Page 2 PRODUCT PUBLICATIONS INFORMATION 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.
Page 3 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM < < Komatsu America International Company AND RETURN TO 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 PURCHASE ORDER NO.
Page 4 INTRODUCTION...
Page 5: Forward
INTRODUCTION 1. FORWARD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. 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.
Page 6: Safety Information
INTRODUCTION 2. 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 maintenance and machine operations.
Page 7: Intended Use
INTRODUCTION 3. INTRODUCTION 3.1 INTENDED USE This WHEEL LOADER is designed to be used mainly for the following work: Digging Leveling Pushing Loading For details of the operating procedures, see "12.13 WORK POSSIBLE USING WHEEL LOADER" on page 2-46 3.2 FEATURES Curved glass and improved sealing for reduced noise, low vibration cab.
Page 8: Location Of Plates, Table To Enter Serial No. And Distributor
INTRODUCTION 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION (A) Position of plate On the center right of the front frame. (B) Position of stamp This is stamped on the center of the front frame on the right hand side of the machine.
Page 9: Table Of Contents
INTRODUCTION 5. CONTENTS INTRODUCTION 1. FORWARD ................0-2 2.
Page 10 INTRODUCTION 11.10 SLOW BLOW FUSE ..............2-22 11.11 STORAGE PLACE FOR THIS MANUAL .
Page 11 INTRODUCTION 12.18 STOPPING ENGINE ..............2-55 12.19 CHECKS AFTER STOPPING ENGINE .
Page 12 INTRODUCTION 20.1 ENGINE OIL SPECIFICATIONS ............3-11 20.2 DIESEL FUEL SPECIFICATIONS .
Page 13 INTRODUCTION 24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT ..3-61 24.9 EVERY 2000 HOURS SERVICE ............3-62 24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM .
Page 14 SAFETY WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equipment and attachments.
Page 15: General Precautions
WARNING: For reasons of safety, always follow these safety precautions. SAFETY 6. GENERAL PRECAUTIONS SAFETY RULES ONLY trained and authorized personnel should be allowed to operate and service this machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
Page 16 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable. Also do not wear oily clothes, because they are flammable.
Page 17 WARNING: For reasons of safety, always follow these safety precautions. SAFETY MOUNTING AND DISMOUNTING NEVER jump on or off the machine. NEVER get on or off a moving machine. When mounting or dismounting, always face the machine and use the handrails and steps. Do not use the machine's controls or hoses as handrails when climbing on or off the machine.
Page 18 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY Immediately after operations are stopped, the engine coolant, engine oil, and hydraulic oil are at high temperatures, and are still under pressure. Attempting to remove the cap, drain the oil or water, or replace the filters may lead to serious burns.
Page 19 WARNING: For reasons of safety, always follow these safety precautions. SAFETY Be sure fire extinguishers have been provided and know how to use them. Provide a first aid kit at the storage point. Know what to do in the event of a fire. Be sure you know the phone numbers of persons you should contact in case of an emergency.
Page 20 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PRECAUTION WHEN HANDLING ACCUMULATOR If the travel damper switch is turned ON when the machine is traveling or when the work equipment is raised, the hydraulic accumulator in the travel damper will instantaneously be connected with the lift cylinder bottom circuit.
Page 21: Precautions During Operation
WARNING: For reasons of safety, always follow these safety precautions. SAFETY 7. PRECAUTIONS DURING OPERATION 7.1 BEFORE STARTING ENGINE (Also see “12.1 WALK AROUND CHECK” on page 2-24) SAFETY AT WORKSITE Before entering the operator's compartment, walk completely around the machine and clear the area of personnel and obstructions.
Page 22 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY IN OPERATOR’S CAB Do not leave tools, spare parts or personal items lying around in the operator's compartment. They may damage, break or jam the control levers or switches. Always put them in their proper place. Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Page 23 WARNING: For reasons of safety, always follow these safety precautions. SAFETY WHEN STARTING ENGINE 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.
Page 24: After Starting Engine
WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE Failure to carry out checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.
Page 25 WARNING: For reasons of safety, always follow these safety precautions. SAFETY CHECK WHEN CHANGING DIRECTION To prevent serious injury or death, always do the following before moving the machine or the work equipment. Sound the horn to warn people in the area. Check that there is no one near the machine.
Page 26 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS WHEN TRAVELING Never turn the key in the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the machine is traveling, because the steering becomes heavy. If the engine stops, apply the brake immediately to stop the machine.
Page 27 WARNING: For reasons of safety, always follow these safety precautions. SAFETY TRAVELING ON SLOPES Traveling on hills, banks or slopes that are steep could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket closer to the ground. Approximately 20 to 30 cm (8 to 12 in) above the ground.
Page 28 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS WHEN TRAVELING Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile to push the first pile.
Page 29 WARNING: For reasons of safety, always follow these safety precautions. SAFETY DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not let the machine touch any electrical cables Even going close to high-voltage cables can cause an electric shock. Always maintain the safe distance given below between the machine and any electric cable. To prevent accidents, always do as follows.
Page 30 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY ENSURE GOOD VISIBILITY When working in dark places, install working lamps and head lamps, and set up lighting in the work area if necessary. Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a condition that allows the operation to be carried out safely.
Page 31 WARNING: For reasons of safety, always follow these safety precautions. SAFETY WORKING ON LOOSE GROUND Do not operate the machine on soft ground. It is difficult to get the machine out again. Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse your machine could fall or tip over and result in serious injury or death.
Page 32 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PRECAUTIONS IN COLD AREAS After completing operations, remove all water, snow, or mud stuck to the wiring harness, connector (1), switches, or sensors, and cover these parts. If the water freezes, it will cause malfunctions of the machine when it is next used, and this may lead to unexpected accidents.
Page 33: Transportation
WARNING: For reasons of safety, always follow these safety precautions. SAFETY 7.3 TRANSPORTATION LOADING AND UN LOADING Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. When loading or unloading the machine, run the engine at low idle and travel at low speed. Perform loading and unloading on firm, level ground only.
Page 34: Battery
WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Never bring any lighted cigarette or flame near the battery.
Page 35 WARNING: For reasons of safety, always follow these safety precautions. SAFETY STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows. Carry out the starting operation with two workers (with one worker sitting in the operator's seat) Always wear safety glasses when handling tools or booster cables near the batteries.
Page 36 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY CHARGING BATTERY If the battery is handled incorrectly when it is being charged, there is danger that the battery may explode, so follow the instructions in HANDLING BATTERY and in the instruction manual for the charger, and always observe the following precautions.
Page 37: Towing
WARNING: For reasons of safety, always follow these safety precautions. SAFETY 7.5 TOWING WHEN TOWING Towing in the wrong way may lead to serious personal injury or damage, so always do as follows. Do not tow in a different way from the method given in the section METHOD OF TOWING. Always wear leather gloves when handling wire rope.
Page 38: Precautions For Maintenance
WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 8. PRECAUTIONS FOR MAINTENANCE 8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual may lead to unexpected failures.
Page 39 WARNING: For reasons of safety, always follow these safety precautions. SAFETY STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE When carrying out inspection and maintenance, park the machine on level ground where there is no danger of failing rocks or landslides, or of flooding if the land is low, then lower the work equipment to the ground and stop the engine.
Page 40 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PROPER TOOLS Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. Tools ö ö See “21.1 INTRODUCTION OF NECESSARY TOOLS” on page 3-19. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically.
Page 41 WARNING: For reasons of safety, always follow these safety precautions. SAFETY KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely. If the work place is not kept clean and tidy, there is danger that you will trip, slip, or fall over and injure yourself.
Page 42 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PREVENTION OF FIRE There is danger of the fuel and battery gas catching fire during maintenance, so always follow the precautions below when carrying out maintenance. Store fuel, oil, grease, and other flammable materials away from flame.
Page 43: During Maintenance
WARNING: For reasons of safety, always follow these safety precautions. SAFETY 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments.
Page 44 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY DO NOT DROP TOOLS OR PARTS INSIDE MACHINE When opening the inspection window or tank oil filler to carry out inspection, be careful not to drop any nuts, bolts, or tools inside the machine.
Page 45 WARNING: For reasons of safety, always follow these safety precautions. SAFETY WHEN ABNORMALITY IS LOCATED if any abnormality is found during inspection, always carry out repairs. In particular, if the machine is used when there is any abnormality in the brakes or work equipment systems, it may lead to serious accident. Depending on the type of failure, please contact your Komatsu distributor for repairs.
Page 46 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY PRECAUTION HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure. Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.
Page 47 WARNING: For reasons of safety, always follow these safety precautions. SAFETY TIRE MAINTENANCE Disassembly, repair, and assembly of tires requires specialist equipment and skill, please ask your specialist tire repair shop to carry out repairs. CHECKS AFTER INSPECTION AND MAINTENANCE Failure to carry out inspection and maintenance fully, or failure to check the function of various maintenance locations may cause unexpected problems and may even lead to personal injury or damage, so always do as follows.
Page 48: Tires
WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 8.3 TIRES HANDLING TIRES If tires are not used under the specified conditions, they may overheat and burst or be cut and burst from sharp stones on rough road surfaces. This may lead to serious injury or damage. To maintain safety, always keep the following conditions.
Page 49 WARNING: For reasons of safety, always follow these safety precautions. SAFETY STORING TIRES AFTER REMOVAL As a basic rule, store the tire in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up a "No Entry" and other warning signs that even children can understand.
Page 50: Position For Attaching Safety Labels
WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 9. POSITION FOR ATTACHING SAFETY LABELS Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way.
Page 51 WARNING: For reasons of safety, always follow these safety precautions. SAFETY 1. Precautions before starting. 2. Precautions for safety lock lever. 3. Precaution when traveling in reverse. 4. Precautions for parking brake. 5. Do not use ether. 1-38...
Page 52 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 7. Precautions for safety bar. 6. Do not enter. 8. Precautions when coolant is at high temperature. 1-39...
Page 53 WARNING: For reasons of safety, always follow these safety precautions. SAFETY 9. Precautions when oil is at high temperature. Order 417-93-21310 for safety labels (6 - 11) 10. Precautions for brake oil. 11. Precaution s when handling battery cable. Order 417-93-21360 for safety labels (1 - 5) 1-40...
Page 54 WARNING: Failure to follow these safety precautions may lead to a serious accident. SAFETY 1-41...
Page 55 OPERATION...
Page 56: General View
OPERATION 10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this manual, they refer to the directions shown by the arrows in the diagram below.
Page 57: General View Of Controls And Gauges
OPERATION 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 58 OPERATION...
Page 59: Explanation Of Components
OPERATION 11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. 11.1 METER, LAMPS 1.
Page 60 OPERATION 3. FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank. E: Tank is EMPTY F: Tank is FUEL If the fuel gauge indicates E during operation, check and supply fuel. 4. SERVICE METER This meter shows the total operation hours of the machine. The service meter advances while the engine is running - even if the machine is not traveling.
Page 61 OPERATION 9. WORKING LAMP PILOT LAMP This lamp lights up when the working lamp is switch ON. 10. BRAKE OIL LEVEL CAUTION PILOT LAMP This lamp indicates a low brake oil level. It is kept turned OFF if the brake level is normal. If the lamp lights, check the oil level and add brake oil as required.
Page 62 OPERATION 14 TRANSMISSION CUT-OFF PILOT LAMP This lamp lights up when the transmission cut-off switch is turned to ON If the lamp is ON and the brake pedal is depressed, the transmission will returned to neutral. 15. EMERGENCY STEERING NORMAL PILOT LAMP (BLUE) When the machine is traveling, this lamp is ON to show that emergency steering pump is operating normally.
Page 63: Switches
OPERATION 11.2 SWITCHES 1. STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted and moved at this position. When the key is turned to this position, the electric circuit is turned off and the engine stops. ON position Electric current flows in the charging, lamp and accessory circuits.
Page 64 OPERATION 2. TRANSMISSION CUT-OFF SWITCH WARNING If the machine has to be stared on a slope, always turn the transmission cut-off 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.
Page 65 OPERATION 4. TURN SIGNAL LEVER This lever operates the turn signal lamps. (1) LEFT TURN: Push lever FORWARD. (2) RIGHT TURN: Pull lever BACK. REMARKS: When the lever is operated, the turn signal pilot lamp will also light up. When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to OFF.
Page 66 OPERATION 7. KICKDOWN SWITCH When the speed control lever is in 2nd, and the switch at the top of the knob of the work equipment control lever is pressed, the transmission will shift down to 1st gear. This switch is used to increase the drawbar pull in digging operations. REMARKS To cancel the kickdown switch, move the directional lever to REVERSE or NEUTRAL, or move the speed control lever to any position except 2nd.
Page 67 OPERATION MACHINE EQUIPPED WITH CAB (The following items 8 - 11 are added when the cab is installed as standard.) 8. FRONT WIPER SWITCH Turn switch (A) to operate the front wiper. If button (B) is pressed, washer fluid will spray out on to the front glass. 9.
Page 68 OPERATION 10. CIGARETTE LIGHTER This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back. At that time remove the lighter and light your cigarette. 11. ROOM LAMP SWITCH This lights up the room lamp. ON position: lights up Position 1: Position 2...
Page 69: Control Levers, Pedal
OPERATION 11.3 CONTROL LEVERS, PEDAL 1. SPEED CONTROL LEVER This lever controls the travel speed of the machine. This machine has a 4-FORWARD, 4-REVERSE speed transmission. Place the speed control lever into the desired speed range. 1st and 2nd speeds are used for working. 3rd and 4th speeds are used for traveling.
Page 70 OPERATION 2. DIRECTIONAL LEVER This lever is used to change the direction of travel of the machine. The engine can not be started if the directional lever is not at N (neutral). Position (1): Forward Position N: Neutral Position (2): Reverse REMARKS The length of the lever can be adjusted to 3 stages (positions A, B, C).
Page 71 OPERATION 5. WORK EQUIPMENT CONTROL This lever operates the lift arm and the bucket. (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. (A) TILT ( (B) DUMP ( When the work equipment control lever is pulled further from the RAISE...
Page 72 OPERATION 7. BRAKE PEDALS WARNING When traveling downhill, use the engine as a brake, and always use the right brake pedal. Do not use the brake pedals repeatedly unless necessary. Do not put your foot on this pedal unless necessary. Note that when the engine of a machine with booster stops, the brake pedal becomes 3.5 times heavier.
Page 73: Cap With Lock
OPERATION 11.4 CAP WITH LOCK The fuel tank filler port and the hydraulic tank filler port are equipped with locks. Use the starter key to open and close the cap as follows. 11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK TO OPEN THE CAP (For the fuel tank filler port) 1.
Page 74: Towing Pin
OPERATION 11.6 TOWING PIN 1. Align protrusion (1) on the towing pin with groove (2) in the counterweight, then insert and turn the pin 180E 2. To prevent the pin from turning , bend the towing pin handle down and set it in position.
Page 75: Fuse
OPERATION 11.9 FUSE NOTICE Before replacing a fuse, be sure to turn OFF the starting switch. The fuse protects the electrical equipment and wiring from burning out. If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the fuse holder, replace the fuse.
Page 76: Slow Blow Fuse
OPERATION Machine equipped with CAB The following fuses are added Fuse Name of circuit capacity Spare Spare Spare Room lamp, Air conditioner Rotating lamp Cigarette lighter, radio Air conditioner Air conditioner Wiper motor 11.10 SLOW BLOW FUSE If the power does not come on when the starting switch is turned ON, the slow-blow fuse could be blown, so check and replace it.
Page 77: Storage Place For This Manual
OPERATION 11.11 STORAGE PLACE FOR THIS MANUAL Store this manual in the pocket provided on the back of the operator’s seat. So it is immediately accessible when needed. 11.12 AUXILIARY POWER SOURCE The fuse terminal (1) in the right console box provides optional power. The maximum electric supply is 10 A (240 W) 11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB The cigarette lighter (1) can also be used as an option power source.
Page 78: Check Before Starting Engine
OPERATION 12. CHECK BEFORE STARTING ENGINE 12.1 WALK AROUND CHECK WARNING Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or turbocharger, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your distributor for assistance.
Page 79 OPERATION 1. Check for damage, wear, or play in the work equipment, cylinders, linkage and hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any abnormality is found, repair 2.
Page 80 OPERATION 11. Check seat belt and equipment WARNING Even if there appears to be no abnormality with the seat belt, always replace it once every three years. REMARKS The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram on the right.
Page 81: Check Before Starting
OPERATION 12.2 CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day 12.2.1 CHECK COOLANT LEVEL, ADD COOLANT WARNING Always wait for the engine to cool down before checking the water level, and check using the radiator overflow sub-tank 1.
Page 82: Check Oil Level In Engine Oil Pan, Add Oil
OPERATION 12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover at the right rear side of the machine. 2. Remove dipstick (G) and wipe the oil off with a clean cloth. 3. Insert dipstick (G) fully in the guide tube, then take it out again. 4.
Page 83: Check Dust Indicator
OPERATION 12.2.5 CHECK DUST INDICATOR 1. Check that the red piston of dust indicator (1)has not reached the service level. 2. If the red piston is showing, clean or replace the element immediately. For details of cleaning the element, see “24.2 WHEN REQUIRED, CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT on page 3- 31.”...
Page 84: Drain The Water From The Fuel-Water Separator
OPERATION 12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR With the engine shut-off, open the drain valve (1). Turn the valve counterclockwise approximately 1-1/2 to 2 turns until draining occurs. Drain the filter sump of water until clear fuel is visible. Do not over tighten the valve.
Page 85: Check Effect Of Wheel Brakes
OPERATION 12.2.9 CHECK EFFECT OF WHEEL BRAKES Drive the machine at a speed of 20 km/h (12.4 mph) on a dry flat concrete road surface, and check that the stopping distance is less than 5 m (16.4 ft). 12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM 12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE 12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND 12.2.13 CHECK OPERATIONS OF GAUGES...
Page 86: Adjustment Before Operation
OPERATION 12.3 ADJUSTMENT BEFORE OPERATION 12.3.1 OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat before starting operations or when changing operators. Check that you can depress the brake pedal fully with your back against the seat backrest.
Page 87 OPERATION E: Seat height adjustment Move lever (2) up/down, then move seat up or down as desired. Since lever (2) is also used for adjusting seat angle, set the seat to the desired height while adjusting the angle. Adjustment range: 60 mm (2.36 in) F: Adjusting height of headrest Move the headrest up and down to the desired height.
Page 88: Adjust Seat Belt
OPERATION 12.3.2 ADJUST SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting of the belt. If the belt is worn or damaged, replace it.
Page 89: Adjust Rear Veiw Mirrors
OPERATION 12.3.3 ADJUST REAR VEIW MIRRORS Sit in the operator's seat and adjust the rear view mirror so that you can see properly to the rear. 2-35...
Page 90: Operations And Checks Before Starting Engine
OPERATION 12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING If the control levers are touched by accident, the work equipment could move suddenly. When leaving the operators compartment, always set the safety lever securely to the LOCK position. Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery or on the starting mortar and alternator.
Page 91: Starting Engine
OPERATION 12.5 STARTING ENGINE 12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. WARNING NEVER use starting fluid (such as ether) to help start the engine. This engine has a preheater in the intake manifold and this combination can cause an explosion.
Page 92: Starting Procedures After Extended Shutdown Or Oil Change
OPERATION 12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE Complete the following steps after each oil change, or after the engine has been shut off for more than 30 days to make sure the engine receives the correct oil flow through the lubricating oil system: Disconnect the electrical wire from the fuel pump solenoid valve.
Page 93: Operations And Checks After Starting Engine
OPERATION 12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine do not immediately start operations. First carry out the following operations and checks. NOTICE Do not suddenly accelerate the engine before the warming-up operation is completed. Do not run the engine at low idle or high idle continuously for more than 10 minutes.
Page 94: Moving Machine Off
OPERATION 12.7 MOVING MACHINE OFF WARNING When moving the machine off, check that the area around the machine is safe, then sound the horn before starting. Do not allow people near the machine. There is a blind spot behind the machine, so be particularly careful when traveling in reverse.
Page 95 OPERATION 4. Depress right brake pedal (7) and pull parking brake release lever (8) to the FREE position to release the parking brake. Keep right brake pedal (7) depressed. 5. Set speed control lever (9) to the desired position. 6. Set directional control lever (10) to the desired position. 7.
Page 96: Changing Gear Speed
OPERATION 12.8 CHANGING GEAR SPEED WARNING When traveling at high speed, do not change the gear speed suddenly. When shifting gears, use the brake to reduce the travel speed, then shift gears Shift gear as follows. Move speed control lever (1) to the desired position. Only 1st or 2nd speeds are used for digging and loading operations, so actuate speed control lever stopper.
Page 97: Turning
OPERATION 12.10 TURNING WARNING It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. If the engine quits while the machine is traveling, the steering wheel becomes heavy and hard to turn, so avoid killing the engine.
Page 98: Stopping Machine
OPERATION 12.11 STOPPING MACHINE WARNING Avoid stopping suddenly. Allow ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 99: Operation Of Work Equipment
OPERATION 12.12 OPERATION OF WORK EQUIPMENT Work equipment control lever (1) can be used to operate the lift arm and bucket as follows. LIFT ARM OPERATION (LEVER) (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.
Page 100: Work Possible Using Wheel Loader
OPERATION 12.13 WORK POSSIBLE USING WHEEL LOADER In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.13.1 DIGGING OPERATIONS WITH ROCK PILES WARNING Always set the machine facing directly to the front when carrying out digging or scooping operations. Never carry out these operations with the machine articulated.
Page 101: Digging Operations On Level Ground
OPERATION 5. Check that there is enough material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load the bucket fully. REMARKS: If the bucket edge is moved up and down while pushing in the bucket and digging, the front wheels could raise up and cause the tires to slip.
Page 102: Leveling Operation
OPERATION 12.13.3 LEVELING OPERATION NOTICE: Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20E E . 1.
Page 103: Loading Operations
OPERATION 12.13.6 LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel and provide the most efficient method for the jobsite. WARNING Always keep the working area flat. Do not turn suddenly or apply the brake suddenly when traveling with a raised load.
Page 104: Precautions For Operation
OPERATION 12.14 PRECAUTIONS FOR OPERATION 12.14.1 PERMISSIBLE WATER DEPTH When working in water or on swampy ground, do not let the water come above the bottom of the axle housing. After finishing the operation, wash and check the lubricating points. 12.14.2 IF WHEEL BRAKE DOES NOT WORK If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine.
Page 105: Precautions When Driving Machine
OPERATION 12.14.4 PRECAUTIONS WHEN DRIVING MACHINE 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.
Page 106: Adjusting Work Equipment Posture
OPERATION 12.15 ADJUSTING WORK EQUIPMENT POSTURE WARNING Stop the machine on flat ground and put blocks in front and behind the wheels. Apply the parking brake. Secure the front and rear frames with safety bar. Never go under the work equipment when the arm is raised. The boom kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (work equipment higher than horizontal) and the bucket positioner makes it possible to set the bucket so that it...
Page 107: Adjusting Bucket Positioner
OPERATION 12.15.2 ADJUSTING BUCKET POSITIONER 1.Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the work equipment control lever at HOLD, stop the engine and adjust as follows. 2.Loosen two bolts (1) and adjust mounting bracket (4) of the proximity switch so that the rear tip of angle (2) is in line with the center of the sensing surface of the proximity switch (3).
Page 108: Parking Machine
OPERATION 12.16 PARKING MACHINE WARNING Avoid stopping suddenly. Allow ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it facing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 109: Checks After Completion Of Engine Operation
OPERATION 4. Operate work equipment control lever (5) to lower the bucket to the ground. 5. Lock work equipment control lever (5) with safety lock (6). 12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION Check the engine water temperature, engine oil pressure, torque converter oil temperature, and fuel level with the meter and lamps.
Page 110: Checks After Stopping Engine
OPERATION 12.19 CHECKS AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, body work, and undercarriage, and check for oil and water leaks. If there are any leaks or abnormalities found, carry out repairs. 2. Fill the fuel tank. 3.
Page 111: Handling The Tires
OPERATION 12.21 HANDLING THE TIRES 12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES If the following defects are found in a tire, for safety reason the tire should be replaced with a new one. Bead wire is broken or bent, or the tire is greatly deformed. Wear is excessive and the carcass ply (excluding breaker) is exposed for more than 1/4 of the circumference.
Page 112 OPERATION If the deflection of the tire is excessive, raise the inflation pressure within the limits given in this table to give a suitable deflection (see deflection ratio). Inflation pressure (kg/cm²) Soft Normal road Tire size (pattern) ground When shipped rating (sandy from factory...
Page 113: Transportation
OPERATION 13. TRANSPORTATION When transporting the machine, observe all the related laws and regulations, and always assure safety. 13.1 LOADING, UNLOADING WORK WARNING Make sure the ramp has sufficient with, length and thickness to enable the machine to be safety loaded and unloaded. When loading and unloading the machine, park the trailer on a flat firm roadbed.
Page 114: Precaution For Loading
OPERATION 13.2 PRECAUTION FOR LOADING After loading the machine in the specified position, secure it in place as follows. 1. Lower the work equipment slowly. 2. Apply the safety lock to lock all the control levers securely. 3. Turn the starting switch to the OFF position and stop the engine. Remove the key from the starting switch.
Page 115: The Location Of Decals Referring To Lifting Positions
OPERATION 13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS 13.3.2 WEIGHT LIST POSITION OF THE VEHICLE FRONT AXLE REAR AXLE CENTER OF GRAVITY WEIGHT WEIGHT WEIGHT (FROM FRONT AXLE) wA180-3 8750 kg 3460 kg 5290 kg 1632 mm 2-61...
Page 116: Lifting Procedure
OPERATION 13.3.3 LIFTING PROCEDURE Lifting is only for vehicles which have decals indicating lifting positions First stop the vehicle on level ground to ensure the vehicle will be lifted horizontally Then proceed with the follow instructions: 1. Start the engine, be sure the vehicle is on level ground, then set the work equipment to the travel position.
Page 117: Cold Weather Operations
OPERATION 14. COLD WEATHER OPERATIONS 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature drops real low, it may becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see "20.
Page 118: Battery
OPERATION 14.1.3 BATTERY WARNING To avoid gas explosions, do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult your doctor.
Page 119: Precautions After Completion Of Work
OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud and water in and on the machine from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. Mud and water in and on the machine should be completely removed. Park the machine on hard, dry ground.
Page 120: Long Term Storage
OPERATION 15. LONG TERM STORAGE 15.1 BEFORE STORAGE When putting the machine in storage for a long time, proceed as follows. After every part is washed and dried, house the machine in a dry building. If the machine must be left outdoors, park it on well drained concrete and cover it with canvas, etc.
Page 121: Troubleshooting
OPERATION 16. TROUBLESHOOTING 16.1 WHEN MACHINE RUNS OUT OF FUEL WARNING The engine could start, so check carefully that the area around the engine is safe before cranking the engine If the machine has run out of fuel, add fuel to the fuel tank and to the fuel filters to minimis any air in the system.
Page 122: Towing The Machine
OPERATION 16.2 TOWING THE MACHINE WARNING If the wheel loader is towed in the wrong way, it could lead to serious injury or damage. If there is a failure in the brake lines and the brakes can not be used, be extremely careful when towing. NOTICE: Towing is for moving the machine to a place where inspection and maintenance can be carried out, and not for moving it long...
Page 123 OPERATION The towing machine should normally be of the same class as the machine being towed. Check that the towing machine has ample braking power, weight, and rim pull to allow it to control both machines while on a slope. When towing the machine downhill, use a larger machine for towing to provide ample rim pull and braking power, or connect another machine to the rear of the machine being towed, in order to prevent either...
Page 124: When Engine Can Be Used
OPERATION 16.2.1 WHEN ENGINE CAN BE USED If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of the mud or move it for a short distance to the edge of the road. The operator should sit on the machine being towed and operate the steering in the direction that the machine is being towed.
Page 125: If Battery Is Discharged
OPERATION 16.3 IF BATTERY IS DISCHARGED WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position before starting. Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.
Page 126: Precautions For Charging Battery
OPERATION 16.3.2 PRECAUTIONS FOR CHARGING BATTERY CHARGING BATTERY WHEN MOUNTED ON MACHINE Before charging, disconnect the cable from the negative (-) terminal of the battery. Otherwise, an unusually high voltage could damage the alternator. While charging the battery, remove all battery plugs for satisfactory ventilation.
Page 127: Starting Engine With Booster Cable
OPERATION 16.3.3 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: Precautions when connecting and disconnecting booster cable WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals together. When starting the engine with a booster cable, always wear safety glasses.
Page 128 OPERATION Connecting the booster cables Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 129: Other Trouble
OPERATION 16.4 OTHER TROUBLE 16.4.1 ELECTRICAL SYSTEM ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main cause Remedy !Defective wiring (! Check, repair loose Lamp does not glow brightly even terminals, disconnections)
Page 130: Chassis
OPERATION 16.4.2 CHASSIS ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main causes Remedy TRANSMISSION Engine is running but Parking brake is applied Release parking brake machine does not move...
Page 131 OPERATION CHASSIS continued (16.4.2) Problem Main causes Remedy BRAKE Brake is not applied when Disc has reach wear limit (Replace disc) pedal is depressed Lack of brake oil Add oil to specified level. See "24.5 EVERY 100 HOURS SERVICE" on page 3-44. Air in brake line Bleed air Brake drags or remains...
Page 132 OPERATION CHASSIS continued (16.4.2) Problem Main causes Remedy HYDRAULIC SYSTEM Lack of lifting power for Lack of oil Add oil to specified level. See "24.5 bucket EVERY 100 HOURS SERVICE" on page 3-44. Bucket takes time to raise Clogged hydraulic tank filter Replace filter.
Page 133: Engine
OPERATION 16.4.3 ENGINE ( ): Always contact your distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. Problem Main causes Remedy Engine oil pressure Engine oil pan oil level is low Add oil, see 12.2.3 CHECK OIL LEVEL, caution pilot lamp lights (sucking in air)
Page 134 OPERATION Problem Main causes Remedy Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see 24.2.1 black CLEAN / REPLACE AIR CLEANER ELEMENT page 3-31 Defective nozzle (! Replace nozzle) Defective compression (! See defective compression above) Defective turbocharger (! Clean or replace turbocharger) Combustion noise occasionally...
Page 135 MAINTENANCE...
Page 136: Guides To Maintenance
MAINTENANCE 17. GUIDES TO MAINTENANCE Do not carry out any inspection and maintenance operation that is not given in this manual. Perform maintenance work on hard, flat ground. Set to the inspection and maintenance posture. Always carry out inspection with the machine in the following posture unless otherwise specified.
Page 137 MAINTENANCE Check for foreign materials in drained oil and on filter: After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign materials. If large quantities of metallic particles or foreign materials are found, consult your distributor. Fuel strainer: If your machine is equipped with a fuel strainer, do not remove it while fueling.
Page 138 MAINTENANCE Checking underneath machine: When working in rocky areas, check for damage underneath the machine, wear and damaged bolts and nuts. Precautions when washing machine: Never spray steam or water directly at the radiator. Do not allow water to get on any electrical component Pre-and post-work checks: Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness.
Page 139: Outlines Of Service
MAINTENANCE 18. OUTLINES OF SERVICE Use genuine Komatsu parts for replacement. When changing or adding oil, do not use a different type of oil. Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.
Page 140: Coolant
MAINTENANCE Be extremely careful not to let impurities get in when storing or adding fuel. Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the temperature when it is used (particularly in low temperatures below-15EC (5EF)), so it is necessary to change to a fuel that matches the temperature.
Page 141: Grease
MAINTENANCE 18.1.4 GREASE Grease is used to reduce friction and help prevent wear, twisting and noise at the joints. Grease fittings that were not referred to in the maintenance schedule do not require any scheduled greasing. Add grease to these areas only If something becomes stiff or squeaky. Always wipe off all of the old grease that is pushed out when greasing.
Page 142: Outline Of Electric System
MAINTENANCE 18.2 OUTLINE OF ELECTRIC SYSTEM If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result in hazardous malfunction of the machine. Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear in the fan belt and (3) check of battery fluid level.
Page 143: Wear Parts List
MAINTENANCE 19. WEAR PARTS LIST Wear parts such as filter elements, bucket teeth, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits. The wear parts should be changed correctly in order to use the machine economically. For part replacement, genuine Komatsu parts of excellent quality should be used.
Page 144: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS Capacity Ambient Temperature Kind of Reservoir 104EF fluid Specified Refill SAE 5W-30 22 R 19.5 R SAE 10W-30 Engine oil pan 5.8 US gal 5.1 US gal 4.8 UK gal...
Page 145: Engine Oil Specifications
MAINTENANCE ASTM: American Society of Testing ans Material SAE: Society of Automotive Engineers API: American petroleum Institute 20.1 ENGINE OIL SPECIFICATIONS Normal operation Oil performance recommendations are as follows: The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability.
Page 146: Diesel Fuel Specifications
MAINTENANCE decrease engine life due to factors such as; corrosion, deposits and wear. 20.2 DIESEL FUEL SPECIFICATIONS WARNING Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. NOTICE: 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.
Page 147: Coolant Specifications
MAINTENANCE 20.3 COOLANT SPECIFICATIONS 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 coolant inhibitors. Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the section entitled "Inhibitors/Conditioners".
Page 148 MAINTENANCE The following table shows the approximate percentage of antifreeze solution required for various temperatures. Percentage of Antifreeze Approximate Freezing Point Specific Gravity at 16EC (60EF) Concentration by Volume 0EC (+32EF) 1.000 -7EC (+20EF) 1.025 -12EC (+10EF) 1.040 -18EC (0EF) 1.053 -23EC (-10EF) 1.062...
Page 149 MAINTENANCE COOLANT TESTING FOR CONDITIONER CONCENTRATION When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4 concentration must not fall below 1.0 unit per 3.8R (1 US gal) or exceed 2 units per 3.8R (1 US gal) of coolant.The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis.
Page 150 MAINTENANCE DCA4 Unit Guide Fleetguard Part No. DCA4 Units DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077 DCA4 Liquid DCA60L 4 (1 Pint) DCA80L 1760 (55 US gal) DCA4 Powder DCA95 DCA4 Precharge and Service Filters System Capacity Precharge Filter Service Filter (See NOTE 1)
Page 151 MAINTENANCE To check the DCA4 concentration level, use the Fleetguard coolant test kit, CC2626. Instructions are included with the test kit. DCA4 Unit Concentration Guide Number of Solution A Drops to Coolant Condition Action Required Cause Color Change Extremely under-concentrated - less Initially charge the system to a 0 - 10 Drops than 0.4 DCA4 units per 3.8R (1 US minimum of 1.0 DCA4 unit per 3.8R (1...
Page 152 MAINTENANCE TOOLS The following tools may be purchased from your Komatsu America International Company distributor. Cooling system test kit The Fleetguard® Coolant Test Kit is used to check the concentration of coolant additives in the cooling system. Part Number: CC-2626 1.
Page 153: Standard Tightening Torque For Bolts And Nuts
MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 21.1 INTRODUCTION OF NECESSARY TOOLS The following tools are needed when carrying out maintenance. Name of tool Part No. Remarks Wrench set 09000-30006 Applicable width across flats (S - S ) 8 mm - 10 mm 12 mm - 14 mm 13 mm - 17 mm 19 mm - 22 mm...
Page 154: Torque List
MAINTENANCE 21.2 TORQUE LIST Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table. The torque value is determined by the width across the flats (b)of the nut and bolt. If it is necessary to replace any nut or bolt, always use a genuine Komatsu part of the same size as the part that was replaced.
Page 155 MAINTENANCE Memoranda 3-20...
Page 156: Periodic Replacement Of Safety Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table.
Page 157 MAINTENANCE SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (fuel tank - injection pump) Every 2 years or 4000 hours, whichever Fuel hose (fuel tank - strainer) comes first Fuel hose (strainer - feed pump) Fuel spill hose (fuel return) Fuel spill hose cap Steering hose (pump - priority valve)
Page 158 MAINTENANCE 3-23...
Page 159 MAINTENANCE 3-24...
Page 160: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filters 3-30 Replace transmission oil filter element 3-30 Replace hydraulic tank filter element 3-30 WHEN REQUIRED Check, clean or replace air cleaner element 3-31 Check transmission oil level, add oil 3-33...
Page 161 MAINTENANCE SERVICE ITEM PAGE CHECKS BEFORE STARTING (continued) Check effect of parking brake 2-30 Check effect of wheel brakes 2-31 Check sound of horn and backup alarm 2-31 Check flashing of lamps, check for dirt or damage 2-31 Check engine exhaust color and sound 2-31 Check operation of gauges 2-31...
Page 162 MAINTENANCE SERVICE ITEM PAGE EVERY 250 HOURS SERVICE (continued) Lift cylinder pin (4 places) 3-51 Lift arm pivot pin (2 places) 3-51 Tilt lever pin (1 place) 3-51 Steering cylinder pin (4 places) 3-51 EVERY 500 HOURS SERVICE Replace fuel filters 3-52 Replace transmission oil filter element 3-54...
Page 163 MAINTENANCE SERVICE ITEM PAGE EVERY 2000 HOURS SERVICE (continued) Check alternator 3-66 Check starter motor 3-66 Check vibration damper 3-66 Replace element in air conditioner recirculation air filter and fresh air filter 3-66 Adjust engine valve lash clearance 3-67 3-28...
Page 164: Service Procedures
MAINTENANCE SERVICE PROCEDURES 24.1 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. 24.1.1 REPLACE FUEL FILTERS For Information of replacing or maintaining, see the sections on “EVERY 500 HOURS SERVICE” 24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT For Information of replacing or maintaining, see the sections on “EVERY 500 HOURS SERVICE”...
Page 165: When Required
MAINTENANCE 24.2 WHEN REQUIRED 24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT WARNING ! ! Never clean or replace the air cleaner element with the engine running. ! ! When using pressurized air to clean the element wear safety glasses or goggles to protect the eyes. CHECKING Whenever the red piston in the dust indicator (1) appears, clean the air cleaner element.
Page 166 MAINTENANCE 7) After cleaning, reinstall. (Torque to 5.4 ± 0.5 Nm (0.55 ± 0.05 kgm) 8) Press the button of the indicator (1) to return the red piston to its original position. REPLACING INNER ELEMENT 1. First remove the cover and the outer element, and then remove the inner element.
Page 167: Check Transmission Oil Level, Add Oil
MAINTENANCE 24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL WARNING ! ! When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar and pin. ! ! The oil is at a high temperature after the machine has been operated.
Page 168: Check Axle Oil Level , Add Oil
MAINTENANCE 24.2.3 CHECK AXLE OIL LEVEL , ADD OIL WARNING ! ! When checking the oil level, apply the parking brake and lock the front and rear frames with the safety bar and pin. ! ! The oil is at a high temperature after the machine has been operated.
Page 169: Clean The Axle Case Breather
MAINTENANCE 24.2.4 CLEAN THE AXLE CASE BREATHER WARNING ! ! When cleaning the axle case breathers, apply the parking brake and lock the front and rear frames with the safety bar and pin. There are two breathers to clean, one on the front axle and one on the rear Remove all mud and dirt from around the breather with a brush.
Page 170: Replace The Bolt-On Cutting Edges
MAINTENANCE 24.2.6 REPLACE THE BOLT-ON CUTTING EDGES WARNING It is extremely dangerous if the work equipment moves when performing this procedure. Set the work equipment in a stable position, turn off the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.
Page 171: Replace Bucket Teeth (If Equipped)
MAINTENANCE 24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED) WARNING It is extremely dangerous if the work equipment moves when performing this procedure. Set the work equipment in a stable position, turn off the engine, then set the safety lock for the work equipment control lever securely to the LOCK position.
Page 172: Check Air Conditioner (If Equipped)
MAINTENANCE 24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED) Check twice a year, spring time and autumn. CHECK LEVELS OF REFRIGERANT (GAS) WARNING If the refrigerant used in the system gets into your eyes or on your hands, it could cause loss of sight or frostbite, so NEVER loosen any part of the refrigerant circuit.
Page 173: Check The Air Conditioner Condenser (If Equipped)
MAINTENANCE 24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED) WARNING Do not wash the condenser with a steam cleaner. Otherwise, the condenser will get hot and could break down If there is mud or dust on the air conditioner condenser, clean it with water.
Page 174: Adjust Parking Brake
MAINTENANCE 24.2.11 ADJUST PARKING BRAKE the parking brake is a sealed wet type disc brake, so the brake itself does not need adjusting. However, if the travel of the brake pedal increases because of looseness of the control cable mount or elongation of the control cable, adjust as follows.
Page 175: Replace Slow Blow Fuse
MAINTENANCE 24.2.12 REPLACE SLOW BLOW FUSE WARNING Whenever replacing slow blow fuse, be sure to turn OFF the power source by turning OFF the main starting switch. The slow blow fuse must be replaced with one that has the same capacity.
Page 176: Check Before Starting
MAINTENANCE 24.3 CHECK BEFORE STARTING See section on CHECK BEFORE STARTING ENGINE aforementioned in SECTION 2 page 2-24 3-41...
Page 177: Every 50 Hours Service
MAINTENANCE 24.4 EVERY 50 HOURS SERVICE 24.4.1 CHECK THE TIRE INFLATION PRESSURE Measure the inflation pressure before operation when the tires are cool. Standard tire inflation pressure: 17.5-25 12pr FRONT tire: 294 kPa (3.0 kg/cm², 42.6 psi) REAR tire: 294 kPa (3.0 kg/cm², 42.6 psi) NOTE: The appropriate tire inflation pressure differs according to the type of work, see "12.21 HANDLING THE TIRES"...
Page 178: Every 100 Hours Service
MAINTENANCE 24.5 EVERY 100 HOURS SERVICE Maintenance for every 50 hours should be carried out at the same time. 24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING ! ! When the oil filler cap is removed, oil may spurt out, so turn OFF the engine and wait for the oil temperature to cool down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 179: Clean Element In Air Conditioner Fresh Air Filter
MAINTENANCE 24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER WARNING When using compressed air, wear safety glasses and other things required to maintain safety. If the air conditioner has been used, then its air filter element could need cleaning. Before cleaning the elements, turn the air conditioner OFF.
Page 180: Lubricating
MAINTENANCE 24.5.3 LUBRICATING WARNING ! ! Apply the parking brake, and lock the front and rear frames with the safety bar and pin. ! ! set the work equipment in a stable condition, then turn OFF the engine and apply the locks for the work equipment control levers. Use a grease pump tp pump in grease through the grease fittings marked by the arrows in the following diagrams.
Page 181: Every 250 Hours Service
MAINTENANCE 24.6 EVERY 250 HOURS SERVICE Maintenance for every 50 and 100 hours should be carried out at the same time. 24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER WARNING Before changing the oil, wait, at least 10 minutes for the engine to cool down after running it.
Page 182: Check For Loose Wheel Hub Nuts. Tighten
MAINTENANCE 11. Close the engine hoods. Ú Diluted oil can cause severe damage to the engine. Check the condition of the used oil. Thin, black oil indicates fuel dilution. Milky discoloration indicates coolant dilution. If you notice any excessive metal particles or foreign material then consult your distributor.
Page 183: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE 24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST 1. Open the engine hood and lock in place. 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 tension show even pulley and belt wear.
Page 184: Check Battery Electrolyte Level
MAINTENANCE 24.6.5 CHECK BATTERY ELECTROLYTE LEVEL Open the rear grill. Remove caps (1), and check each cell, the electrolyte should be at a specified level (10 to 12 mm (0.40 to 0.47 in) above the plate). If the electrolyte level is low, add distilled water to the specified level. If distill water has been added to any cell of the battery, add distill water also to the other cells.
Page 185: Lubricating
MAINTENANCE 24.6.7 LUBRICATING WARNING ! ! Set the work equipment in a stable condition, then turn OFF the machine and apply the lock for the work equipment control levers. ! ! Apply the parking brake, and lock the front and rear frames with the safety bar and pin.
Page 186: Every 500 Hours Service
MAINTENANCE 24.7 EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours should be carried out at the same time. 24.7.1 REPLACE FUEL FILTERS WARNING ! ! Engine ia at a high temperature immediately after the machine has been operated.
Page 187 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. 6. Install the filters on the filter header until the filter seal contacts the seal surface of the filter header and then, turn the filter an additional 1/2 to 3/4 turn by hand.
Page 188: Replace Transmission Oil Filter Element
MAINTENANCE 24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT 1. Set a container under the filter case to catch the oil then remove drain plug (1) at the bottom of the filter case, and drain the oil. After draining the oil, tighten the plug. Torque to: 107.9 ±...
Page 189: Lubricate
MAINTENANCE 24.7.3 LUBRICATE WARNING ! ! Set the work equipment in a stable condition, then turn OFF the machine and apply the lock for the work equipment control levers. ! ! Apply the parking brake, and lock the front and rear frames with the safety bar and pin.
Page 190: Every 1000 Hours Service
MAINTENANCE 24.8 EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time. 24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER WARNING ! ! The oil is hot if the machine has just been operated. Wait for the oil to cool down before changing 1.
Page 191: Clean Transmission Case Breather
MAINTENANCE 24.8.2 CLEAN TRANSMISSION CASE BREATHER Remove all mud and dirt from around the breather, then remove the breather and put it into a cleaning fluid to clean. Take care, so as not to let any dust or dirt get inside the transmission case through the port while the breather is removed.
Page 192: Lubricate
MAINTENANCE 24.8.3 LUBRICATE WARNING ! ! Set the work equipment in a stable condition, then turn OFF the machine and apply the lock for the work equipment control levers. ! ! Apply the parking brake, and lock the front and rear frames with the safety bar and pin.
Page 193: Change Oil In Hydraulic Oil Tank, Replace Hydraulic Filter Element
MAINTENANCE 24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT WARNING ! ! The oil is hot if the machine has just been operated. Wait for the oil to cool down before changing it. ! ! When removing the oil filler cap turn it slowly to release the internal pressure, then remove it carefully.
Page 194: Adjust Engine Valve Lash Clearance
MAINTENANCE 12 Add hydraulic oil through oil filler port (F) to the specified level, then install cap. For details of the oil to use and refill capacity see "20. USE OF FUEL, COOLANT LUBRICANTS ACCORDING AMBIENT TEMPERATURE on page 3-10 13 Check that the hydraulic oil is at the standard level.
Page 195: Check Fan Belt Tension
MAINTENANCE 24.8.6 CHECK FAN BELT TENSION Measure the belt deflection at the longest span of the belt when pressed with the finger. Maximum deflection: 9.5 - 12.7 mm (3/8 to 1/2 in) NOTE: Cummins belt tension gauge ST-1293 may be used. The required gauge value is 267 to 578 N (60 to 130 lbf).
Page 196: Every 2000 Hours Service
MAINTENANCE 24.9 EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. 24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM WARNING ! ! If the engine was just running, then the coolant could be hot and cause personal injury. Allow the engine to cool before draining water.
Page 197 MAINTENANCE RADIATOR CAP GENERAL INFORMATION The radiator cap seals the coolant filler opening of the radiator. Positive sealing requires a cap gasket and its contacting surfaces to be in good condition and a properly tightened cap. The radiator cap incorporates a pressure relief valve. The pressure relief valve keeps the pressure of the coolant at approximately 34 to 64 kPa or 0.35 to 0.65 kg/cm²...
Page 198 MAINTENANCE 6. Refill the system with water only. 7. Then run the engine at low idle and open the drain valve (described in step 3.). 8. While the engine is running continue adding water in the top of the radiator, so that you are passing water through the cooling system for about 10 minutes.
Page 199: Replace Hydraulic Tank Breather Element
MAINTENANCE 24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING ! ! The oil is hot if the machine has just been operated. Wait for the oil to cool down before changing it. ! ! When removing the oil filler cap turn it slowly to release the internal pressure, then remove it carefully.
Page 200: Check Brake Disc Wear
MAINTENANCE 24.9.4 CHECK BRAKE DISC WEAR Have your distributor check and repair brake discs. 24.9.5 CHECK ALTERNATOR The brushes and bearings may be worn. Have your distributor inspect and repair. 24.9.6 CHECK STARTER MOTOR The brushes and bearings may be worn. Have your distributor inspect and repair.
Page 201: Adjust Engine Valve Lash Clearance
MAINTENANCE 24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE 15 mm wrench Remove the valve cover ½ inch drive, engine barring cover Locate Top Dead Center (TDC) for Cylinder Number 1 by barring engine slowly while pressing on the engine timing pin. The barring gear inserts into the flywheel housing and engages the flywheel ring gear.
Page 202 MAINTENANCE 14 mm, Flatblade Screwdriver Locate Top Dead Center (TDC) for Cylinder Number 1 Check and adjust the valves as indicated in the illustration (I = intake, E = Exhaust). Tighten the lock nut and measure the valve lash again. Torque Value: 24 Nm [18 ft-lb] Mark the pulley/vibration damper and rotate the crankshaft 360 degrees.
Page 203: Specifications
SPECIFICATIONS...
Page 204 SPECIFICATIONS SPECIFICATIONS WA180-3 PERFORMANCE Bucket capacity 1.7 m³ (2.25 cu.yd) Normal load 2720 kg (6000 lb) FORWARD 7.2 km/h (4.5 mph) 12.0 km/h (7.5 mph) 22.0 km/h (13.7 mph) 34.5 km/h (21.4 mph) Travel speed 7.7 km/h (4.8 mph) 12.6 km/h (7.8 mph) REVERSE 22.9 km/h (14.2 mph)
Page 205 SPECIFICATIONS...
Page 206 SPECIFICATIONS MEMORANDA...
Page 207: Options, Attachments
OPTIONS, ATTACHMENTS...
Page 208: Available Attachments
OPTIONS, ATTACHMENTS 26. AVAILABLE ATTACHMENTS NAME SPECIFICATION, USE Excavating bucket Capacity (flat edge for rock) 1.5 m³ (2.0 cu yd) Light material bucket Capacity (for light duty work, snow bucket) 2.2 m³ (2.9 cu yd) ! Bolt-on tooth Bucket tooth ! Tip tooth Lumber grapple Loading and transporting large logs or lumber...
Page 209 OPTIONS, ATTACHMENTS Select the most suitable bucket and tires for the type of work and jobsite conditions. TYPE OF WORK BUCKET GROUND CONDITIONS TIRE 17.5-24-12pr 18.4-24-10pr General ground condition (Traction) (Traction) 14.00-24-12pr 17.5-24-12pr Level ground ! Loading products (Traction) (Traction) Stockpile bucket ! Loading and (1.7 m³...
Page 210: Heater And Air Conditioning (If Equipped)
OPTIONS, ATTACHMENTS 27. HEATER AND AIR CONDITIONING (IF EQUIPPED) 27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL 1. Press the "ON/OFF" square and light (1) and the "TEMPERATURE SETTING" will light up to indicate ON mode, press it again and the light will go out to indicate OFF mode. 2.
Page 211: Cool Box Compartment
OPTIONS, ATTACHMENTS Defroster (6) and down Arrow (3) when pressed simultaneously it will show whether the evaporator thermostat is open (OP) or closed (CL). OP Displayed - Clutch not engaged / coil to cold CL Displayed - Clutch is engaged / coil is at temperature set point, (opening temperature). 7.
Page 212: Handling E.c.s.s. (Electronic Controlled Suspension System)
OPTIONS, ATTACHMENTS 28. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) Always read this section before using the E.C.S.S. in order to enable you to use it safely and effectively. 28.1 STRUCTURE AND FUNCTION OF E.C.S.S. The E.C.S.S. uses the hydraulic spring effect of the hydraulic accumulator installed to the circuit at the lift cylinder bottom to absorb the vibration of the chassis when the machine is traveling.
Page 213: Method Of Operating E.c.s.s
OPTIONS, ATTACHMENTS 28.2 METHOD OF OPERATING E.C.S.S. The E.C.S.S. switch is at the top of the console box on the right side oof theoperator’s compartment. (1) OFF: E.C.S.S. canot be actuated (2) ON: E.C.S.S. is in actuation condition It is possible to carry out operation with the E.C.S.S. switch kept ON. If the damper is kept ON during operations, and the hydraulic pressure in the circuit at the bottom end of the lift cylinder exceeds 14710 kpa (150 kg/cm², 2130 psi) during operations, the solenoid valves are automatically...
Page 214: Precautions When Handling Accumulator
OPTIONS, ATTACHMENTS 28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR WARNING The accumulator is charged with high-pressure nitrogen gas, which is extremely dangerous, so read the following items and be careful to handle the accumulator properly. If any problem or failure occurs with the accumulator, contact your distributor immediately.
Page 215 Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. PROPOSAL FOR MANUAL REVISION Attn: Technical Publications Fax No. (847) 970-4186 FOR INTERNAL USE ONLY -- No. PMR P NAME OF COMPANY: LOCATION: PHONE NO: DEPARTMENT: DATE: NAME: MANUAL NAME: MANUAL NO:...

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