside. Dry the element and check it as follows.
For removing oil and grease as well as carbon etc. on the element, the element may be cleaned in a lukewarm solution
of mild detergent, then rinsed in clean water and left to air dry.
* Using warm water at about 40°C (104°F) instead of soapy water may also be effective.
* The drying process can be speeded up by appling dry compressed air, at less than 7 kg/cm’ (100 psi / 689 kPa),
to the element from the inside to the outside of the element.
A
WARNING! When checking the oil level,
apply the parking brake, and lock the front
and rear frames with the frame locking bar
and pin.
1. Stop the engine and remove the cap of oil filler tube
(F).
3. The oil level should be between mark ‘I” and “H”, if necessary, add oil at the oil filler tube.
3-26
MAINTENANCE
* It is possible to measure the oil level when the engine is at low idle, but in such cases, do as follows.
Start the engine and run it until the oil level is stable, then wait for 5 minutes and measure with the “ENG IDLE’
marks.
RADIATOR CORE
3-27
MAINTENANCE
Carry out this procedure if there is any sign of oil on the :ront
axle housing. \
Remove oil level plug (I), and check that the oil level
reaches the bottom of the plug hole. If necessary, add oil 5
through the hole of oil filler plug (2).
* Use the same procedure to check and add oil for the
L07FM014
front and rear drive axles.
3-28
MAINTENANCE
3ear
L07FROlC
Carry out this procedure if there is any mud or dirt stuck :ront
around the breather.
L07FM0161
I LO7FROI11
3-29
MAINTENANCE
LUBRICATION
L05AMOO!
3-30
MAINTENANCE
HYDRAULIC TANK
The hydraulic tank and system should be bleed free of air after the following:
l Replacing the hydraulic oil and filter elements or cleaning the oil strainer.
After reassembly, bleed the air from the hydraulic tank and system as follows:
1. Check and if necessary refill the hydraulic tank with oil up to the specified oil level of the sight gauge.
NOTICE: Check the hydraulic tank oil level and refill with oil frequently when bleeding the system.
* At first, if the engine is operated at high speed or if the hydraulic cylinder is moved to the end of its stroke, the air
in the cylinder may damage the cylinder piston packing, etc.
2. Run the engine at low idle. One at a time, operate the hydraulic steering, bucket and lift arm cylinders four (4) to
five (5) times, stopping 100 mm (3.9 in) from the end of its full stroke.
3. Next, operate each hydraulic cylinder three (3) to four (4) times, to the end of its stroke, then stop the engine.
7. After bleeding the air, tighten the two air bleed plugs
(1).
8. Recheck the oil level in the hydraulic tank and add oil as necessary. After adding oil, tighten the oil filler cap
securely.
The PPC, proportional pressure control, circuit should be bleed free of air after the following:
After reassembly, bleed the air from within the pressure control circuit as follows:
1. Check and if necessary refill the hydraulic tank with oil up to the specified oil level of the sight gauge.
3-31
MAINTENANCE
2. Start the engine. Move the bucket control lever to the “Tilt” position and the lift arm control lever to the “Float”
position and after the hydraulic bucket and lift arm cylinders reach the end of their stroke, maintain this cylinder
position for one (1) minute.
3. Place the bucket control lever in the “Dump” position and the lift arm control lever in the “Raise” position and after
the hydraulic bucket and lift arm cylinders reach the end of their stroke, maintain this cylinder position for one (1)
minute.
5. Recheck the oil level in the hydraulic tank and add oil as necessary. After adding oil, tighten the oil filler cap
securely.
The wheel brake hydraulic circuit should be bleed free of air after the following:
After reassembly, bleed the air from within the brake hydraulic circuit as follows:
A WARNING! When bleeding air from within the brake hydraulic circuit, always place blocks or chocks
&& under the tires to prevent the machine from moving.
1. Check and if necessary refill the brake oil tank with oil up to the specified oil level of the sight gauge.
NOTICE: Check the brake oil level and refill with oil frequently when bleeding the system.
Repeat Steps 2 thru 5 to bleed the air at the remaining three (3) brakes.
Recheck the oil level in the brake oil tank and add oil as necessary. After adding oil, tighten the oil filler cap
securely.
3-32
MAINTENANCE
PARKING BRAKE
L04BH012
3-33
MAINTENANCE
3. Install the new teeth on the bucket. When installing the teeth, insert a shim so that there is no clearance between
the teeth and the top surface of the bucket.
* Thickness of shims is 0.5 mm (0.01 in) and 1.6 mm (0.06 in). So the clearance should be less than 0.5 mm (0.01
in).
4. To prevent any clearance between the tooth and the edge of the bucket, tighten the mounting nut partially, then
hit the tip of the tooth with a hammer.
* Tightening torque of mounting bolt: 225 + 25 kgm (1627 f 180 Ibf ft / 2206 f 244 N*m)
* After operating the machine for a few hours, retighten the mounting bolts again.
* When extracting pin (2) strike the part (either the left 1
or right part) with a sharp object. This will enable the
pin to be extracted from the opposite side.
3-34
MAINTENANCE
2. Insert the new tooth (1) on to the adaptor (3), and
insert pin (2) partway as shown in the diagram. Then
drive it home by means of a hammer.
17DHOOOZ
3-35
MAINTENANCE
WINDOW WASHER TANKS - IF EQUIPPED
A
WARNING! Do not clean the condenser with
a stream cleaner. The condenser will become
hot and may be damaged.
00 I ,L;3FD023
Check the air conditioner refrigerant charge twice a year, in spring and autumn.
Operate the air conditioner for 5 - 10 minutes at the coolest setting, then touch the high pressure hose and low
pressure hoses at the refrigerant compressor by hand. Next, check the flow of refrigerant gas (freon 12) through the
sight glass to check the gas level.
The sight glass is located on the air conditioner dryer receiver, which is located on the right side of the machine next
to the condenser.
A
WARNING! Air conditioner refrigerant is colorless and odorless and does not cause pollution of the
atmosphere, if handled properly. However, it may cause injury if it gets in the eyes or on the hands,
so never loosen any parts of the refrigerant system.
3-36
MAINTENANCE
Temperature of high & High pressure line is hot High pressure line is Almost no difference in
low pressure lines Low pressure line is cold warm temperature between
Clear difference in tem- Low pressure line is cold high & low pressure
perature Little difference in tem- lines
perature
Sight glass Almost transparent. Any Bubbles are always flow- Misty substance is flow-
bubbles disappear if en- ing. Sometimes becomes ing.
gine speed is raised or transparent or white bub-
Iow- bles
System line connections Properly connected Some parts dirty with oil Some parts very dirty
with oil
General condition of air Refrigerant level correct, May have refrigerant Almost all refrigerant has
conditioner no abnomalities. Ready leak. Contact your dis- leaked out. Contact your
for use. tributor for inspection and distributor for immediate
repair. repair.
Adjust or replace alternator drive belt. For the detailed procedure, refer to the Engine Operation and Maintenance
Manual.
Adjust or replace fan drive belt. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
Adjust or replace water pump drive belt. For the detailed procedure, refer to the Engine Operation and Maintenance
Manual.
ALTERNATOR
CRANKING MOTOR
Under normal operating conditions, no maintenance is required between engine overhaul periods. At the time of engine
overhaul, the motor should be disassembled, inspected, cleaned and tested. Contact your distributor for the detailed
information.
3-37
MAINTENANCE
AIR GOVERNOR
It is possible to adjust the length of the directional lever and speed control levers.
3-38
MAINTENANCE
COOLANT LEVEL
A
WARNING! Do not remove radiator cap (1)
when the engine coolant is hot. Hot coolant
may spout out and cause seriuos personal
injury. When removing radiator cap, lift the
safety lever to relieve the system inner pres-
sure.
LO6AMOli
3-39
MAINTENANCE
* Never operate the engine with the oil level below the
L mark or above the H mark.
l-l II-1
I-UIZL LEVEL
1. Check the fuel level using fuel level gauge (G) on the
monitor panel.
3-40
MAINTENANCE
+ L12AR074
AIR TANKS
L03ADOlE
3-41
MAINTENANCE
A
WARNING! Always use engine oil to refill the
brake oil tank.
LO4A
With the engine shut-off, open the drain valve. Turn the
valve counterclockwise approximately l-112 to 2 turns
until draining occurs. Drain the filter sump of water until
clear fuel is visible.
L12BM005
3-42
MAINTENANCE
ENGINE FAN
DRIVE BELTS
BELT INSPECTION
0 Incorrect tension
l Incorrect size or length --Y
02AA0003
0 Pulley misalignment
0 Incorrect installation
0 Severe operating environment
l Oil or grease on the belts
All new belts will lose tension during use. They must be adjusted to the tension value listed in the following chart.
* A belt is considered used if has been in operation for ten (10) minutes or longer.
3-43
MAINTENANCE
NOTE: A belt is considered used if has been in service for ten (10) minutes or longer.
NOTE: If the used belt tension is less than the minimum value, adjust and tighten the belt to the maximum value.
MONITOR PANEL
3-44
MAINTENANCE
ADDITIONAL CHECKS
Check for any sign of disconnection or short circuit in the electrical wiring. Check also for loose terminals and
tighten any loose parts. Check the following points carefully:
l Batteries
l Cranking motor
l Alternator
TIRES
Measure the tire inflation pressures before operating when the tires are cool. Refer to “HANDLING TIRES” in Section
2. Also at this time, check for tire damage.
3-45
MAINTENANCE
A
WARNING! When removing the oil filler cap,
turn it slowly to relieve inner pressure.
3-46
MAINTENANCE
LUBRICATION
A WARNING!
safety.
When using compressed air, wear safety glasses and other things required to maintain
3. After cleaning the filter element, reinstall it with the arrow pointing inward.
4. Install filter holder (2) spacers (3) and mounting knobs (1).
6. Move the operator’s seat forward, then tilt the seat backrest forward and down.
7. Loosen the two access panel thumb screws (5) and retainers (6) and remove access panel (7) to gain access to
recirculating air filter (8). Remove air filter and clean it.
8. After cleaning the recirculating air filter, reinstall air filter (8).
9. Install access panel (7) retainers (6) and thumb screws (5). Tighten the access panel thumb screws.
3-47
MAINTENANCE
10. Return the operator’s seat back to its original position.
L13FFOO6
3-48
MAINTENANCE
* Maintenance for every 50 hours should be carried out at the same time.
* Change the engine lubricating oil AND filter at every oil change interval.
1. Operate the engine until it reaches operating temperature. Park the machine on a level surface, apply the parking
brake, lower the bucket to the ground and stop the engine.
2. Open the engine side access door on the left side of the machine.
A WARNING! Avoid direct contact of hot oil with your skin. Hot oil can cause personal injury.
3-49
MAINTENANCE
7. Fill a new filter with clean engine oil. Then, apply a
thin coat of clean engine oil to the seal of the filter.
6. Install the filter on the filter header until the filter seal
contacts the seal surface of the filter header and
then, turn the filter an additional l/2 to 314 turn by
hand.
9. Clean and check the oil drain plug threads and the
seal surface. Reinstall and tighten the oil drain plug.
Ll2AM002
IO. Clean and check the oil drain plug threads and the
seal surface. Reinstall and tighten the oil drain plug.
11. Remove oil filler cap (F). Fill the engine with the specified type and quantity of engine oil at the oil filler.
* The type of lubricant used depends on the ambient temperature. Select according to the table entitled
“LUBRICANTS, FUEL AND COOLANT”.
12. After refilling the engine with oil and before starting the engine, perform the procedure outlined under ” SPECIAL
STARTING” in Section 2. This procedure insures that the engine receives proper lubricating oil flow. Lack of
lubrication will damage the engine.
13. Start the engine and idle it for a few minutes. Inspect for oil leaks at the filters and drain plug. Then, stop the
engine, wait for 5 minutes to allow the oil to drain and check the oil level. As necessary, add oil to bring the oil
level up to the specified mark on the oil level gauge.
* Diluted oil can cause severe damage to the engine. Check the condition of the used oil.
3-50
MAINTENANCE
FUEL FILTERS
GENERAL
The fuel filters are spin-on type filters. These filters cannot be cleaned and should not be disturbed except when it
becomes necessary to replace them.
Change the fuel filters as listed on the SCHEDULED MAINTENANCE GUIDE or sooner if a power loss is evident. If
a power loss persists, consult your distributor.
NOTE: Fuel with more than the average impurities may require changing filters at shorter intervals.
The fuel filters are located on the right side of the engine.
Be careful not to allow dirt, water or other foreign material to get in the new filter. Keep new filters in the original
package until ready for installation.
REPLACEMENT
3-51
MAINTENANCE
5. Fill the new filters with clean diesel fuel. Then, apply
a thin coat of clean engine oil to the seal of the filter.
COOLANT FILTER
GENERAL
Be careful not to allow dirt, water or other foreign material to get in the new filter. Keep new filters in the original
package until ready for installation.
3-52
MAINTENANCE
REPLACEMENT
A
WARNING! Do not remove the radiator cap
when the engine coolant is hot. Hot coolant
will cause serious personal injury. Remove
the radiator cap and close the shutoff valves,
before removing the coolant filter. Failure to
do so can result in personal injury from
heated coolant spray.
I 1 LlZAMOl(
3-53
MAINTENANCE
7. Install the new filter on the filter header until the filter
seal contacts the seal surface of the filter header and
then, turn the filter an additional l/2 to 314 turn by
hand.
Clean or replace the engine crankcase breather and tube/hose. If the breather and/or tube become plugged up, this
condition could produce excessive crankcase pressure. For the detailed procedure, refer to the Engine Operation and
Maintenance Manual.
a
1.
WARNING! To avoid gas explosions,
bring fire or sparks near the battery.
the
battery caps.
* Should any of the acid be spilt, have it replenished by the nearest battery shop with acid of the correct specific
gravity.
* When checking electrolyte level, clean the vent hole in the battery caps.
3. Reinstall the battery caps and close the battery box covers,
LUBRICATION
NOTICE: When operating under average conditions, lubricate the loader linkage pivot points as listed on the
SCHEDULED MAINTENANCE GUIDE. When operating under severe service conditions, lubricate the
loader linkage pivot points at every work shift change or every work day, whichever comes first.
3-54
MAINTENANCE
To ensure proper lubrication, grease the linkage pivot points as follows:
1. Apply grease to the grease fittings shown by the arrows until it seeps out of the pivot points.
2. Start the engine and operate the work equipment through several complete cycles.
* If grease does not flow into the pivot point, correct the problem before operating or damage could occur.
LOZAVOO7
3-55
MAINTENANCE
2. Bucket link pins (2 points)
3-56
MAINTENANCE
5. Lift cylinder pins (4 points)
I LO2AVO13
3-57
MAINTENANCE
6. Lift arm pivot pins (2 points)
I - ’ ’
, II \\ LOZAVO141
In
3-58
MAINTENANCE
WHEEL HUB NUTS
If wheel hub nuts (1) are loose, tire wear will be in-
creased and accidents may be caused. If any hub nuts
are loose, tighten them to the specified tightening torque.
1. Open the engine side access door on the right side of the machine.
2. Visually inspect the drive belt. Replace belts that are cracked or frayed. Adjust belts that have a glazed or shiny
surface, indicating belt slippage. Correctly installed and tensioned belts show even pulley and belt wear.
3. Check each belt pulley for damage and pulley groove wear. Particularly, check whether the drive belt is contacting
the bottom of the pulley groove through wear. Also, check for pulley alignment.
4. Check belt tension at the midway point of the longest pulley span using the deflection method.
* Proper belt deflection is 1O-15 mm (13/32-19/32 in) when applying approximately 6 kg (13 Ibf / 58 N) of force on
the belt between the compressor drive pulley and the magnetic clutch. If the deflection is more than the specified
range, the belt tension must be adjusted.
1) Loosen the arm adjusting bolts and the mounting bracket pivot bolt.
* When adjusting drive belt tension, do not attempt to move the compressor directly with a bar or similar tool,
but use a wood block to prevent damage.
3) When proper belt tension is obtained, tighten the arm adjusting bolts and the mounting bracket pivot bolt
securely to hold the compressor in place.
6. Close the engine side access door on the right side of the machine.
* If proper belt tension can not be obtained, the drive belt may be stretched, leaving no allowance for adjustment,
and should be replaced.
* When the belt is replaced, readjust its tension after running for one (1) hour.
3-59
MAINTENANCE
EVERY 500 HOURS SERVICE
* Maintenance for every 50,100 and 250 hours should be carried out at the same time.
2. Hold filter cases (2) and loosen center bolts (3) then
remove the filter cases.
3-60
MAINTENANCE
TRANSMISSION OIL FILTER - S/N A61018 AND UP
2. Empty and discard the oil in the filter case, then clean
out the filter case.
L07BVOl:
3-61
MAINTENANCE
LUBRICATION
Perform the following inspection of the air dryer and if there is any abnormality, contact your distributor.
* Open the air tank drain valves and check that only a small amount of water is drained. Note that if the ambient
temperature is lower than 16°C (61 “F), a small amount of water may be collected in the drain.
* Check that there is no abnormal inclusion of oil in water drained from the exhaust port of the air dryer.
2. Remove oil drain plug (P). After the oil has drained
completely, reinstall and tighten the drain plug.
3-62
MAINTENANCE
4. Remove the four mounting bolts (2) and strainer
cover (3) then remove spring (4) together with
strainer (5).
* For the oil level checking procedure, refer to “TRANSMISSION OIL LEVEL” in this section.
Remove all mud and dirt from around the breather, then
remove the breather. Using cleaning fluid, clean the
breather. Reinstall the breather.
3-63
MAINTENANCE
LUBRICATION
L
\I F LO2AVOl’
\ LOSAVOlE
3-64
MAINTENANCE
4. Center drive shaft (2 points)
3-65
MAINTENANCE
7. Damper (1 point)
LO2AVO2d
Engine valves and injectors must be correctly adjusted for the engine to operate efficiently. Check and adjust the
engine valves and injectors. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
ENGINE
LlZAD068
3-66
MAINTENANCE
ENGINE MOUNTED HOSES
_k Tightening torques:
Mounting cushion bolts and nuts 67.5-84.5 kgm
(488-611 Ibf ft / 662-828 Nmm)
Front mounting bracket bolts Standard torque
Rear mounting bracket bolts and nuts 25-31.5 kgm
(181-228 Ibf ft/ 245-309 Nem)
TURBOCHARGER MOUNTING
WATER PUMP
Check the engine water pump. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
3-67
MAINTENANCE
EVERY 2000 HOURS SERVICE
_k Maintenance for every 50,100,250,500 and 1000 hours should be carried out at the same time.
BATTERIES
Check the batteries and mounting for defective cables, loose connections, loose or damaged hold down parts,
damaged terminal posts, clogged vent holes, cracked, or distorted battery case or cover and accumulations of dirt,
moisture and corrosion. Replace any damaged parts.
If corrosion is found on the terminal posts, disconnect the cables from the battery, ground cable first, using the proper
tools. A terminal cleaning brush can be usedto clean tapered posts and the mating surfaces of the cable clamps. The
cable terminals should then be cleaned with an acid neutralizing solution of baking soda and water. Clean the dirt from
the battery top with a cloth wetted with baking soda and water. Then wipe with a cloth with clear water. A wire brush
can be used to remove dirt, corrosion or rust from the battery tray or hold down parts. After the tray and/or hold down
parts are cleaned, rinse with clear water, dry with compressed air and repaint.
After cleaning, reinstall the battery and hold down parts. Coat the battery and cable terminals with terminal grease,
and connect the cables to the battery terminals. Connect ground cable last.
IMPORTANT: Frequent need for refilling battery cells may indicate that battery is being overcharged. Check charging
system and voltage regulator as needed.
A
WARNING! When performing battery tests, observe the rules of safety. Always follow instructions of
the test equipment manufacturer.
1. Visually inspect the outside of the battery for obvious damage such as cracked or broken case or cover which
would allow electrolyte loss. Check for terminal damage. If obvious physical damage is found, replace the battery.
If possible, determine the cause of damage and correct.
3. If the electrolyte level is above the separator plates in all cells, proceed to Step II.
4. If the electrolyte level is below the tops of the separator plates in one or more cells, add distilled water until the
electrolyte level is at the level indicator or 13 mm (l/2 in) above the tops of the separator plates.
5. Then charge the battery for 15 minutes at 15-25 amperes to mix the water with the electrolyte. After mixing
electrolyte proceed to Step II.
The battery’s state of charge can be determined by either the specific gravity hydrometer test or by the stabilized open
circuit voltage test.
3-68
MAINTENANCE
1. Using a hydrometer, extract electrolyte from each battery cell. Measure and record the specific gravity, corrected
to 26.7”C (80°F) of each ceil. Compare the readings obtained with the following table to determine battery’s state
of charge.
2. If the specific gravity readings of all cells are 1.225 or higher and are within 50 points (0.050 specific gravity)
between the highest and lowest cells, the battery is OK.
3. If the specific gravity readings are below 1.225 or vary more than 50 points between the highest and lowest cells,
recharge the battery. Inspect the electrical system to determine the cause for the under-charged battery.
4. If, after charging, the specific gravity readings are within 50 points between the highest and lowest cells, the
battery is OK. If the readings still vary more than 50 points after charging, replace the battery.
If the battery has just been recharged or has been in vehicle service, the surface charge must be removed before
an accurate voltage measurement can be made. Do this by turning “ON” the high beam headlights for fifteen (15)
seconds or by placing a 15 ampere load across the battery terminals for fifteen (15) seconds. Turn “OFF” the lights
or remove the load, then let the battery stand for at least three (3) minutes to stabilize voltage.
Connect a Voltmeter or Electronic Battery Tester across the battery terminals and observe the reading. Compare
the reading obtained with the following table to determine battery’s state of charge.
3. If the stabilized voltage is at least 12.4 volts or higher, the battery is OK.
4. If stabilized voltage is below 12.4 volts, recharge the battery. Inspect the electrical system to determine the cause
for the under-charged battery.
3-69
MAINTENANCE
HYDRAULIC TANK OIL AND FILTERS
2. Remove oil filler cap (F) and the two air vent plugs
(1) on the filter covers.
3. Remove oil drain plug (2) and loosen drain valve (3).
After the oil has drained completely, reinstall and
tighten the drain plug and valve.
A
WARNING! Filter covers (4) are pushed up by
spring tension, so hold the covers down
when removing the mounting bolts.
* If the O-ring of the filter cover is damaged or deteriorated, replace it with a new part.
* When installing the filter cover mounting bolts, push down the cover and tighten the bolts evenly.
8. Fill the hydraulic tank with the specified type and quantity of engine oil at oil filler (F).
3-70
MAINTENANCE
* The type of lubricant used depends on the ambient temperature. Select according to the table entitled
“LUBRICANTS, FUEL AND COOLANT”.
9. Bleed the air from the hydraulic tank as described under “HYDRAULIC TANK’ in this section. Lower the bucket
horizontally to the ground and stop the engine.
IO. Check that there is no oil leaking at the oil drain plug and valve and the filter covers.
11. Check the oil level and ensure that it is correct. For the procedure, refer to “HYDRAULIC TANK OIL LEVEL” in
this section.
A
WARNING! When removing oil filler cap (F),
turn it slowly to relieve inner pressure.
3-71
MAINTENANCE
CAB AIR FILTER - IF EQUIPPED
1. Remove front and rear oil filler plugs (I), then re-
move oil drain plugs (2) to drain the oil.
3-72
MAINTENANCE
2. Remove front and rear oil drain plugs (3) on each
side of the axle to drain the oil.
5. Fill the drive axles with the specified type and quan-
tity of axle oil at the plug openings of oil filler plugs
(1) on the axle housing and oil filler plugs (5) of the
left and right final drives.
Ln7GHnOi
3-73
MAINTENANCE
ACCUMULATOR
1. Stop the machine on level ground and apply the parking brake.
2. Raise the work equipment to the maximum height, then place the lift arm control lever the HOLD position.
3. Leave the work equipment in this position, and stop the engine.
4. Confirm that it is safe around the machine, then set the lift arm control lever in FLOAT and lower the work equip-
ment to a position of 1 m (1 yd) from the ground.
5. When the work equipment reaches a position 1 m (1 yd) from the ground, move the lift arm control lever to the
LOWER position, and lower the work equipment slowly to the ground.
* If the work equipment stops moving during checking, the gas pressure may be below the service limit of 7 kg/cm*
(100 psi I689 kPa). If so, contact your distributor to have the gas pressure measured and/or gas charged.
* Carry out the checks within five minutes of stopping the engine. If the machine is left with the engine stopped, the
accumulator pressure will drop and it will be impossible to carry out the check.
COOLING SYSTEM
COOLANT RECOMMENDATlONS/SPEClFlCATlONS
For coolant recommendations/specifications, refer to “COOLANT’ under “LUBRICANTS, FUEL AND COOLANT”.
3-74
MAINTENANCE
A
WARNING! Do not remove radiator cap (2)
when the engine coolant is hot. Hot coolant
may spout out and cause serious personal
inj&y.-When removing the radiate; cap, lift
the cap lever to relieve the system inner
pressure.
3-75
MAINTENANCE
13. Replace the coolant filter as described under “COOLANT FILTER”. Open the coolant filter shut-off valve (I),
located on the left side of the engine.
14. Fill the cooling system with the correct mixture of water, antifreeze and the correct amount of SCA units.
15. Run the engine for 5 minutes at low idle to eliminate air trapped in the cooling system, and run the engine for 5
minutes at high idle. Leave radiator cap (2) off during this operation.
16. Stop the engine and 3 minutes later supply the system with the correct mixture of water, antifreeze and the correct
amount of SCA units up to the bottom of the radiator filler opening.
17. Repeat Steps 15 and 16 to ensure that the coolant mixture is up to the bottom of the radiator filler opening. Install
and tighten the radiator cap.
FUEL PUMP
Clean and calibrate the fuel pump. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
FUEL INJECTORS
Clean and calibrate the fuel injectors. For the detailed procedure, refer to the Engine Operation and Maintenance
Manual.
Check the engine fan hub. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
Check the engine idler pulley. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
TURBOCHARGER
Check the engine turbocharger. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
AIR COMPRESSOR
Inspect the air compressor. For the detailed procedure, refer to the Engine Operation and Maintenance Manual.
Inspect the engine vibration damper. For the detailed procedure, refer to the Engine Operation and Maintenance
Manual.
3-76
SECTION 4
SPECIFICATIONS
4-l
SPECIFICATIONS
GENERAL SPECIFICATIONS
With Spade Nose Rock
Bucket 4.0 m3 (5.2 yd3)
PERFORMANCE
Forward 1st 7.3 km/h 7.5 km/h 7.3 km/h 7.5 km/h 7.3 km/h 7.5 km/h
(4.5 mph) (4.7 mph) (4.5 mph) (4.7 mph) (4.5 mph) (4.7 mph)
Forward 2nd 12.6 km/h 12.9 km/h 12.6 km/h 12.9 km/h 12.6 km/h 12.9 km/h
(7.8 mph) (8.0 mph) (7.8 mph) (8.0 mph) (7.8 mph) (8.0 mph)
Forward 3rd 21.1 km/h 21.8 km/h 21.1 km/h 21.8 km/h 21.1 km/h 21.8 km/h
(13.1 mph) (13.5 mph) (13.1 mph) (13.5 mph) (13.1 mph) (13.5 mph)
Forward 4th 34.2 km/h 34.9 km/h 34.2 km/h 34.9 km/h 34.2 km/h 34.9 km/h
(21.3 mph) (21.7 mph) (21.3 mph) (21.7 mph) (21.3 mph) (21.7 mph)
Reverse 1st 7.8 km/h 8.2 km/h 7.8 km/h 8.2 km/h 7.8 km/h 8.2 km/h
(4.8 mph) (5.1 mph) (4.8 mph) (5.1 mph) (4.8 mph) (5.1 mph)
Reverse 2nd 13.4 km/h 14.0 km/h 13.4 km/h 14.0 km/h 13.4 km/h 14.0 km/h
(8.3 mph) (8.7 mph) (8.3 mph) (8.7 mph) (8.3 mph) (8.7 mph)
Reverse 3rd 22.5 km/h 23.6 km/h 22.5 km/h 23.6 km/h 22.5 km/h 23.6 km/h
(14.0 mph) (14.7 mph) (14.0 mph) (14.7 mph) (14.0 mph) (14.7 mph)
Reverse 4th 36.4 km/h 37.5 km/h 36.4 km/h 37.5 km/h 36.4 km/h 37.5 km/h
(22.6 mph) (23.3 mph) (22.6 mph) (23.3 mph) (22.6 mph) (23.3 mph)
ENGINE
4-2
SPECIFICATIONS
DIMENSIONS
LO1AD009
With General Purpose With Excavating Bucket With Spade Nose Rock
Bucket 4.3 m3 (5.6 yd3) 4.0 m3 (5.2 yd3) Bucket 4.0 m3 (5.2 yd3)
C Hinge pin height - carry 0.54 m 0.59 m 0.54 m 0.59 m 0.54 m 0.59 m
position (1 it9 in) (1 ftll in) (1 ft 9 in) (1 ft 11 in) (1 ft 9 in) (1 ftll in)
4-3
SPECIFICATIONS
DIMENSIONS
LO1ADO09
With General Purpose With Excavating Bucket With Spade Nose Rock
Bucket 4.3 m3 (5.6 yd3) 4.0 m3 (5.2 yd3) Bucket 4.0 m3 (5.2 yd3)
Reach with lift arm hori- 2.81 m 2.76 m 2.73 m 2.68 m 2.95 m 2.90 m
zontal & bucket level (9 ft 3 in) (9 ft 1 in) (8 ft 11 in) (8 ft 10 in) (9 ft 8 in) (9 ft 6 in)
4-4
SPECIFICATIONS
DIMENSIONS
With General Purpose With Excavating Bucket With Spade Nose Rock
Bucket 4.3 m3 (5.6 yd3) 4.0 m3 (5.2 yd3) Bucket 4.0 m3 (5.2 yd3)
4-5
SPECIFICATIONS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of this
manual.
6 IO 1.35+0.15 13.2k1.4
8 13 3.2kO.3 31.4k2.9
IO 17 6.7kO.7 65.7k6.8
12 19 11.5+1 .o 112k9.8
14 22 18.Ok2.0 177+19
16 24 28.5*3 279*29
18 27 39*4 383+39
20 30 56+6 549&58
22 32 76&8 745&78
24 36 94.5&l 0 927&98
27 41 135+15 1320?140
30 46 175&20 1720*190
33 50 225225 2210*240
36 55 280+30 2750+290
39 60 335&35 3280+340
This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be
used, or which require tightening to otherwise specified torque.
IO 14 6.7kO.7 65.7k6.8
12 17 11.5&l 112+9.8
4-6
SPECIFICATIONS
14 19 2.5kO.5 24.5k4.9
18 24 5+2 49&l 9.6
22 27 8k2 78.5k19.6
24 32 14*3 137.3k29.4
30 36 18+3 176.5k29.4
33 41 2Ok5 196.1&49
36 46 25+5 245.2549
42 55 30*5 294.2*49
4-7
SPECIFICATIONS
MEMORANDA
4-8
Komatsu America international Company
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Vernon Hills, IL 66061-8112 U.S.A.
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PFMRl 081696