KOMATSU WA480-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A37001 & UP) KOMATSU WA480-5L – PDF

CEAM009001

Operation and Maintenance Manual

WA480-5L WHEEL LOADER

SERIAL NUMBERS

WA480-5L

A37001

and UP

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp.

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.

June 2005

Copyright 2005 Komatsu Published in USA Komatsu America Corp.

PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB020601

OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM009001

SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM009604 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM024208

SAFETY MANUAL Machine Specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT03-04

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America Corp. Extranet Literature Ordering System.

If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders.

PUB INFO PAGE.fm

6/9/05

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO

DataKom Publications and Training Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887

COMPANY NAME PURCHASE ORDER NO.

SHIP TO ATTN.

TYPE or PRINT ONLY

STREET ADDRESS

ORDER DATE

CITY, STATE, ZIP CODE COUNTRY

PHONE NO.

FAX NO.

SHIPPING METHOD

DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY.

PUBLICATION FORM NO.

➥

PARTS BOOK P-Paper M-Microfiche

KDC91E 071403

PUBLICATION DESCRIPTION

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1.

Products Warranted Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.

2.

Coverage Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.

3.

Limitations Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business costs or other losses resulting from a warrantable failure.

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT): 1.

Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle nonroutière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de Komatsu au Canada .

2.

Couverture: Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir de la date de livraison du moteur au client ultime.

3.

Limitations: Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.

CEKQ000600 - Komatsu America International Company 12/99

DEG. BTDC

RÉGLAGE DE L’ALLUMAGE INJECTION INITIALE

VITESSE STATIQUE

PORTÉE DE VALVE À FROID (mm)

IN.

HP)

ENGINE DATAPLATE - ENGLISH / FRENCH

KOMATSU LTÉE FABRIQUÉ AU JAPON

KOMATSU LTD. MADE IN JAPAN

DEG. BTDC DATE OF MANUFACTURE

RPM FAMILY EMISSION LIMIT

EX. FUEL RATE AT ADV.

Kw (

_____________________________________________

INITIAL INJECTION TIMING

IDLE SPEED

VALVE LASH COLD (mm)

ADV. LOAD OUTPUT

FIRING ORDER

EXHAUST EMISSION CONTROL SYSTEM

CHARGE DE SORTIE ADV.

DISPLACEMENT

ENGINE FAMILY

SYSTÈME DE CONTROLE DES ÉMISSIONS D’ÉCHAPPEMENT

SERIAL NO.

ENGINE MODEL

FAMILLE DU MOTEUR

MODÈLE DU MOTEUR

RPM mm3/STROKE

1-5-3-6-2-4

LITERS

DATE DE FABRICATION

LIMITE D’ÉMISSION DE LA FAMILLE

TAUX D’ESSENCE À ADV.

mm3/BATTEMENT

SÉQUENCE DE MISE À FEU

LITRES

DÉPLACEMENT

NO. SÉRIE

AVERTISSEMENT DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE MODÈLE ET SON APPLICATION.

IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL. WARNING INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.

INFORMATION IMPORTANTE SUR LE MOTEUR CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DEL’EPA (ANNÉE DU MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNITION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE DIÉSEL.

0INTRODUCTION

WA480-5L

0-1

INTRODUCTION

FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve 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, damaged or becomes dirty and can not be read, request a replacement manual from your local 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, which may not be reflected in this manual.

Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual.

This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require.

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 or with the machine for reference and periodically reviewed by all personnel who operate it.

• Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual.

• The procedures and precautions given in this manual apply only to the intended uses of this machine.

If you use your 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.

• KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this 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 standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine.

• The safety description is given in SAFETY INFORMATION and in the SAFETY section 1 ★

0-2

WA480-5L

INTRODUCTION â?‰

Storage location for Operation and Maintenance Manual is in the pocket (1) at rear of operators seat back rest.

WA480-5L

0-3

INTRODUCTION

SAFETY INFORMATION Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine.

To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations.

To identify safety messages in this manual and on machine product graphics, the following signal words are used: 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 result in serious damage to the machine, injury or even death.

WARNING! - This word is used on safety messages and product graphics where there is a potentially dangerous situation, which could result in serious injury or possibly 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 result in serious damage to the machine or possible injury.

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.

Remark This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage the machine.

Safety precautions are described in SAFETY section (1-1) KOMATSU 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 or causing injury. If you are unsure about the safety of some procedures, contact your local KOMATSU Distributor.

0-4

WA480-5L

INTRODUCTION

APPROVED AND NON-APPROVED USES The Komatsu WHEEL LOADER described in this manual has been designed and constructed to be used mainly for the following functions, any non-approved used may void the warranty, damage the machine or possibly injure the operator.

APPROVED • Loading operations.

• Excavating.

• Grading.

• Pushing Installation of optional equipment can also be used in the following applications, use only KOMATSU approved equipment.

• Handling of materials (bucket - pallet forks).

• Waste Handler application

NON-APPROVED This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is important to contact your Authorized Komatsu Dealer before carrying out the work operations.

• • • • • • •

Use of machine for lifting or transporting personnel in any manner.

Transportation of flammable liquids.

Lifting, moving or transporting other machines with the front end equipment.

Towing other equipment with the tractor unit or work equipment.

Using the loader as a hammer or for striking or driving objects.

Towing the machine at high speeds Traveling at high speeds.

WA480-5L

0-5

INTRODUCTION

PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your dealer will need when requiring assistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-7 (Serial Number And Dealer Information). All views indicated below are viewed from the operators sitting position.

MACHINE SERIAL NUMBER The machine serial number is stamped on the right side center of the front frame.

0-6

WA480-5L

INTRODUCTION

ENGINE SERIAL NUMBER AND EMISSION LABEL The engine serial number is on a plate located on the top side face of the engine cylinder block on the left side of the machine and on the muffler bracket on the right side of the machine..

SERVICE METER LOCATION The service meter is located in the center bottom of the machines monitor bezel.

WA480-5L

0-7

INTRODUCTION

SERIAL NUMBERS AND DEALER INFORMATION Model: WA480-5L Machine # Engine #

Dealer:

Address:

Phone # Contacts:

NOTES:

0-8

WA480-5L

INTRODUCTION

CONTENTS INTRODUCTION FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPROVED AND NON-APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE METER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-2 0-4 0-5 0-5 0-6 0-6 0-7 0-7 0-8 0-9

SAFETY GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 WASTE HANDLER APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 FIRE PREVENTION FOR FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 PRECAUTIONS FOR ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 WA480-5L

0-9

INTRODUCTION RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-18 1-18 1-19 1-19 1-20 1-20 1-20 1-21 1-21 1-21 1-21 1-22 1-22 1-23 1-23

OPERATION GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 OUTSIDE VIEW OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 INSIDE VIEW OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 2-4 INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 SWITCH PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2-7 INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 TYPES OF WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 MACHINE ELECTRONIC MONITORING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 MONITOR MODE SELECTOR SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 MONITOR DISPLAY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 HOUR METER AND ODOMETER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ADJUSTING MONITOR BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 PROGRAMMING TELEPHONE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ACTION CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 SERVICE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 SELECTING LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 EMERGENCY STOP WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 BRAKE PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 BATTERY CHARGE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 STEERING OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 CAUTION ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 AXLE OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 TORQUE CONVERTER CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 0-10

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INTRODUCTION FUEL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . 2-19 ENGINE OIL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 RADIATOR COOLANT LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 BATTERY ELECTROLYTE LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 MODE ALERT LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 PARKING BRAKE PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 COOLING FAN REVERSE ROTATION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 EMERGENCY STEERING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 OUTPUT MODE PILOT LAMP (POWER MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 PREHEATING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 JOYSTICK PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 DIRECTIONAL SELECTOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 AUTO-SHIFT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 LOCKUP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 SHIFT HOLD PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 SHIFT LEVER POSITION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 TURN SIGNAL PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 HEADLAMP HIGH BEAM PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 ENGINE TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 HYDRAULIC TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 METER DISPLAY PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 DISPLAYING ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 RESET FOR FILTER, OIL REPLACEMENT TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 ENTERING A TELEPHONE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 SELECTING A LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 ADJUSTING MONITOR BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 MACHINE SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 POWER MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 TRANSMISSION MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 TRANSMISSION CUT-OFF SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 TURN SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 DIMMER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 HAZARD LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 FRONT WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 WA480-5L

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INTRODUCTION REAR WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 MONITOR PANEL MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 MONITOR PANEL MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 KICKDOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 FRONT WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 REAR WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 REAR DEFROSTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 E.C.S.S. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 EMERGENCY STEERING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 COOLING FAN REVERSE ROTATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 DIRECTIONAL SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 DIRECTIONAL SELECTOR ACTUATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 LOAD METER CANCEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 LOAD METER SUBTOTAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 SOUND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 DIGITAL ESPERIA RADIO SERIAL NUMBER A37001 - A37046 . . . . . . . . . . . . . . . . . . . . . 2-44 POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 TONE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 CLOCK BUTTON/DISPLAYING FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 AST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 PRESET BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 SEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 BAND SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 TUNING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 LISTENING TO THE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 AUTOMATIC TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 MANUAL TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 SETTING THE PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 AUTOMATIC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO . . . . . . . . . . . . . . . 2-48 ADJUSTING THE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 BLAUPUNKT CALAIS RADIO SERIAL NUMBER A37047 AND UP . . . . . . . . . . . . . . . . . . 2-49 POWER SWITCH/MUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 VOLUME CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 FMT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 IR REMOTE CONTROL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 RDS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 ML CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 EJECT CASSETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 CASSETTE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 FF AND RW BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 GEO BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 SRC BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 AUDIO BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 0-12

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INTRODUCTION MULTIFUNCTION ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 MENU BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 KEYPAD 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 TRAFFIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 THEFT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 PRECAUTIONS WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 AIR CONDITIONER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 FAN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 AIR CONDITIONER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 FRESH/RECIRC SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 EXTERNAL AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 WHEN NOT USING THE AIR CONDITIONER REGULARLY . . . . . . . . . . . . . . . . . . . . . 2-58 COOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 PRECAUTIONS WHEN USING THE AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 2-59 CONTROL LEVERS, PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 SPEED CONTROL LEVER STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 SAFETY LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 BUCKET CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 LIFT ARM CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 STEERING TILT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 SECURITY AND LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 IGNITION KEY LOCKED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 CAB DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 ENGINE ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 PADLOCKED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 BATTERY AND TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 UPPER HOOD ACCESS PANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 PASSIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 ROLL-OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY) . . . . . . . . . . . . . 2-69 BACKUP WARNING ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 ACTIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 MACHINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 CAB DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 WA480-5L

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INTRODUCTION OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 FUSE CAPACITY AND NAME OF CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 SLOW BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 MACHINE CAB AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 SEAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 HANDLING CAB WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 DUST INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 GREASE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 PERFORM A WALK AROUND CHECK OF YOUR MACHINE . . . . . . . . . . . . . . . . . . . . 2-78 UNDER THE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 CHECK COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 CHECK ENGINE OIL LEVEL, ADD OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 REAR-VIEW MIRROR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 IN THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 SEAT BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 LEVER STAND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 LEVER STAND ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 CHECK FUEL LEVEL, ADD FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 CHECK THE BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 CHECK THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 NORMAL START-UP AND WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 TRAVELING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 TURNING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 CHANGING GEAR SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 WHEN USING AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 USING THE SWITCH TO CHANGE DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 TRANSMISSION CUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 ADJUSTING THE TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 STOPPING WHEN TRANSMISSION CUT-OFF IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 USING THE EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 EMERGENCY STEERING SELF-CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 LIFT ARM LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 0-14

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INTRODUCTION BUCKET LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 SCOOPING A LOAD OR CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 LOADING PILED SOIL OR BLASTED ROCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 CUTTING A GRADE ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 LEVELING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 PUSHING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 LOAD AND CARRY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 CROSS DRIVE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 V-SHAPE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 PRECAUTIONS WHEN PILING UP LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 IF WHEEL BRAKE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 BRAKING ON DOWNHILL SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 IF THE ENGINE STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 PRECAUTIONS WHEN DRIVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 PRECAUTIONS REGARDING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 WORK EQUIPMENT AND MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 ADJUSTING BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 BOOM KICKOUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111 BUCKET POSITIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 LIFTING LOCATIONS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 USING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 PRE LIFTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 PRECAUTIONS AFTER COMPLETION OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 WARMING UP THE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 MAINTENANCE GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALWAYS USE CLEAN WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALWAYS USE CLEAN OIL AND GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS . . . . . . . . .

FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WA480-5L

3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2

0-15

INTRODUCTION DO NOT DROP THINGS INSIDE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 DUSTY WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 AVOID MIXING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 LOCKING INSPECTION COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BLEEDING AIR FROM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 CHECKS AFTER INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SYSTEMS TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 OUTLINES OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . 3-12 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS) . . . . . . . . . . . . . . . . . . . . . . . . 3-13 KOWA ANALYSIS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OIL SAMPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 STORING OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 OUTLINE OF ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . 3-17 LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 3-19 STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES . . . . . . . . . . . . . . . . . . . 3-21 TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 EVERY 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 EVERY 500 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 EVERY 2000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 EVERY 4000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 EVERY 8000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 CHANGE TRANSMISSION OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 REPLACE HYDRAULIC TANK FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 0-16

WA480-5L

INTRODUCTION TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 WINDOW WASHING FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 CLEANING RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 CHECKING ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 REPLACE BOLT-ON CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 REPLACING SLOW-BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 EVERY SPECIFIC HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 DRAIN SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 LUBRICATE THE REAR AXLE PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . 3-43 CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT . . . . . . . . . . . . 3-44 EVERY 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 EVERY 500 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE . . . 3-50 REPLACING FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 CLEANING THE FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER . . . . 3-54 CLEAN THE TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 CHECKING PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 REPLACE CORROSION RESISTOR CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 EVERY 2000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT . . . . . 3-57 HYDRAULIC TANK VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 CHANGE THE AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 CLEAN PPC CIRCUIT STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 CLEAN THE ENGINE VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 CHECK ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 CHECK TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 CHECK INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 CHECK ACCUMULATOR GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 WA480-5L

0-17

INTRODUCTION CHECKING BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 4000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE INJECTOR NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 8000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE FUEL SPRAY PREVENTION CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-63 3-64 3-64 3-65 3-65 3-65 3-65 3-65 3-66 3-66 3-66

SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WA480-5L WITH BOLT-ON CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEIGHT CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLES AND FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-2 4-3 4-3 4-4 4-5 4-6 4-6 4-7 4-7 4-7 4-7 4-7

OPTIONS, ATTACHMENTS MONITOR WITH LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 LOAD METER CANCEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 LOAD METER SUB TOTAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 LOAD METER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LOAD METER ADDITION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LOAD METER REMAIN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 SELECTION OF DISPLAY FOR TYPE OF LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 METHOD OF CALIBRATION (ADJUSTING 0 POINT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 DELETING LOAD METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 SPEED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 USING LOAD METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 SETTING ADDITION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 SETTING THE REMAIN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 TOTAL LOAD DATA DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 STOPPING THE CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY . . . . . . . . . . . . 5-12 0-18

WA480-5L

INTRODUCTION PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED . . . . . . . . . . 5-13 SUBTRACTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 SETTING THE TIME ON THE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 PRINTER OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 PRINTOUT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 SELECTING THE PRINTOUT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 TORQUE CONVERTER LOCK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 GENERAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 TORQUE CONVERTER LOCK-UP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 TRAVEL SPEED WARNING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 TRAVEL SPEED LIMIT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5-25 FAN SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 FORWARD/REVERSE TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 REVERSE/FORWARD INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 FORWARD SETTING KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 REVERSE SETTING KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 FORWARD TIME UNIT SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 SCALE FIGURE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 DIRECTION SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 REVERSE PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 CLEANING RADIATOR AND COOLER FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 HANDLING JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 EXPLANATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 SHIFT UP, SHIFT DOWN SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 FNR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 JOYSTICK STEERING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 JOYSTICK ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 HI/LOW SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 CONSOLE LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 HEIGHT ADJUSTMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 STRUCTURE AND FUNCTION OF JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 JOYSTICK AND STEERING WHEEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 GETTING IN OR OUT OF THE OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 JOYSTICK CONSOLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 JOYSTICK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 EPC WORK EQUIPMENT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 AUTO-GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 OPERATING AUTO-GREASING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 REMAINING NUMBER OF TIMES OF GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 OPERATION AS DESIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 WA480-5L

0-19

INTRODUCTION PILOT LAMP DISPLAY ON MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SETTING GREASE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SETTING GREASING TIME IN COLD AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METHOD OF SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK THE AMOUNT OF GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACEMENT OF GREASE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS WHEN HANDLING AUTO GREASING SYSTEM . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-20

5-43 5-43 5-43 5-44 5-45 5-45 5-47 5-47

WA480-5L

SAFETY

1

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.

WA480-5L

1-1

SAFETY

GENERAL SAFETY RULES AND PRECAUTIONS GENERAL SAFETY RULES Only trained and authorized personnel shall be allowed to operate and service this machine.

Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy and quick reference.

Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating condition.

Always perform a pre-operational check on your machine before operating it.

If the machine is equipped with a seat belt and rollover protective structure, OSHA law requires the operator remain within the confines of the rollover protective structure, with the seat belt fastened snugly around their waist before operating the machine.

OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other personnel to ride on your machine.

Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment.

Be sure that all personnel are at least 12 m (40 ft) away from any point on the machine before moving or operating the machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more restricted your visibility will be.

If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded or smaller machine has the right away over an unloaded machine.

Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.

Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.

It is the owner and /or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the machine.

Think before you act, study the job carefully. Careful operator’s and service personnel are the best insurance against accidents.

The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that might affect there eyesight, hearing, or reactions.

When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used.

When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel.

Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you approach them and acknowledge your approach.

Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.

1-2

WA480-5L

SAFETY

SAFETY FEATURES Be sure all guards and covers are in place especially after servicing the machine.

Have guards or covers repaired immediately if they are damaged. See “STARTING THE ENGINE” on page 2-85 Use safety equipment such as safety locks and seat belt properly.

Never remove any safety features. Always keep them in good operating condition.

Always secure the machine in a safe position: See “STOPPING AND PARKING THE MACHINE” on page 2-96 Seat belt: See “INSIDE OPERATOR’S COMPARTMENT” on page 1-8 Improper use of safety features could result in serious bodily injury or death.

Be sure the machine has the correct equipment required by local rules and regulations.

PERSONAL PROTECTIVE EQUIPMENT If your machine is equipped with safety equipment OSHA law requires this equipment to be used when operating your machine.

Avoid loose fitting clothing, jewelry and loose long hair. These can catch on controls or in moving parts and cause serious injury.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine.

Always wear safety goggles, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air.

Check to be sure no one is near your work area.

Check to be sure all personal protective equipment are in good condition before using.

WA480-5L

1-3

SAFETY

UNAUTHORIZED MODIFICATIONS Any modification made without authorization from Komatsu can create a hazards. Before making any modifications, consult your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications.

LEAVING OPERATOR’S COMPARTMENT Below are listed procedures that must be followed when exiting the operator’s cab.

1.

2.

Park the machine in a level area, lower all work equipment to the ground.

Engage the parking brake in the (LOCKED) position.

3.

Place safety lock lever for loader control in the (LOCKED) position.

4.

Turn the engine OFF, remove ignition key and keep the key with you.

5.

Use the key to lock and secure all the equipment locks. This will prevent other unauthorized personnel from tampering with your machine. Keep in mind you are responsible for securing your machine.

Remark Never leave your machine running and unattended, even for a moment.

Work equipment posture: See “STOPPING AND PARKING THE MACHINE” on page 2-96 Lock: See “WORK EQUIPMENT” on page 2-102

1-4

WA480-5L

SAFETY

MOUNTING AND DISMOUNTING When mounting or dismounting this machine, always be sure the work equipment is fully lowered to the ground and the engine is OFF. Use all hand holds and step plates on your machine.

Never jump off or on to the machine.

Before getting on the machine, if there is any oil, grease, or mud on your shoes, rails, steps or platforms, wipe it off immediately, always keep these areas clean, and in good condition.

Never get on or off a moving machine. These actions may lead to serious injury. Always bring the machine to a full stop.

Be sure machine is at a full stop, equipment lowered and parking brake set before entering or exiting machine.

WASTE HANDLER APPLICATIONS On the waste handler application, there is no right side ladder equipped with the machine.

This area is not an entrance and exit point during normal operations.

Use this as an emergency exit only if necessary.

WA480-5L

1-5

SAFETY When getting on or off the machine, always face the machine and maintain a Three Point Contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself properly.

When entering the cab and opening the cab door, push the door open until it is securely into the door klatch (1) and held in position. Use the hand rails on the inside of the door while entering or exiting the cab.

Never hold any control levers or the steering wheel when getting on or off the machine.

FIRE PREVENTION FOR FUEL AND OIL Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following: • Keep any open flames away from flammable fluids.

• Stop the engine and do not smoke when refueling.

• Tighten all fuel and oil caps securely.

• Refueling or adding oil should be made in well ventilated areas.

• Keep oil and fuel in its proper place.

• Clean up any fluid spills.

DUST HAZARD PRECAUTIONS Dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers or other dust materials during demolition operations, always do as follows.

• Never use compressed air for cleaning.

• Use water to keep down the dust when cleaning.

• If there is a danger there may be asbestos dust in the air, operate the machine with the wind to your back whenever possible.

• Use an approved respirator.

• Do not allow any other person into the area during operation.

1-6

WA480-5L

SAFETY • •

There may be a danger that non genuine parts may contain asbestos, use only genuine Komatsu parts.

Always observe rules and regulations related to the job site and working environment.

CRUSH OR PINCH POINT DANGERS Never stand in or place any part of your body between the movable components such as the articulating portions of the machine or between the machines work equipment.

Keep in mind, when the machine is operated, the clearance will change, this may lead to serious personal injury or death.

Never drive up to any one standing in front of a solid object or your path of travel. The brakes could fail or the machine could slide on a slippery surface causing injury or even death.

FIRE EXTINGUISHER AND FIRST AID KIT As a precaution if a fire or an injury should occur, always keep a fire extinguisher and first aid kit on your machine and do as follows: • Be sure that fire extinguisher is in good condition and read the label on it to ensure you know how to use it.

• Keep a first aid kit in the storage area. Check the kit periodically and make any additions if necessary.

• Keep a list of emergency phone numbers in case of an accident.

WA480-5L

1-7

SAFETY

INSIDE OPERATOR’S COMPARTMENT When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. If you operate the brake pedal with mud or oil on your shoes, your foot may slip and may cause an accident.

After using the ashtray, make sure matches or cigarettes are properly extinguished and be sure to close the lid. If the ashtray is left open, there is danger of fire. Do not leave lighters or aerosol cans lying around the operator’s compartment. If the temperature inside the operator’s compartment get’s too high, there is danger that the lighter may explode.

Do not stick suction pads to the window glass. Suction pads may act as a lens and could cause fire. Do not use cellular telephones inside the operator’s compartment when driving or operating the machine.

Never bring any dangerous objects such as flammable or explosive items into the operator’s cab. To ensure safety, do not use the radio or music headphones when operating the machine. Keep the operator’s compartment clean, never allow trash or tools to accumulate, these may hinder the operation of the controls or pedals.

When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS. Always use the seat belt equipped with your machine. Be sure the seat belt is fastened snugly around your waist before operating the machine.

PRECAUTIONS WHEN USING ROPS The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support the load if the machine should roll over, but also to absorb the impact of the energy.

The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is damaged, the strength may be reduced and it may not able to fulfill its function properly. Never drill, cut or modify the ROPS structure, if the ROPS structure should become damaged in any way, replace it immediately. Do not make repairs to the ROPS structure its self.

PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment, read the instruction manual for the attachment and information related to the attachments. Do not use attachments that are not authorized by your Komatsu Distributor. Use of unauthorized attachments could create a safety problem and adversely affect proper operation and useful life of the machine. Any injuries, accidents, product failures resulting from use of unauthorized attachments will not be the responsibility of Komatsu.

1-8

WA480-5L

SAFETY

STARTING YOUR WORK OPERATIONS Using the work equipment may pose some hazards that may damage the machine or injure the operator. It is important to be aware of some of these hazards to avoid becoming involved in them. A safety conscious operator is the most important insurance when on a job site. Below are several situations and information the operator should be aware of: • • • • • •

Before operating the machine, walk around it and check for people or objects that might be in the way.

Make sure the safety bar (1) is securely in place.

Do not start the engine if warning tags have been attached to the steering wheel or control levers.

Sound your horn to warn others in the area before starting the engine or moving the machine.

Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.

Do not allow anyone in the cab or on the machine during operations.

WORK SITE HAZARDS Before proceeding with any excavating or grading operations it is important to be aware of the hazards involved with this operation. Below is a list outlining what to do to avoid some of these hazards.

• Before starting any excavating or grading operations, contact all utility departments in your area and have them identify and mark any underground system locations, (gas lines, water lines, electrical lines, sewer lines, etc.).

• Check your work area for any unusual ground conditions.

• Make sure your work area is as level as possible and you will be able to maneuver your work equipment or machine easily.

• If you will be working near a high traffic area, (pedestrians or cars) have a dedicated worker available to direct traffic or install safety fencing around your work site.

• Always be aware of all your work site dangers or distractions.

AVOIDING DANGEROUS SITUATIONS Avoid traveling with the bucket raised. Rasing the bucket raises the center of gravity on the machine. Traveling with a raised bucket, especially a loaded bucket may result in loss of control or a rollover situation. Never raise the bucket unless the machine is stopped.

WA480-5L

1-9

SAFETY When the bucket is raised and loaded, never make sharp turns or stop the machine suddenly, this may cause the machine to tip forward.

Always handle unstable loads carefully, avoid tipping the bucket back or raising the load too high. Be sure to operate the work equipment carefully and keep the load as close to the ground as possible.

Do not use the bucket or lift arms as a crane. The object you are lifting may swing or shift causing the machine to tip, sway or possibly rollover.

Never work under overhangs or excavated bank areas. These could collapse and damage the machine or injure the operator.

1-10

WA480-5L

SAFETY

WORKING CLEARANCES It is always a good idea to be aware of your clearances around, in front, behind and especially above your work area or travel rout. .Some basic safety precautions to prevent risk are: • When working or traveling in an area where clearances are a problem, travel at a slow cautious speed.

• If you are not sure of your clearances, request the aid of another person who can guide or warn you if you get too close to objects.

•

•

•

Be aware of the dangers when working around overhead electrical lines, high humidity may pose an electrical hazard even if your machine clears the overhead power lines.

If your machine should come in contact with overhead electrical lines, stop the machine and remain on the machine until the power company clears the lines and it is safe to get off or move the machine.

If low power lines pose a greater hazard, ask the power company to remove the lines until your work is finished.

Cable Voltage

WA480-5L

Min. Safe Distance

6.6kV

3m

10 ft.

66.0kV

5m

16 ft.

275kV

10 m

33 ft.

500kV

11 m

36 ft.

1-11

SAFETY

RULES FOR ROAD TRAVEL Traveling with your machine may pose some hazards. When traveling, always travel in a safe manor and remain alert at all times A safety conscious operator is the most important insurance when traveling with the machine. Below are several situations and information the operator should be aware of: 1.

Raise the loader bucket to a safe travel height of 40-50 cm (16-20 in) from the ground, lock the loader control levers using the safety lock equipped with the machine.

2.

Obey all traffic rules when traveling on local and state roads.

Always travel at a safe controllable speed.

3.

Never turn the ignition key off when traveling. If the engine should stop, apply the brakes and stop the machine immediately.

4.

Always be aware of your clearances and road surface. Some areas may not support the weight of your machine. Plan your rout in advance. If necessary, obtain the aid of an escort to lead or prepare your travel rout.

5.

Never travel at high speeds, loss of control or tire damage may result.

TRAVELING IN REVERSE Traveling in reverse may pose several hazards. Below is a list if some basic rules to follow when traveling in reverse: • Be sure the area behind you is clear of people or objects that might be in the way • Before moving your machine, sound the horn to warn others in your area you are moving.

• When operating in areas that may pose a hazard or has poor visibility, designate a person to direct your movements.

• Do not rely totally on you machines mirrors, keep in mind there are blind spot when using the mirrors.

TRAVELING ON ICY OR SNOW-COVERED SURFACES If the ground is icy or covered with snow, the response of the machine to the movements of the steering wheel may not be as precise as expected. To limit the risk resulting from reduced maneuverability, proceed as follows: • Travel at a slow safe speed. Avoid rapped accelerations or breaking.

• Remember your stopping distances are reduced during slippery conditions.

WORKING ON LOOSE OR UNSTABLE GROUND To limit the risk when working in these areas: • Avoid operating the machine too close too the edge of a cliff, open trenches or ditch lines. These areas may collapse under the weight of your machine causing serious damage to the machine or injury to the operator.

• Keep in mind after a heavy rain or thaw, the surface conditions become worse and less stable.

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SAFETY

TRAVEL ON SLOPES Traveling on slopes may pose a hazard. In order to prevent tipping the machine or losing control it is important to follow some basic simple rules: .

Never turn the ignition key off when traveling up or down a slope.

If the engine should stop, apply the brakes and stop the machine immediately.

When traveling over rough ground travel at a slow controllable speed.

When traveling up or down slopes with an empty bucket it is important to travel at a safe controllable speed with the bucket set in position “A� 20 to 30 cm (8 to 12 in) above the ground.

When traveling up or down a slope with a load, always keep the bucket 20 to 30 cm (8 to 12 in) above the ground and the load facing the top of the hill.

Never travel up or down a slope with the load facing the bottom of the hill. Loss of control may result when the brakes are applied.

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1-13

SAFETY Always travel straight up or straight down a slope, traveling at an angle on a slope may cause the machine to tip or possibly rollover.

PARKING THE MACHINE When parking the machine it is important to follow several basic safety rules. Keep in mind you are responsible for the security of the machine when it is parked. Below is a list if some basic rules to follow when parking your machine.

1.

Always park the machine on a flat level location away from moving equipment, pedestrians or traffic.

2.

Lower all work equipment on to the ground and neutralize all controls.

3.

Remove the ignition key, set the parking brake in the “PARK” mode and lock the controls.

See “LEAVING OPERATOR’S COMPARTMENT” on page 1-4 Be sure all access panels, cab, fuel and oil tanks are locked and secure to prevent tampering with the machine while unattended.

4.

Avoid parking the machine on a slope of any kind. If you must park on a slope, park with the bucket facing down the slope and the wheels blocked to prevent any movement of the machine.

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SAFETY

PRECAUTIONS DURING MAINTENANCE OPERATIONS All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

WARNING TAGS For machines equipped with the Electronically Controlled Suspension System (ECSS) be sure the system is off before proceeding with any maintenance procedures.

Before performing any maintenance operations on this machine, position the machine on level and firm surface.

Lock the equipment controls, remove the ignition key and tag the steering wheel.

Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine around specific points to warn others that this machine is down for maintenance.

If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.

EQUIPMENT STORAGE Always store optional or extra work equipment in a safe and secure location.

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1-15

SAFETY Store equipment in such a way that it cannot fall or cause injury to others.

WORKING UNDER THE MACHINE Always use approved jack stands to support the machine when performing maintenance under the chassis.

Never rely on hydraulic jacks or the machines work equipment to support the machine when working under or on the machine.

Always lower the work equipment to the ground after raising the machine for repairs.

When carrying out maintenance or repairs with the bucket raised, always support the bucket safely with the proper support (1) as shown in the illustration.

USING DROP LAMPS Use only approved anti-explosion proof lamps when checking fuel, oil, or batteries. Non-approved lamps can cause an explosion or fire.

.

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SAFETY

KEEPING THE MACHINE CLEAN Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts or the machine itself.

Avoid using high pressure steam cleaners or caustic soaps to wash the machine if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s cab. Doing so may damage sensitive electrical components.

When pressure washing, use high pressure hot water and mild grease cutting soaps.

Always grease the machine after cleaning to push any water out of the pivot point connections.

RUNNING THE MACHINE DURING MAINTENANCE If during maintenance the engine must be run have someone remain in the operator’s seat while the engine is running. This is if the engine must be shut down quickly.

Be sure all work equipment is “LOCKED” and the ECSS system is off.

For machines equipped with the Electronically Controlled Suspension System (ECSS) be sure the system is off before proceeding with any maintenance procedures.

Set the parking brake in the “LOCK” mode and instruct the person sitting in the cab not to operate any controls unless instructed to.

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1-17

SAFETY Always lock the front and rear frames with the safety bar (4).

Be aware of rotating parts while the engine is running.

RULES FOR REFUELING THE MACHINE Always clean up any spills. Grease, fuel, oil or coolant spills can pose a trip hazard if not moped up immediately.

Be sure you are adding the correct fluids to the proper location.

Mixing fluids can cause damage to internal components.

When refueling or adding any fluids, be sure you are in a well ventilated area. Never smoke or allow open flames near you while you are refueling the machine.

Never mix gasoline with diesel fuel. Gasoline is extremely flammable and could cause an explosion. Do not fill the fuel tank completely, leave room for the fuel to expand.

COOLING SYSTEM PRECAUTIONS Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap.

Never dump used coolant on the ground, in a lake, stream or in a sewer system. EPA Law requires these fluids to be captured and recycled properly. Failure to do so is in violation of the law.

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SAFETY

BATTERY PRECAUTIONS When working on the electrical system, disconnect the negative (-) battery cable first then the positive (+) battery cable last.

On completion of work, reconnect the positive (+) cable first then the negative (-) cable last.

When using jumper cables to start the machine as shown below, hook the positive (+) jumper up first, then the negative (-) jumper last to a remote location on the chassis.

STARTING THE MACHINE Never try to start the machine by tampering or shorting the starter terminals. Accidental movements of the machine could cause injury or even death.

Always start the machine seated in the operators cab using the ignition switch.

See “ELECTRICAL SYSTEM� on page 3-5

Never use a welder or a machine with a higher voltage system to jump start the machine. Using a higher voltage to jump-start a machine may damage the machines electrical system or cause an unexpected explosion or fire. Always jump-start a machine with equal voltages

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SAFETY

HIGH PRESSURE HOSES Do not use bent, cut or cracked tubing or hoses which have been previously rejected because of leaks or other defects. Faulty hoses can burst during operation causing injury or fire.

Repair or replace any loose or faulty fuel or hydraulic lines immediately. Do not operate the machine with damaged or leaking hoses or lines.

Remember that working hydraulic systems are always under pressure. If you have to add or drain hydraulic fluid, service or inspect the hydraulic system, lower the equipment to the ground and release system pressure and residual tank pressure before starting any work.

Leaks from pressurized hydraulic lines are extremely dangerous since the spray from them can penetrate your skin and enter the bloodstream, or the eyes.

Always wear thick gloves and protective goggles when working on the hydraulic systems Use a sheet of cardboard or plywood to search for leaks.

If you are struck by a jet of hydraulic fluid under pressure, or if you are injured even slightly, consult a doctor immediately for appropriate treatment.

HIGH TEMPERATURES AREAS When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system is still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns.

Carry out maintenance procedures described in this manual only when the machine has had time to cool down.

DISPOSAL OF WASTE MATERIALS Never dump waste fluids in a sewer system, on the ground in rivers, etc.

Always drain fluids from your machine into the appropriate containers.Never drain fluids directly onto the ground.

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil.

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SAFETY

INFLATING TIRES Always bear in mind that tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions: • Before inflating tires, always check the wheel rims, tire walls and tread for cuts, broken cords, or other damage.

• Have a tire expert perform checks and tire maintenance.

• When inflating tires, use a protective cage, and a compressed air gun with extension hose and pressure gauge.

• Make sure there is nobody in the vicinity before starting to inflate a tire. Stand at the tread side of the tire to inflate it.

ACCUMULATOR This machine is equipped with an accumulator charged with high-pressure nitrogen gas. Before servicing the accumulator, observe the following precautions: • Do not dissemble the accumulator.

• Do not expose the accumulator to high heat or an open flame.

• Do not weld on the accumulator.

• Do not drill or cut the accumulator.

• Do not strike or crush the accumulator.

• When replacing or disposing of the accumulator, always release the nitrogen pressure from the chamber.

CRITICAL PARTS Periodically some parts must be replaced due to safety purpose. Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or pedestrian. Listed are some of the systems containing these components that may fail under extended use: • Seat belts.

• Fuel supply and delivery hoses.

• Hydraulic system: main delivery hoses and tubing.

• Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment.

For additional information: See “WEAR PARTS” on page (3-7)

VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED According to test results carried out to determine the vibrations transmitted to the operator by the machine, the upper limbs are subjected to vibrations lower than 2.5 m/sec2 (8.2 ft/sec2). The seated part of the body is subject to vibrations lower than 0.5 m/sec2 (1.7 ft/sec2).

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SAFETY

SAFETY AND WARNING DECALS It is important that all safety and warning decals are in place, not damaged, covered up or removed. It is also important for the operator to be aware of the decal content and location.

LOCATION OF THE SAFETY DECALS • • •

Your Komatsu Dealer can supply you with new replacement decals if the ones on the machine are damaged or missing.

When replacing damaged or missing decals, be sure they are placed in the proper location.

Additional safety or warning decals may be added to your machine if desired.

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SAFETY

LOCATION OF SAFETY LABELS The rear full fender is available as an option only; item 14 indicates that the machine is equipped with full fender.

SAFETY LABELS (1) Precaution before starting (09651-A0481).

Warning! Read the manual before operation, maintenance, disassembly, assembly and transportation.

(2) Precautions for safety lock lever (09654-C0481).

Sign indicates a hazard of unexpected moving of stopped machine.

Lower the working device to the ground, move the safety lever to the look position and take the engine key with you before leaving the machine.

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SAFETY (3) Precautions when travelling in reverse.

To prevent SEVERE INJURY or DEATH, do the following before moving the machine or its attachments: ❥ ❥ ❥

Honk horn to alert people nearby.

Be sure no on is on or near the machine.

Use a spotter if view is obstructed.

Follow the above even if the machine is equipped with back-up alarm and mirrors.

(4) Precautions for parking brake (421-93-23351).

If the release valve is set to RELEASE, a serious accident may occur as this operation releases the parking brake and the car body may suddenly start to move.

Never set the release valve to RELEASE, except when towing the car in case of machine trouble.

Before towing the car, carefully read the manual and be sure to follow the instructions given therein.

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SAFETY (5) Do not enter (09162-C0641).

Sign indicates a crush hazard between the articulating parts of the vehicle.

(6) Precautions for safety bar (09161-C0641).

Sign indicates a crush hazard between articulating parts of the vehicle.

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SAFETY (7) Precautions for going close to electric cables (09801-C0481).

Sign indicates an electrocution hazard if the machine is brought too near the electric power lines.

Keep a safe distance from the electric power lines.

(8) Precautions for high voltage (7872-10-1600) There is danger of electrocution. Turn the starter switch OFF before starting the inspection or repairs and read the Operation and Maintenance Manual.

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SAFETY (9) Precautions when coolant is at high temperature (09653-A0641).

Sign indicates a burn hazard from spurting hot water or oil if the radiator or hydraulic tank is uncapped while hot.

Allow the radiator or hydraulic tank to cool before removing the cap.

(10) Precautions when oil is at high temperature (09653-A0641).

Sign indicates a burn hazard from spurting hot water or oil if the radiator or hydraulic tank is uncapped while hot.

Allow the radiator or hydraulic tank to cool before removing the cap.

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SAFETY (11) Precautions when handling battery cables (09808-A1201).

Sign indicates an electrical hazard from handling the cable.

Read the manual for safe and proper handling.

12) Precautions when handling the battery.

Shield eyes. Explosive gases can cause blindness or injury. No sparks or flames. Sulfuric acid can cause blindness or severe burns. Flush eyes immediately with water. Get medical help fast. Keep out of the reach of children. Do not tip. Keep the vent caps tight and level.

(13) High-pressure warning (09659-A057B).

There is the hazard of explosion causing injury.

Do not disassemble the accumulator, make holes in it, weld it, cut it, hit it, roll it or bring it near the flame.

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SAFETY (14) Do not climb on fender (09805-C0881) (machines equipped with full rear fender) Sign indicates a hazard of falling.

Do not stand on this place.

(15) Do not work on equipment (09807-C0883).

Sign indicates a crush hazard from falling off of the working device.

Keep away when the working device is raised.

Please request part number 421-93-23250 for safety labels 1 through 3 and 7.

Please request part number 426-93-21570 for safety labels 5, 6, 9 through 11 and 16.

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SAFETY (16) Do not open when the engine is running (09667-A0880).

Sign indicates a hazard of rotating parts, such as a belt.

Turn off before inspection and maintenance.

(17) Do not come near the machine.

Sign indicates a hazard of being run over by a moving vehicle.

Keep a safe distance from the vehicle when it is moving.

(18) Do not modify ROPS (09620-30200)

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SAFETY (19) Do not use this door ROPS (421-93-A1460) This door is for emergency exit only

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SAFETY

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2

2-1

OPERATION

GENERAL VIEW OF MACHINE OUTSIDE VIEW OF THE MACHINE

1.

2.

3.

4.

5.

6.

7.

2-2

Bucket Tilt lever Front wheel Bucket cylinder Front working lamp ROPS cab Rear wheel

8.

9.

10.

11.

12.

13.

Turn signal lamp Head lamp Lift cylinder Lift arm Rear working lamp Rear combination lamp

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OPERATION

INSIDE VIEW OF THE CAB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Directional lever stopper Rear wiper switch Front wiper switch Speed control lever Front switch panel Directional lever E.C.S.S. switch Horn switch Hazard lamp switch Machine monitor Steering wheel Transmission cut-off switch Lamp switch, Turn signal lever, Dimmer switch Parking brake switch

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15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Cigarette lighter Load meter cancel switch (if equipped) Kickdown switch Lift arm control lever Hold switch Bucket control lever Load meter subtotal switch (if equipped) Ignition switch Right switch panel Accelerator pedal Right brake pedal Steering tilt lock lever Left brake pedal Safety lock lever

2-3

OPERATION

DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS Before operating the machine it is important to understand all the functions equipped with your machines monitor.

Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all monitoring functions.

INSTRUMENT BEZEL

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

2-4

Central warning lamp Brake oil pressure caution lamp Engine oil pressure caution lamp Engine oil level caution lamp Radiator water level caution lamp Air cleaner clogging caution lamp Parking brake pilot lamp Axle oil temperature caution lamp Cooling fan reverse rotation pilot lamp (not used on Waste Handler) Maintenance caution lamp Battery electrolyte level caution lamp (if equipped) Battery charge circuit caution lamp Steering oil pressure caution lamp Emergency steering pilot lamp Character display Output mode pilot lamp (power mode) Preheating pilot lamp (Not used in North America) Auto-greasing pilot lamp (if equipped) Joystick pilot lamp (if equipped) Directional selector pilot lamp

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

Shift indicator Auto-shift pilot lamp Lockup pilot lamp (if equipped) Shift hold pilot lamp Shift lever position pilot lamp Torque converter oil temperature gauge Torque converter oil temperature caution lamp Engine coolant temperature gauge Engine cooling water temperature caution lamp Speedometer Turn signal pilot lamp Head lamp high beam pilot lamp Meter display pilot lamp Hydraulic oil temperature caution lamp Hydraulic temperature gauge Fuel level caution lamp Fuel gauge (Not used in North America) (Not used in North America)

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OPERATION

SWITCH PANELS These switches are used to control various functions relating to the machines operating system, it is important the operator become familiar with the switch function and what system they control Without knowledge of all the switch controlled systems damage the machine, property or possibly cause injury to the operator may result.

RIGHT SWITCH PANEL 1. Transmission shift mode selector switch 2. Transmission cut-off set switch 3. ✱ Cooling fan reverse rotation switch 4. Emergency steering switch (if equipped) 5. (Not used in North America) 6. Torque converter lock-up switch (if equipped) 7. Directional selector actuation switch (if equipped) 8. Auto greasing switch (if equipped)

9.

10.

11.

12.

13.

Torque converter lock-up switch Remote positioner lower mode switch (if equipped) Remote positioner raise/lower set switch (if equipped) Ignition switch Power mode selector switch

LEFT FRONT SWITCH PANEL 14.

15.

16.

17.

Monitor panel mode selector switch 1 Monitor panel mode selector switch 2 Front working lamp switch Rear working lamp switch

FAR RIGHT SWITCH PANEL (WASTE HANDLER ONLY) 18. Fan directional switch 19. Fan mode switch 20. Auto reverse interval timer ✱ Not on Waste Handling applications

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DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM Before operating the machine it is important to understand all the functions equipped with your machines monitor.

Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all monitoring functions.

INSTRUMENT BEZEL

A. Character display B. Emergency stop items C. CAUTION items D. Inspection and maintenance items ❉

E. Pilot display F. Meter display G. Central warning lamp

When turning the ignition switch to the “ON” position before starting the engine, the central warning lamp, caution lamps, and pilot lamps light up for 2 seconds to check the system. ● After the alarm buzzer sounds for 2 seconds, it goes off if the condition is normal. ● The shift indicator display shows “88” for 2 seconds. ● The indicator gauges and meters are actuated after the above system check is completed. ● The character display shows “KOMATSU SYSTEM CHECK” for 3 seconds. ● If the lamps do not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection.

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OPERATION TYPES OF WARNING If an abnormality occurs on the machine, or if any switch or lever is operated mistakenly, the monitor display and buzzer alert the operator. These are the following types of warnings depending on the level of warning.

EMERGENCY STOP This warning is given if there is a serious failure that affects the normal operation of the machine or if a setting is incorrect.

The central warning lamp on the monitor and the caution lamp for the location of the abnormality will light up. At the same time, the alarm buzzer sounds and action code “E03” is displayed on the character display (1).

CAUTION This warning is given if the engine coolant or lubricating oil overheats.

The central warning lamp on the monitor and the individual caution lamps light up also. At the same time, the alarm buzzer sounds and action code “E02” is displayed on the alert display (1).

MISTAKEN OPERATION This warning is given if any switch or lever is operated mistakenly.

The central warning lamp on the monitor lights up. At the same time, the alarm buzzer sounds and action code “E00” is displayed on the character display (1).

If there is an individual caution lamp for the mistaken operation, it flashes when the buzzer sounds.

INSPECTION AND MAINTENANCE This warning is given if it is necessary to perform inspection and maintenance of wear parts, or if it is necessary to check the oil or engine coolant level. The individual caution lamp on the monitor lights up. At the same time, action code “E01” is displayed on the character display (1).

In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound CENTRAL WARNING LAMP This display portion (1) lights up if any emergency stop item, caution item, or mistaken operation of any switch or lever occurs. At the same time, the alarm buzzer sounds.

Check the content of the display and perform the specified action for the item.

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MACHINE ELECTRONIC MONITORING DISPLAY This display system electronically monitors several major functions, these functions include the amount of operating hours on the machine, all operating alert and failure information and service intervals. These functions can be accessed by using the mode selector switches (1) and (2). It is important for the operator of this machine to know how to access this information and understand what this information contains

1.

2.

3.

Service meter Clock (only machines equipped with optional load meter) Action code display

4.

5.

Failure code display Filter, oil replacement time display

MONITOR MODE SELECTOR SWITCHES In order to access information on the monitor, the mode selector switches must be used in conjunction with each other. These switches are located on the right hand side of the instrument panel as shown in the illustration. They allow you to enter or exit a mode as well as navigate within the mode. There operating function is listed below:

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OPERATION MODE SELECTOR SWITCH 1 Mode selector switch (1) is used to switch the function of the character display on the monitor screen. The basic operation is as follows.

Position: To select, confirm or enter a mode or operation.

Position: To exit or cancel mode or operation.

MODE SELECTOR SWITCH 2 Mode selector switch (2) is used to navigate within the chosen display on the monitor screen. The basic operation is as follows.

Position: To go on to the next screen or function, move the cursor forward, or to increase the number when entering numerals Position: To go back to the previous screen or function, or to move the cursor back, or to reduce the number when entering numerals

MONITOR DISPLAY INFORMATION Once you know the operating functions of the mode selector switches (1) and (2) it is important to be able to access this information and navigate within the mode you have selected, below is a list of these mode and how to access and navigate within them.

HOUR METER AND ODOMETER DISPLAY An hour meter reading or an odometer reading can be displayed in this mode if desired.

Hour Meter Display During normal operation display (1) shows the total time in hours that the machine has been operating. While the engine is running, the hour meter advances even if the machine is not moving. The hour meter advances by 1 hour of operation, regardless of the engine speed.

You can also access the hours on the machine with the ignition switch in the “OFF” position simply by pressing the ( ) button.

Clock (only machines equipped with optional load meter) This display portion (2) shows the time.

For details of the method of adjusting the time, see “CLOCK BUTTON/DISPLAYING FREQUENCY” on page 2-45.

Even when the ignition switch is at the “OFF” position, the time is displayed while the top ( ) position of the monitor panel mode selector switch 1 is being pressed.

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OPERATION Odometer Display To check the total distance that the machine has traveled or to simply use the odometer feature while traveling: With the ignition switch in the “ON” position or the machine running.

Press the ( )button and the display will change from the hour meter display to the odometer display. The display will remain in the odometer mode until the ignition switch is turned to the “OFF” position or the ( ) is pressed.

ADJUSTING MONITOR BRIGHTNESS To adjust monitor display. “MONITOR MODE SELECTOR SWITCHES” on page 2-9

PROGRAMMING TELEPHONE NUMBER To program in phone numbers.“MONITOR DISPLAY INFORMATION” on page 2-10

ACTION CODE DISPLAY If an inspection or maintenance procedure must be performed, if there is a failure on the machine, or if it should become necessary to change your operating methods, An action code E00, E01, E02, or E03 will be displayed on the monitor display portion (3). If different failures should occur at the same time, the action code for the most serious problem is displayed. The action code will be displayed first, then the system with the failure will be displayed at 3 second intervals.

The level of seriousness in the action code order is as follows, starting with the most serious: E03, E02, E01, E00. In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp lights up.

Action Code (E03) This code is the most serious of all the codes, it usually indicates an oil pressure loss or a malfunction in a safety related system. If this code should appear on the monitor, stop and shut the machine down immediately. Contact your Komatsu Dealer and do not operate the machine until the problem is repaired.

Action Code (E02) This code warns the operator of a potential failure if action is not taken immediately. This would be an over heat condition or an engine over speed. If this code should appear while operating the machine, stop the machine and allow the system to cool down or slow the machine down to a safe controllable speed.

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OPERATION Action Code (E01) This code alerts the operator of a problem in the system. This would be low coolant level or a maintenance due item. If this code should appear while operating the machine, take the machine to a maintenance area so servicing can be carried out or the problem can be checked.

Action Code (E00) This code will appear if the parking brake is not fully released or the machine is traveling at an excessive road speed or down hill at an excessive speed. If this should occur, slow the machine down immediately to a safe speed. Never over speed the engine, damage to the engine will occur.

Remark Action codes cannot be erased or canceled, after repairs have been made the system will automatically reset its self and the code will disappear.

FAILURE CODE DISPLAY If an action code is displayed, check the failure code using the failure code display method given below.When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code.

Method Of Displaying Failure Code If an action code is displayed on the monitor display portion (4), press the mode selector switch (>)button.

1.

The action code will change to the failure code. • •

•

The failure code is displayed with the first 6 digits on the left side of the character display.

The code displayed after the space on the right side of the failure code indicates the controller that detected the failure code.

The failure code and the component causing the failure are displayed on the character display for 3 seconds each.

Top right code

The controller in the system detecting the failure will be indicated.

MON TM

Controller detecting failure code Machine monitor Transmission controller

ENG

Engine controller

WRK

Work equipment controller (if equipped)

Press the selector switch (>) button again. If the condition is normal, the service meter is displayed for several seconds, then the display returns to the action code. If more than one failure has occurred at the same time, the next failure code is displayed.

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OPERATION SERVICE DISPLAY After a complete system check when the ignition switch is turned to the “ON” position, if any filter or oil related item is approaching it’s replacement time, this display (5) shows the item for approx. 30 seconds. When this happens, the maintenance caution lamp also flashes or lights up. If this should occur during operation of the machine, have the maintenance performed as soon as possible. After replacing the filter or changing the oil, it is important to reset the time for replacement.

Service Items List Item

Service Interval (hrs.)

System Needing Service

System ID Number

Engine oil

500

ENG OIL

01

Engine oil filter

500

ENG FILT

02

Fuel filter

500

FUEL FILT

03

Corrosion resistor

1000

CORR RES

06

Transmission oil

1000

TM OIL

12

Transmission filter

1000

TM FILT

13

Hydraulic filter

2000

HYD FILT

04

Hydraulic tank vent element

2000

HYD BREATH

05

Hydraulic oil

2000

HYD OIL

10

Axle oil

2000

AXLE OIL

15

Service Alert Display The ID number and item name needing service are displayed on the monitor display, the remaining time to service the item and the number of times a service has been performed are displayed in 3 second intervals. If the service time has already passed, a minus (-) sign appears before the time display. After the display has been on for 30 seconds, it does not appear again until the ignition switch is turned to the “ON” position again.

The service information in the illustration is not shown on the monitor display if an action code is being displayed.

If there are two or more items to be displayed, they are displayed in a simultaneous order. If there are more than 10 items, all the items are displayed in a simultaneous order also, then the display will return to it’s normal display. The display appears when there is 30 hours remaining on the service items time. If the replacement time has passed, a minus (-) sign appears before the time for the first 999 hours. When more than 999 hours have passed, a display is no longer given. The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time has passed.

Resetting Service Times After Servicing Once an item has been serviced and the machine is ready to go back into operation it is necessary to reset the service time interval. It is important to do this in order to keep track of when it will be time to perform service on the machine again.

Below is the procedure for resetting the service time interval.

1.

To enter reset mode the ignition key must be in the “ON” position.

2.

Press the ( ) selector switch button and it will display the odometer.

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OPERATION 3.

Using the (>) selector switch button scroll thought the menu to the [MAINTENANCE] display.

4.

Once the [MAINTENANCE] display is reached, press the ( ) selector switch button to enter the system.

5.

Once in the system using the (< >)selector switch buttons you can scroll through the eight service items listed on page 2-24.

6.

When you have found the item that was serviced, using the ( ) selector button switch reset the service time interval, a [00: RESET] will appear on the monitor display. 3 seconds later a [YES <> NO ■ ENTER] will appear.

7.

To reset the service interval, select YES or NO using the (< >) selector switch buttons. Once you have chosen yes or no, use the ( ) selector button to reset the maintenance time interval If yes is selected the service time interval is reset and a beep is heard.

If no is selected the service time is not reset.

SELECTING LANGUAGE To switch the language on the mode display. The following explanation outlines the procedure for changing the language to either English, Japanese, German, French, Italian, Spanish or Swedish.

To Select A Language 1.

To enter reset language mode the ignition key must be in the “ON” position.

2.

Press the ( )selector switch button and it will display the odometer.

3.

Using the (>)selector switch button scroll through the menu to the [LANGUAGE] display.

4.

Once the [LANGUAGE] display is reached, press the ( ) selector switch button to enter the system. The current language is displayed.

5.

Once in the system using the(< >)selector switch buttons you can scroll through the seven languages.

6.

After selecting a language, press the ( ) selector switch button.

This confirms the language. To abort, press the ( ) selector switch button. When completing the operation, press the ( ) selector switch button twice or turn the ignition switch “OFF”.

2-14

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OPERATION

EMERGENCY STOP WARNING SYSTEM If any abnormality occurs in the (Emergency Stop Warning System), an audible alarm will sound intermittently. The lamp for the location of the abnormality will light up also. If any of these lamps are illuminated during operation of the machine, park the machine in a safe location, lower the work equipment, set the parking brake and shut the engine “OFF”. Contact your local Komatsu Dealer for repairs.Do not operate the machine until repairs have been made.

1.

2.

Brake oil pressure caution lamp Engine oil pressure caution lamp

3.

4.

Battery charge circuit caution lamp Steering oil pressure caution lamp

BRAKE PRESSURE WARNING LAMP Lamp (1) monitors the brake oil pressure. If the brake oil pressure goes below the specified set value, the brake oil pressure warning lamp as well as the central warning lamp will light up and the alarm buzzer will sound. At this point stop the machine immediately and do not operate it until repairs have been made.

During checks before starting (ignition switch in the ““ON”” position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

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2-15

OPERATION ENGINE OIL PRESSURE WARNING LAMP Lamp (2) warns the operator that the engine oil pressure has dropped below the specified set value. During operation (engine running) if the engine oil pressure drops, the engine oil pressure warning lamp as well as the central warning lamp should light up and the alarm buzzer will sound intermittently. If the engine oil pressure lamp should come on shut the engine down immediately.

During checks before starting (ignition switch in the “ON” position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

BATTERY CHARGE WARNING LAMP Lamp (3) warns the operator that the charging system has dropped below the specified set value. During operation (engine running) if the charging system should fail, the battery charge warning lamp as well as the central warning lamp should light up and the alarm buzzer will sound intermittently.

During checks before starting (ignition switch in the “ON” position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

STEERING OIL PRESSURE WARNING LAMP Red lamp (4) warns the operator that the steering oil pressure has dropped below the specified set value. During operation (engine running) if the steering oil pressure should drop, the steering oil pressure warning lamp as well as the central warning lamp should light up and the alarm buzzer will sound. At this point stop the machine immediately and do not operate it until repairs have been made. During checks before starting (ignition switch in the “ON” position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

If any steering warnings should occur, do not operate the machine until diagnostics or repairs have been made to this system. Operating the machine with a steering alert or warning could lead to loss of control on the machine.

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OPERATION

CAUTION ALERT WARNING SYSTEM If an operator alert is required the (Caution Lamps), and an audible alarm will sound intermittently. The lamp for the location of the alert as well as the central warning lamp will light up. If any of these lamps are illuminated during operation of the machine, stop the machine in a safe location, lower the work equipment, set the parking brake and run the engine at a low idle until the light goes out or check the system showing the problem. Contact your Komatsu Dealer

1.

2.

3.

Axle oil temperature caution lamp Torque converter oil temperature caution lamp Engine coolant temperature caution lamp

4.

5.

Hydraulic oil temperature caution lamp Fuel level caution lamp

AXLE OIL TEMPERATURE CAUTION LAMP Lamp (1) alerts the operator that the axle oil temperature has risen above the specified set value. During operation if the axle oil temperature lamp, as well as the central warning lamp should light up and the alarm buzzer sounds, stop the machine until the system cools down. At that point the lamps should go out and the buzzer should stop.

During checks before starting (ignition switch in the â&#x20AC;&#x153;ONâ&#x20AC;? position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

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2-17

OPERATION TORQUE CONVERTER CAUTION LAMP Lamp (2) alerts the operator that the torque converter oil temperature has risen above the specified set value. During operation if the oil temperature lamp, as well as the central warning lamp should light up and the alarm buzzer sounds, stop the machine and idle engine at a low idle until the system cools down. At that point the lamps should go out and the buzzer should stop.

During checks before starting (ignition switch in the “ON” position, engine stopped) the lamps will not be illuminated.

COOLANT TEMPERATURE CAUTION LAMP Lamp (3) alerts the operator that the engine coolant temperature has risen above the specified set value. During operation if the engine coolant temperature lamp, as well as the central warning lamp should light up and the alarm buzzer sounds, shut the engine down until the engine cools down. At that point the lamps should go out and the buzzer should stop once engine is started back up.

During checks before starting (ignition switch in the “ON” position, engine stopped) the lamps should be illuminated, and when the engine is running, these lamps should go out.

HYDRAULIC OIL TEMPERATURE CAUTION LAMP This meter (4) indicates the hydraulic oil temperature During normal operations, it should be in the white range.

If it enters the red range during operation, the alarm buzzer will sound and the central warning lamp will light up at the same time. “E02 HYD OVERHEAT” is displayed on the character display. Run the engine under no load at a mid-range speed and wait until the indicator returns to the white range.

FUEL LEVEL CAUTION LAMP Lamp (5) alerts the operator that the fuel in the tank is below 36 liters (9.19 gal). Add fuel as soon as possible.

Remark If the caution lamp lights up, action code “E02” will not be display on the character display.

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OPERATION

INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM If there is need for service or inspection, the lamp for the location needing an inspection or service will light up. If any of these lamps are illuminated during operation of the machine, take the machine to a service location immediately, lower the work equipment, set the parking brake and shut the engine down. These items must be attended to immediately.

Failure to do so may result in a system break down. Contact your local Komatsu Dealer for service on these items. Do not continue machine operations

1.

2.

3.

4.

Engine oil level caution lamp Radiator coolant level caution lamp 5.

6.

Air cleaner clogging caution lamp 7.

Maintenance alert lamp Battery electrolyte level caution lamp Brake oil level caution lamp (not available in North America) Transmission filter clogging caution lamp (not available in North America)

ENGINE OIL LEVEL CAUTION LAMP This monitor (1) lights up to warn the operator that the oil level in the engine oil level has gone down.

During checks before starting (when the ignition switch is turned to the “ON” position but the engine has not started), this monitor lights up if the oil level in the engine oil level is low, and at the same time, the “E01 ENG OIL LEV LOW” is displayed on the character display. Do not start the engine. Check the oil level in the engine and add oil.

Remark During checks before starting, if the engine is started with the engine oil level caution lamp lit up, the lamp will stay lit.

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2-19

OPERATION RADIATOR COOLANT LEVEL CAUTION LAMP This monitor (2) lights up to warn the operator that the coolant level in the radiator has gone down.

During checks before starting (when the ignition switch is turned to the “ON” position but the engine is not running), this monitor lights up if the coolant level in the radiator is low and at the same time, the “E01 COOLANT LOW” is displayed on the character display. Check the coolant level in the radiator and add if needed.

AIR CLEANER CLOGGING CAUTION LAMP This lamp (3) lights up to warn the operator that the air cleaner is clogged.

During checks before starting (when the ignition switch is turned to the “ON” position but the engine is not running), this monitor does not light up. ❉ During operation (engine running) If the air cleaner becomes clogged, the air cleaner clogging caution lamp will light up, and at the same time, the “E01 AIR FILTER” is displayed on the character display. Stop the engine and clean or replace the element.

Remark Check the dust indicator installed at the side of the air cleaner.

MAINTENANCE CAUTION LAMP When the oil change interval is reached, this monitor (4) flashes or lights up for about 30 seconds after completion of the system check when the ignition switch is at the “ON” position.

Remark The maintenance caution lamp flashes when there is less than 30 hours to the replacement time. After the replacement time has passed, it lights up.

BATTERY ELECTROLYTE LEVEL CAUTION LAMP This monitor (5) lights up to warn the operator that the battery electrolyte level has gone down.

During checks before starting (when the ignition switch is turned to the “ON” position but the engine is not running), this monitor lights up if the battery electrolyte level is low, and at the same time, the “E01 BATTERY LEV LOW” is displayed on the character display. Check the electrolyte level and add distilled water. ❉ During operation (engine running) If the battery electrolyte level becomes too low, the battery electrolyte level caution lamp will light up, and at the same time, “E01 BATTERY LEV LOW” is displayed on the character display. Check the electrolyte level and add distilled water.

2-20

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OPERATION

MODE ALERT LAMPS These indicators alert the operator that the machine is in a certain operating mode or a function is operating. It is important for the operator of this machine to pay close attention to these indications especially when the machines engine is running or the machine is mobile, failure to do so may shorten the life of a component or inadvertently cause an accident

1.

2.

3.

4.

5.

6.

7.

8.

Parking brake pilot lamp â&#x153;¸ Cooling fan reverse rotation pilot lamp Emergency steering pilot lamp Output mode pilot lamp (power mode) Preheating pilot lamp Auto dig pilot lamp (not used in North America) Auto grease pilot lamp (if equipped) Joystick pilot lamp (if equipped)

9.

10.

11.

12.

13.

14.

15.

16.

Directional selector pilot lamp (if equipped) Shift indicator Auto-shift pilot lamp Lockup pilot lamp (if equipped) Shift hold pilot lamp Shift lever position pilot lamp Turn signal indicators High beam indicator

â&#x153;¸ This feature is not used on Waste Handler applications

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OPERATION PARKING BRAKE PILOT LAMP This monitor (1) lights up when the ignition switch is in the “ON” position or when the parking brake is applied.

COOLING FAN REVERSE ROTATION PILOT LAMP This monitor (2) lights up when the when the ignition switch is in the “ON” position or when direction of rotation of the cooling fan is reversed, and at the same time, the “COOLING FAN REVERSE” is displayed on the character display. ✸ Not used on Waste Handler applications

(WASTE HANDLER ONLY) This LED flashes when the direction of rotation of the cooling fan is reversed. The fan will coast for approx. 8 seconds before reversing, the indicator light will light up until condition has stopped.

EMERGENCY STEERING PILOT LAMP This monitor (3) lights up when the ignition switch is in the “ON” position or when the emergency steering is being actuated.

If the engine stops when the machine is traveling or an abnormality occurs in the steering oil pressure circuit, and the machine is traveling at a speed of more than 2 km/h (1.2 mph), the emergency steering is automatically actuated and the lamp lights up.

If the lamp lights up, move the machine immediately to a safe place, stop the engine, and check the condition. The lamp flashes, if the emergency steering is actuated continuously for one minute, and at the same time, “E02 EMR S/T OVERRUN” is displayed on the character display.

There is an emergency steering self-check function. For details, “EMERGENCY STEERING SELF-CHECK FUNCTION” on page 2-101.

2-22

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OPERATION OUTPUT MODE PILOT LAMP (POWER MODE) This monitor (4) lights up when the ignition switch is in the “ON” position or when the power mode is selected.

Use the power mode selector switch to select the output mode.

PREHEATING PILOT LAMP This monitor (5) lights up when the when the ignition switch is in the “ON” position or when engine preheating electric heater is actuated.

In cold weather, when the ignition switch is turned to the “ON” position, this lamp lights up. When the preheating is completed, it goes out. The preheating time differs according to the ambient temperature.

JOYSTICK PILOT LAMP This monitor (8) lights up when the when the ignition switch is in the “ON” position or when the joystick switch is turned “ON”.

For details, “JOYSTICK CONSOLE ADJUSTMENT” on page 5-37.

DIRECTIONAL SELECTOR LAMP This monitor (9) lights up when the directional selector switch actuation switch on the right switch panel is turned “ON”. When “ON”, it is possible to switch the direction of travel between FORWARD and REVERSE using the directional selector switch (located on the side of the lift arm control lever).

For details, “CHANGING DIRECTION” on page 2-93.

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OPERATION SHIFT INDICATOR This monitor (10) indicates the transmission gear range (actual travel speed range).

AUTO-SHIFT PILOT LAMP This monitor (11) lights up when the when the ignition switch is in the “ON” position or the auto-shift function is selected.

Use the transmission shift mode selector switch to select the shift mode.

LOCKUP PILOT LAMP This monitor (12) lights up when the when the ignition switch is in the “ON” position or the torque converter lock-up is engaged and the transmission is set to direct drive.

For details, “TORQUE CONVERTER LOCK-UP SWITCH” on page 5-22.

SHIFT HOLD PILOT LAMP This monitor (13) lights up when the when the ignition switch is in the “ON” position or the shift hold is actuated.

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OPERATION SHIFT LEVER POSITION PILOT LAMP This monitor (14) displays the transmission position of the gearshift lever.

TURN SIGNAL PILOT LAMP This monitor (15) flashes at the same time as the turn signal lamp flashes.

If an open circuit exists in the turn signal indicator lamp system, the flashing interval becomes shorter.

HEADLAMP HIGH BEAM PILOT LAMP This monitor (16) lights up when the head lamps are set to high beam.

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OPERATION

GAUGE DISPLAY These gauges allow the operator of the machine the ability to monitor the operating systems on the machine. It is important for the operator to pay close attention to these gauges especially when the machines engine is running, mobile or the working

1.

2.

3.

Torque converter oil temperature gauge Engine water temperature gauge Hydraulic temperature gauge

4.

5.

6.

Fuel gauge Speedometer Meter display pilot lamp

TORQUE CONVERTER OIL TEMPERATURE GAUGE This meter (1) indicates the torque converter oil temperature.

It should be in the white range during operation.

If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up. â&#x20AC;&#x153;E02 TC OVERHEATâ&#x20AC;? is displayed on the character display. Run the engine under no load at a mid-range speed and wait until the meter enters the white range.

2-26

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OPERATION ENGINE TEMPERATURE GAUGE This meter (2) indicates the engine water temperature.

It should be in the white range during operation.

If it is in the red range during operation, the alarm buzzer will sound and the central warning lamp will light up and the “E02 ENGINE OVERHEAT” is displayed on the character display. Run the engine under no load at a mid-range speed and wait until the meter enters the white range.

If it is in the red range, the engine output is automatically limited.

HYDRAULIC TEMPERATURE GAUGE This meter (3) indicates the hydraulic oil temperature.

During normal operations, it should be in the white range.

If it enters the red range during operation, the alarm buzzer will sound and the central warning lamp will light up at the same time. “E02 HYD OVERHEAT” is displayed on the character display. Run the engine under no load at a mid-range speed and wait until the indicator returns to the white range.

FUEL GAUGE This meter (4) indicates the amount of fuel remaining in the fuel tank.

F: Full tank E: Fuel level is low When the amount of remaining fuel goes below 30 liters (7.93 US gal), the caution lamp inside the fuel gauge lights up.

If it lights up, check and add fuel.

SPEEDOMETER This meter (5) indicates the travel speed of the machine.

The display unit is indicated on meter display pilot lamp (6).

It is also possible to display the engine speed by switching meter (5).

If you wish to switch between the speedometer and tachometer, please contact your Komatsu distributor to have it switched.

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OPERATION METER DISPLAY PILOT LAMP This lamp (6) displays the unit for the travel speed or engine tachometer.

MACHINE MONITOR The machine monitor (1) also has the following functions: Odometer, filter/oil replacement time reset, telephone number input, language selection, and monitor brightness adjustment.

DISPLAYING ODOMETER Use this when checking the total distance that the machine has traveled.

1.

2.

3.

Check that the character display is showing the service meter or the action code. If it is giving any other display, turn the ignition switch “OFF”, then turn the ignition switch to the “ON” position and wait for the above display to be given.

Press the ( ) of monitor panel mode selector switch 1. It displays the odometer.

When completing the operation, press (■ ) on the monitor panel mode selector switch 1, or turn the ignition switch “OFF”.

RESET FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time.

1.

2.

Press the ( ) of monitor panel mode selector switch 1, and display the odometer.

Press (>) or (<) of monitor panel mode selector switch 2 until “MAINTENANCE MONITOR” is displayed.

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OPERATION 3.

4.

5.

6.

7.

Press the ( ) of monitor panel mode selector switch 1. It will change to the display in the diagram on the right. The bottom line shows two items: the replacement time on the left and the total number of times the item has been replaced on the right.

Press the (>) or (<) of monitor panel mode selector switch 2 to display the item (filter or oil) which has reached the replacement time.

Press the ( ) of monitor panel mode selector switch 1. It will change to the display in the diagram on the right.

The top line shows [Reset] and [Item to be reset] in turn.

When resetting the replacement time, press ( ) of machine monitor mode selector switch 1. It will reset and return to the previous screen.To abandon, align the cursor with “NO”, then press ( ) of monitor panel mode selector switch 1.

ENTERING A TELEPHONE NUMBER It is possible to display the telephone number on the right side of “CALL” displayed on the character display when action code “E03” is generated.

1.

2.

3.

4.

5.

6.

Press the ( ) of monitor panel mode selector switch 1, and display the odometer.

Press (>) or (<) of monitor panel mode selector switch 2 until “TEL” is displayed.

Press ( ) of monitor panel mode selector switch 1. It will change to the display in the diagram on the right. Once the telephone number is entered, the number will be displayed next time.

Up to 12 digits can be displayed for the telephone number. The cursor is displayed at the enter position. Press (>) or (<) of monitor panel mode selector switch 2 to display “0 - 9". To leave a blank, select “*”. When the input value is decided, press ( ) of monitor panel mode selector switch 1. The cursor will move to the next position.

Repeat the procedure in Step 4 until the last digit. At the last digit, press ( ) of monitor panel mode selector switch 1 to return to the previous screen. If there is a mistake in the input or the input is to be stopped, press ( ) of monitor panel mode selector switch 1 to return to the previous screen.

When completing the operation, press ( ) on the monitor panel mode selector switch 2 twice, or turn the ignition switch ignition switch “OFF”.

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OPERATION SELECTING A LANGUAGE Use this when switching the language displayed on the character display.

The following is for when English is set as the language for the character display.

1.

2.

3.

4.

Press the ( ) on the monitor panel mode selector switch 1, and display the odometer.

Press (>) or (<) of monitor panel mode selector switch 2 until “LGUAGE” is displayed.

Press the ( ) of machine mode panel selector switch 1. The presently selected language is displayed.

Press (>) or (<) of monitor panel mode selector switch 2 and select the language.

The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish.

5.

6.

After selecting the language, press the ( ) of monitor panel mode selector switch 1. To confirm, set the cursor at “YES”, then press the ( ) of monitor panel mode selector switch 1. The language will be selected and the screen will return to the previous screen. To abort, set the cursor at “NO”, then press the ( ) of monitor panel mode selector switch 1.

When completing the operation, press ( ) of monitor panel mode selector switch 2 twice, or turn the ignition switch “OFF”.

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OPERATION ADJUSTING MONITOR BRIGHTNESS To adjust the brightness of the monitor.

1.

2.

3.

Press the ( ) of monitor panel mode selector switch 1, and display the odometer.

Press (>) or (<) on the monitor panel mode selector switch 2 until “BRIGHTNESS ADJUST” is displayed.

Press the ( ) of monitor panel mode selector switch 1.

“MONITOR PANEL” will be displayed on the bottom line and it will be possible to adjust the brightness of the monitor.

The brightness can be adjusted for the overall monitor or for the liquid crystal display only.

To adjust only the brightness of the liquid crystal display, press the (>) or (<) of monitor panel mode selector switch 2 to switch the display to “LCD PANEL”.

4.

5.

6.

7.

Press the ( ) of monitor panel mode selector switch 1. The screen will change to the display shown on the right and it will be possible to adjust the brightness.

Press the (>) or (<) of the monitor panel mode selector switch 2 to select a level between L and H (available range: 7 stages).

After selecting the brightness, press the ( ) of monitor panel mode selector switch 1. The brightness will be selected and the screen will return to the previous screen.

When completing the operation, press ( ) of monitor panel mode selector switch 2 twice, or turn the ignition switch “OFF”.

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OPERATION

MACHINE SWITCHES AND CONTROLS Before operating the machine it is also important to understand all the functions of your machines controls and switches.

Operating the machine without full knowledge of all control systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all switch and controls functions.

SWITCH LOCATION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Ignition switch Power mode selector switch Transmission shift mode selector switch Transmission cut-off switch Transmission cut-off set switch Lamp switch, Turn signal lever, Dimmer switch Horn switch Hazard lamp switch Parking brake switch Front working lamp switch Rear working lamp switch Monitor panel mode selector switch 1 Monitor panel mode selector switch 2 Kickdown switch Hold switch Front wiper switch Rear wiper switch

2-32

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

Cigarette lighter Cab lamp switch Rear defroster switch E.C.S.S. switch Emergency steering switch (if equipped) â&#x153;¸ Cooling fan reverse rotation switch Directional selector switch Directional selector actuation switch Torque converter lock-up switch (if equipped) Load meter cancel switch (if equipped) Load meter subtotal switch (if equipped) (Not used in North America) (Not used in North America) Torque converter lock-up switch (if equipped) Load meter cancel switch (if equipped) Load meter subtotal switch (if equipped) Radio (if equipped) Air Conditioning controls

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OPERATION ✸ This feature is not used on Waste Handler applications

IGNITION SWITCH This switch (1) is used to start or stop the engine.

“OFF” position It is possible to insert and remove the ignition switch key, all the electric system switches are turned off, and the engine stops. In addition, the parking brake is automatically applied.

“ON” position Electric current flows in the charging circuit, lamp circuit, and accessory circuit. Keep the ignition switch key at the “ON” position while the engine is running.

“START” position This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to the “ON” position when released.

POWER MODE SELECTOR SWITCH This switch (2) can be used to switch the engine output to match the purpose of the operation.

When the POWER mode is selected, the output mode pilot lamp (POWER mode) on the machine monitor lights up.

NORMAL position: Normal mode (low engine output), operations where emphasis is on fuel consumption, such as operations on flat ground where high engine output is not needed.

POWER position: Power mode (high engine output), operations where emphasis is on production.

Remark For efficient fuel consumption, use the NORMAL mode.

The maximum engine speed is set lower than in the POWER mode, except for hard operations such as heavyduty digging of rock. Ample power and low fuel consumption can be obtained in the NORMAL mode. Furthermore, by pressing the accelerator pedal lightly, it is possible to reduce fuel consumption.

Use the POWER mode when performing heavy-duty digging operations of rock or operations where speed is required, or when traveling at speed under the machine's own power on flat ground or on slopes.

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OPERATION TRANSMISSION MODE SELECTOR SWITCH This switch (3) is used to change the shift point when the AUTO SHIFT/MANUAL selector switch has been switched to auto shift.

At each of the L, M, and H positions, the system switches to auto shift and the auto shift pilot lamp on the machine monitor lights up.

Normally, set to auto shift.

MANUAL position: System is set to manual shift and speed range is position selected by gearshift lever L position: Travel speed when shifting up is low (flat ground, normal travel) M position: Travel speed when shifting up is medium (traveling uphill, traveling at high speed) H position: Travel speed when shifting up is high (traveling uphill, traveling at high speed) Remark For details of the manual shift, see “Manual Shift” on page 2-60.

For details of the auto-shift, see “AUTOMATIC SHIFT” on page 2-61.

TRANSMISSION CUT-OFF SWITCH

When moving the machine on an uphill slope, set the transmission cut-off switch to the “OFF” position, depress the accelerator pedal while keeping the left brake pedal depressed, then gradually release the brake pedal and allow the machine to move. This way the machine can be prevented from traveling backwards.

Turn this switch (4) “ON” and “OFF”.

When the switch is pressed, the pilot lamp lights up and the system is turned “ON”. The transmission is shifted to neutral at the adjusted brake depression position. Normally, keep the switch at the “ON” position.

For details of the method of adjusting the cut-off position, “ADJUSTING THE TRANSMISSION CUT-OFF” on page 2-98.

Position (a): OFF The left brake pedal acts in the same way as the normal brake (right brake pedal).

Position (b): ON The left brake pedal acts in the same way as the normal brake, and at the same time, sets the transmission to neutral.

Remark The brake pedal position can be adjusted when the system is actuated with the transmission cut-off set switch on the right switch panel.

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OPERATION TRANSMISSION CUT-OFF SET SWITCH

Apply the parking brake before adjusting the transmission cut-off position.

Turning the switch (5) to the “ON” position sets the transmission to Neutral and sets the transmission cut-off function, which allows the brake pedal applied position to be adjusted.

Position (a): ON Cut-off position can be adjusted When the switch is released, it automatically returns to its original position.

For details of the method of adjusting the cut-off position, “ADJUSTING THE TRANSMISSION CUT-OFF” on page 2-98.

LAMP SWITCH This (6) is used to light up the head lamps, side clearance lamps, tail lamps, and instrument panel lighting.

Position (a): OFF Position (b): Side clearance lamps, tail lamps, and instrument panel lights up Position (c): Head lamps light up in addition to lamps at b position.

Remark The lamp switch can be operated regardless of the position of the lever.

TURN SIGNAL LEVER This lever (6) operates the turn signal lamps.

Position (a): LEFT TURN: (Push lever FORWARD).

Position (b): RIGHT TURN (Pull lever BACK).

Remark 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”. If not, return the lever to “OFF” manually.

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OPERATION DIMMER SWITCH This (6) switches the head lamp between high beam and low beam.

Position (a): Low beam Position (b): High beam

HORN BUTTON When the button (7) in the center of the steering wheel is pressed, the horn will sound.

HAZARD LAMP SWITCH

Use the hazard lamp only in emergencies. Using the hazard lamp when traveling could confuse the drivers of other machines.

This switch (8) is used in emergencies, such as the case of emergency parking on the street when the machine breaks down.

“ON”: All turn signal lamps flash.

PARKING BRAKE SWITCH

Always apply the parking brake when leaving the machine or when parking it.

Even if the parking brake switch is turned “ON”, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

This switch (9) operates the parking brake.

Position (a): ON. The parking brake is applied, and the parking brake pilot lamp lights up.

Position (b): OFF The parking brake is released.

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OPERATION

Never use the parking brake switch to apply the brakes when traveling, except in an emergency. The parking brake may be damaged and this may lead to a serious accident. Apply the parking brake only after the machine has stopped.

If the parking brake has been used as an emergency brake when traveling at high speed, contact your Komatsu distributor to have the parking brake checked for any abnormality.

Remark When the parking brake is applied, the machine will not move even if the directional lever is operated.

If the directional lever is placed at the F or R position with the parking brake still applied, the central warning lamp will light up and the buzzer will sound. At the same time, “E00 PARKING BRAKE” will be displayed on the character display.

Before starting the engine, turn the parking brake switch “ON”, then turn it “OFF” again.

FRONT WORKING LAMP SWITCH

Always turn the working lamp off before traveling on public roads.

When turning the front working lamp “ON”, operate the lamp switch to turn the side clearance lamp “ON” or the head lamp “ON”, then operate this switch (10).

Position (a): Working lamp lights up Position (b): Working lamp goes out If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched “ON”.

If the lamp switch is not at the “ON” position for the side clearance lamp or head lamp, the working lamp will not light up.

REAR WORKING LAMP SWITCH

Always turn the working lamp off before traveling on public roads.

When turning the rear working lamp “ON”, operate the lamp switch to turn the side clearance lamp “ON” or the head lamp “ON”, then operate this switch (11).

Position (a): Working lamp lights up Position (b): Working lamp goes out If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched “ON”.

If the lamp switch is not at the “ON” position for the side clearance lamp or head lamp, the working lamp will not light up.

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OPERATION MONITOR PANEL MODE SELECTOR SWITCH 1 This switch (12) is used to switch the function of the character display.

When the switch is released, it automatically returns to its original position.

The basic operation is as follows.

Position ( ): press to select or confirm each mode or operation.

Position ( ): press to cancel each mode or operation.

MONITOR PANEL MODE SELECTOR SWITCH 2 This switch (13) is used to switch the function of the character display.

When the switch is released, it automatically returns to its original position.

The basic operation is as follows.

Position (>): Press here to go to the next screen, or to move the cursor forward, or to increase the number when entering numerals Position (<): Press here to go back to the previous screen, or to move the cursor back, or to reduce the number when entering numerals

KICKDOWN SWITCH When the gearshift lever is in 2nd, if switch (14) on the head of the left arm control lever is pressed, the transmission will shift down to 1st.

This switch is used to increase the drawbar pull in digging operations.

If the transmission is in auto-shift, and the travel speed is below 12.5 km/h (7.8 mph) in any speed range when traveling in either forward or in reverse, the kick-down switch is actuated and it is possible to shift down to 1st.

This makes it easy to perform load and carry operations.

Even if the travel speed is more than 12.5 km/h (7.8 mph), this switch can be used to shift the transmission down. Each time the kick-down switch is pressed, the speed range will shift down one range at a time (F4 → F3 → F2).

When the torque converter is in the lock-up condition (if equipped), the lock-up is canceled.

Remark When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be canceled by operating the gearshift lever to any position other than 2nd. It is also possible to cancel the kick-down by turning the ignition switch “OFF”.

In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift.

In auto-shift, when traveling at more than 25 km/h (15.5 mph) in 3rd or at more than 35 km/h (21.7 mph) in 4th, even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of the engine.

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OPERATION HOLD SWITCH To set the speed range when traveling in automatic transmission, press switch (15) at the side of the left arm control lever knob. The transmission will be set in the speed range displayed on shift indicator (A) on the machine monitor and shift hold pilot lamp (B) will light up.

When the switch is pressed again, the display goes out.

Use this function to select the desired speed range when traveling up or down hills or when performing operations such as grading.

Remark When the torque converter is in the lock-up condition (if equipped), the transmission cannot be set.

When canceling the shift hold, operate the directional lever or gearshift lever or operate the transmission shift mode selector switch to MANUAL. It is also possible to cancel the hold shift by turning the ignition switch â&#x20AC;&#x153;OFFâ&#x20AC;?.

FRONT WIPER SWITCH When the rotary switch (A) of this switch (16) is turned, the front wiper will move.

If button (B) is kept pressed, washer fluid will be sprayed out on to the front glass.

Position (a): (OFF) stop Position (b): (INT) Intermittent wiper Position (c): Low-speed wiper Position (d): High-speed wiper

REAR WIPER SWITCH When lever (C) of this switch (17) is turned, the rear wiper will move.

Position (a): Washer liquid is sprayed out Position (b): OFF Position (c): Wiper is operated Position (d): Washer liquid is sprayed out, wiper is operated.

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OPERATION CIGARETTE LIGHTER This is used to light cigarettes.

After the cigarette lighter (18) is pushed in, its element will heat up and return to its original position after a few seconds. Pull it out and light your cigarette.

CAB LAMP SWITCH The switch (19) is used to turn the cab lamp “ON” and “OFF”.

Position (a): OFF Position (b): Lights up when the cab door opens Position (c): Lights up

Remark The cab lamp lights up even when the main switch is “OFF”, so when leaving the operator's compartment, turn the switch to position (a) (OFF) or (b).

When operating with the cab door fully open, set the switch to position (a) (OFF).

REAR DEFROSTER SWITCH When this switch (20) is pressed, electric current flows through the heated wire glass at the rear and the mist is removed from the glass.

Position (a): “ON” (removes mist from glass) Position (b): “OFF”

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OPERATION E.C.S.S. SWITCH

If the machine is traveling or the work equipment is raised, the moment the E.C.S.S. switch is turned “ON”, the work equipment will move.

If operations are performed with the E.C.S.S. switch at the “ON” position, the moment the E.C.S.S. switch is operated, the work equipment may move.

Never turn on the E.C.S.S. switch during inspection or maintenance. The work equipment will move and this will create a dangerous situation. ❥ ❥ ❥

Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S. switch.

When performing an inspection and maintenance, first lower the work equipment to the ground, then turn the E.C.S.S. switch “OFF” before starting the inspection and maintenance operation.

When carrying out leveling work, turn the E.C.S.S. switch “OFF”.

This switch (21) is used to turn the E.C.S.S. “ON” and “OFF”.

Position (a): “ON” The pilot lamp lights up and the E.C.S.S. is actuated.

Position (b): “OFF” The E.C.S.S. is not actuated.

Remark The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration of the chassis during travel and allows the machine to travel smoothly and at high speed.

When traveling in 1st, the E.C.S.S. is not actuated.

When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h (3.1 mph), the E.C.S.S. is automatically actuated; when the travel speed goes below 3 km/h (1.9 mph), it is automatically disengaged.

EMERGENCY STEERING SWITCH This switch (22) is the manual control switch for the emergency steering.

Even when the engine has stopped, steering operations are made possible by pressing this switch.

Position (a): ON The pilot lamp inside the switch and the emergency steering pilot lamp on the machine monitor light up and it becomes possible to operate the steering. When the switch is released, it automatically returns to its original position.

Actuate the emergency steering only in cases of emergency or when checking the function.The maximum operating time for continuous emergency steering is 60 seconds. When using emergency steering, travel at a speed of less than 5 km/h (3.1 mph).

For details, see “EMERGENCY STEERING” on page 2-100.

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OPERATION COOLING FAN REVERSE ROTATION SWITCH ✸ This feature is not used on Waste Handler applications This switch (23) is used to rotate the cooling fan in the reverse direction when cleaning the radiator.

Position (a): ON The pilot lamp inside the switch and the cooling fan reverse rotation pilot lamp on the machine monitor light up. At the same time, “COOLING FAN REVERSE” is displayed on the character display, and the fan is set to rotate in reverse.

Position (b): OFF The cooling fan is set to rotate in the normal direction.

Stop the engine before operating the switch.

Switching normal rotation to reverse rotation: With the engine stopped, do as follows: Ignition switch “ON” → reverse rotation switch “ON” → check machine monitor → ignition switch “START” → fan reverse rotation Switching reverse rotation to normal rotation: Engine at low speed → ignition switch “OFF” reverse rotation switch “OFF” → ignition switch “START” → fan normal rotation

→ ignition switch “ON” →

For details, “CLEANING RADIATOR FINS” on page 3-37.

Remark When the engine is running, even if the switch is pressed, the direction of rotation of the fan does not change, but the cooling fan reverse rotation pilot lamp on the machine monitor flashes.

Use the reverse rotation of the fan only for cleaning. For normal operations, rotate the fan in the normal direction. If operations are carried out with the fan rotating in the reverse direction, the machine will not display its full function and will tend to overheat.

DIRECTIONAL SELECTOR SWITCH This switch (24) is used to switch the machine direction of travel between forward and reverse.

F Position: FORWARD N Position: Neutral R Position: REVERSE Before operating this switch, check that the condition is as follows.

Directional lever is at N Directional selector switch actuation switch is at “ON” If the condition is not as above, the switch will not work.

For details, “CHANGING DIRECTION” on page 2-93.

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OPERATION DIRECTIONAL SELECTOR ACTUATION SWITCH When this switch (25) is turned on, the directional selector switch on the side of the lift arm control lever is actuated.

Position (a): ON The directional selector switch is actuated.

The directional selector pilot lamp on the machine monitor lights up.

Position (b): OFF The directional selector switch is turned off.

TORQUE CONVERTER LOCK-UP SWITCH For details of the torque converter lock-up, see “TORQUE CONVERTER LOCK-UP SWITCH” on page 5-22.

LOAD METER CANCEL SWITCH For details of the load meter, see “LOAD METER CANCEL SWITCH” on page 5-3.

LOAD METER SUBTOTAL SWITCH For details of the load meter, see “LOAD METER SUB TOTAL SWITCH” on page 5-3.

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OPERATION

SOUND SYSTEM As an option your machine may be equipped with one of the listed premium sound system for your audio pleasure. Remember safety has priority. Only operate your radio if the operating conditions allow. Familiarize yourself with the units before starting your work operations. When listening to your radio, you should set the volume so you can hear what is going on around you.

DIGITAL ESPERIA RADIO SERIAL NUMBER A37001 - A37046

1.

2.

3.

4.

5.

Power switch/Volume Tone control knob Display Clock button/Displaying frequency AST

6.

7.

8.

9.

Preset switch Seek Band selector switch Tuning switch

POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on. If it is turned further, the speaker volume is adjusted.

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OPERATION TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced.

DISPLAY This display (3) shows the radio reception frequency and the operating mode.

CLOCK BUTTON/DISPLAYING FREQUENCY When this button (4) is pressed, the display changes to the time. If it is pressed again, it displays the frequency.

AST Pressing this button (5) and the preset stations are called up in turn.

When the desired broadcasting station is reached, press the button again to stop it. If the button is kept pressed continuously for 2 seconds, it is set to auto memory.

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OPERATION PRESET BUTTON With this switch (6), each button can be set to one station each for FM and AM. For details of the method of resetting, see “SETTING THE PRESET BUTTONS” on page 2-47.

SEEK When the SEEK button (7) is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.

BAND SELECTOR SWITCH Pressing the BAND button (8) causes the band to switch between FM and AM. The reception band and frequency are displayed on the display.

TUNING SWITCH When the “TUNE” button U of switch (9) is pressed, the frequency goes up; when the V button is pressed, the frequency goes down. If it is kept pressed, the frequency changes continuously.

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OPERATION LISTENING TO THE RADIO 1.

2.

3.

4.

5.

6.

7.

Turn the starting switch ON, then turn radio power (1) ON. BAND button (2) is used to select AM or FM. Use the preset switch or tuning switch (3) to select the station.

Adjust the volume and tone as desired.

To turn the radio OFF, turn VOL knob (1) to the left until a click is heard.

Turn the ignition key to the ACC or ON position.

Turn the radio power (1) ON.

AUTOMATIC TUNING When the SEEK button is pressed, it moves up to higher frequencies and when it finds a station that can be received, it stops automatically.

MANUAL TUNING When the TUNE button U is pressed, the frequency goes up; when the V button is pressed, the frequency goes down. If it is kept pressed, the frequency changes continuously.

SETTING THE PRESET BUTTONS 1.

2.

3.

Select the desired preset station. Use the BAND button to select AM or FM, and use the TUNE button to select the frequency of the broadcasting station.

Decide the number of the button to be preset, and keep it pressed for 2 seconds. The number of the button will be displayed and the presetting is completed.

Repeat Steps 1 - 2 to preset other broadcasting stations. ● To change the setting of a preset switch to another station, repeat Steps 1 - 2. ● If the battery is replaced or the power is switched off, all the preset settings are deleted. Perform the presetting operation again. ● It is possible to preset 6 AM stations and 6 FM stations.

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OPERATION AUTOMATIC MEMORY If the â&#x20AC;&#x153;ASTâ&#x20AC;? button is pressed for 2 seconds, the broadcasting stations that can be received in the area are called up in turn, and the broadcasting stations are automatically saved in the preset memory.

AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO If the reception of the FM stereo broadcast being received is weak (when you are far from the broadcasting station or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference. When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting.

ADJUSTING THE TIME 1.

Turn the starting switch ON, then turn the radio power source (1) ON. If the display is showing the frequency, press the CLOCK button to display the time.

2.

To set the time, keep the CLOCK button pressed and Press the U button to change the minutes Press the V button to change the hours

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OPERATION

BLAUPUNKT CALAIS RADIO SERIAL NUMBER A37047 AND UP

1.

2.

3.

4.

5.

6.

7.

8.

9.

Power switch/Mute Volume control knob FMT button, selects FM IR Remote control (optional) RDS button M-L button selects the MW Eject cassette Cassette compartment FR Fast rewind button

10.

11.

12.

13.

14.

15.

16.

17.

18.

FF Rewind button GEO button SRC button AUDIO button Multifunction rocker switch MENU button Keypad 1-5 TRAFFIC button Display

POWER SWITCH/MUTE When this button (1) is pressed the radio is turned ON or OFF. Once the button is turned ON or OFF the radio will hold the previously set settings.

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OPERATION VOLUME CONTROL This button (2) is used to control the volume on the radio.

FMT CONTROL This button (3) selects the FM, MW, and LW memory, starts the Travel Store function. Five stations can be stored on each memory level.

IR REMOTE CONTROL (OPTIONAL) A remote control (4) is obtainable as an accessory. The most important function can be selected using the remote control.

RDS CONTROL Use (5) to switch RDS function on/off. The RDS light will illuminate (16)

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OPERATION ML CONTROL Use (6) to switch between the MW and LW memory levels.

EJECT CASSETTE Press (7) to eject the cassette

CASSETTE COMPARTMENT Insert a cassette into (8) for listening pleasure.

FF AND RW BUTTONS Rewind (9) is used to rewind the tape and fast forward (10) is used to move the tape casette forward rapidly.

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OPERATION GEO BUTTON Button (11) is used to set the balance and fader, resets balance of tone and volume settings.

SRC BUTTON Button (12) is the source selection between cassette, radio and CD changer if installed.

AUDIO BUTTON Button (13) is used to set the base and treble, switches loudness function on or off.

MULTIFUNCTION ROCKER SWITCH Switch (14) is used ti set the level of sensitivity using the < > buttons or you can tune into a radio station manually.

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OPERATION MENU BUTTON Button (15) opens the basic display settings

KEYPAD 1-5 Buttons (16) 1 -5 are used to store the stations. Locate a station and then press the key for longer than one second to store the desired station.

TRAFFIC Button (17) activates and deactivated traffic information stand by.

DISPLAY Display (18) displays the functions on the radio.

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OPERATION THEFT PROTECTION To set the theft feature, switch the unit on, a code appears on the display (18) and then four zeros 0000 A. Press station button 1 (16) repeatedly until the first number of your code appears on the display (18) B. Press station button 2 (16) repeatedly until the second number of your code appears on the display (18).

C. Press station button 3 (16) repeatedly until the third number of your code appears on the display (18) D. Press station button 4 (16) repeatedly until the fourth number of your code appears on the display (18) E. Once the correct code is displayed, press the ▲ button (14)

PRECAUTIONS WHEN USING ❥ ❥ ❥ ❥

Stow the antenna when traveling in places with low overhead clearance.

To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation.

If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.

Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth soaked in alcohol if the equipment is extremely dirty.

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OPERATION

AIR CONDITIONER CONTROL PANEL By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This action makes it possible to provide a pleasant working environment, especially on dusty jobsites

1.

2.

3.

Fan Switch Air Conditioner Switch Mode Selector Switch

4.

5.

External/internal Air Changeover Switch Temperature Control Switch

FAN SWITCH This switch (1) can be used to adjust the air flow in four stages.

It also acts as the main switch for the air conditioner. When the OFF switch is pressed, the fan stops.

When the switch is pressed, the indicator lamp above the switch lights to display which level of air flow is selected.

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OPERATION AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function.

When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.

MODE SELECTOR SWITCH This switch (3) is used to select the vents from which the air will flow.

The following five vent modes are available: FACE, FACE/FLOOR, FOOT, FOOT/DEF, DEF. When the switch is pressed, the indicator lamp above the switch lights to display the vent mode.

FRESH/RECIRC SELECTOR SWITCH This switch (4) changes between internal air recirculation and external air intake.

When pressing the switch, the indicator lamp on the top of the switch lights.

Internal air recirculation This switch (4) is used when the cab needs to be quickly cooled or warmed.

EXTERNAL AIR INTAKE This switch (4) is used to cool or warm the cab with the external air intake.

Also, it is used for fresh air intake or to remove condensation on the windows or when the air inside the cab is stale.

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OPERATION TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (5) without hesitation, from low to high temperature.

The temperature level indicator lamp lights to display the temperature of the air coming from the vents.

The more the blue lamps that light, the lower the temperature while the more red lamps that light the warmer the temperature.

The color of the indicator lamps change while the switch is being pressed.

When the temperature reaches the desired level, release the switch to set the temperature.

The settings for each mode are retained in memory even when the starting switch is turned OFF. However, in the following cases the settings must be made again: ❥

When the machine has been out of use for more than seven days.

When the battery voltage is extremely low. ❥ When there has been abnormal interference from outside. ❥ When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch on).

If the air conditioner is used in the FRESH position, the inside of the cab will be pressurized and this will prevent the entry of dust. ❥

The higher the speed of the fan, the more effective the pressurizing becomes.

METHOD OF OPERATION

Switch Condition Of Use

Air Conditioner Fan Switch Switch

Temperature Control Switch

FRESH/RECIRC Air Changeover Switch

Mode Selector Switch

Rapid

HI

ON

All blue

RECIRC

FACE

Normal

HI - LO

ON

More than half are blue

FRESH

FACE

HI - LO

ON

More than half are red

FRESH

FOOT

Rapid

HI

OFF

All red

RECIRC

FOOT

Normal

HI - LO

OFF

More than half are red

FRESH

FOOT

Defroster

HI

ON

More than half are red

FRESH

DEF

Ventilation or Pressurizing

HI - LO

OFF

All blue

FRESH

FACE

Cooling

Dehumidifying, Heating Heating

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OPERATION The warmer the setting of the temperature control switch, the faster the defrosting and demisting operations will be completed.

Set the vent mode selector switch to the best position to give the desired effect.

With the FACE vents, it is possible to adjust the direction and volume of the air flow and to turn it on or off.

However, do not use the FACE mode with the vents closed.

WHEN NOT USING THE AIR CONDITIONER REGULARLY Run the air conditioner at cooling or dehumidification + heating for several minutes from time to time to provide lubrication to the seals of the compressor.

Remark If the temperature inside the cab is cool, the air conditioner may not work. In such cases, use the recirculated air to heat up the inside of the cab, then turn the air conditioner switch on to run the air conditioner.

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OPERATION COOL BOX When the air conditioner is being used, the cool box can be used for keeping drinks and other things cool.

When the heat is being used, it can be used to keep things warm.

When using the box, open the vent grill.

When not using the box, close the grill.

Do not use the cool box for things which smell or leak water or break easily.

Do not use it as a holder for tools or other small objects.

PRECAUTIONS WHEN USING THE AIR CONDITIONER ❥

If you smoke when using the air conditioner in the recirculate mode, your eyes may start to itch or burn. Therefore, ventilate the cab (switch to FRESH) every so often to remove the smoke. ❥ When using the air conditioner for a long period of time, carry out the ventilation process at least once every hour.

When using the air conditioner, it is recommended, for health reasons, that it should feel only slightly cooler (5° or 6° C lower than the outside temperature) when you enter the cab. ❥

Be careful when adjusting the temperature so it is not too cold.

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OPERATION

CONTROL LEVERS, PEDALS

1.

2.

3.

4.

Speed control lever Directional lever Directional lever stopper Safety lock lever

5.

6.

7.

8.

Bucket control lever Lift arm control lever Brake pedals Accelerator pedal

SPEED CONTROL LEVER This lever (1) controls the travel speed of the machine.

Manual Shift This machine has a 4-FORWARD, 4-REVERSE speed transmission.

Place the speed control lever in a suitable position to obtain the desired speed range.

1st and 2nd speeds are used for working.

3rd and 4th speeds are used for traveling.

However, when the speed control lever stopper is being used, it is impossible to shift to 3rd or 4th. Disengage the speed control lever stopper before trying to shift gears.

Position (a): 1st Position (b): 2nd Position (c): 3rd Position (d): 4th (disabled for Waste Handler machine)

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OPERATION Remark The length of the lever can be adjusted to 3 stages (positions A, B, C). To adjust the length, remove the screw at the bottom of the lever knob, slide the knob to the desired position, then tighten the screw again. The lever is installed to position B when it is shipped from the factory.

AUTOMATIC SHIFT Automatic gear shifting can be performed in the 2nd and 4th speed range of the four forward and reverse speeds depending on the travel conditions.

Position (a): 1st Position (b): 2nd Position (c): 3rd Position (d): 4th (disabled for Waste Handler machine)

The range of speeds during automatic gear shifting is determined by the position of the gear shift lever as shown in the chart on the right.

Remark The 1st position for the gearshift lever sets the transmission in 1st. There is no automatic shifting of the transmission.

When shifting down from 2nd to 1st, press the kick-down switch on the lift arm control lever.

If the transmission is in auto-shift and the travel speed is below 12.5 km/h (7.8 mph) in any speed range when traveling in either forward or in reverse, the kick-down switch is actuated and makes it possible to shift down to 1st.

This makes it easy to perform load and carry operations.

Even if the travel speed is more than 12.5 km/h (7.8 mph), this switch can be used to shift the transmission down. Each time the kick-down switch is pressed, the speed range will shift down one range at a time (when in 4th: F4 → F3 → F2; when in 3rd: F3

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→ F2).

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OPERATION To set to the desired speed range when traveling uphill or downhill, or when grading, do as follows. ❥

When setting the speed range, press the HOLD switch on the lift arm control lever. ❥ The speed range is setting at the speed range displayed on the transmission indicator on the main monitor. ❥ When shifting up or down from set speed range, use the gear shift lever to shift gears.

Remark When downshifting the transmission from 2nd to 1st with the kickdown switch, an upshift from 1st to 2nd occurs when travel speed increases.

DIRECTIONAL LEVER This lever (2) is used to change the direction of travel of the machine.

The engine cannot be started if the directional lever is not at N (neutral).

In this case, the central warning lamp will light up and the buzzer will sound.

At the same time, “E00 SHIFT LEVER NEUT” is displayed on the character display.

Return the gearshift lever to the N position and start the engine.

Position (a): Forward Position N: Neutral Position (b): Reverse Remark The length of the lever can be adjusted to 3 stages (positions A, B, C). To adjust the length, remove the screw at the bottom of the lever knob, slide the knob to the desired position, then tighten the screw again. (The lever is installed to position B when it is shipped from the factory.)

SPEED CONTROL LEVER STOPPER This stopper (3) prevents the speed control lever from entering the 3rd and 4th positions when working.

Position (a): Stopper actuated.

Position (b): Stopper released.

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OPERATION SAFETY LOCK LEVER

Before getting up from the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is not at the LOCK position, and work equipment control lever (A) is touched by mistake, it may lead to a serious accident.

If the safety lock lever is not placed securely at the LOCK position, the work equipment may move, and this may lead to a serious accident or personal injury. Check that the lever is in the position shown in the diagram.

When pulling up or pushing down the safety lock lever, be careful not to touch work equipment control lever (A).

This lever (4) is a locking device for the work equipment control lever.

Push the safety lock lever down to lock it.

Remark This lever electrically locks the hydraulic circuit for the work equipment, so if it is at the LOCK position, the work equipment will not move even when work equipment control lever (A) is operated.

If the work equipment control lever is operated when this lever is at the LOCK position, the central warning lamp lights up and the alarm buzzer sounds. At the same time, â&#x20AC;&#x153;E00 WORK LEVER POSIâ&#x20AC;? is displayed on the character display.

BUCKET CONTROL LEVER Lever (5) operates the bucket.

Position (a): TILT When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.

Position (b): HOLD The bucket is kept in the same position.

Position (c): DUMP

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OPERATION LIFT ARM CONTROL LEVER This lever (6) operates the lift arm.

This lever (6) operates the lift arm.

Position (a): RAISE When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this position. When the lift arm reaches the preset position of the kick-out, the lever is returned to the HOLD position.

Position (b): HOLD The lift arm is kept in the same position.

Position (c): LOWER Position (d): FLOAT The lift arm moves freely under external force.

Do not use the FLOAT feature when traveling forward, the bucket will dig in and raise the front of the machine. The FLOAT feature should only be used in reverse.

BRAKE PEDAL

When traveling downhill, downshift the transmission to use the engine as a brake.

When needed, use the right brake pedal. Do not use the brake pedals repeatedly unless necessary.

Do not rest your foot on either the left or right brake pedal.

These pedals (7) operate the brakes.

Right Brake Pedal The right brake pedal operates the wheel brakes, and is used for normal braking.

Left Brake Pedal The left brake pedal operates the wheel brakes, and if the transmission cut-off switch is at “ON”, it also returns the transmission to neutral.

If the transmission cut-off switch is at “OFF”, the left brake pedal acts in the same way as the right brake pedal.

Remark 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 switch to the “ON” position.

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OPERATION ACCELERATOR PEDAL This pedal (8) controls the engine speed and output.

The engine speed can be freely controlled between low idling and full speed.

STEERING TILT LOCK LEVER

Stop the machine before adjusting the angle of the steering wheel. If the adjustment is made when the machine is moving, serious injury may result.

This lever is used to set the steering wheel to the FREE position when adjusting the position of the steering wheel to the front or rear or up or down.

Pull the lever up, set the steering wheel to the desired position, then push the lever down to lock the steering wheel securely in position.

The amount of adjustment is as follows.

Up-down movement

When at 0 mm (0 in.)

When moved up to 40 mm (1.6 in.)

Tilt amount

0 - 105 mm (0 - 4.1 in.)

0 - 130 mm (0 - 5.1 in.)

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OPERATION

SECURITY AND LOCKS This machine is equipped with several security, locks and safety features designed to protect the operator, persons performing service, repair or inspections on the machine as well as the general public when the machine is not in use and unattended. It is important for the operator of the machine to know where these features are located and when to use them.

Failure to do so may result in damage to the machine or injury to personnel.

IGNITION KEY LOCKED AREAS These areas require the ignition key to lock and secure them.

Whenever you leave the machine unattended for any length of time it is advised to lock and secure the machine safely. Doing so will prevent unauthorized personnel from accessing the machine.

CAB DOOR LOCKS Both cab doors are equipped with a key lock. Locking the cab prevents access to the machine operating controls.

ENGINE ACCESS DOORS Both sides of the engine access doors right and left are set up with a security lock to prevent unauthorized access. Always keep these doors locked to avoid the possibility of vandalism.

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OPERATION REAR GRILL To access the fuel tank fill cap, both the rear grill and fuel cap are locked. The lock for the rear grill is located on the lower portion of the grill.

FUEL CAP After refueling the machine lock the fuel tank cap.

To unlock the fuel tank cap, lift the protective cover, insert the ignition key and turn the key to the OPEN position, remove the key and unscrew the cap. To lock, fully install the cap, insert the ignition key and turn the key to the LOCK position, after locking, remove the ignition key and close the protective cover.

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OPERATION

PADLOCKED AREAS Several areas are secured with a latching device and a padlock. These areas must be locked at all times to avoid unnecessary tampering.

BATTERY AND TOOL BOX Both battery and tool boxes are locked and should only be accessed by maintenance personnel.

TRANSFER CASE The transfer case fill access is secured with a pad lock, the location is on the left side of the machine under the steps.

UPPER HOOD ACCESS PANNEL This area contains the system for the cab environment. This lock must remain in place and only be removed by maintenance personnel. It is located behind the cab on the front part of the hood top.

It is important to remember when performing a daily inspection that all locks are in place and the area is properly secured. Never leave the machine with these areas unsecured.

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OPERATION

SAFETY FEATURES Before performing any type of operation or maintenance on the machine it is important to know where and how to use the safety features built into the machine. These safety features are of the passive type or active type.

PASSIVE SAFETY FEATURES Passive safety features are built into the machine and need little or no attention. It is important to inspect these safety features for damage or ware occasionally.

ROLL-OVER PROTECTIVE STRUCTURE (ROPS) This is to protect the operator in a rollover situation or from falling objects. When operating the machine, it is important to remain within the ROPS structure to avoid any contact with falling objects Never modify, cut or drill on any part of this structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation.

CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY) This feature is only available on the waste handler machines. It is designed to protect the operator from objects falling back onto the cab and entering the operators compartment.

When using this machine in waste handler applications do not remove or modify this protective cage. If it is damaged, replace it.

BACKUP WARNING ALARM This sounds an alarm when the directional lever is set to the R position. It is used to warn people behind the machine that the machine will travel in reverse.

If the alarm cannot be heard clearly or is too loud, adjust the volume as follows.

Remark The alarm is set to the highest level when the machine is shipped from the factory.

CHANGING ALARM VOLUME Operate the sound pressure selector switch at the rear face of the backup alarm to adjust the volume.

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OPERATION

ACTIVE SAFETY FEATURES Active safety features are safety devices that must be used by the operator in order to be effective. Failure to use these installed features may lead to serious injury or even death.

When performing maintenance or transporting the machine, always lock the safety bar.

Always remove the safety bar for general travel operations. If it is not removed, the steering wheel will not be able to turn the machine. This situation is extremely dangerous.

SAFETY BAR The bar locks the front frame and rear frame to prevent the machine from bending during normal travel or when servicing or transporting the machine.

SEAT BELT The seat belt is installed to keep the operator in the seat within the cab of the machine if the machine is ever in a rollover situation.

Always use the seat belt when operating the machine. It is important to inspect this component for ware or damage. If the belt is worn or damaged, replace it immediately.

Even if there appears to be no abnormality with the seat belt, replace it once every three years.

Remark 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.

Check that the bolts that connect the seat belt to the machine are not loose. Tighten if necessary.

Tightening torque: 24.5 ¹ 4.9 N¡m (18.1 ¹ 3.6 lb. ft.)

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OPERATION If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt with a new one.

EQUIPMENT LOCK LEVER This lever is used to lock the equipment controls. By locking the controls they cannot be operated inadvertently.

When leaving the operators cab or working within the cab always lock the controls

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OPERATION

MACHINE FEATURES These features are important for the operator to know about. Although not safety related these features offer operator comfort and convenience as well as easy care for the machine.

CAB DOORS OPEN LOCK When getting in or out of the operator's compartment, or when operating with the door open, use this lock to hold the door in position.

1.

2.

3.

Push the door against the catch (1) to set it in position.

When setting the door in position, attach it firmly to the catch.

When getting on or off the machine, hold the handrail on the inside.

4.

When closing the door from the operator's seat, push lever (2) up to release the latch.

When closing the door after getting of the machine, push lever (3) down to release the latch.

5.

ELECTRICAL FUSE The fuses protect the electrical equipment and wiring from burning out.

If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

Replace the fuse with another of the same capacity.

Loosen the knob (1) at two places, then remove cover (2). The fuse boxes are A and B.

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OPERATION FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX A

No.

Fuse Capacity

Name Of Circuit

1.

10A

Horn, air suspension

2.

20A

Transmission control

3.

10A

Parking brake

4.

10A

Emergency steering

5.

20A

Work equipment positioner

6.

20A

Rear defroster

7.

20A

Wiper, washer

8.

10A

Rotating lamp (if equipped)

9.

10A

(KOMTRAX)

10.

10A

Backup lamp, brake lamp

11.

20A

Main lamp circuit

12.

10A

Right side clearance lamp

13.

10A

Left side clearance lamp

14.

10A

Right head lamp

15.

10A

Left head lamp

FUSE BOX B

No.

Fuse Capacity

Name Of Circuit

1.

20A

Ignition switch

2.

10A

Hazard lamp

3.

10A

Instrument panel A

4.

10A

Cab lamp

5.

10A

Auxiliary 1

6.

20A

Engine controller

7.

10A

Turn signal indicator

8.

20A

Front working lamp

9.

20A

Rear working lamp

10.

10A

Instrument panel B

11.

10A

Car radio

12.

10A

Auxiliary 2

13.

10A

DC-DC converter

14.

20A

Air conditioner A

15.

20A

Air conditioner B

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OPERATION SLOW BLOW FUSE If the power does not come on when the ignition switch is turned â&#x20AC;&#x153;ONâ&#x20AC;?, the slow-blow fuse may be blown. Check and replace it, if it is blown.

The slow-blow fuse is beside the engine on the left side of the machine.

1.

120 A: Heater relay (electrical intake air heater) 120 A: Main power

2.

30 A: Battery power (ignition switch, hazard)

AUXILIARY POWER

There are two power sources: 12 V and 24 V. Check the voltage of the electrical equipment and select the appropriate power source.

Mistaken use, such as using 24 V as the power source for 12 V equipment, will cause equipment failure.

When using the electric power source, do not install any equipment which will exceed the maximum amperage.

After removing the cigarette lighter (1), the lighter socket can be used as a 24 V power source.

Maximum amperage: 9 A (216 W)

Electric power source (2) can be used as a 12 V power source.

Maximum amperage: 10 A (120 W)

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OPERATION

MACHINE CAB AND CHASSIS SEAT ADJUSTMENT

When adjusting the operator's seat, stop the machine in a safe place before starting the operation.

Adjust the seat before starting operations for the day or when changing operators.

When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.

Optional type (fabric) A. Fore-and-aft adjustment: Pull lever (1) up, set the seat to the desired position, then release the lever. Fore-and-aft adjustment: 160 mm (6.3 in.) (16 mm (0.6 in.) x 10 stages) B. Adjusting seat angle: Move lever (2) up and push down on the rear of the seat to tilt it backward. Move lever (2) down and push down on the front of the seat to tilt it forward. Adjustment range: 13º (Front tilt, rear tilt: 4 stages each) C. Adjusting seat weight: Turn grip (3) to adjust the strength of the suspension. Adjustment range: (Target) 50 kg to 120 kg (110 to 265 lb.)

D. Adjusting backrest angle: Move lever (4)up and move the backrest to the front or rear. When doing this, keep your back pressed against the seat back. If your back is not against the seat back, the seat back may spring forward suddenly. Adjustment range: 66º to the front (3º x 22 stages) 72º to rear (3º x 24 stages) If the seat back is reclined too far, the seat back may hit the rear glass, so use it in a position where it does not contact the glass.

When reclining the seat fully to take a rest, set the seat in the following position. ❥ ❥ ❥ ❥

Fore-and-aft adjustment: Max. front position Up-down adjustment: Max. height Seat angle adjustment: Horizontal or fully tilted Reclining adjustment: Fully tilted backward 36 degrees (12 stages) E. Seat height adjustment: Move lever (2) up/down, then move the 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 (2.4 in.)

F.

Headrest height adjustment: Move the headrest up and down to the desired height. Adjustment range: 50 mm (2.0 in.)

G. Headrest angle adjustment: Rotate the headrest to the front or rear.

H. Armrest angle: Adjust armrest angle by rotating knob (5) (left side only) Adjustment range: 30 degrees (forward tilt: 25 degrees; backward tilt: 5 degrees) Also, when armrest is turned, it will spring up (both left and right sides).

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OPERATION Standard type Adjustments (E), (J), and (K) use the air compressor built into the seat, so turn the engine ignition switch to the “ON” position when carrying out the adjustment.

A. Fore-and-aft adjustment: Pull lever (1) up, set the seat to the desired position, then release the lever.Amount of adjustment: 180 mm (7.1 in.) (10 mm (0.4 in.) x 18 stages) B. Seat angle adjustment: Move lever (2) up and apply your weight to the rear of the seat. The seat will tilt to the rear. Move lever (3) up and apply your weight to the front of the seat. The seat will tilt to the front. Amount of adjustment: 24 degrees (front and rear tilt: 3 stages each) C. Seat height adjustment: Move levers (2) and (3) up and move the seat up or down to desired position. These levers are also used for adjusting the seat angle, so adjust the seat angle to set the seat to the desired height. Amount of adjustment: 65 mm (2.6 in.)

D. Adjusting fore-and-aft position of seat cushion: Push lever (4) in, set the seat cushion to the desired position, then release lever. Amount of adjustment: 65 mm (2.6 in.)

E. Adjusting weight setting for seat: Sit on the seat, raise your body slightly, then operate switch (5) to adjust the strength of the suspension. Amount of adjustment: 50 - 130 kg (110 - 287 lb.)(target) ●

F.

When + is pressed: Suspension becomes stronger ● When - is pressed: Suspension becomes weaker Reclining angle adjustment: Move lever (6) up and move the seat backrest to the front or rear. Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the backrest, the backrest may suddenly spring forward. ●

Amount of adjustment: Front tilt: Free Rear tilt:40 degrees (2 degrees x 20 stages) G. Head rest angle adjustment (if equipped): Rotate the headrest to the front or rear. ● Amount of adjustment: Front tilt: 13 degrees Rear tilt: 13 degrees H. Head rest height adjustment Move the head rest up or down. Amount of adjustment: 80 mm (3.2 in.)

I.

Arm rest angle adjustment: Rotate the knob (7) and adjust the angle of the arm rest. (Left side only) Amount of adjustment: 73 degrees (front: 54 degrees; rear: 19 degrees) If the arm rest is turned, it will spring up. (Both left and right sides)

J.

Lumbar support Operate switch (8) to give a suitable tension to the lower lumbar region. Operate switch (9) to give a suitable tension to the upper lumbar region.

●

When + is pressed: Tension becomes stronger ● When - is pressed: Tension becomes weaker K. Side support: Operate switch (10) to give a suitable tension to the left and right lumbar region. ● ●

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When + is pressed: Tension becomes stronger When - is pressed: Tension becomes weaker

WA480-5L

OPERATION HANDLING CAB WIPER Preventing Wiper Arm Bracket Damage Remark When angling the wiper arm to the front, check that the wiper blade is hanging free.

When angling the wiper arm to the front, such as when wiping the glass clean, if the wiper arm is angled with the wiper blade locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting bracket and the bracket may break.

DUST INDICATOR Open the top front cover at the right side of the machine. The dust indicator is under the air cleaner. The display is given in five stages according to the degree of clogging of the element.

The air cleaner clogging caution lamp on the machine monitor lights up to inform the operator to clean or replace the air cleaner.

After cleaning, press the reset button to cancel the display.

For details of the cleaning method, see â&#x20AC;&#x153;ENGINE AIR FILTERâ&#x20AC;? on page 3-27.

GREASE PUMP The grease pump is stored inside the battery box at the rear of the machine. After using it, wipe off all grease stuck to the outside of the pump and then store it in the box.

The grease pump can be stored in either the left or right battery box.

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OPERATION

PRECAUTIONS BEFORE STARTING WORK OPERATIONS Before starting your work operations it is important to perform several procedures to be sure your equipment is in a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.

PRE-OPERATIONAL CHECKS Before starting your machine and preceding with any work operations it is important to be sure your machine is safe to operate. Below is a list of some basic items to check before any work is to begin. If any problems are found during your Pre-operational Check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.

PERFORM A WALK AROUND CHECK OF YOUR MACHINE A. Look for any obvious missing or damaged items.

B. Check the condition of the loading bucket, look for loose or missing attachment pins, damaged surfaces or missing parts.

C. Check the condition of all visible hydraulic hoses, look for worn or leaking fittings, cut, scuffed or cracked hose surfaces. If any hose is found to be worn, cracked or leaking have it repaired or replaced immediately.

D. Check for leaking or damaged hydraulic cylinders. If any cylinder is damaged or leaking have it repaired immediately.

E. Inspect the mechanical lift, dump and pivot points. Look for any loose or missing parts, cracked, bent or damaged areas.

F.

Be sure all safety decals are in place and are not damaged. Be sure they are clean and visible for all personnel to see.

G. Check the condition of the front and rear tires. Look for excess wear or cut surfaces, objects imbedded in the tire or under inflation.

H. Check under the machine for any build-up of debris, trash or leaks. Remove any debris that is found and have the leak checked by authorized personnel.

I.

Inspect the fuel and hydraulic tanks for damage or leaks. Be sure the fill caps are installed and locked in place.

J.

Be sure the steps are not damaged or covered with mud.

K. Check the condition of the cab. inspect the windows, mirrors, hand holds, work lights, directional and canopy for any damage or missing parts. Be sure all locks are functional.

L. Check the exhaust stack, be sure it is not damaged, kinked or restricted in any way. Be sure the exhaust outlet is facing away from the cab and is not restricted.

UNDER THE HOOD A. Open the hood and check all fluid levels. be sure they are at the specified level outlined in the maintenance section.

B. Check the engine and radiator for any build up of trash, wood chips, rubbish, leaves or other flammable materials.

If flammable materials are found as well as excess build up of oil or dust, remove the flammable material or have the engine cleaned.

C. Be sure the hood closes properly and will lock securely to prevent tampering by others.

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OPERATION CHECK COOLANT LEVEL

Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.

Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns. After waiting for the temperature to decrease, turn the cap slowly before removing it. This action allows the pressure inside the radiator to release gradually.

When adding water, use the step and handrail to support yourself securely.

1.

2.

3.

4.

Open side door (1) of the engine hood on the right side of the machine.

Look through inspection window (A) and check that the water level is in the range between FULL and LOW on sub tank (2). If the water level is low, open cover (3) and add water through the filler port of sub tank (2) until it reaches the FULL level.

After adding water, tighten the cap securely.

If sub tank (2) is empty, check for water leakage, then check the water level in the radiator. If the water level is low, add water to the radiator, then add water to sub tank (2).

If the volume of coolant added is more than usual, check for possible water leakage.

Confirm that there is no oil in the coolant.

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OPERATION CHECK ENGINE OIL LEVEL, ADD OIL

The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.

1.

2.

3.

4.

5.

6.

7.

Open the inspection cover of the right side at the rear of the machine.

Take out the dipstick (G) and wipe off the oil with cloth.

Insert dipstick (G) fully in the oil filler pipe, then take it out again.

The oil level should be between the H and L marks on dipstick (G).

If the oil level is below the L mark, add engine oil through oil filler (F).

If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again.

If the oil level is correct, tighten oil filler cap (F) securely and close the inspection cover.

Remark When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.

If the machine is at an angle, make it horizontal before checking.

REAR-VIEW MIRROR ADJUSTMENT Sit in the operator's seat and adjust the rear view mirror so that you can see properly to the rear.

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OPERATION IN THE OPERATORâ&#x20AC;&#x2122;S CAB A. Check the condition of the cab floor. Be sure it is clean and free from tools, objects, excess dirt, trash or grease.

B. Check to be sure both doors open and close properly. Be sure the right door is unlocked for safety purpose.

C. Check the windows for cleanliness, remove any stickers or objects pasted to the windows.

D. Make sure the fire extinguisher is in place and in operating condition.

E. Be sure the operatorâ&#x20AC;&#x2122;s manual, safety manual and all cab safety decals are in place and in good condition.

F.

Check to be sure the seat belt and seat works properly.

SEAT BELT ADJUSTMENT â&#x2DC;&#x2026; Always wear the seat belt.

Before fastening the seat belt, check that there is no abnormality in the belt mounting bracket or bolt. If the belt is worn or damaged, replace it.

Fasten the seat belt before starting operations.

Always wear the seat belt during operations.

Make sure that the left and right belts are not twisted when fastening the seat belt.

Fastening and removing the belt 1.

2.

3.

4.

Fasten the belt so that it is snug without being too tight. Sit on the seat, depress the brake pedal fully, and adjust the seat so that your back is pressed against the backrest.

After adjusting the seat position, adjust tether belt (1). Tense the tether belt and install it when there is no one sitting on the seat.

Sit on the seat, hold buckle (2) and tongue (3) with your left and right hands, insert tongue (3) into buckle (2), then pull the belt to check that it is securely locked.

When removing the belt, press the red button in buckle (2) to free the belt. Fasten the belt along your body without kinking it. Adjust the lengths of the belt on both the buckle and the tongue sides so that the buckle is located at the mid-point of your body front.

Belt length adjustment To make the belt shorter: Pull the free end if the tether belt.

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OPERATION To make the belt longer: Set the fixed end of the tether belt at 90 degrees to the holder and pull.

LEVER STAND ADJUSTMENT Adjust wrist rest height Loosen lock lever (2) and adjust the height of the wrist rest.

Amount of adjustment: 55 mm (2.2 in.)

Remark Keep button (3) pressed and operate lock lever (2) to the FREE position. The lever can be turned in the desired direction.

LEVER STAND ANGLE ADJUSTMENT Operate the lock lever (1) to the FREE position, grip the wrist rest and tilt lever stand (2) to the front or rear, then return lock lever (1) to the LOCK position.

Amount of adjustment: 65 mm (2.6 in.).

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OPERATION

START-UP PROCEDURES

When performing start-up checks, be sure your machine is in a well ventilated area.

1.

Turn the ignition switch to â&#x20AC;&#x153;ONâ&#x20AC;? position.

CHECK MONITOR PANEL 2.

Check that all the monitor lamps, the gauges and the warning lamp light up for about 3 seconds and the alarm buzzer sounds for about 1 second. If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection.

Remark It is important that a pre-operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator, always perform a pre-operational check before you start work.

CHECK FUEL LEVEL, ADD FUEL

When adding fuel, never let the fuel overflow. This action may cause a fire. If any fuel is spilled, wipe it up completely. Never bring the flames near the fuel because it is highly flammable and dangerous.

Remark If the engine has run out of fuel and has stopped, it is necessary to operate the priming pump to bleed the air completely from the fuel line before starting the engine again.

Take care not to let the engine stop because of lack of fuel.

If the engine has run out of fuel, the air bleeding operation can be performed more quickly if the fuel tank is completely filled with fuel.

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OPERATION 1.

Ignition key must be in the “ON” position to check the fuel level with fuel level gauge (G).

●

If necessary add fuel through fuel filler (F) to fill the tank. For details of the method for opening and closing the cap, see “SECURITY AND LOCKS” on page 2-66.

●

Fuel capacity: 390 liters (103.04 US gal.)

CHECK THE BRAKE PEDALS Drive the machine forward and check the effect of the brakes.

If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted.

CHECK THE PARKING BRAKE Check that the parking brake works properly.

If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking effect, please contact your Komatsu distributor for adjustment.

Always set the safety lever securely to the LOCK position before starting the engine. If the control levers are touched by accident at the time of starting the engine, the work equipment may move suddenly, which may cause serious injury.

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OPERATION 1.

Check to see if the parking brake switch is in the “ON” position.

2.

Check directional lever is in the N position.When starting the engine, if directional lever (2) is not at the N position, the engine will not start.

3.

Be sure the work equipment lock lever is in the LOCK position.

STARTING THE ENGINE

Start the engine only after sitting down in the operator’s seat with seat belt fastened around your waist.

Do not attempt to start the engine by short-ciruiting the engine starting circuit. Doing so may cause serious bodily injury or fire.

Check to be sure that there are no persons or obstacles in the surrounding area, sound the horn and start the engine.

Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

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OPERATION 1.

With the key to the “ON” position. Preheating will automatically start and preheating pilot lamp (2) will light up.

❥

The table shown below gives a guide to preheating time.(sec)

❥

The preheating time in cold areas changes according to the water temperature when starting the engine.

2.

Depress accelerator pedal (3) lightly.

3.

When preheating pilot lamp (2) goes out, turn the key in ignition switch to the “START” position. The starting motor will be cranked and after the engine rotates under no load for 2 or 3 seconds, the engine should start. ★ Do not accelerate the engine suddenly before the warm-up operation is completed. ★ Do not crank the starting motor continuously for more than 20 seconds. ★ If the engine does not start, wait for at least two minutes before trying again. ★ If the accelerator pedal is kept pressed after the engine is started, the engine speed will rise suddenly after the turbo protect time, and this may damage the turbocharger.

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OPERATION 4.

5.

When engine is started, release the key of ignition switch (1) and the key will return automatically to “ON”.

After the engine starts and the engine water temperature is below 20º C (68º F)), the warm-up operation (engine speed: 1130 rpm) is automatically performed. For details, see “STARTING THE ENGINE” on page 2-85.

Remark Because of the turbo protect function, immediately after the engine starts, even if the accelerator pedal is depressed, the engine speed will not rise above 1130 rpm.

Engine coolant temperature

Turbo protection time

above 20º C (68º F)

0 sec.

-18º C to 20º C (-0.4º F to 68º F)

0 to 12 sec.

Below -18º C (-0.4º F)

15 sec.

❥

❥

The turbocharger rotates at extremely high speed. Immediately after the engine is started, the pressure of the lubricating oil has not risen sufficiently, so if the engine speed is suddenly raised, it may lead to damage or seizure of the turbocharger bearing. The turbo protect function acts to prevent this problem. It uses electronic control to prevent the engine speed from rising above a certain speed for the first few seconds after the engine started.

To improve the ease of starting in cold weather, the low idle speed becomes slightly higher for the time given below and the engine sound is different. In addition, it functions to make the acceleration gradual during this time.

Engine coolant temperature

Injection characteristics change time

above 20º C (68º F)

0 seconds

0º C to 20º C (32º F to 68º F)

0 to 6 seconds

-20º C to 0º C (-4º F to 32º F)

6 to 12 seconds

-30º C to -20º C (-22º F to -4º F)

12 to 15 seconds

After the engine starts and the engine water temperature is below 20º C (68º F), the warm-up operation (engine speed: 1130 rpm) is automatically performed. When the water temperature goes above 50º C (122º F), the warm-up operation is canceled.

Remark The automatic warm-up operation changes as shown in the diagram on the right according to the engine water temperature.

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OPERATION

OPERATIONS AND CHECKS AFTER STARTING ENGINE If any problems occur, turn the ignition switch to the “OFF” position.

If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always perform the warm-up operation. Particularly in cold areas, be sure to perform the warm-up operation fully.

BREAKING IN THE MACHINE Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. ❥ ❥ ❥ ❥ ❥

Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).

During break-in operations, follow the precautions described in this manual.

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.

Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

NORMAL START-UP AND WARM-UP After starting the engine, do not immediately start operations. First, perform the following operations and checks.

Remark Do not suddenly accelerate the engine before the warm-up operation is completed.

Do not run the engine at low or high idle continuously for more than 20 minutes.

If it is necessary to run the engine at idle, apply a load from time to time or run the engine at a midrange speed.

1.

Depress the accelerator pedal (1) lightly and run the engine with no load at midrange speed for about 5 minutes.

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OPERATION 2.

To warm up the hydraulic oil only in cold areas, do as follows.

During the warming-up operation, check that the engine rotation is smooth, then set the safety lock of the work equipment control lever to the FREE position and move the bucket control lever in and out of the TILT position to warm up the hydraulic oil. The relief time at the tilt position should be a maximum of 10 seconds.With this operation, the oil will reach the relief pressure and this will warm up the hydraulic oil more quickly

3.

After performing the warm-up operation, check that the gauges and caution lamps are normal. If there is any abnormality, perform maintenance or repair. Run the engine under a light load until engine water temperature gauge (2) and torque converter oil gauge (3) are in the green range.

Check that there is no abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor.

4.

Remark The sound of the cooling fan rotation differs according to the following conditions, but this does not indicate any abnormality.

The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or transmission oil temperature are high.

However, when the cooling fan is rotating in reverse, it rotates at a set speed proportional to the engine speed, regardless of any oil or coolant temperature.

STOPPING THE ENGINE Remark If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened.

Consequently, do not abruptly stop the engine apart from an emergency.

In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

1.

2.

3.

Run the engine at low idling for about 5 minutes to cool down gradually.

Turn the ignition switch (1) to the â&#x20AC;&#x153;OFFâ&#x20AC;? position to stop the engine.

Remove the key from ignition switch (1).

After Stopping The Engine 4.

5.

6.

7.

Walk around the machine and check the work equipment, body and undercarriage check for leakage of oil and coolant.

Fill the fuel tank.

Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.

Remove any mud attached to the undercarriage.

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OPERATION

TRAVELING, STOPPING AND PARKING THE MACHINE Before traveling or moving the machine, it is important to know all the control functions and relevant safety regulations for the area you will be traveling or moving the machine in. If you will be traveling on state or local roadways, observe all traffic safety laws. Travel at a safe controllable speed.

TRAVELING 1.

Check that the warning pilot lamp (1) is not lit up.

2.

Set the safety lock of bucket control lever and lift arm control lever to the FREE position.

3.

Raise the work equipment to the travel posture shown in the diagram on the right.

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OPERATION 4.

Depress right brake pedal (5) and turn parking brake switch (6) to the “OFF” (RELEASE) position to release the parking brake. Keep right brake pedal (5) depressed.

Remark If the parking brake is still actuated when parking brake switch is at the “OFF” (RELEASE) position, turn the parking brake switch “ON”, then turn it “OFF” again.

5.

Set the speed control lever to the desired speed range.

6.

Set the directional lever to the desired direction.

7.

After releasing the right brake pedal, depress the accelerator pedal to begin moving the machine

.

Always travel at a safe controllable speed.

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OPERATION When traveling, and turning the machine. Keep in mind the front frame is joined to the rear frame at the center of the machine by the center pin. Therefore, the front and rear frames bend at this point, and the rear wheels follow in the same track as the front wheels when turning. When turning, turn the steering wheel carefully to follow the machine as it turns.

Remark When the steering wheel reaches the end of its stroke, do not try to turn it any further. Check the play it should be 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. If any abnormality is found, contact your Komatsu dealer for inspection.

TURNING ON SLOPES Traveling on slopes is dangerous in general. However, turning on a slope can be fatal. When traveling on a slope never turn the steering wheel. Always travel straight up or straight down a slope. If the machine should start to tip, lower the bucket to the ground immediately to stabilize the machine. Travel at a slow pace in the lower speed ranges, avoid dragging the brakes when traveling down a slope.

Remark When starting to move the machine on a hill, turn transmission cut-off switch (1) â&#x20AC;&#x153;OFFâ&#x20AC;?, depress left brake pedal (2), operate the gearshift lever to the travel position, then depress accelerator pedal (3) and gradually release left brake pedal (2) to let the machine move. This makes it possible to prevent the machine from rolling back.

CHANGING GEAR SPEED RANGES

When traveling at high speed, do not shift gears suddenly.

Use the brake to reduce the travel speed before shifting gears.

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OPERATION ★ Shift Gears As Follows.

Move the gearshift lever (1) to the desired position to shift.

When digging or loading, perform the operation in 1st or 2nd. Use the gearshift lever stopper.

Remark This machine is equipped with the kick-down switch. When the machine is traveling in 2nd, press the button on the tip of the lift arm control lever to downshift to 1st. We recommend use of the kick-down switch when carrying out operations in 1st or 2nd, such as digging or loading. For details of the method of use, see “KICKDOWN SWITCH” on page 2-38.

This machine is equipped with an auto-shift system that automatically shifts the gear. For details of the method of use, see “TRANSMISSION MODE SELECTOR SWITCH” on page 2-34 and ““AUTOMATIC SHIFT” on page 2-61.

If the gearshift lever is operated slowly or is stopped between gear positions, “E01 MAINTENANCE” may be displayed on the character display. In this case, there is no failure, but try to operate the gearshift lever so that the gearshifts is completed within 2 seconds.

CHANGING DIRECTION

When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe.

There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.

Do not switch between FORWARD and REVERSE when traveling at high speed.

When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed sufficiently, then change the direction of travel. (Max.speed for changing direction: 12 km/h (7.5 mph)) There is no need to stop the machine even when switching between FORWARD and REVERSE. Place the directional lever (1) in the desired position.

Remark The directional selector switch makes it possible to change the direction of travel by operating a switch.

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OPERATION If an attempt is made to switch the direction between forward and reverse while traveling at high speed (when using 3rd or 4th), if the travel speed and engine speed are in ranges I or II in the chart on the right, the central warning lamp will light up and the buzzer will sound.

At the same time, “E00 OVERRUN PROTECT” is displayed on the character display.

If the alarm buzzer sounds, depress the brake immediately to reduce the travel speed, then operate the directional lever to switch between forward and reverse.

WHEN USING AUTO-SHIFT If an attempt is made to switch the direction between forward and reverse when the auto-shift is “ON”, the gearshift range will normally switch F3 → R2, F4 → R2, or R3 → F2, R4 → F2 to make the machine move quickly.

However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed, as shown in ranges I or II in the chart on the right, the central warning lamp will light up and the buzzer will sound.

Simultaneously, “E00 OVERRUN PROTECT” displays.

If the alarm buzzer sounds, depress the brake immediately to reduce the travel speed, then operate the directional lever to switch between forward and reverse.

In particular, if you attempt to switch between forward and reverse in range II, the gearshift range will not shift to 2nd, but will switch F3 → R3, F4 → R4, or R3 → F3, R4 → F4. As a result, the reduction in travel speed will be less than in range I, so care is necessary.

Remark If the gearshift lever is operated slowly or is stopped midway between the forward and reverse directions, “E01 MAINTENANCE” may be displayed on the character display. In this case, there is no failure, but try to operate the directional lever so that the change in direction is completed within 2 seconds.

USING THE SWITCH TO CHANGE DIRECTION 1.

Place the directional lever at the N position.

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OPERATION 2.

Turn the directional selector switch actuation switch on the right switch panel ON. Position (a): ON Position (b): OFF The pilot lamp inside the switch and the directional selector pilot lamp on the machine monitor light up.

This actuates the operation of the directional selector switch.

If the directional selector pilot lamp on the machine monitor flashes, the switch for the lever is in one of the following conditions. Set it to the correct position. ❥

❥

3.

When directional lever is not at N position. If the directional lever is not at the N position, the pilot lamp flashes, and at the same time, the central warning lamp lights up and the alarm buzzer sounds. In addition, “E00 SHIFTLEVER NEUT” is displayed on the character display. In this condition, the machine will move forward or in reverse according to the set position of the directional lever. Return the directional lever to the N position.

When directional selector switch is at F or R when engine is started.

If the directional selector switch is at F or R, the pilot lamp flashes, and at the same time, the central warning lamp lights up and the alarm buzzer sounds. In addition, “E00 SHIFT SW NEUT” is displayed on the character display. In this condition, the engine will not start, so set the directional selector switch to N. Press the selector switch on the side of the control lever to the desired position.

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OPERATION

STOPPING AND PARKING THE MACHINE

Avoid stopping suddenly. Give yourself ample room when stopping.

Even if the parking brake switch is turned “ON”, there is danger until the parking brake pilot lamp lights up, so keep the brake pedal depressed.

Remark Never use the parking brake switch to brake the machine when traveling except in an emergency. Apply the parking brake only after the machine has stopped.

1.

Release the accelerator pedal (1), then depress brake pedal (2) to stop the machine.

●

2.

Brake and accelerator pedals

Place directional lever (3) in N (neutral).

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OPERATION 3.

Turn the parking brake switch to the “ON” position to apply the parking brake.

Remark When the parking brake is applied, the transmission is automatically returned to neutral.

4.

5.

Lower the lift arm and bucket to the ground.

Set safety lock lever to the LOCK position.

6.

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.

7.

Allow the engine to run at a low idle for about 5 minutes to cool down gradually. Never shut down an engine that is over heating or has just finished work operations always allow it a time to cool down before turning the ignition key to the “OFF” position.

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OPERATION 7.

Always lock the following areas.

(1) Fuel filler cap (2) Rear grill (3) Engine side cover (2 places) (4) Cab door (2 places) Remark The ignition switch key is used also for locks (1), (2), (3) and (4).

TRANSMISSION CUT-OFF SWITCH When the transmission cut-off switch is pressed, the pilot lamp lights up, and the following transmission cut-off function is actuated.

Position (a): OFF Position (b): ON

When the left brake pedal is depressed, the brake is actuated, and in addition, the transmission is shifted to neutral at the pre-selected brake pedal depression position.

Remark The cut-off function is actuated only with the left brake pedal.

When the transmission cut-off switch is at the “OFF” position, the left brake pedal works in the same way as the right brake pedal.

For details of adjusting the brake pedal depression position, see “ADJUSTING THE TRANSMISSION CUTOFF” on page 2-98.

Raise or lower the pre-selected brake pedal depression position to adjust the cut-off to match the type of work.

ADJUSTING THE TRANSMISSION CUT-OFF

Apply the parking brake before adjusting the transmission cut-off position.

In the transmission cut-off function, it is possible to adjust the depression position of the left brake pedal used to shift the transmission to neutral.

1.

Start the engine with the ignition switch (1), then set the parking brake switch (2) to the “ON” position.

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OPERATION 2.

3.

4.

Set the transmission cut-off switch (3) to the “ON” position.

Depress left brake pedal (4) and set it to the desired position to shift the transmission to neutral.

Press the transmission cut-off set switch (5), then release it. When the switch is released, the buzzer will sound with a repeated short sound, and the cut-off position is set.

Method of canceling cut-off position

5.

6.

After the buzzer sounds in Step 4 of the adjustment procedure, the transmission cut-off switch flashes for 2 seconds. While it is flashing, press transmission cut-off set switch (5) again and release it.

The buzzer will sound with a long sound and the adjusted cut-off position is canceled.

STOPPING WHEN TRANSMISSION CUT-OFF IS ON When the transmission cut-off switch is at the “ON” position and the left brake pedal is depressed, the transmission is shifted to neutral at the pre-selected brake pedal depression position.

The transmission is not shifted to neutral when the right brake pedal is operated.

Remark When the transmission cut-off switch is “OFF”, the left brake pedal acts in the same way as the right brake pedal, and the transmission is not shifted to neutral.

TURNING

Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes is dangerous. Do not operate the steering wheel in such situations.

If the engine stops when the machine is traveling, the emergency steering is actuated. This system is only for steering in emergencies, so never stop the engine. It is particularly dangerous if the engine stops when the machine is traveling on slopes, so never let the engine stop when traveling on slopes. If the engine stops, stop the machine immediately at a safe place.

When traveling, use the steering wheel to turn the machine.

The center pin joins the front frame to the rear frame. The front and rear frames pivot at the center point, and the rear wheels follow in the same track as the front wheels when turning. Turn the steering wheel lightly to follow the machine as it turns.

Remark When the steering wheel is turned fully, if it reaches the end of its stroke, do not try to turn it further. Check that there is a play of 50 to 100 mm (2.0 to 3.9 in.) in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your Komatsu distributor for inspection.

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OPERATION

EMERGENCY STEERING ❉ ❉ ❉

Never actuate the emergency steering except during emergencies or when checking the function.

The emergency steering can be used continuously for a maximum of 60 seconds. Operating it continuously for more than 60 seconds may damage the system.

When using the emergency steering, travel at less than 5 km/h (3.1 mph).

USING THE EMERGENCY STEERING During emergencies or when stopping the engine to check the function, press emergency steering switch (1). Emergency steering pilot lamp (green) (2) when the engine is running or when the machine is operated, indicating the condition is normal.

The emergency steering system is provided to enable the machine to be steered under the following conditions.

The ignition switch is at the “ON” position.

The steering oil pressure is low or there is no pressure.

(When the engine has stopped or there is a failure in the steering oil pressure pump, etc.)

When Key SW is turned on, during the emergency steering motor is running for automatic self-checking, it indicates that the emergency steering system is functional. For details, see “EMERGENCY STEERING SELF-CHECK FUNCTION” on page 2-101.

When the emergency steering controller detects lack of oil pressure in the steering system, steering oil pressure caution lamp (red) (3) and central warning lamp (4) light up, and the alarm buzzer sounds intermittently.

When this happens, if the machine is traveling at a speed of more than 2 km/h (1.2 mph), the electric pump motor is automatically actuated and emergency steering pilot lamp (green) (2) lights up.

Steering oil pressure caution lamp (red) (3) lights up to inform the operator that there is a failure in the steering system.

If steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it.

Locate the cause and do not operate the machine until it has been repaired.

Remark If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure caution lamp (red) (4) may light up for a moment, but if the lamp goes out again soon, there is no problem.

When the emergency steering controller detects that the oil pressure in the steering circuit has been restored, the actuation of the emergency steering system is stopped.

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OPERATION EMERGENCY STEERING SELF-CHECK FUNCTION When the ignition switch is turned “ON”, the emergency steering is automatically actuated for approximately 3 seconds to check that the emergency steering is functioning properly.

When this happens, steering oil pressure caution lamp (red) (1) and emergency steering pilot lamp (green) (2) light up.

The emergency steering function check is not performed in the following cases. ❥ ❥

❥

If the ignition switch is turned “ON”, turned “OFF” again without starting the engine, and is then turned “ON” again.

If the ignition switch is turned “ON” again immediately after stopping the engine when the steering oil pressure has not gone down completely.

When automatic preheating is being carried out.

Remark During automatic preheating, the emergency steering self-check function is not actuated.

To check the emergency steering function, press the emergency steering switch after completing the warm-up operation.

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OPERATION

STARTING YOUR WORK OPERATIONS • • • • •

Do not start the engine if warning tags have been attached to the steering wheel or control levers.

Sound your horn to warn others in the area before starting the engine or moving the machine.

Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.

Do not allow anyone in the cab or on the machine during operations.

Check the area to be sure all personnel are clear of the machine and your work area.

WORK EQUIPMENT 1.

Lift arm control lever (1) and bucket control lever (2) can be used to operate the lift arm and bucket as follows.

LIFT ARM LEVER Position (a): RAISE Position (b): HOLD The lift arm is kept in the same position.

Position (c): LOWER Position (d): FLOAT The lift arm moves freely under external force.

When the lift arm control lever is pulled further from the raise position, the lever is stopped in this position until the lift arm reaches the preset kick-out position, and the lever is return to the hold position.

Remark Do not use the FLOAT position when lowering the lift arm.

Use the FLOAT position when leveling in reverse direction only.

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OPERATION BUCKET LEVER Position (a): TILT Position (b): HOLD The bucket is kept in the same position.

Position (c): DUMP

When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.

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OPERATION

SCOOPING A LOAD OR CUTTING A GRADE

Never perform digging or scooping operations with the machine articulated because the machine may tip over.

The work equipment will move when the travel damper switch is turned “ON” (ECCS), regardless if the machine is traveling or the work equipment is raised.

Remark If the tires slip, tire life will be reduced. Do not allow the tires to slip during operation.

LOADING PILED SOIL OR BLASTED ROCK When loading piled soil or blasted rock, drive the machine forward (as follows) to load. To prevent the tires from getting cut caused by the tires slipping, be careful of the following points during the operation. ●

1.

Always keep the operating job site flat, and remove any fallen rocks. ● When working with stockpiles, operate the machine in 1st or 2nd; when loading blasted rock operate the machine in 1st.

When driving the machine forward and lowering the bucket, stop the bucket about 30 cm (12 in.) from the ground, then lower it slowly.

Remark If the bucket hits the ground, the front tires will come off the ground and the tires will slip.

2.

Downshift immediately in front of the material to be loaded. After downshifting, depress the accelerator pedal at the same time and thrust the bucket into the load.

Remark To reduce fuel consumption, depress the accelerator pedal the minimum possible amount. If it is fully depressed, the fuel consumption will increase, but there will be no increase in the amount loaded.

3.

When the material is in a stockpile, keep the cutting edge of the bucket horizontal; when loading blasted rock, have the bucket tilting slightly down.

Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip.

Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be unbalanced.

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OPERATION 4.

At the same time you are thrusting the bucket into the material, raise the lift arm slightly to help keep the tires from slipping. While continuing to enter the pile of material, roll the bucket back to fully fill it.

5.

Once the bucket is full check the amount of material loaded into the bucket, then operate the bucket control lever to tilt the bucket and load back fully.

Remark If the bucket edge is moved up and down while pushing in the bucket and digging, the front tires will come off the ground and this will cause the tires to slip.

6.

If there is too much material loaded in the bucket, dump and tilt the bucket quickly to remove the excessive load. This prevents spillage of the load during hauling.

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OPERATION CUTTING A GRADE ON LEVEL GROUND 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. Perform this operation in 1st gear.

Do not set the bucket facing down more than 20 degrees.

1.

Set the edge of the bucket facing slightly down.

2.

Drive the machine forward and operate the lift arm control lever forward to cut a thin layer of the surface each time when excavating the soil.

3.

Operate the lift arm control lever slightly up and down to reduce the resistance when driving the machine forward.

When digging with the bucket, avoid imposing the digging force onto only one side of the bucket.

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OPERATION

LEVELING OPERATIONS ❥ ❥ ❥

1.

2.

3.

Always operate the machine in reverse when carrying out leveling operations.

If it is necessary to perform leveling operations when traveling forward, do not set the bucket dumping angle to more than 20 degrees.

Turn the E.C.S.S. OFF carrying out leveling operations.

Scoop soil into the bucket. Move the machine backward while spreading soil from the bucket little by little.

Go over the spread soil with the bucket teeth touching the ground and level the ground by back-dragging.

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.

PUSHING OPERATION

Never set the bucket to the DUMP position when pushing.

When pushing, set the bottom of the bucket parallel to the ground surface.

LOAD AND CARRY OPERATIONS

• • •

When carrying a load, lower the bucket to lower the center of gravity when traveling.

Always stop the machine and lower the work equipment to the ground before operating the E.C.S.S. switch.

When performing inspection and maintenance, first lower the work equipment to the ground, then turn the E.C.S.S. switch “OFF” before starting the inspection and maintenance operation.

The load and carry method for wheel loaders consists of a cycle of scooping → hauling →loading (into a hopper, truck, etc.)

Always keep the travel path properly maintained.

When using the load and carry method, see “LOAD AND CARRY OPERATIONS” on page 2-107.

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OPERATION

LOADING OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the job site.

Always keep the job site flat, and do not operate the steering wheel suddenly or apply the brakes suddenly when the lift arm is raised with a loaded bucket. This action is dangerous.

Never thrust the bucket in when traveling at high speed (when loading soil or crushed rock). This action is dangerous.

The work equipment will move when the travel damper switch is turned â&#x20AC;&#x153;ONâ&#x20AC;? (ECCS), regardless if the machine is traveling or the work equipment is raised.

CROSS DRIVE LOADING Always set the wheel loader facing at a right angle to the stockpile.

After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pile and the wheel loader. This method requires the least time for loading, and is extremely effective in reducing the cycle time.

Remark If the tires slip, the life of the tires will be reduced. Do do not allow the tires to slip during operation. Avoid excessive bucket shaking also.

V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approximately 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.

The smaller the turning angle of the wheel loader is, the more efficient the operation becomes.

When loading a full bucket and raising it to the maximum height, first shake the bucket to stabilize the load before raising the bucket. This will prevent the load from spilling to the rear.

PRECAUTIONS WHEN PILING UP LOADS When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground.

Do not set the bucket to the DUMP position when piling-up loads.

Remark When scooping-up, avoid using the transmission cut-off function as much as possible. It will prevent the machine from moving back.

When using the transmission cut-off function, adjust the cut-off position to match the amount that the brake pedal is depressed in order to ensure ample braking force.

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OPERATION

PRECAUTIONS DURING OPERATION 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.

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.

Remark If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality.

PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES BRAKING ON DOWNHILL SLOPE If the footbrake is used frequently when traveling downhill, the brake will overheat and may be damaged. Place the gearshift lever at a low speed range and use the braking force of the engine when traveling downhill.

Use the right brake pedal for braking.

If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may sound intermittently. For details of the necessary action to take, see â&#x20AC;&#x153;AXLE OIL TEMPERATURE CAUTION LAMPâ&#x20AC;? on page 2-17.

If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this situation happens, downshift one gear range to reduce the oil temperature.

If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine, return the directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the white range.

IF THE ENGINE STOPS If the engine stops on a slope, apply the parking brake immediately, lower the work equipment, then stop the work machine.

Put the directional lever in neutral, and start the engine again.

WA480-5L

2-109

OPERATION

PRECAUTIONS WHEN DRIVING THE MACHINE When the machine travels at high speed for a long distance, the tires become extremely hot. This action causes early wear of the tires, so it should be avoided as much as possible. If the machine must be driven for a long distance, take the following precautions. ❥ ❥ ❥ ❥ ❥

❥ ❥ ❥ ❥

Follow the regulations related to this machine, and drive carefully.

Before driving the machine, perform the checks before starting.

The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your Komatsu distributor or tire dealer for information.

The following is a guide to suitable tire pressures and speeds when traveling on a paved surface with standard tires.

(26.5-25-20PR) Check the tire pressure before starting when each tire is cool ● Front wheel: 0.34 MPa (49.7 psi) ● Rear wheel: 0.29 MPa (42.6 psi) Speed: 14 km/h (8.7 mph) After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage; also check the oil and coolant levels.

Always travel with the bucket empty.

Never put “calcium chloride” or “dry ballast” in the tires when traveling.

PRECAUTIONS REGARDING BRAKE FUNCTION When traveling long distances continuously downhill, the frequency of using the brake may increase. As a result, depending on the weight of the machine and the grade of the slope, the machine's braking capacity may be exceeded and the brakes may overheat.

The table below shows a guideline of the values for this machine.

Braking capacity limit Machine weight (t)

Slope grade (%)

22 - 24 (unloaded ) 28.5 30.5 (loaded)

Average travel speed limit (km/h (mph))

Downhill distance limit (continuous) (km)

10

40 (24.9)

2

20

17 (10.6)

1.2

10

30 (18.6)

1.8

20

12 (7.5)

0.6

If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed. Please consult your Komatsu distributor.

2-110

WA480-5L

OPERATION

WORK EQUIPMENT AND MACHINE POSTURE ❥ ❥ ❥ ❥ ❥

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 the safety bar.

Be sure to put a warning tag on work equipment control levers.

Do not go under the work equipment when the arm is raised.

ADJUSTING BUCKET The kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (lift arm higher than horizontal) and the bucket positioner makes it possible to set the bucket so that it automatically stops at the desired digging angle. The setting can be adjusted to match the working conditions. ●

Set the parking brake

●

Lock the frame of the machine

BOOM KICKOUT ADJUSTMENT 1.

2.

3.

Raise the bucket to the desired height, set the lift arm control lever at HOLD and lock the lever in position with the safety lock lever.

Then stop the engine.

Loosen two bolts (1), and adjust plate (2) so that the bottom edge is in line with the center of the sensing surface of proximity switch (3). Then tighten the bolts to hold the plate in position.

Loosen two nuts (4) to make a clearance of 3 to 5 mm (0.118 to 0.197 in.) between plate (2) and the sensing surface of proximity switch (3). Then tighten the nuts to hold in position.

Tightening torque: 17.2 ± 2.5 N·m (12.7 ± 1.8 lbft)

4.

After adjusting, start the engine and raise the lift arm. Check that the bucket control lever is automatically returned to HOLD when the lift arm reaches the desired height.

WA480-5L

2-111

OPERATION BUCKET POSITIONER ADJUSTMENT 1.

2.

3.

4.

Lower the bucket to the ground and adjust the bucket to the desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows.

Loosen the bolts (1), adjust the position of mounting bracket (4) of the proximity switch so that the rear tip of bar (2) is in line with the center of the sensing surface of proximity switch (3), then tighten the bolts to hold the bracket in position.

Loosen the bolts (5), adjust so that the clearance between the bar (2) and support (6) is 0.5 to 2 mm (0.020 to 0.079 in.), then tighten the bolts (5) to hold in position.

Loosen the nuts (7), adjust so that the clearance between bar (2) and the sensing surface of proximity switch (3) is 3 to 5 mm (0.118 to 0.197 in.), then tighten the nuts to hold in position.

Tightening torque: 17.2 ± 2.5 N·m (12.7 ± 1.8 lbft)

5.

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 BACK position and check that the lever is automatically returned to the HOLD position when the bucket reaches the desired digging angle.

BUCKET LEVEL INDICATOR (A) and (B) at the top rear of the bucket are the level indicators, so the bucket angle can be checked during operations.

(A): Parallel with cutting edge (B): 90 degrees to cutting edge

2-112

WA480-5L

OPERATION

TRANSPORTING THE MACHINE Before transporting the machine be sure what you are using to transport the machine is capable of supporting the weight and size of the machine. Be sure it is wide enough and rated for the load.

LOADING AND SECURING THE MACHINE •

• •

Be sure the area you will be loading the machine in is flat and dry.

Be sure the machine is free of mud or debris that may hinder loading.

Check the ramps and support surfaces for damage, week spots, missing boards or excess ware. If these surfaces look unsafe, too week or unstable do not load the machine. Be sure the loading equipment and transportation equipment are in good condition and rated for your load.

Block the wheels on the trailer (D) before attempting to load the machine.

Locate the tie down and transportation brackets (A & C)on the machine. Be sure they are in good condition.

Position the machine squarely on the deck. Raise the loader bucket high enough to clear all surfaces.

Once the machine has been loaded, rest the front bucket on the floor, set the machine in neutral and set the parking brake and lock the controls.

Center the machines frame and lock the frame with the safety bar.

Secure the machine with tie-downs/chains (C) at the anchor points shown in illustrations (A).

• •

To help keep the machine in position, place blocks (B) in front and behind the front and rear wheels for extra support.

Protect the exhaust stack from moisture if needed.

• •

• • • •

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2-113

OPERATION

LIFTING THE MACHINE Lifting hooks (A) are located in 4 places on the machine as shown in the diagram below. Use only these 4 places when lifting; do not use any other places. There is a serious danger that the machine may lose its balance. Always stay clear of the machine and maintain a safe distance when lifting it.

LIFTING LOCATIONS AND PROCEDURES

Weight Table

WA470-5L standard specification machine

2-114

Operating weight

Front wheel load

Rear wheel load

Center of gravity (from front axle)

47,452 kg.

(47,452 lb)

10,260 kg.

22,623 lb)

11,260 kg 24,828 lb

1,810 mm (5 ft 11 in)

WA480-5L

OPERATION

USING WIRE ROPE

•

• • • • •

When lifting the machine, if the wire rope is not installed correctly on the machine, the machine may fall and cause serous injury or even death. Raise the machine 100 to 200 mm (3.9 to 7.9 in) from the ground, check to be sure the machine is horizontal, level and that there is no slack in the wire rope, then continue to lift the machine.

Before lifting the machine, always stop the engine and lock the brakes. Lock front frame and rear frame with safety bar.

Lifting operations using a crane must be carried out by a qualified operator.

Never raise the machine with any personnel on it.

Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine.

When carrying out the lifting operation, please contact your Komatsu distributor.

The lifting procedure applies to machines with standard specifications.The method of lifting differs according to the attachments and options actually installed. In such cases, contact your Komatsu distributor for information.

For details of the weight. See “WEIGHT TABLE” on page (2-79) Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the lifting process.

PRE LIFTING PROCEDURES 1.

Start the engine and raise the work equipment to the travel height and roll the bucket back. Be sure the bucket is empty.

WA480-5L

2-115

OPERATION 2.

Once at the travel height, lock the controls and cut the engine off.

3.

Place the directional lever in the N (neutral) position and set the parking brake.

4.

Lock the frames with the safety bar.

5.

Using the lifting points, carefully lift the machine. Stay clear of the machine at a safe distance until at this point the machine is fully resting in place and the cables are slack.

2-116

WA480-5L

OPERATION

TOWING THE MACHINE If this machine must not be towed except in emergencies. When towing the machine, take the following precautions.

1.

Align the towing pin (1) with groove (2) in the counterweight, then insert the pin and turn it 1800.

2.

To prevent the towing pin from turning, fold the handle of the towing pin and set it in position. Reverse this operation to remove the pin.

3.

Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing process.

4.

Before releasing the brakes, put blocks under the wheels to prevent the machine from moving. If the wheels are not blocked, the machine may suddenly move.

5.

When towing a machine, tow it at a low speed of less than 2 km h (1.2 MPH), and for a distance of a few meters to a place where repairs can be carried out. If the machine must be moved long distances, use a transporter.

6.

To protect the operator if the towing rope or bar should break, install a protector plate to the machine being towed.

7.

If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the machine.

8.

Check that the tow rope or bar is of ample strength for the weight of the machine being towed. If the machine being towed must travel through mud or up hills, use a tow rope or bar of a strength of at least 1.5 times the weight of the machine being towed.

9.

Keep the angle of the tow rope as small as possible. Keep the angle between the center lines of the two machines to within 30 degrees.

10. If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break. Start the machine gradually and travel at a constant speed.

11. 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 on slopes or on the tow road.

12. When towing a 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. This way it is possible to prevent the machine from losing control and turning over.

13. Towing may be carried out under various differing conditions, so it is impossible to determine beforehand there requirements for towing. Towing on flat horizontal roads will require the minimum rim pull, while towing on slopes or on uneven road surfaces will require the maximum rim pull.

WA480-5L

2-117

OPERATION

COLD WEATHER OPERATION If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity.

See “FUEL, LUBRICANTS COOLANT SPECIFICATIONS” on page (3-8).

COOLANT Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash it off with large amount of fresh water and see a doctor at once. When changing the coolant contact your Komatsu distributor. Antifreeze is toxic, so do not dispose of antifreeze in drainage ditches, sewers, on the ground or other areas always trap and recycle this fluid.

Never use methanol, ethanol or propanol based antifreeze. Never use flammable liquids in the cooling system. Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze. do not mix one antifreeze with a different brand.

For details on the antifreeze mixture when changing the coolant.

See “FLUSHING THE COOLING SYSTEM” on page (3-20).

Standard requirements for permanent antifreeze: ● SAE J1034 ● FEDERAL STANDARD O-A-548D

PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions.

Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.

Park the machine on hard, dry ground. If this is impossible, park the machine on wooden boards. The boards help protect the wheels from being frozen in soil and the machine can start next morning.

Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.

AFTER COLD WEATHER When season changes and the weather becomes warmer, do as follows.

Replace the fuel and oil for all parts with oil of the viscosity specified. For details. See “FUEL LUBRICANTS AND COOLANTS” on page (3-8).

WARMING UP THE STEERING When the temperature is low, do not start the operation of the machine immediately after starting the engine.

Slowly operate the steering wheel to the left and right to warm up the oil in the steering valve. (Repeat this operation for about 10 minutes to warm up the oil.)

2-118

WA480-5L

MAINTENANCE

WA480-5L

3

3-1

MAINTENANCE

GUIDES TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual.

CHECK SERVICE METER Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed.

KOMATSU GENUINE REPLACEMENT PARTS Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE OILS Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature.

ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.

ALWAYS USE CLEAN OIL AND GREASE Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.

CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large quantities of metal particles or foreign materials are found, always report to the person in charge, and perform suitable action.

FUEL STRAINER If your machine is equipped with a fuel strainer, do not remove it while fueling.

WELDING INSTRUCTIONS • • • • •

3-2

Turn off the engine starting switch.

Do not apply more than 200V continuously.

Connect grounding cable within 1 m (3.3 ft.) from the area to be welded. If grounding cable is connected near instruments, connectors, etc., the instruments may have troubles.

Avoid seals or bearings from being between the area to be welded and the position of grounding point.

Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

WA480-5L

MAINTENANCE

DO NOT DROP THINGS INSIDE THE MACHINE •

•

When opening inspection windows or the oil filler port of the tank to perform an inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead to failure. If you drop anything inside the machine, always remove it immediately.

Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY WORKSITES When working at dusty worksites, do as follows: • • • • • •

Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged.

Clean the air cleaner element at a shorter interval than specified.

Clean the radiator core frequently to avoid clogging.

Clean and replace the fuel filter frequently.

Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil.

AVOID MIXING OIL Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with the new type of oil.

LOCKING INSPECTION COVERS Lock inspection cover in position securely with a lock bar. If inspection or maintenance is performed with the inspection cover open and not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause injury to the worker.

BLEEDING AIR FROM HYDRAULIC CIRCUIT If the hydraulic oil equipment has been repaired or replaced and if the hydraulic hoses, pipes, etc. have been disconnected, it is necessary to bleed air in the circuit. See “CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT” on page 3-57.

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES • •

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets.

When installing the hoses, do not twist them or bend them into loops with a small radius. This action will cause damage to the hose and markedly reduce its service life.

WA480-5L

3-3

MAINTENANCE

CHECKS AFTER INSPECTION AND MAINTENANCE If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do as follows.

•

•

3-4

Checks after operation (with engine stopped) • Have any inspection and maintenance points been forgotten?

• Have all inspection and maintenance items been carried out correctly?

• Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside machine and get caught in the lever linkage mechanism.

• Is there any leakage of water or oil? Have all the bolts been tightened?

Check when the engine is running • Safety for checking when the engine is running.

• Check if the inspected and maintenance area is normally operated.

• Increase the engine speed to check for the leak of fuel and oil.

WA480-5L

MAINTENANCE

SYSTEMS TROUBLESHOOTING CHARTS ELECTRICAL SYSTEM • •

( ): Always contact your Komatsu distributor when dealing with these items.

In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.

Problem

Main causes

Remedy

Lamp does not glow brightly even when the engine runs at high speed

Defective wiring

(• Check, repair loose terminals, disconnections)

Lamp flickers while engine is running

Defective adjustment of belt tension.

Adjust alternator belt tension For details, see “EVERY 250 HOURS SERVICE” on page 3-45.

Even when the engine is rotating, the charge caution pilot lamp does not go out

Defective alternator Defective wiring Defective adjustment of alternator belt tension

(• Replace) (• Check, repair) Adjust alternator belt tension For details, see “EVERY 250 HOURS SERVICE” on page 3-45

Abnormal noise is generated from alternator

Defective alternator

(• Replace)

Starting motor does not turn when starting switch is turned to ON

Defective wiring Insufficient battery charge

(• Check, repair) Charge

Pinion of starting motor keeps going in and out

Insufficient battery charge

•Charge

Starting motor turns engine sluggishly

Insufficient battery charge Defective starting motor

Charge (• Replace)

Starting motor disengages before engine starts

Defective wiring Insufficient battery charge

(• Check, repair) Charge

Preheating pilot lamp does not light up

Defective wiring Defective glow relay, glow controller, water temperature sensor Defective preheating pilot lamp

(• Check, repair) (• Replace)

Defective wiring Defective monitor

(• Check, repair) (• Replace)

Even when engine is stopped, charge caution pilot lamp does not light up (starting switch at ON position)

WA480-5L

(• Replace)

3-5

MAINTENANCE

CHASSIS • •

( ): Always contact your Komatsu distributor when dealing with these items.

In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.

Problem

Main causes

Remedy

Engine is running but machine does not move

Parking brake is applied Directional lever is not shifted properly Lack of oil in transmission case

Release parking brake Shift lever properly Add oil to specified level. See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

Even when engine is run at full throttle, machine only move slowly and lacks power

Lack of oil in transmission case

Add oil to specified level.

See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

(• Disassemble, clean)

Transmission

Screen is clogged Oil overheats

Too much oil or too little oil

Machine is not traveling in correct speed range Torque converter is stalled for long periods Engine is overheating Noise generated

Lack of oil

Add or drain oil to specified level.

See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

Place in correct speed range Reduce stall time (• Check engine) Add oil to specified level.

See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25

Axle Noise generated

Lack of oil

Add oil to specified level.

See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25

Improper oil used (for machines with anti-slip differential)

Change to specified oil

Disc has reached wear limit Defective hydraulic system Lack of oil

(• Replace disc)

Brake Brake is not applied when pedal is depressed

Air in brake line

Add oil to specified level.

See “EVERY 100 HOURS SERVICE” on page 3-43 Bleed air See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25

Brake drags or remains applied

Vent hole of brake valve is clogged

Clean

Brakes squeal

Disc is worn Large amount of water in axle oil Deteriorated axle oil due to overuse of brake

(• Replace disc) Change axle oil Change axle oil

3-6

WA480-5L

MAINTENANCE Problem

Main causes

Remedy

Steering Steering wheel is heavy

Defective hydraulic system Lack of oil

Add oil to specified level.

See“EVERY 100 HOURS SERVICE” on page 3-43

Defective hydraulic system Lack of oil

Grease bearing or replace pin and bushing where there is play Add oil to specified level. See “EVERY 100 HOURS SERVICE” on page 3-43

Braking effect is poor

Disc is worn

(• Replace disc)

Brake drags or remains applied

Lack of oil in transmission case

Add oil to specified level.

See “GENERAL MAINTENANCE AND INSPECTION” on page 3-25 (• Disassemble and clean)

Steering wheel is loose

Play in steering cylinder pin

Parking brake

Screen is clogged Hydraulic system Lack of lifting power for bucket

Lack of oil

Bucket takes time to rise

Clogged hydraulic tank filter

Excessive bubbles in oil

Low quality oil being used Oil level is low Air in oil line

Add oil to specified level.

See “EVERY 100 HOURS SERVICE” on page 3-43 Replace filter.

See “EVERY 2000 HOURS SERVICE” on page 3-57 Replace with good quality oil Add oil to specified level. See “EVERY 100 HOURS SERVICE” on page 3-43 Bleed air, see “EVERY 2000 HOURS SERVICE” on page 3-57.

Hydraulic pressure is low

Oil level is low and pump is sucking in air

Add oil to specified level.

See “EVERY 100 HOURS SERVICE” on page 3-43 Then bleed air.

Movement of cylinder is irregular

Oil level is low

Add oil to specified level.

See “EVERY 100 HOURS SERVICE” on page 3-43.

WA480-5L

3-7

MAINTENANCE Cooling fan (Waste Handler) Cooling fan runs forward but will not reverse in AUTO mode

FORWARD/REVERSE timer “reverse” time set too short.

Check operation in MANUAL mode. If fan does not reverse, than service is required. Keep in mind that there is an 8 second coast period in between direction changes. If fan does reverse, then switch back to AUTO mode and continue to the next step.

Check FORWARD/REVERSE timer scale selection.

Normally “3”.

Check reverse time unit selector switch setting. Normally “10s” Increase reverse time by turning the reverse setting knob clockwise.

Normally set to “1.5”.

FORWARD/REVERSE timer “forward” time set too long.

Check forward time unit selector switch setting.

Normally “hrs”.

Decrease forward time by turning the forward setting knob counterclockwise. Normally set to “0.5” )Check, repair)

Cooling fan runs in reverse continually in AUTO mode.

FORWARD/REVERSE timer “reverse” time set too short.

Check operation in MANUAL mode. If fan does not reverse, than service is required. Keep in mind that there is an 8 second coast period in between direction changes. If fan does reverse, then switch back to AUTO mode and continue to the next step.

Check FORWARD/REVERSE timer scale selection.

Normally “3”.

Check forward time unit selector switch setting.

Normally “hrs”.

Increase reverse time by turning the reverse setting knob clockwise.

Normally set to “0.5”.

FORWARD/REVERSE timer “forward” time set too long.

Check reverse time unit selector switch setting.

Normally “10s” )Check, repair)

3-8

WA480-5L

MAINTENANCE Cooling fan does not rotate in AUTO mode.

FORWARD/REVERSE timer “forward” and “reverse” time set too short.

Check operation in MANUAL mode. If fan does not reverse, than service is required. Keep in mind that there is an 8 second coast period in between direction changes. If fan does reverse, then switch back to AUTO mode and continue to the next step.

Check FORWARD/REVERSE timer scale selection.

Normally “3”.

Check forward time unit selector switch setting.

Normally “hrs”.

Increase forward time by turning the reverse setting knob clockwise.

Normally set to “0.5”.

Check reverse time unit selector switch setting.

Normally “10s” Increase reverse time by turning the reverse setting knob clockwise.

Normally set to “1.5”. )Check, repair)

WA480-5L

3-9

MAINTENANCE

ENGINE • •

( ): Always contact your Komatsu distributor when dealing with these items.

In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.

Problem

Main causes

Remedy

Engine oil pressure caution pilot lamp lights up

Engine oil pan oil level is low (sucking in air) Clogged oil filter cartridge Defective tightening of oil pipe joint, oil leakage from damaged part Defective monitor

Add oil to specified level, see “PREOPERATIONAL CHECKS” on page 278.

Replace cartridge, see “EVERY 500 HOURS SERVICE” on page 3-50.

(• Check, repair) (• Replace)

Steam is emitted from top part of radiator (pressure valve)

Cooling water level low, water leakage Defective fan pump or motor Dirt or scale accumulated in cooling system (cooling fan in reverse) Clogged radiator fin or damaged fin

Check, add cooling water, repair, see “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

(• Check, repair) Change cooling water, clean inside of cooling system, see “GENERAL MAINTENANCE AND INSPECTION” on page 3-25. Clean or repair, see “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

Set cooling fan to “FORWARD” (• Replace thermostat) (• Replace thermostat seal) Tighten cap or replace packing (• Replace)

Water temperature gauge is in red range Coolant temperature monitor lights up

Defective thermostat Defective thermostat seal Loose radiator filler cap (high altitude operation) Defective monitor

Water temperature gauge is in white range on left

Defective thermostat Defective monitor

(• Replace thermostat) (• Replace)

Engine does not start when starting motor is turned

Lack of fuel

Add fuel, see “START-UP PROCEDURES” on page 2-83.

Repair place where air is sucked in.

Air in fuel system No fuel in fuel filter Defective supply pump or injector Starting motor cranks engine too slowly Starting motor does not turn Preheating pilot lamp does not light up Defective valve clearance (Defective compression)

Fuel filter with fuel. See “EVERY 500 HOURS SERVICE” on page 3-50 (• Replace pump or injector) See “ELECTRICAL SYSTEM” on page 3-5 See “ELECTRICAL SYSTEM” on page 3-5 See “ELECTRICAL SYSTEM” on page 3-5 (• Adjust valve clearance)

Exhaust gas is white or blue

Too much oil in oil pan Improper fuel

3-10

Add oil to specified level, see “START-UP PROCEDURES” on page 2-83.

Change to specified fuel

WA480-5L

MAINTENANCE Problem

Main causes

Remedy

Defective turbocharger

Clean or replace, see “GENERAL MAINTENANCE AND INSPECTION” on page 3-25.

(• Replace injector) (• See defective compression above) (• Clean or replace turbocharger)

Combustion noise occasionally makes breathing sound

Defective nozzle

(• Replace nozzle)

Abnormal noise generated (combustion or mechanical)

Low grade fuel being used Overheating

Change to specified fuel Refer to “Water temperature gauge is in red range” as above (• Replace muffler) (• Adjust valve clearance)

Exhaust gas occasionally turns black

Clogged air cleaner element Defective injector Defective compression

Damage inside muffler Excessive valve clearance

WA480-5L

3-11

MAINTENANCE

OUTLINES OF SERVICE HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC OIL •

•

• • • • •

Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it deteriorates with use. Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil after the specified interval.

Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal particles, dirt, etc.) from getting in. The majority of problems with machine are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

Never mix oils of different grades or brands.

Always add the specified amount of oil. Having too much oil or too little oil are both causes of problems.

If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please contact your Komatsu distributor.

When changing the oil, always replace the related filters at the same time.

We recommend you have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.

FUEL • • • • • • • •

The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

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 temperature below -15º C (5º F). It is necessary to change for the fuel that is suitable for the temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank.

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

The engine mounted on this machine employs electronic control and a high-pressure fuel injection system to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in the durability, so do not use such fuel.

COOLANT • • •

• • • •

River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating. Do not use water that is not suitable for drinking.

When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original antifreeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system. The antifreeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

The proportion of antifreeze to water differs according to the ambient temperature.

For details of the mixing proportions, see “CLEANING THE COOLING SYSTEM” on page 3-30.

If the engine overheats, wait for the engine to cool before adding coolant.

A low coolant level will cause overheating and will also cause problems with corrosion from the air in the coolant.

3-12

WA480-5L

MAINTENANCE GREASE • • • • •

Grease is used to prevent twisting and noise at the joints.

The grease fittings not included in the MAINTENANCE section are grease fittings for overhaul, so they do not need grease.

If any part becomes stiff or makes noise after being used for long time, apply grease.

Always wipe off all of the old grease that is pushed out when greasing.

Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts.

PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS) KOWA (Komatsu Oil Wear Analysis) is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other abnormalities.

Periodic use of KOWA makes the following possible:

• •

It enables the accurate understanding of the machine condition by utilizing our long experience and accumulated data base.

The report on the result of analysis and recommendation will be delivered to the customer soon at low cost (only the actual expenses will be charged). Use of this service is strongly recommended.

WA480-5L

3-13

MAINTENANCE

KOWA ANALYSIS ITEMS •

Analysis of metal wear particles.

This uses the latest ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil.

•

Measurement of particle quantity This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of large iron particles (larger than 5 microns) in the oil, which enables the early detection of defect.

•

Others.

Measurements are made of items such as the ratio of water in oil or fuel in the oil, and the dynamic viscosity.

OIL SAMPLING •

Sampling interval • 250 hours: Engine • 500 hours: Other components • Precautions when sampling • Make sure that the oil is well mixed before sampling.

• Perform sampling regularly at fixed intervals.

• Do not perform sampling on rainy or windy days when water or dust can get into the oil.

For further details of KOWA, please contact your Komatsu distributor.

STORING OIL AND FUEL • •

•

Keep indoors to prevent any water, dirt, or other impurities from getting in.

When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side.

This action prevents moisture from being sucked in. If the drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the oldest oil or fuel first).

3-14

WA480-5L

MAINTENANCE FILTERS •

• • • • •

Filters are extremely important safety parts. Filters prevent impurities in the fuel and air circuits from entering important equipment and causing problems. Replace all filters periodically. For details, see the Operation and Maintenance Manual.

However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found, please contact your Komatsu distributor.

When replacing the engine oil filter, fill the new filter with the specified clean oil, then install it.

Do not open packs of spare filters until just before they are to be used.

Always use Komatsu genuine filters.

OUTLINE OF ELECTRIC SYSTEM •

• • • • •

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This situation will cause an electrical short circuit and may cause the machine to malfunction. Do not wash the inside of the operator's cab with water. When washing the machine, be careful not to let water get into the electrical components.

Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and check of battery fluid level.

Never install any electric components other than there specified by Komatsu.

External electrical interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.

When working at the seashore, carefully clean the electric system to prevent corrosion.

The optional power source must never be connected to the fuse, starting switch, or battery relay.

WA480-5L

3-15

MAINTENANCE

WEAR PARTS LIST Wear parts such as the filter element, air cleaner element, bucket tooth, 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 change, Komatsu genuine parts of excellent quality should be used.

When ordering parts, please check the part number in the parts book.

The parts in parentheses are to be replaced at the same time.

Item

Part Name

Q'ty

Replacement frequency

Engine oil filter

Cartridge

1

EVERY 500 HOURS

Fuel filter

Cartridge

1

EVERY 500 HOURS

Fuel strainer

O-ring

1

-

Transmission oil filter

Cartridge

1

EVERY 1000 HOURS

Transmission strainer

O-ring

1

EVERY 1000 HOURS

Corrosion resistor

Cartridge

1

EVERY 1000 HOURS

Hydraulic filter

Element (O-ring)

1 (1)

EVERY 2000 HOURS

Hydraulic tank breather

Element

1

EVERY 2000 HOURS

Air cleaner

Element assembly

1

WHEN REQUIRED

Air conditioner air filter

Element

1

EVERY 2000 HOURS

Standard type

Center edge Side edge (Bolt) (Nut) (Washer)

2 2 (18) (18) (18)

WHEN REQUIRED

Long life type

Center edge Side edge (Bolt) (Nut) (Washer)

2 2 (18) (18) (18)

WHEN REQUIRED

Segmented type

Center edge Side edge (Bolt) (Nut) (Washer)

6 2 (16) (16) (16)

WHEN REQUIRED

Articulation guards

Rubber sheets

2

WHEN REQUIRED

Boom cylinder hose guard

Top belt Bottom belt

2 2

WHEN REQUIRED

Bolt on cutting edge

3-16

WA480-5L

MAINTENANCE

FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

Capacity Engine oil pan

Transmission case

Hydraulic system

Axle (front and rear) (each)

Pins

Pins (with auto-greasing system)

Fuel tank

Cooling system

Liters

47

65

295

55

-

-

417

50

USgal

12.42

17.17

77.94

14.53

-

-

110.17

13.21

Liters

38

54

190

55

-

-

-

-

USgal

10.04

14.27

50.20

14.53

-

-

-

-

Reservoirs Specified

Refill

Use only #2 diesel fuel.

WA480-5L

3-17

MAINTENANCE The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication.

If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. *1: ASTM D975 No. 1 *2 : Use only diesel fuel. *3: If a machine equipped with an auto-greasing system is operated at temperatures below -20º C (-4º F), use lithium-based grease No. 0.

If the machine is operated below -20° C (-4° F), a separate device is needed. Consult your Komatsu distributor for details. *4: The letters “ASD” are stamped on the name plate of machines equipped with the antislip differential axle. *5: For the conventional differential, except for “AX075,” the oil for machines equipped with the antislip differential in the table below and E030 can be used. However, in the case of “E030,” depending on conditions such as the way the brakes are used and the oil temperature, the brakes may squeal just before the machine stops, but there is no problem with the brake performance or durability. AX075 is used in the conventional differential is shown in the table below. *6: For machines equipped with the antislip differential axle, select from the oil given in the table below.

Maker

Brand (antislip differential)

Brand (conventional differential)

Remarks

SHELL

DONAX TD 5W-30

North American manufactured DONAX TD 20W-40 cannot be used in antislip differentials.

ESSO

TORQUE FLUID 56

North American manufactured cannot be used in antislip differentials

MOBIL

MOBILFLUID 424

FUCHS

RENOGEAR HYDRA ZF 20W-40

CALTEX

RPM TRACTOR HYDRAULIC FLUID

CHEVRON

TRACTOR HYDRAULIC FLUID

TEXACO

TDH OIL

Remark When fuel sulphur content is less than 0.5%, change the oil in the oil pan according to the periodic maintenance hours described in this manual.

Change oil according to the following table if fuel sulphur content is above 0.5%.

Starting the engine when ambient temperature is lower than 0° C (32° F), be sure to use engine oil of SAE 10W, SAE 10W-30 and SAE 15W-40, even though the atmospheric temperature goes up to 10° C (50° F) more or less during the day.

Use API classification CI-4 as engine oil. If any other API classification is used, reduce the engine oil change interval to half.

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

3-18

WA480-5L

MAINTENANCE 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.

ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Fuel sulfur content

Charge interval of oil in engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS No. Supplier

Engine Oil [CI-4] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.)

Gear Oil [GL-4 or GL-5] SAE80, 90, 140

Grease [Lithium-Base] NLGI No.2

Antifreeze Coolant [Ethylene Glycol Base] Permanent Type

1

KOMATSU EO10-CD EO30-CD EO10-30CD EO15-40CD

GO90 GO140

G2-LI G2-LI-S

AF-ACL AF-PTL AF-PT (Winter, one-season type)

2

AGIP

Diesel sigma S super diesel multigrade *Sigma turbo

Rotra MP

GR MU/EP

-

3

AMOCO

*Amoco 300

Multi-purpose gear oil

PYKON premium grease

-

4

ARCO

*Arcofleet S3 pius

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

-

5

BP

Vanellus C3

Gear oil EP Hypogear EP

Energrease LS-EP2

Antifreeze

6

CALTEX

*RPM delo 400 RPM delo 450

Universal thuban Universal thuban EP

Marfak all purpose 2 Ultra-duty grease 2

AF engine coolant

7

CASTROL *Turbomax *RX super CRD

EP EPX Hypoy Hypoy B Hypoy C

MS3 Spheerol EPL2

Antifreeze

8

CHEVRON *Delo 400

Universal gear

Ultra-duty grease 2

-

9

CONOCO

*Fleet motor oil

Universal gear lubricant

Super-sta grease

-

10

ELF

Multiperformance 3C Performance 3C

-

Tranself EP Tranself EP type 2

Glacelf

11

EXXON (ESSO)

Gear oil GP Essolube D3 Gear oil GX *Essolube XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty

Beacon EP2

All-season coolant

12

GULF

Super duty motor oil *Super duty plus

WA480-5L

Multi-purpose gear lubri- Gulfcrown EP2 cant Gulfcrown EP special

Antifeeze and coolant

3-19

MAINTENANCE No. Supplier

Engine Oil [CI-4] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.)

Gear Oil [GL-4 or GL-5] SAE80, 90, 140

Grease [Lithium-Base] NLGI No.2

Antifreeze Coolant [Ethylene Glycol Base] Permanent Type

13

MOBIL

Delvac 1300 *Delvac super 10W-30, 15W-40

Mobilube GX Mobilube HD

Mobilux EP2 Mobilgease 77 Mobilgrease special

-

14

PENNZOIL *Supreme duty fleet motor oil

Multi-purpose 4092 Multi-purpose 4140

Multi-purpose white grease 705 707L White-bearing grease

Antifreeze and summer coolant

15

PETROFINE

FINA kappa TD

FINA potonic N FINA potonic NE

FINA marson EPL2

FINA tamidor

16

SHELL

Rimura X

Spirax EP Spirax heavy duty

Albania EP grease

-

17

SUN

-

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

18

TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak EP2 Starplex 2

Coda 2055 startex antifreeze coolant

19

TOTAL

Rubia S *Rubia X

Total EP Total Transmission TM

Multis EP2

Antigel/antifreeze

20

UNION

*Guardol

MP gear lube LS

Unoba EP

-

21

VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear B Multigear C

-

Antifreeze

3-20

WA480-5L

MAINTENANCE

STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES TORQUE LIST If nuts, bolts, or other parts are not tightened to the specified torque, looseness or damage to the tightened parts, which will cause machine failure or problems with operation.

Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.

The tightening torque is determined by the width across the flats of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Tightening torque Thread diameter a(mm)

Width across flat b(mm)

Target value

Service limit

N•m

lbft

N•m

lbft

6

10

13.2

9.8

11.8 - 14.7

8.7 - 10.8

8

13

31

23.1

27 - 34

20.3 - 25.3

10

17

66

48.5

59 - 74

43.4 - 54.2

12

19

11

83.2

98 - 123

72.3 - 90.4

14

22

177

130.2

157 - 196

115.7 - 144.7

16

24

279

206.1

245 - 309

180.8 - 227.8

18

27

382

282.1

343 - 425

253.2 - 314.6

20

30

549

405.0

490 - 608

361.7 - 448.4

22

32

745

549.7

662 - 829

488.2 - 611.2

24

36

927

683.5

824 - 1030

607.6 - 759.5

27

41

1320

976.5

1180 - 1470

868.0 - 1085.0

30

46

1720

1265.8

1520 - 1910

1121.1 - 1410.4

33

50

2210

1627.4

1960 - 2450

1446.6 - 1808.3

36

55

2750

2025.2

2450 - 3040

1808.3 - 2242.2

39

60

3280

2423.1

2890 - 3630

2133.7 - 2676.2

★ Use the following table for Hydraulic Hose.

Thread diameter a(mm)

Width across flat b(mm)

Tightening torque Target value N•m

lbft

Service limit N•m

lbft

14

19

29.4

21.7

27.5 - 39.2

20.3 - 28.9

18

24

78.5

57.3

58.8 - 98.1

43.4 - 72.3

22

27

117.7

86.8

88.3 - 137.3

65.1 - 101.3

24

32

147.1

108.5

117.7 - 176.5

86.8 - 130.2

30

36

215.7

159.1

176.5 - 245.2

130.2 - 180.8

33

41

255.0

188.1

215.7 - 284.4

159.1 - 209.8

WA480-5L

3-21

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 perform periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page must also be replaced at the specified interval. These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced.

With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely.

However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses.

In addition, perform the checks for the hydraulic hoses other than periodic replacement parts. If any abnormality is found, tighten the clamps or replace the parts.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

No. Safety critical parts for periodic replacement

Q'ty Replacement interval

1

Fuel hose (fuel tank - fuel strainer)

1

2

Fuel hose (fuel strainer - supply pump)

1

3

Fuel return hose (supply pump - fuel tank)

1

4

Fuel hose (supply pump - fuel filter)

1

5

Fuel hose (fuel filter - supply pump)

1

6

Fuel spill hose (unit injector - fuel tank)

1

7

Steering hose (pump - steering valve)

1

8

Steering hose (steering valve - steering cylinder)

4

9

Steering hose (steering valve - hydraulic tank)

2

10

Brake hose (pump - accumulator charge valve)

2

11

Brake hose (accumulator charge valve - check valve))

1

12

Brake hose (check valve - tandem valve)

2

13

Brake hose (check valve - single valve)

1

14

Brake hose (check valve - accumulator P.P port)

1

15

Brake hose (tandem valve - front brake)

2

16

Brake hose (tandem valve - rear brake)

2

17

Brake hose (single valve - tandem valve)

1

18

Brake hose (tandem valve - drain block)

1

19

Brake hose (single valve - drain block)

1

20

Brake hose (drain block - hydraulic tank)

1

21

Brake hose brake accumulator - reduction valve for emergency parking brake cancel)

1

22

Brake hose transmission valve - reduction valve for emergency parking brake cancel)

1

23

Brake hose (charge valve drain - hydraulic tank)

1

24

Seat belt

1

3-22

Every 2 years or every 4000 hours, whichever comes first

Every 3 years

WA480-5L

MAINTENANCE

MAINTENANCE SCHEDULE CHART This is a schedule outlining the maintenance to be performed on the machine according to the hours accumulated on the machine. Following these scheduled items will prolong the life of the machine.

Maintenance Interval And Item

Section - Page

INITIAL 250 HOURS SERVICE CHANGE TRANSMISSION OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE HYDRAULIC TANK FILTER ELEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-25 3-25

WHEN REQUIRED CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONDITIONER CONDENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING ELECTRICAL INTAKE AIR HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE BOLT ON CUTTING EDGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING SLOW BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-25 3-27 3-30 3-32 3-33 3-35 3-35 3-36 3-37 3-38 3-38 3-39 3-40 3-41

EVERY 50 HOURS SERVICE DRAIN SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-43

EVERY 100 HOURS SERVICE LUBRICAT REAR AXLE PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE AIR CONDITIONER FRESH ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-43 3-43 3-44

EVERY 250 HOURS SERVICE CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WA480-5L

3-45 3-47 3-47 3-47 3-48 3-48 3-49

3-23

MAINTENANCE

EVERY 500 HOURS SERVICE CHANGE ENGINE OIL, REPLACING ENGINE OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . .

REPLACING FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-50 3-51 3-52

EVERY 1000 HOURS SERVICE CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEANING STRAINER . . . . . . . . .

CLEAN THE TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE CORROSION RESISTOR CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-54 3-55 3-56 3-56 3-56

EVERY 2000 HOURS SERVICE CHANGE HYDRAULIC OIL REPLACE HYDRAULIC OIL FILTER ELEMENT. . . . . . . . . . . . . . . .

HYDRAULIC TANK VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGE AXLE OIL (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONDITIONER RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAN PPC CIRCUIT STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAN THE ENGINE VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEAN ENGINE VALVE CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK ACCUMULATOR GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or the brakes make a sound, change the oil after a shorter interval.

3-57 3-59 3-60 3-60 3-61 3-61 3-62 3-62 3-62 3-62 3-62 3-62 3-63

EVERY 4000 HOURS SERVICE LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECK AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE INJECTOR NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDNING OF RUBBER . . . . . .

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDNING OF RUBBER . . . . . .

3-64 3-65 3-65 3-65 3-65 3-65

EVERY 8000 HOURS SERVICE REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACE FUEL SPRAY PREVENTION CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-24

3-66 3-66

WA480-5L

MAINTENANCE

GENERAL MAINTENANCE AND INSPECTION INITIAL 250 HOURS SERVICE ★ Perform the following maintenance only after the first 250 hours.

CHANGE TRANSMISSION OIL FILTER CARTRIDGE REPLACE HYDRAULIC TANK FILTER ELEMENT For details of the method of replacing or maintaining, see the section EVERY 1000 HOURS and 2000 HOURS SERVICE.

WHEN REQUIRED CLEANING THE MACHINE CLEAN TIPS Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts or the machine itself. Avoid using high pressure steam cleaners or caustic soaps to wash the machine if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s cab. Doing so may damage sensitive electrical components.

When pressure washing, use high pressure hot water and mild grease cutting soaps.

WASTE HANDLER MACHINE Before preparing to pressure wash this machine it is important to open protective covers (1), (2) and (3) as well as any other covers due to the possible build-up of trash which could hinder operation of the machine or possibly cause a fire. ★ Belly Pans

WA480-5L

3-25

MAINTENANCE â&#x2DC;&#x2026; Air Cleaner and Exhaust area Inspect areas (1) and (2) for excessive build up of trash.

After cleaning grease the machine to push any water out of the pivot point connections.

Always reinstall all protective covers.

FAN SOLENOID VALVE â&#x2DC;&#x2026; Waste Handler When cleaning the machine, this area should be protected from high pressure water and soaps. Due to the location and design of the fan solenoid valve damage or premature failure may result if high pressure water or soaps come in contact with the solenoid valve assembly. Use only mild soaps and low pressure water to clean this valve.

Remark This valve area should be cleaned every 250 hours of operation.

When washing around this area it is advised to protect this component with a plastic cover.

3-26

WA480-5L

MAINTENANCE

If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine will suffer damage. Always stop the engine before performing these operations.

When using compressed air, there is danger that dirt may be blown around and cause serious injury.

Always use safety glasses, dust mask, and other protective equipment.

ENGINE AIR FILTER If air cleaner clogging caution lamp (1) on the machine monitor lights up, clean the air cleaner element.

Remark Do not clean the element until the air cleaner clogging caution lamp lights up. If the element is cleaned frequently before the air cleaner clogging caution lamp lights up, the air cleaner will not be able to display its performance fully and the cleaning efficiency will drop. In addition, the frequency of dirt stuck to the element falling inside the inner element will increase.

It is also possible to check the condition of the air cleaner by using the dust indicator installed to the air cleaner.

After cleaning or replacing the air cleaner, press the reset button at the top of the dust indicator to return the display to its original position.

WA480-5L

3-27

MAINTENANCE CLEANING OR REPLACING OUTER ELEMENT 1.

2.

Open the top cover at the front of the engine side cover on the right side of the machine.

Remove three clips (2), then remove dust cup (3).

3.

Remove the outer element (4). â&#x2DC;&#x2026; Never remove the inner element (5). If it is removed, dust will enter and cause engine trouble.

4.

Clean the inside of the air cleaner body and dust cup. â&#x2DC;&#x2026; The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time.

5.

Direct dry compressed air (less than 0.69 MPa (99.4 psi)) to the outer element (4) from inside along its folds, then direct it from outside along its folds and again from inside.

3-28

WA480-5L

MAINTENANCE 6.

7.

If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element.

Seat the cleaned outer element and install dust cup (3), then secure them with clips (2).

Remark When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.

8. Press the dust indicator button to return the yellow piston to its original position.

9. Close the top cover at the front of the engine side cover on the right side of the machine.

10. After cleaning, if the air cleaner clogging caution lamp lights up immediately or the yellow piston reaches the red line (7.5 kPa), replace the inner and outer elements.

WA480-5L

3-29

MAINTENANCE CLEANING THE COOLING SYSTEM

Immediately after stopping the engine, the engine coolant is HOT and the pressure inside the radiator is high. Removing the cap and draining the water under this condition could cause burns. Allow the engine to cool down, then turn the cap slowly to release the pressure.

Start the engine and flush the system. When standing up or leaving the operator's seat, set the shift lever to the N position and set the parking brake switch to the PARKING position.

For details of starting the engine, see “PRECAUTIONS BEFORE STARTING WORK OPERATIONS” on page 2-78 and “STOPPING THE ENGINE” on page 2-89.

When the undercover is removed, there is danger of touching the fan.

Never go to the rear of the machine when the engine is running.

Stop the machine on level ground when cleaning or changing the coolant.

Clean the inside of the cooling system, change the coolant, and replace the corrosion resistor according to the table below.

Type of coolant

Cleaning inside of cooling system and changing coolant

Permanent type antifreeze (All-season type)

Every year (autumn) or every 2000 hours, whichever comes first

Non-permanent type antifreeze containing ethylene glycol (winter, one season type)

Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn).

When not using antifreeze

Every 6 months or every 1000 hours, whichever comes first

Replacing corrosion resistor

Every 1, 000 hours and when cleaning the inside of the cooling system and when changing coolant.

Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.

The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect, a minimum ratio of 30 % by volume is necessary.

When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a temperature about 10º C (50º F) lower when deciding the mixing rate.

Mixing rate of water and antifreeze Min. atmospheric temperature Amount of antifreeze

Amount of water

3-30

°C

-10

-15

-20

-25

-30

°F

14

5

-4

-13

-22

Liters

15.0

17.5

20

22.5

25.0

US gal

3.96

4.62

5.28

5.94

6.61

Liters

35.0

32.5

30.0

27.5

25.0

US gal

9.25

8.59

7.93

7.27

6.60

WA480-5L

MAINTENANCE • • •

Use distilled water for the cooling system water.

We recommend use of an antifreeze density gauge to control the mixing proportions.

Prepare the following: Container should hold a minimum of 50 liters (13.21 US gal) capacity to mix the coolant.

1.

Stop the engine and tighten 2 valves (1) of the corrosion resistor.

2.

Turn the radiator cap (2) slowly to release the pressure, then remove it.

3.

Set a container in position to catch the drained antifreeze mixture, then open drain valve (3) under the left side of the fuel tank and drain plug (4) at the side face of the cylinder block, and drain the coolant.

4. After draining the coolant, close drain valve (3) and drain plug (4) and fill with city water.

5. When the radiator is full of water, start the engine and run the engine at low idling for about 10 minutes with the water temperature at 90° or higher.

6. Stop the engine, open drain valve (3) and drain plug (4), drain the water, then tighten them again.

7. After draining the water, clean the cooling system with cleaning agent. For the cleaning method, see the instructions for the cleaning agent.

8. Replace the corrosion resistor, then open 2 valves (1). For details of the procedure for replacing the corrosion resistor, see “REPLACE CORROSION RESISTOR CARTRIDGE” on page 3-56.

9. Pour the coolant and water through the filler port. Fill up to the filler port. See “Mixing rate of coolant and water table” for the mixing rate of coolant and water.

10. To remove the air in the cooling system, run the engine for 5 minutes at low idling, and for another 5 minutes at high idle.

When doing this step, leave the radiator cap off.

WA480-5L

3-31

MAINTENANCE 11. Drain the coolant from sub-tank (5), clean the inside of the subtank, then add water until the coolant level is between the FULL and LOW marks.

12. Stop the engine, wait for approximately 3 minutes, then add tap water until the water level is near the water filler port, and tighten the cap. Check the coolant level and add water, if necessary.

TRANSMISSION OIL LEVEL

The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

Perform this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling water.

1.

2.

Start the engine and run it for at least 5 minutes.

Open the cap of oil filler port (F), remove dipstick (G), and wipe the oil off with a cloth.

3-32

WA480-5L

MAINTENANCE 3.

Insert the dipstick (G) again from the top of the oil filler port diagonally as shown in the diagram, then pull it out again. When doing this, insert the dipstick so that the tip contacts the bottom of the dipstick guide.

4.

The oil level should be between the H and L marks on dipstick (G).

If the oil level is below the L mark, add engine oil through oil filler (F).

5.

If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again.

If the oil level is correct, insert dipstick (G) into the oil filler pipe, then tighten the cap.

6.

AXLE OIL LEVEL

When checking the oil level, apply parking brake and lock the front and rear frames with the safety bar.

After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the operation.

Perform this procedure if there is any sign of oil on the axle case. Perform the inspection with the machine on a horizontal road surface. If the road surface is at an angle, the oil level cannot be checked correctly.

WA480-5L

3-33

MAINTENANCE 1.

Stop the engine and remove the oil level plug (1).

Remark Remove the mud and dirt from around plug (1), then remove the plug.

2.

Wipe off any oil adhering to the oil level gauge attached to plug (1) with waste cloth.

3.

Set the oil level gauge (G) as shown in the right diagram.

4.

The oil level is correct when it is between the two lines provided on the oil level gauge. If the oil level does not reach the lower line, add axle oil through the filler port (F).

Remark For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified lubricating oil.

5.

6.

If the oil level is above the upper line, drain off the excess oil through drain plug (P) and check the oil level again.

If the oil level is correct, install plug (1). Tightening torque: 132 ± 39 N·m (97.6 ± 28.9 lb. ft.).

3-34

WA480-5L

MAINTENANCE CHECK AXLE VENT

When cleaning the axle breather, apply the parking brake and lock the front and rear frames with the safety bar.

Remove all mud and dirt from around the breather with a brush.

After removing the mud or dirt from around the breather, remove the breather, immerse it in cleaning fluid and clean it.

When cleaning the breather, clean the breathers at two places (front and rear).

After removing the breather, take steps to prevent dirt or dust from entering the mount.

AIR CONDITIONER CONDENSER

Do not wash the condenser using a steam cleaner because the condenser could overheat.

If high-pressure water hits your body directly or high-pressure water sends dirt flying, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.

If there is mud or dust on the air conditioner condenser, clean it with water.

If the water pressure is too high, the fins may get deformed. When washing with a high-pressure washing machine, apply the water from a reasonable distance.

WA480-5L

3-35

MAINTENANCE CLEANING METHOD 1.

2.

3.

4.

5.

6.

Open top cover (1) at the front of the engine hood.

Move radiator sub tank (2) to make space so that air conditioner condenser (3) can swing to the rear.

Remove 4 bolts (4) at the top of the condenser.

Using pin (5) at the bottom of the condenser as the fulcrum, push over to the rear.

Washer with water from the top.

Install bolts (4), then install sub tank (2) to its original position.

WINDOW WASHING FLUID LEVEL Check the washing fluid levels in washer tank (1). When the fluid has run short, add automotive window washing fluid.

To prevent the nozzles from clogging, be careful not to let dust get into the fluid.

3-36

WA480-5L

MAINTENANCE CLEANING RADIATOR FINS

Never open the engine side cover when the engine is running. Stop the engine completely before starting the cleaning operation.

If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury. Always wear safety glasses, dust mask, or other protective equipment.

Perform this procedure if there is any mud or dirt stuck to the radiator.

USING COMPRESSED AIR Tilt the aftercooler (1) at the top front face of the radiator, swing oil cooler (2) at the bottom, then insert the steam jet nozzle through the gap and clean the fins.

TILTING AND SWINGING COOLER 1.

2.

Turn the starter switch to the OFF position and stop the engine.

Pull lever (3) down to release the lock, then tilt aftercooler (1).

Turn the knob (4) counterclockwise to release the lock, then swing oil cooler (2). If necessary, band (5) can be fitted to oil cooler (2) to hold it in position after swinging it. Use the steam jet nozzle to blow out the mud, dirt, or leaves clogging the radiator fins or cooler fins.

3.

Use the steam jet nozzle to blow out the mud, dirt, or leaves clogging the radiator fins or cooler fins.

Remark If the steam nozzle is brought too close to the radiator fins, they may be damaged. Accordingly, keep the nozzle away from the fins.

4.

Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by aging. Further, check hose clamps for looseness.

WA480-5L

3-37

MAINTENANCE 5.

6.

Loosen the wing bolts (6), use hook (7) to slide cleaning covers (8), and open the left and right covers.

Insert the air nozzle and blow the dirt out to the front of the machine.

Remark Steam or water can be used instead of compressed air.

7.

8.

After blowing out the dirt, install left and right cleaning covers (8).

After completing the cleaning, push the bottom of aftercooler (1) to lock it, then push the front of oil cooler (2) to lock it. Check that they are both securely locked in position.

CHECKING ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.

REPLACE BOLT-ON CUTTING EDGE

It is extremely dangerous if the work equipment moves when performing the turning or replacement operation. Set the work equipment in a stable position, stop the engine, then set the safety lock lever securely to the LOCK position.

Turn or replace the cutting edge before the wear reaches the edge of the bucket.

1.

2.

3.

4.

5.

6.

7.

Raise the bucket to a suitable height, then put blocks under the bucket to prevent the bucket from coming down.

• Raise the bucket so that the bottom surface of the bucket is horizontal.

Remove the nuts and bolts (1).

Remove the cutting edge (2).

Clean the mounting surface of the cutting edge (2).

Turn cutting edge (2) and install it to the bucket. When turning the edge, install it to the opposite side (left edge to right side, right edge to left side).

• If both sides of the cutting edge are worn, replace with a new part.

• If the wear extends to the mounting surface, repair the mounting surface before installing the cutting edge.

Tighten nuts and bolts (1) uniformly so that there is no gap between the bucket and cutting edge. Tightening the torque for the mounting bolt: 745 ± 108 N·m (549.7 ± 79.6 lb. ft.))

Tighten the mounting bolts again after operating for several hours.

3-38

WA480-5L

MAINTENANCE REPLACE BUCKET TEETH

If the pin is hit with a strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area.

There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and gloves.

Replace the bucket teeth before they wear down as far as the bucket edge.

1.

2.

3.

4.

Raise the bucket to a suitable height, then put blocks under the bucket to prevent the bucket from coming down. Raise the bucket so that the bottom surface of the bucket is horizontal.

Remove the bolt and nuts (1) and (2), then remove bucket tooth (3).

Clean the installation surface of bucket tooth (3).

Install new teeth to the bucket. When installing new teeth, insert shims so that there is no clearance between the teeth and the top surface of the bucket. Continue to add shims until it becomes impossible to add a 0.5 mm (0.02 in.) shim.

If the mounting surface is worn, correct the mounting surface before installing the teeth.

5.

To prevent any gap from forming between the teeth and tip of the bucket, tighten bolts and nuts (1) and (2) temporarily, then hit the tip of the teeth with a hammer.

Tightening torque of mounting bolt (1): 902 ± 39 N·m (665.4 ± 28.9 lb. ft.)

Tightening torque of mounting bolt (2): 902 ± 39 N·m (665.4 ± 28.9 lb. ft.)

After operating the machine for a few hours, tighten the mounting bolts again

WA480-5L

3-39

MAINTENANCE REPLACING SLOW-BLOW FUSE Remark Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). Always replace the slow blow fuse with one of the same capacity.

1.

Turn the starting switch to the OFF position.

2.

3.

Remove the slow blow fuse box from the chassis.

Open covers (1), (2), and (3) of the slow blow fuse box. Covers (2) and (3) can be removed easily by using protrusion (A) on the body as a fulcrum and levering the catch of the cover with a flat-headed screwdriver to release it.

Loosen screws (4) and (5), and remove. When screws (4) and (5) are removed, slow blow fuse (6) will also come off together with electric wiring (7) and (8).

Using screws (4) and (5), install a new slow blow fuse together with electric wiring (7) and (8) to the slow blow fuse box, then close covers (1), (2), and (3).

Install the slow blow fuse box to the chassis.

4.

5.

6.

3-40

WA480-5L

MAINTENANCE INSPECTION OF TIRES

If a tire or a rim is handled wrongly, the tire may burst or may be damaged and the rim may be broken and scattered, and that can cause serious injury and death. â&#x20AC;˘ Because maintenance, disassembly, repair and assembly of the tires and rims require special equipment and skill, ask a tire repair shop to perform the work. â&#x20AC;˘ Do not heat or weld the rim to which the tire is installed.

Do not make a fire near the tire.

Select the tires according to the conditions of use and attachments on the machine. Use only specified tires and inflate them to the specified pressure.

Because the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires.

Standard

If equipped

Maximum load [kg (lb.)]

Tire size

Front wheel

10,760 (23726)

23.5-25-20PR (L3 Rock)

Rear wheel

10,760 (23726)

23.5-25-20PR (L3 Rock)

Front wheel

11,140 (24564)

26.5-25-16PR (L3 Rock)

Rear wheel

11,140 (24564)

26.5-25-16PR (L3 Rock)

Front wheel

12,690 (27981)

26.5-25-20PR (L3 Rock)

Rear wheel

12,690 (27981)

26.5-25-20PR (L3 Rock)

Remarks

CHECKING TIRE PRESSURE

When inflating a tire, check that no one will enter the working area and use an air chuck which has a clip and which can be fixed to the air valve.

While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.

If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. To ensure safety, place a guard around the tire and do not work in front of the rim but work on the tread side of the tire.

Abnormal drop of inflation pressure and abnormal fitting of the rim indicate a trouble in the tire or rim. In this case, be sure to ask a tire repair shop to perform repairs.

Be sure to observe the specified inflation pressure.

Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-duty work.

WA480-5L

3-41

MAINTENANCE CHECK Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.

INFLATION OF TIRES Adjust the inflation pressure properly.

When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not work in front of the rim but work on the tread side of the tire.

The proper inflation pressure is shown below.

Tire size

Inflation pressure

26.5-25-20PR (L3 Rock) (standard)

Front Tire: 0.41 MPa (58.8 psi) Rear Tire: 0.34 MPa (46.4 psi)

26.5-25-16PR (L3 Rock) (if equipped)

Front Tire: 0.41 MPa (51.7 psi) Rear Tire: 0.34 MPa (44.6 psi)

26.5-25-20PR (L3 Rock) (standard) SEMI-PNEUMATIC OR SOLID TIRES The waste handler machines are usually equipped with a semi-pneumatic tire due to the type of environment the machine is exposed to.

Inspect the condition of the tire, it is important to keep these tires clean remove any objects embedded in the tire. If the tire has large chunks of rubber missing or hanging off the tire this may effect the performance of the machine, it is advised to replace the tire.

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MAINTENANCE

EVERY SPECIFIC HOURS SERVICE EVERY 50 HOURS SERVICE DRAIN SEDIMENT FROM FUEL TANK Open the drain plug (1) on the right side of the fuel tank so that the sediment and water will be drained together.

EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be performed at the same time.

LUBRICATE THE REAR AXLE PIVOT PIN (3 points) 1.

2.

Using a grease pump, pump in grease through the grease fittings marked by the arrow.

After greasing, wipe off any old grease that was pushed out.

CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL

The parts and oil are HOT after stopping the engine, and may cause burns. Wait for the temperature to decrease before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1.

Lower the bucket horizontally to the ground. It is correct if the oil amount is between H and L marks on the gauge (G) when measured approximately 5 minutes after the engine stopped.

Remark Do not add oil if the level is above the H line. If the oil has been added to above “H” level, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug. If the oil is above H level, it will damage the hydraulic circuit or cause the oil to spurt out.

2.

If the oil is below the L mark, open the inspection cover on the step and add the oil through the filler (F).

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3-43

MAINTENANCE CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT

If compressed air is used, there is danger that dirt may fly and cause personal injury.

Always wear safety glasses, dust mask, and other protective equipment.

If the air conditioner has been used, the air filter should be cleaned. Stop the air conditioner before cleaning the element.

1.

Push handle (1) and open cover (2).

2.

3.

Remove element (3) and clean it.

Direct dry compressed air (less than 0.69 MPa (99.4 PSI)) to the element from inside along its folds, then direct it from outside along its folds and again from inside.

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WA480-5L

MAINTENANCE

EVERY 250 HOURS SERVICE Maintenance for every 50 and 100 hours service should be performed at the same time.

CHECK BATTERY ELECTROLYTE LEVEL Perform this check before operating the machine.

Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This situation will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.

The battery generates flammable gas and there is danger of explosion, so 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 amount of water and consult a doctor.

When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.

Remark When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery, check as follows.

1.

2.

Open the cover of the battery box.There are two battery boxes: One on each side at the rear of the machine.

Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U.L) and LOWER LEVEL (L.L) lines. If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.

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3-45

MAINTENANCE 3.

4.

5.

If the electrolyte level is below the midway point between the U.L and L.L lines, remove cap (1) and add distilled water to the U.L line.

If distilled water has been added to any cell of cap (1), add distilled water also to the other cells.

Clean the vents of the battery caps, then close the caps securely.

Keep the top of the battery clean and wipe it with a wet cloth.

Remark If distilled water is added to above the U.L line, use a pipette to lower the level to the U.L line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.

1.

Open the cover of the battery box.There are two battery boxes: One on each side at the rear of the machine.

2.

Remove cap (1) at the top of the battery, look through the water filler port, and check the electrolyte surface. If the electrolyte does not reach the sleeve, add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line).

3.

If distilled water has been added to any cell of cap (1), add distilled water also to the other cells.

Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.

4.

After adding distilled water, tighten the cap (1) securely.

Remark If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.

3-46

WA480-5L

MAINTENANCE CHECK PARKING BRAKE 1.

2.

Set the machine on a dry downhill slope. Press the parking brake switch to the ON position. Check if the parking brake holds the machine in position.

If any abnormality is found, please contact your Komatsu distributor.

ALTERNATOR BELT TENSION The standard belt deflection between the alternator pulley and crank pulley when pressed with a thumb (approximately 59N (43.5 lbf)) should be about 13 mm (0.5 in.).

ADJUSTING 1.

2.

3.

4.

5.

6.

Loosen the bolts and nuts (1), (2), (3), and (4).

Turn the nut (5) clockwise and move the alternator (6) so that the belt deflection is about 13 mm (0.5 in.) (approximately 59N (43.5 lbf)).

Tighten the bolts and nuts (1), (2), (3), and (4) to hold the alternator (6) in position.

Check pulleys for damage, pulley grooves for wear, and V-belt for wear. Be particularly careful to check that the V-belt does not touch the bottom of the pulley groove.

If the belt has stretched and there is no allowance for adjustment, or it is cut or cracked, replace the belt.

After replacing the belt, operate for one hour and adjust again.

AIR CONDITIONER COMPRESSOR BELT TENSION The standard belt deflection between the air conditioner compressor pulley and crank pulley when pressed with a thumb (approximately 98 N (72.3 lbf)) should be approximately 16 to 20 mm (0.6 to 0.8 in.).

When a belt tension gauge is used, the standard tension is within a range from 353 to 530 N (260.3 to 390.9 lbf).

CHECK WHEN CHANGING THE V-BELT The standard deflection between the air conditioner compressor pulley and fan pulley when pressed with a thumb (approximately 98 N (72.3 lbf)) should be approximately 12 to 17 mm (0.5 to 0.7 in.). When a belt-tension gauge is used, the standard tension is within a range from 530 to 745 N (390.9 to 549.5 lbf).

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3-47

MAINTENANCE Remark When the belt has been replaced with a new one, a high belt tension is necessary. Thus, the initial tension is the value given above.

ADJUSTING 1.

2.

3.

4.

Loosen the nuts (1) and (2), and move the compressor (3) to adjust.

Tighten nuts (1) and (2) to hold compressor (3) in position.

Check each pulley for damage, wear of the V-groove, and wear of the V-belt. Be particularly careful to check that the V-belt is not in contact with the bottom of the V-groove.

If the V-belt has stretched, leaving no allowance for adjustment, or if there is any cut or crack on belt, replace the belt. If the V-belt has been replaced with a new one, there will be initial elongation.

Inspect and adjust it again after one-hour of operation.

WHEEL HUB NUTS If wheel hub nuts (1) are loose, tire wear will be increased and accidents may be caused.

1.

Check for loose nuts, and tighten if necessary. When checking for loose nuts, always turn the nuts in the direction of tightening to check.

Tightening torque: 825 to 1030 N¡m (608.5 to 759.7 lbft).

2.

If any stud bolt is broken, replace all the stud bolts for that wheel.

AIR CONDITIONER RECIRCULATION FILTER 1.

Loosen the knob (1), remove the filter inspection cover (2) then open the filter inspection cover (3).

2.

3.

Pull the filters (4) and (5) out in the direction of the arrow.

Clean with compressed air in the same way as for the fresh air filter.

If the filter is extremely dirty, rinse it in water. After rinsing the filter, dry it completely before installing it again.

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WA480-5L

MAINTENANCE LUBRICATING POINTS 1.

Using a grease pump, pump in the grease through the grease fittings marked by the arrows.

2.

After greasing, wipe off any old grease that was pushed out.

Remark On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are performed continuously for more than eight hours, grease the machine more frequently than prescribed.

1.

2.

3.

4.

WA480-5L

Bucket pin (2 points) Bucket link pin (2 points) Dump cylinder pin (2 points) Lift cylinder pin (4 points)

5.

6.

7.

Lift arm pivot pin (2 points) Tilt lever pin (1 point) Steering cylinder pin (4 points)

3-49

MAINTENANCE

EVERY 500 HOURS SERVICE Maintenance for every 50, 100 and 250 hours service should be performed at the same time.

CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE

The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

• •

Refill capacity: 38 liters (10.04 US gal) Filter wrench

1.

2.

3.

4.

Open the engine side cover located on the right of machine.

Open the engine oil filler (F).

Loosen the drain plug (P), and drain the oil.

Check the drained oil. If excessive metal particles or foreign material exist, please contact your Komatsu distributor.

Install drain plug (P).

5.

6.

7.

8.

9.

Using a filter wrench, turn the filter cartridge (1) counterclockwise to remove it.

If this operation is carried out immediately after stopping the engine, a large amount of oil will come out. Therefore, wait for 10 minutes before starting the operation.

Clean the filter holder, fill a new filter cartridge with clean engine oil (or coat thinly with grease), then coat the seal and thread of the filter cartridge with engine oil. Install the filter.

When installing, bring the seal surface into contact with the filter holder, and tighten another 3/4 to 1 turn.

10. Run the engine at idle for a while, then stop the engine. Check that the oil level is between the H and L marks on the dipstick. For details, see “CHECK ENGINE OIL LEVEL, ADD OIL” on page 2-80.

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WA480-5L

MAINTENANCE REPLACING FUEL FILTER CARTRIDGE

Immediately after the engine is stopped, all parts are at high temperature, so do not replace the filter immediately.

Wait for the engine to cool down before starting the operation.

The inside of fuel piping system of the engine is under high-pressure when the engine is running. When replacing the filter, wait for at least 30 seconds after the engine stops to let the internal pressure go down before replacing the filter.

Do not bring any fire or spark close.

This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely.

Always use a Komatsu genuine part for the fuel filter cartridge. If filters other than genuine filters are used, problems may occur in the injection system, so never use substitute parts.

Be careful when opening the air bleed plug at the fuel filter head and the air bleeder of the supply pump.

The system is still under pressure and fuel may spurt out. â&#x20AC;˘ â&#x20AC;˘

Container to catch the oil Filter wrench

1.

2.

Set the container to catch the fuel under the filter cartridge.

Using a filter wrench, turn the filter cartridge (1) counterclockwise to remove it.

Clean the filter head, fill the new filter cartridge with clean fuel, coat the packing surface thinly with engine oil, and install it to the filter holder. Always use clean fuel when filling with fuel, and be careful not to let any dirt or dust get in.

3.

A. Add fuel from the small hole (A) (dirty side) at eight places.

Do not add fuel from hole (B) (clean side) at the center.

B. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.

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3-51

MAINTENANCE 4.

After replacing the filter cartridge (1), loosen the air bleed plug (2).

5.

6.

Loosen the air bleeder (4) of the supply pump.

Pump priming pump (3) until no more bubbles come out with the fuel from air bleeder (4), then tighten the air bleeder (4).

Tightening torque: 4.9 to 6.9 N·m (3.6 to 5.1 lb. ft.)

7.

8.

9.

Continue pumping (about 50 times) until the priming pump (3) becomes stiff and the overflow valve release sound becomes continuous.

Push the knob of priming pump (3) in and tighten it.

After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal surface. If fuel leakage exists, check the tightening of the filter cartridge. If fuel leakage still exists, follow Step 1 and 2 to remove the filter cartridge.

Check the packing surface for damage or foreign material. If any damage or foreign material is found in the packing, replace the cartridge with a new part, repeat Steps 3 to 9 to install the filter cartridge.

CLEANING THE FUEL STRAINER

Immediately after stopping the engine, all parts are HOT. Wait for the parts to cool down before replacing the strainer.

The engine fuel piping line is under high pressure when the engine is running. When replacing the strainer, wait at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the strainer.

Never bring any flame close.

This engine consists of higher precision parts than the conventional fuel injection pump and nozzle. If dirt gets in, it will cause problems. If there is any dirt stuck on or near the fuel line fittings, use Komatsu Safety Solvent and Degreaser to remove any dirt before loosening the fittings.

• •

Container to catch the fuel.

Filter wrench

1.

Set the container under the fuel strainer to catch the fuel.

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WA480-5L

MAINTENANCE 2.

Using the filter wrench, turn ring (1) to the left to loosen it, then remove element cup (2) and the element.

3. Wash the element and the inside of element cup (2) with clean fuel.

4. Clean the strainer head, fill the element cup with clean fuel, coat the packing surface thinly with engine oil, then install to the head, taking care not to damage the O-ring. Always use clean fuel when filling the element cup and be careful not to let any dirt or dust get in.

5. When installing, turn the ring (1) to the right to tighten it.

Tightening torque: 23 to 27 N¡m (16.9 to 19.9 lb. ft.). If the ring is loose, it will cause fuel leakage. Always tighten the ring to the specified torque.

6. After installing element cup (2), bleed the air as follows.

7. Loosen air bleed plug (3) of the fuel filter.

8. Loosen the knob of priming pump (4), then pump it up and down until no more bubbles come out with the fuel from air bleed plug (3).

9. Tighten the air bleed plug (2). Tightening torque: 7.8 to 9.8 N¡m (5.8 to 7.2 lb. ft.)

10. Push the priming pump knob (4) in and tighten it.

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3-53

MAINTENANCE

EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.

CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER

Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the temperature to go down before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure. Remove the cap.

• •

Refill capacity: 54 liters (14.27 US gal) Filter wrench

1.

Set a container to catch the oil under drain plug (P), then remove drain plug (P) and drain the oil. To prevent the oil from pouring out suddenly, loosen drain plug (P) and remove it gradually.

After draining the oil, install drain plug (P).

Tightening torque: 68.6 ± 9.8 N·m (50.6 ± 7.2 lb. ft.)

Set a container to catch the oil under the transmission filter.

2.

3.

4.

5.

6.

7.

Remove the drain plug (1) of the transmission filter, drain the oil, then tighten the plug again.

Using a filter wrench, turn filter cartridge (2) to the left to remove it.

Clean the filter holder, coat the seal surface and thread of the new filter cartridge with engine oil, then install it.

When the seal surface comes into contact with the filter holder, tighten another 2/5 turns with the filter wrench.

8.

Remove the bolts (3), move the tube (4), and then remove the strainer (5).

9. Remove any dirt stuck to the strainer (5), then wash it in clean diesel fuel or flushing oil. If the strainer (5) is damaged, replace it with a new one.

10. Install the strainer (5) in the case. Replace the O-ring of tube (4) with a new part, then install the tube (4).

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WA480-5L

MAINTENANCE 11. Pour in the specified amount of engine oil into the oil filler (F).

12. After filling with oil, check that the oil is at the specified level. For details, see â&#x20AC;&#x153;TRANSMISSION OIL LEVELâ&#x20AC;? on page 3-32.

13. Check that there is no oil leakage from the transmission case or oil filter.

CLEAN THE TRANSMISSION CASE VENT 1.

2.

Open the cover (1) on the cab side of the engine hood.

Remove the mud and dirt from around the breather, then remove breather (2), soak it in washing liquid and wash it. After removing the breather, take steps to prevent dirt or dust from entering the mount.

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3-55

MAINTENANCE LUBRICATING POINTS 1.

2.

3.

Using a grease pump, pump in the grease through the grease fittings marked by the arrows.

After greasing, wipe off any old grease that was pushed out. Center hinge pin (2 points).

Drive shaft center support (1 point).

CHECKING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR Please contact your Komatsu distributor to have the rotor play checked.

REPLACE CORROSION RESISTOR CARTRIDGE 1.

2.

3.

4.

5.

Set 2 levers (1) at the top of the corrosion resistor to the side to the CLOSED position.

Using a filter wrench, turn cartridge (2) to the left to remove it.

Apply engine oil to the sealing surface of a new cartridge, then install it to the filter holder.

Bring the packing surface into contact with the seal surface of the filter holder, then tighten an additional 2/3 turn.

Set 2 levers (1) vertically to the OPEN position.

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WA480-5L

MAINTENANCE

EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be performed at the same time.

CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT

The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

•

Refill capacity: 190 liters (50.2 US gal)

1.

Lower the bucket horizontally to the ground and apply the parking brake, then stop the engine.

Remove bolts (1), then remove cover (2).

Remove the cap of oil filler (F).

2.

3.

4.

5.

6.

7.

Set a container to catch the oil under the drain plug (3).

Remove drain plug (3).

Open drain valve (4) gradually and drain the oil.

After draining the oil, close drain valve (4), then tighten drain plug (3).

Tightening torque Drain plug (3): 68.6 ± 9.8 N·m (50.6 ± 7.2 lb. ft.)

Drain valve (4): 63.7 ± 14.7 N·m (47.0 ± 10.8 lb. ft.)

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3-57

MAINTENANCE 8.

Remove the mounting bolts (6) to the filter cover (5) at the top of the tank, then remove the cover. When the cover is removed, the force of spring (7) may make the cover fly off, so keep the cover pushed down when removing the bolts.

9. Remove the spring (7) and bypass valve (8), then remove element (9).

10. Check that there is no foreign material inside the tank, then clean it.

11. Install new element (9), then set bypass valve (8), spring (7), and cover (5) to the tank. If the O-ring of the cover is damaged or deteriorated, replace it.

12. When installing the cover bolts, push down the cover and tighten the bolts evenly.

13. Add engine oil through oil filler port (F) to the specified level, then install cap.

14. Check the hydraulic oil is at the specified level. For details, see “CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL” on page 3-43.

15. Run the engine at low idle and extend and retract the steering, bucket, and lift arm cylinders 4 to 5 times. Be careful not to operate the cylinder to the end of its stroke (stop about 100 mm (3.9 in.) before the end of stroke.

Remark If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder will damage the piston packing.

16. Next, operate the steering, bucket, and lift arm cylinders to the end of their stroke 3 to 4 times, then stop the engine and loosen bleed plug (10) to bleed the air from the hydraulic tank. After bleeding the air, tighten plug (10) again. Run the engine at low idling when bleeding the air.

17. Check the hydraulic oil is at the specified level. For details, see “CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL” on page 3-43.

18. Next, increase the engine speed and repeat the procedure in Step 16 to bleed the air. Continue this operation until no more air comes out from plug (10).

19. After completing the air bleed operation, tighten the plug (10).

Tightening torque: 11.3 ± 1.5 N·m (8.3 ± 1.1 lb. ft.)

20. Check that the hydraulic oil is at the specified level. For details, see “CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL” on page 3-43.

21. Check that there is no oil leakage from the filter cover mount.

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WA480-5L

MAINTENANCE HYDRAULIC TANK VENT ELEMENT

Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the engine temperature to go down before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1.

2.

3.

4.

5.

6.

Before removing the breather, wipe off all the dirt from around the breather.

Remove the oil filler cap (F).

Remove the nut (2) of the breather (1); remove the cover (3).

Replace the filter element (4) with a new one.

Install the cover (3) and nut (2).

Tighten the oil filler cap (F).

Remark It is possible to replace the element with the breather installed in the tank. However, if the breather is removed, do not wrap the taper thread of the breather with seal tape when assembling again, and be careful not to tighten too much.

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3-59

MAINTENANCE CHANGE THE AXLE OIL

When changing the oil, apply the parking brake and secure the front and rear frames with the safety bar.

Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the temperature to go down before starting the operation.

When the plug is removed, oil may spurt out. Therefore, turn the plug slowly to release the internal pressure, then remove the plug carefully.

•

Refill the capacity (front and rear, each): 52 liters (13.74 US gal)

1.

2.

Set a container to catch the oil under drain plug (P).

Remove front and rear oil filler plugs (1), then remove drain plug (P) to drain the oil.

Remark Remove the mud and dirt from around the plug (1), then remove it.

3.

4.

After draining the oil, clean drain plug (P) and install it again.

Add axle oil through plug hole (1) at the specified level.

Remark For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified lubricating oil.

5.

After adding oil, check that the oil is at the specified level (1). For details, see “CHANGE THE AXLE OIL” on page 3-60.

Remark For frequent brake use, change the axle oil at shorter intervals.

AIR CONDITIONER RECIRCULATION FILTER Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with new ones.

For details of cleaning the recirculation air filter, see “AIR CONDITIONER RECIRCULATION FILTER” on page 3-60. To clean the element, see “CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT” on page 3-44.

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WA480-5L

MAINTENANCE CLEAN PPC CIRCUIT STRAINER

Immediately after stopping the engine, the parts and oil are HOT and may cause burns. Wait for the temperature to go down before starting the operation.

After removing the rubber hose, oil may spurt out. So turn the hose slowly to release the internal pressure gradually. Remove the hose carefully.

1.

2.

3.

4.

When rubber hose (1) and flange (2) are removed, oil will spill out, so set a container (capacity: about 300 cc) in position to catch the oil.

Remove rubber hose (1) and flange (2).

Remove strainer (3) and wash it in clean diesel oil.

Install strainer (3) in strainer case (4) from the concave side, then install with flange (2).

Remark Assemble with the protruding side (O-ring side) of the strainer at the front

5.

Install the rubber hose (1).

CLEAN THE ENGINE VENT ELEMENT

Immediately after stopping the engine, the parts and oil are HOT and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather.

When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.

Always use safety glasses, dust mask, or other protective equipment.

1.

2.

3.

4.

5.

Wipe away dust around the breather.

Loosen the clamp and remove the hose. Remove the breather (1).

Clean the breather body with light oil or cleaning oil.

Replace O-ring with new one. Coat a new O-ring with engine oil, set it, then install breather (1).

Check the breather hose and pipe. If caked oil (sludge) adheres to the insides, replace the hose and pipe with new ones.

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3-61

MAINTENANCE CHECK ALTERNATOR, STARTER MOTOR The brush may be worn or may be no grease on the bearing, so contact your Komatsu distributor for inspection or repair.

If the engine is started frequently, perform an inspection every 1000 hours.

CHECK ENGINE VALVE CLEARANCE As special tool is required for removing and adjusting the parts, contact your Komatsu distributor for service.

CHECK TURBOCHARGER If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbocharger or cause it to break, so ask your Komatsu distributor to perform the cleaning.

CHECK INJECTOR Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please contact your Komatsu distributor for inspection or replacement. For details of the action to take if there is an abnormality, see “START-UP PROCEDURES” on page 2-83.

CHECK ACCUMULATOR GAS PRESSURE When performing the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pressure.

CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber.

If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

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MAINTENANCE CHECKING BRAKE DISC WEAR

When checking the brake disc for wear, apply the parking brake and secure the front and rear frames with the safety bar.

Make sure that the brake oil temperature is less than 60° C (140° F) before checking the brake wear.

If the disc is near the wear limit, perform inspection at shorter intervals, regardless of the specified inspection interval.

Check the brake disc for wear at four locations: front axle, rear axle, left, and right.

1.

Remove the cap nut (1).

2.

Depress the brake pedal, keep it depressed, and push in the rod (2) of the gauge until contacts the piston.

The wear is the amount that the end face of rod (2) is protruding from the end face of guide (3). Measure the amount of protrusion.

The point where the rod groove is level with the end face of the guide is the permissible limit for the disc wear. If the wear has reached this point, please ask your Komatsu distributor for inspection and replacement parts. If the disc is near the wear limit, perform inspection at shorter intervals, regardless of the specified inspection interval.

Install the cap nut (1).

Tightening torque: 29.4 to 39.2 N·m (21.7 to 28.9 lb. ft.)

3.

4.

Remark On new machines, the position of the guide is adjusted so that the end face of the rod (2) comes to the end face of the guide (3). For this reason, do not loosen the locknut (4), except when replacing the disc.Perform the operation with two workers: one worker depresses the brake pedal and the other worker pushes the rod (2) in.

WA480-5L

3-63

MAINTENANCE

EVERY 4000 HOURS SERVICE Maintenance for every 50, 100, 250, 500, 1,000 and 2,000 hours service should be performed at the same time.

LUBRICATING POINTS Perform the greasing once every two years, regardless of whether the 4, 000 hour interval has passed.

1.

2.

Using a grease pump, pump in grease through the grease fittings marked by the arrows.

After greasing, wipe off any old grease that was pushed out.

Center drive shaft spline (1 point)

Front drive shaft (2 points)

Rear drive shaft (2 points)

Center drive shaft (2 points)

3-64

WA480-5L

MAINTENANCE CHECK WATER PUMP Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

CHECK AIR CONDITIONER COMPRESSOR Ask Komatsu distributor.

REPLACE INJECTOR NOZZLE TIP Ask your Komatsu distributor to perform this work.

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER

Perform a visual and physical inspection that there are no loose bolts or hardening of rubber parts at the clamps (1) to (10). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement.

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Check for any missing fuel spray prevention caps (1) to (11) or fuel spray prevention cover (12), and check also for any hardened rubber portions. If there are any missing caps or cover or the rubber is hardened, please contact your Komatsu distributor for repairs.

WA480-5L

3-65

MAINTENANCE

EVERY 8000 HOURS SERVICE Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time.

REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to perform this work.

REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to perform this work.

3-66

WA480-5L

SPECIFICATIONS

WA480-5L

4

4-1

SPECIFICATIONS

SPECIFICATIONS WA480-5L WITH BOLT-ON CUTTING EDGE

Item

Unit

WA480-5L standard specification machine (when using POWER mode)

Operating weight, including 1 operator: 80 kg (176 lb) kg (lb.) (with bolt on cutting edge)

24,145 (53,240)

Normal load

7,820 (17,243)

Bucket capacity

kg (lb.)

Heaped

m³ (yd³)

Engine model

-

4.6 (6.0) Komatsu SAA6D125E-3 diesel engine

Flywheel horsepower

kW(HP)/rpm

202 (271)/2,000

A

Overall length

mm (ft. in.)

B

Overall height

mm (ft. in.)

3,500 (11 ft. 6 in.)

C

Max. dimension when shanking bucket

mm (ft. in.)

6,175 (20 ft. 3 in.)

D

Overall width

mm (ft. in.)

3,010 (9 ft. 11 in.)

E

Min. ground clearance

mm (ft. in.)

525 (1 ft. 9 in.)

9,155 (30 ft.)

F

Bucket width

mm (ft. in.)

3,170 (10 ft. 5 in.)

G

Clearance

Cutting edge [BOC tip]

mm (ft. in.)

3,300 (10 ft. 10 in.) [3,205 (10 ft. 6 in.)]

H

Reach

Cutting edge [BOC tip]

mm (ft. in.)

1,370 (4 ft.6 in.) [1,410 (4 ft. 8 in.)]

I

Dump angle Min. turning radius Travel speed

degrees Outside of chassis

mm (ft. in.)

7,030 (23 ft. 1 in.)

Center of outside tire

mm (ft. in.)

5,900 (19 ft. 4 in.)

1st

km/h (mph)

6.3 (3.9)

2nd

km/h (mph)

12.1 (7.5)

3rd

km/h (mph)

21.6 (13.4)

4th

km/h (mph)

34.3 (21.2)

1st

km/h (mph)

6.6 (3.84.1

2nd

km/h (mph)

12.8 (8.0)

3rd

km/h (mph)

22.8 (14.2)

4th

km/h (mph)

35.8 (22.2)

Forward

Reverse

4-2

45

WA480-5L

SPECIFICATIONS

MACHINE DIMENSIONS AND WEIGHTS

TIRES Tire Specifications

mm

(in)

Tread

2300

7’7”

Width over tires

3010

9’11”

A

Wheel base

3450

11’4”

B

Hinge pin height at Max. height

4505

14’9”

C

Hinge pin height at carry position

585

1’11”

D

Ground clearance

525

1’9”

E

Hitch point height

1240

4’1”

F

Overall height, top of stack

3080

10’2”

G

Overall height ROPS cab

3500

11’6”

WA480-5L

4-3

SPECIFICATIONS WORK EQUIPMENT General Purpose Bolt-on Cutting Edge

Bucket

Excavating with Teeth and Segment Edge

Excavating with Teeth

Loose Material Bolt-on Cutting Edge

Light Material Bolt-on Cutting Edge

Heaped

4.6m3

6.0yd3

4.1m3

5.4yd3

3.8m3

5.0yd3

4.9m3

6.4yd3

6.1m3

8.0yd3

Struck

4.0m3

5.2yd3

3.5m3

4.6yd3

3.2m3

4.2yd3

4.2m3

5.5yd3

5.2m3

6.8yd3

Bucket width

3170mm

10’5”

3190mm

10’6”

3190mm

10’6”

3170mm

10’5”

1370mm

10’5”

Bucket weight

2260kg

4,982lb

2255kg

4,971

2125kg

4,685lb

2340kg

5,159lb

2410kg

5,313lb

Straight

20250kg

44,644lb

20155kg

44,434lb

20285kg

44,721lb

20620kg

45,459lb

20000kg

44,092lb

40o full turn

17590kg

38,779lb

1700kg

38,581lb

17630kg

38,868lb

17945kg

39,562lb

17345kg

38,239lb

Dumping clearances maximum height and 45o dump angle

3205mm

10’6”

3170mm

10’5”

3170mm

10’5”

3125mm

10’3”

3080mm

10’1”

Reach at (7’) 2130mm 45o dump angle

2135mm

7’0”

2080mm

6’10”

2135mm

7’0”

2180mm

7’2”

2205mm

7’3”

Reach at maximum height 45o dump angle

1420mm

4’8”

1420mm

4’8”

1420mm

4’8”

1490mm

4’11”

1535mm

5’0”

Reach with Arm Horizontal and Bucket Level

3020mm

9’11”

2895mm

9’6”

3050mm

10’0”

3125mm

10’3”

3205mm

10’6”

Operating Height Fully Raised

6175mm

20’3”

6025mm

19’9”

6025mm

19’9”

6175mm

20’3”

6450mm

21’2”

Overall Length Bucket on Ground

9155mm

30’0”

9185mm

30’2”

9185mm

30’2”

9270mm

30’5”

9330mm

30’7”

14060 mm

46’2”

14120 mm

46’4”

14120 mm

46’4”

14140 mm

46’5”

14170 mm

46’6”

0o

90mm

3.5”

110mm

4.3”

110mm

4.3”

90mm

3.5”

90mm

3.5”

10o

355mm

1’2”

380mm

1.3”

380mm

1’3”

380mm

1’3”

380mm

1.3”

212kN

47,658lb

237kN

53,278lb

249kN

55,975lb

196kN

44,061lb

189kN

42,487lb

24545kg

54,113lb

24420kg

53,837lb

24290kg

53,550lb

24550kg

54,024lb

24575kg

54,179lb

Bucket capacity

Static tipping load

Turning radius Digging depth

Breakout force Operating weight

4-4

WA480-5L

SPECIFICATIONS WEIGHT CHANGES

Tires

Operating weight

Tipping load straight

Tipping load full turn

Width over tires

Ground clearance

Change in vertical dimensions

kg

lb

kg

lb

kg

lb

mm

ft in

mm

ft in

mm

ft in

26.5-2520PR(L-4)

+360

+794

+250

+551

+220

+485

3010

9’11”

525

1’9”

0

0

Remove ROPS cab

-660

-1455

-550

-1213

-530

-1168

Install ROPS canopy

+430

+950

+360

+795

+345

+760

Remove additional counterweight

-400

-880

-950

-2094

-790

-1742

WA480-5L

4-5

SPECIFICATIONS

MACHINE SYSTEMS SPECIFICATIONS

ENGINE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SAA6D125E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPA Tier 2 emission ready Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, and air-to-air after cooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm x 150 mm 4.9" x 5.9" Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.04 ltr 674 in3 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic, all-speed control • Horsepower rating @ 2000 rpm (SAE J1349) Gross horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 kW 283 HP Net horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 kW 271 HP • Tier 2, EU and Japan emissions certified Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic, all speed controlled • Lubrication system Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double radial-sealed elements and dust evacuator, plus dust indicator

4-6

WA480-5L

SPECIFICATIONS

TRANSMISSION Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-powershift, countershaft type Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-element, single-stage, single phase Travel Speed

Forward

Reverse

1st.

6.3 km/hr. (3.9 mph.)

6.6 km/hr (4.1 mph.)

2nd.

12.1 km/hr. (7.5 mph.)

12.8 km/hr (8.0 mph.)

3rd.

21.6 km/hr. (13.4 mph.)

22.8 km/hr (14.2 mph.)

4th.

34.3 km/hr. (21.3 mph.)

35.8 km/hr (22.2 mph.)

★ Measured with 26.5-25 tires ★ 4th gear speed range not used in waste handler applications

AXLES AND FINAL DRIVES Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-wheel drive Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed, semi-floating Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center-pin support, semi-floating 30o total oscillation Reduction gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral bevel gear Differential gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional type Final reduction gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear, single reduction

BRAKES Service brakes . . . . . . . . . . . . . . . . . . Hydraulically-actuated, in-board mounted, wet multi-disc brakes actuate on four wheels Parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multi-disc brake

STEERING SYSTEM Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Articulated type, full-hydraulic power steering Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40o each direction Minimum turning radius at the center of outside tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5900 mm 19'4"

SERVICE REFILL CAPACITIES Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ltr 13.2 U.S. gal Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 ltr 110.2 U.S. gal Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ltr 10.0 U.S. gal Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 ltr 49.1 U.S. gal Axle (each, front and rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ltr 14.5 U.S. gal Torque converter and transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ltr 15.9 U.S. gal

WA480-5L

4-7

SPECIFICATIONS

4-8

WA480-5L

OPTIONS, ATTACHMENTS

WA480-5L

5

5-1

OPTIONS, ATTACHMENTS

MONITOR WITH LOAD METER The only difference from the machine monitor described in EXPLANATION OF COMPONENTS in the OPERATION section is that the load meter panel is installed in place of the speedometer and meter display pilot lamp.

For details of items not given here, see “INSTRAMENT BEZEL” on page 2-7.

LOAD METER

1.

Load meter display

2.

Character display

3.

4.

Monitor panel mode selector switch 1 Monitor panel mode selector switch 2

SWITCHES

1.

2.

Load meter cancel switch Load meter sub total switch

For details of switches (3) and (4), see “MONITOR MODE SELECTOR SWITCHES” on page 2-9 and “SWITCH LOCATION” on page 2-32

5-2

WA480-5L

OPTIONS, ATTACHMENTS LOAD METER CANCEL SWITCH When the measured data is not needed, press the switch at the top of the bucket control lever. The data that has just been calculated will be canceled and the display will return to the display before measuring.

LOAD METER SUB TOTAL SWITCH Press the switch at the side of the bucket control lever to set the TOTAL LOADED display (when in addition mode) or REMAINING TARGET display (when in remain mode) to 0.

WA480-5L

5-3

OPTIONS, ATTACHMENTS

LOAD METER FUNCTIONS

1.

2.

3.

Addition mode display Remain mode display TOTAL LOADED display (addition mode) or REMAINING TARGET display (remain mode)

4.

5.

6.

Bucket load display Material type display Speed display or engine speed display.

Operation of the various functions of the load meter is performed by using the monitor panel mode selector switch 1 or monitor panel mode selector switch 2 on the front switch panel and the load meter cancel switch and load meter sub total switch on the bucket control lever.

There are the following two types of measurement methods in the load meter mode. ❥

❥

Addition mode (measuring total amount loaded). This method is useful for measuring the production, such as the amount loaded into the dump truck, the amount loaded into the hopper, or the total work for half a day. The data can be displayed up to a maximum of 9999 tons for each type of work.

Remain method (measuring amount remaining). Use this method for work requiring a determined amount (prevention of overloading, distribution of material, etc.)

LOAD METER ADDITION MODE ❥ ❥ ❥

5-4

For details of the method of switching to the addition mode, see “SETTING ADDITION MODE” on page 5-7.

“TOTAL LOADED” lights up on load meter display (1).

The bucket load is displayed on load meter display (2), and the total load is displayed on display (3).

WA480-5L

OPTIONS, ATTACHMENTS ❥

❥

If the measured data is not needed, press the load meter cancel switch (4). The data for the last calculation is canceled while the previous measurement is now displayed (3).

To return the total load display (3) to 0, press the load meter sub total switch (5).

LOAD METER REMAIN MODE ❥ ❥ ❥

❥ ❥ ❥

For details of the method of switching to the remain mode, see “SETTING THE REMAIN MODE” on page 5-8.

“REMAINING TARGET” lights up on load meter display (1).

The bucket load is displayed on load meter display (2), and the amount remaining to the target is displayed on display (3).

If the measured data is not needed, press load meter cancel switch (4).

The data for the last calculation is canceled and display (3) returns to the display for the previous measurement.

To return total load display (3) to 0, press load meter sub total switch (5).

SELECTION OF DISPLAY FOR TYPE OF LOAD ❥

❥

❥

For details of the method of selecting the type of load, see “SETTING ADDITION MODE” on page 5-7 and “SETTING THE REMAIN MODE” on page 5-8.

It is possible to make categories for a maximum of five types of material for TOTAL LOADED or REMAINING TARGET. If the settings for types A to E are changed for each type of material when operations are carried out, it is possible to store in memory the data for TOTAL LOADED or REMAINING TARGET for each type of material.

One of the selected types of material A to E is displayed on the load meter display (1).

WA480-5L

5-5

OPTIONS, ATTACHMENTS METHOD OF CALIBRATION (ADJUSTING 0 POINT) ❥

For details of the method of performing the calibration, see “PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY” on page 5-12 and “PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED” on page 5-13.

Remark Normally, it is sufficient to perform the calibration only when empty, but it is also possible to perform calibration when loaded if necessary.

DELETING LOAD METER DISPLAY ❥ ❥

It is possible to set so that there is no load meter display. If there is no display, only the speed is displayed.

To switch the load meter between display and no display, see “STOPPING THE CALCULATION” on page 5-11.

SPEED DISPLAY ❥

The travel speed of the machine is displayed on the load meter display (1).

It is also possible to switch this display (1) so that it displays the engine speed.

If you wish to switch the speed display to the engine speed display, please ask your Komatsu distributor to perform the operation.

5-6

WA480-5L

OPTIONS, ATTACHMENTS

USING LOAD METER DISPLAY SETTING ADDITION MODE 1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel selector switch 1 and display “ADDITION MODE”.

Remark If the previous setting was the addition mode, “ADDITION MODE” is displayed; if the previous setting was the remain mode, “REMAINS MODE” is displayed.

4.

If the display is “REMAINS MODE”, press the (>) or (<) of the monitor panel mode selector switch 2 to display “ADDITION MODE”.

5.

Press the ( ) of monitor panel selector switch 1 and display “MATERIAL < > SELECT”.

WA480-5L

5-7

OPTIONS, ATTACHMENTS 6.

7.

8.

Check the display for the selected material on load meter display (1). The present selection display is A. In the case of the addition mode, “TOTAL LOADED” is displayed on display (2).

If A is to remain selected, press the ( ) of monitor panel mode selector switch 1. A is then selected. If A is to be changed to B to E, press the (>) or (<) of monitor mode selector switch 2 to select the type of material, then press the ( ) of monitor panel mode selector switch 1.

This completes the setting of the addition mode. The character display returns to the normal service meter and time display.

Once the setting has been made, even if the starting switch is turned OFF and operations are stopped, the setting is retained. When operations are started again, there is no need to perform the setting again. All further loads will be added to the total load recorded before operations were stopped.

SETTING THE REMAIN MODE When performing operations in the remain mode, set to the remain mode. For details of the remain mode functions, see “SUBTRACTION FUNCTION” on page 5-15.

1.

2.

3.

Check that the normal service meter and time are displayed on the character display.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

Press the ( ) of monitor panel selector switch 1 and display “REMAINS MODE”.

Remark If the previous setting was the addition mode, “ADDITION MODE” is displayed; if the previous setting was the remain mode, “REMAINS MODE” is displayed.

5-8

WA480-5L

OPTIONS, ATTACHMENTS 4.

If the display is “ADDITION MODE”, press the (>) or (<) of monitor panel mode selector switch 2 to display “REMAINS MODE”.

5.

Press the ( ) on the monitor panel selector switch 1 and display “INPUT TARGET”.

Input the target load. Before the target is input, “000.0 t” is displayed on the target line and the cursor is at the 100 ton position.

6.

The following explanation explains the procedure when inputting 30 tons as the target.

7.

8.

9.

“0” is marked by the cursor at the 100 ton position, so leave it at “0” and press the ( ) of monitor panel selector switch 1.

“0” is selected and the cursor moves to the 10 ton position.

The “0” at the 10 ton position must be changed to “3,” so press the (>) or (<) of monitor panel mode selector switch 2 to change to “3,” so press ( ) on the monitor panel selector switch 1. “3” is selected and the cursor moves to the 1 ton position.

“0” is already displayed at both the 1 ton and 0.1 ton positions, so press the ( ) of monitor panel selector switch 1 twice. “0.0” is selected and 30 tons is set as the target load.

Remark If 0 tons is input as the target load, and it is not accepted, the buzzer gives a long sound and the mode changes to give the addition mode display.

10. Press the ( ) of monitor panel selector switch 1. If the monitor accepts the input amount, the buzzer will give short sounds and “MATERIAL < > SELECT” is displayed.

11. Check the display for the selected material on load meter display (1).

The present selection display is B. In the remain mode, “REMAINING TARGET” is displayed on display (2).

12. If B is to remain selected, press the ( ) on monitor panel mode selector switch 1. B is then selected.

If B is to be changed to A, C, D or E, press the (>) or (<) of monitor panel mode selector switch 2 to select the type of material, then press the ( ) of monitor panel mode selector switch 1.

WA480-5L

5-9

OPTIONS, ATTACHMENTS 13. This action completes the setting of the remain mode. The character display returns to the normal service meter and time display.

Once the setting has been made, even if the starting switch is turned OFF and operations are stopped, the setting is retained. When operations are started again, there is no need to perform the setting again. All further loads will be subtracted from the total load recorded before operations were stopped.

TOTAL LOAD DATA DISPLAY 1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 to display “DATA”.

4.

Press the ( ) of monitor panel selector switch 1 to display “TOTAL DATA”. The time when the load on the bottom line was calculated is displayed as the hour meter standard.

Press the (>) or (<) of monitor panel mode selector switch 2 to select the data for each of A to E or the all lighted-up display.

5.

The total load data for each of A to E and for all data is displayed on the load meter display.

Check the material selection display on load meter display (1). In the example on the right, all of A to E for all data selected light up.

On display (2) the total load data for all data or individual total load data for A to E is displayed.

On display (3) the individual number of loads for A to E is displayed.

5-10

WA480-5L

OPTIONS, ATTACHMENTS The total value can be cleared as follows.

A. Press the (>) or (<) of monitor panel mode selector switch 2, and select the individual items to be cleared from A to E or select the all lighted-up display.

B. Press the ( ) of monitor panel selector switch 1 to display “RESET”.

C. “YES < > NO” is displayed, and the cursor is at the NO position, so press the (<) of monitor panel mode selector switch 2 to move the cursor to the “Y” of YES. D. Press the ( ) of monitor panel mode selector switch 1. The selected individual item from A to E or all the data is cleared.

If the monitor accepts the clear command, the buzzer gives short sounds and the display returns to the normal service meter and time display.

STOPPING THE CALCULATION 1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 and select “OFF” on the bottom line.

4.

Press the ( ) of monitor panel selector switch 1. The load meter display goes out and the screen switches to the speed display. In addition, the character display returns to the normal service meter and time display.

When starting the calculation again, set to the addition mode or remain mode. For details, see “SETTING ADDITION MODE” on page 5-7 or “SETTING THE REMAIN MODE” on page 5-8.

5.

WA480-5L

5-11

OPTIONS, ATTACHMENTS PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY 1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 and select “CALIBRATION”.

4.

Press the ( ) of monitor panel selector switch 1. “EMPTY BUCKET” is displayed on the bottom line.

5.

Press the ( ) of monitor panel selector switch 1. The display changes to “STEP 1" on the top line, and “FULLY ROLL BACK” and “AT CARRY POSI” are displayed in turn for 3 seconds each on the bottom line.

Follow the instructions on the screen, tilt the empty bucket back fully, then lower the lift arm to set to the travel posture.

6.

7.

8.

When the lift arm is lowered, the display changes to “STEP 2" and “RAISE TO TOP”. This completes preparation for setting the calibration when empty.

Follow the instructions on the screen and raise the lift arm fully.

When raising the lift arm, perform the operation as close to actual operation as possible.

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WA480-5L

OPTIONS, ATTACHMENTS 9.

When the setting of the empty calibration is completed correctly, the buzzer gives short sounds, and the character display returns to the normal service meter and time display.

10. If the setting of the empty calibration is not completed correctly, the buzzer gives a long sound, and the display returns to “CALIBRATION” on the top line and “EMPTY BUCKET” on the bottom line.

11. Repeat the procedure again from Step 5.

PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED Remark Normally, there is no need to perform calibration when loaded. It is enough to perform calibration when empty, so perform calibration when loaded only if greater accuracy is required.

1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 and select “CALIBRATION”.

4.

Press the ( ) of monitor panel selector switch 1. “EMPTY BUCKET” is displayed on the bottom line.

WA480-5L

5-13

OPTIONS, ATTACHMENTS 5.

Press the (>) or (<) of monitor panel mode selector switch 2. The bottom line changes to “LOAD BUCKET”, so press the ( ) of monitor panel selector switch 1.

6.

Press the ( ) of monitor panel selector switch 1. The display changes to “STEP 1" on the top line, and “FULLY ROLL BACK” and “AT CARRY POSI” are displayed in turn for 3 seconds each on the bottom line.

Load the bucket with a load of a known amount, then follow the instructions on the screen, tilt the bucket back fully, and lower the lift arm to set to the travel posture.

7.

8.

When the lift arm is lowered, the display changes to “STEP 2" and “RAISE TO TOP”. This completes preparation for setting the calibration when loaded.

9. Follow the instructions on the screen and raise the lift arm fully.

When raising the lift arm, perform the operation as close to actual operation as possible.

10. When the setting of the loaded calibration is completed correctly, the buzzer gives short sounds, and the screen changes to the screen for inputting the target load.

11. If the setting of the loaded calibration is not completed correctly, the buzzer gives a long sound, and the display returns to “CALIBRATION” on the top line and “LOAD BUCKET” on the bottom line.

12. Repeat the procedure again from Step 6.

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WA480-5L

OPTIONS, ATTACHMENTS 13. Input the load on the target load input screen. The data for the previously calculated load is displayed on the input screen.The cursor is at the 100 ton position. The following explains the procedure when inputting 7.5 tons as the target when the previous load (the load set in Step 7) is 7.1 tons.

14. “0” is displayed at the 100 ton position, so leave it at “0” and press the ( ) of monitor panel selector switch 1 twice. “00” is selected and the cursor moves to the 1 ton position.

15. “7” is already displayed at the 1 ton position, so press the ( ) of monitor panel mode selector switch 1. “7” is selected and the cursor moves to the 0.1 ton position.

16. “1” is displayed at the 0.1 ton position, so press the (>) or (<) of monitor panel mode selector switch 2 to select “5”, the press the ( ) of monitor panel mode selector switch 1. “.5” is selected and 7.5 tons is set as the target load.

17. Press the ( ) of monitor panel mode selector switch 1. If the monitor accepts the setting, the buzzer gives short sounds, and the setting of the loaded calibration is completed. The screen returns to the normal service meter and time display.

SUBTRACTION FUNCTION The following explanation assumes that after setting the remain mode, the target load is 12 tons as shown in the diagram on the right and that B is selected as the type of material.

WA480-5L

5-15

OPTIONS, ATTACHMENTS 1.

This is the first load. The result of measuring the load in the bucket is 5.1 tons. 12.0 - 5.1 = 6.9, so the next target load is displayed as 6.9 tons.

2.

When 15 seconds pass after measuring, the bucket load is deleted and the load is displayed as 0.0 tons.

3.

This is the second load.The load in the bucket is 4.9 tons. 6.9 -4.9 = 2.0 tons, so the next target load is displayed as 2.0 tons.

4.

This load is the third load. The result of measuring the load in the bucket is 5.0 tons. This amount is 3.0 tons over the target amount.

Thus, -3.0 tons is displayed.

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WA480-5L

OPTIONS, ATTACHMENTS 5.

6.

7.

The target load is displayed as -3.0 tons, and after 3 seconds, the display changes to the display shown on the right. The target value of 2.0 tons is the target load after completing the loading of the second bucket.

Load the target of 2.0 tons from the 5.0 tons loaded in the bucket.

After loading, lower the lift arm and then raise it again in order to weigh the amount remaining in the bucket. The amount remaining in the bucket is weighed and displayed.

The amount remaining in the bucket is 3.5 tons.

The target load is 2.0 - (5.0 - 3.5) = 0.5 tons The next target load of 0.5 tons is displayed.

8.

9.

Load the target of 0.5 tons from the 3.5 tons loaded in the bucket.

After loading, lower the lift arm and then raise it again in order to weigh the amount remaining in the bucket. The amount remaining in the bucket is weighed and displayed.

10. The amount remaining in the bucket is 3.1 tons. The target load is 0.5 - (3.5 - 3.1) = 0.1 tons

11. To start the next loading operation, press the load meter subtotal switch and the first loading operation is completed.

WA480-5L

5-17

OPTIONS, ATTACHMENTS 12. At this point, the amount remaining in the bucket (3.1 tons) is subtracted from the target load for the next loading operation, and the result (8.9 tons) is displayed as the target load.The amount remaining in the bucket is 3.1 tons. 12.0 - 3.1 = 8.9 tons, so 8.9 tons is displayed as the next target load.

13. If the second loading operation is to be performed without using the load remaining in the bucket, press the load meter cancel switch.

The target load will return to the initial setting (12 tons). The target load is displayed as 12.0 tons.

SETTING THE TIME ON THE CLOCK (The time display is only available on machines equipped with the load meter)

1.

2.

Check that the normal service meter and time are displayed on the character display.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel mode selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 to select “DAY & TIME ADJUST”.

4.

Press the ( ) of monitor panel mode selector switch 1.The top line displays “ADJUST 23: 59". The bottom line displays “2000/01/ 01”.

Remark Once the time is input, the clock will show the correct time from that time on.

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WA480-5L

OPTIONS, ATTACHMENTS 5.

6.

7.

8.

Input the day and time. The cursor is displayed at each input item in the following order: Year, Month, Day, Hour, Minute. Use the (>) or (<) of monitor panel mode selector switch 2 to move the numbers up or down and enter numbers between 0 and 9 at the cursor position.

After inputting the number, press the ( ) of monitor panel mode selector switch 1 to select and move the cursor to the next input position. Repeat Steps 5 and 6 to input and select the numbers from the year to the minute.

When the ( ) of monitor panel mode selector switch 1 is pressed to select the last digit of the minutes, the character display will return to the normal service meter and time display.

To stop the input operation midway, or if the input is mistaken, press the ( ) of monitor panel mode selector switch 1 to go back to the previous display.

WA480-5L

5-19

OPTIONS, ATTACHMENTS

PRINTER OUTPUT PRINTOUT MODE This functions only when the optional printer is installed.

Three types of output mode (A, B, C) can be selected for the load meter printout. For details, see “SELECTING THE PRINTOUT MODE” on page 5-21.

A mode: Printout of totals The number of loads and total amount loaded for each type of material are printed out.

B mode: Printout of subtotals The total for each load, number of loads, and total amount loaded for each type of material are printed out.

C mode: Printout of operating record Besides the items printed out in the A mode, the maintenance items and time remaining until maintenance are also printed out. ★ The printouts shown below are examples of the load meter printouts for the WA480-5L.

5-20

WA480-5L

OPTIONS, ATTACHMENTS SELECTING THE PRINTOUT MODE (This functions only when the optional printer is installed.)

1.

Check that the normal service meter and time are displayed on the character display.

2.

Press the ( ) of monitor panel selector switch 1 and display “LOAD METER”.

3.

Press the ( ) of monitor panel mode selector switch 1, then press the (>) or (<) of monitor panel mode selector switch 2 to select “PRINT TYPE”.

4.

Press the ( ) of monitor panel mode selector switch 1. The bottom line will change to display the printout mode “A < > B < > C”.

Press the (>) or (<) of monitor panel mode selector switch 2 to set the desired printout mode. Three types of output mode (A, B, C) can be selected for the load meter printout. For details, see “PRINTOUT MODE” on page 5-20.

After setting the printout mode, press the ( ) of monitor panel mode selector switch 1. If the monitor accepts it, the buzzer will give short sounds and the screen will return to the load meter display.

To print out in A or B mode, keep the load meter sub total switch pressed for at least 2 seconds and the data will be printed out. When printing out in C mode, the data will be printed out immediately when C mode is selected in Step 5. When the C mode printout is finished, the printout mode setting will return to A or B.

5.

6.

7.

8.

To stop the input operation midway, or if the input is mistaken, press the ( ) of monitor panel mode selector switch 1 to go back to the previous display.

WA480-5L

5-21

OPTIONS, ATTACHMENTS

TORQUE CONVERTER LOCK-UP

When traveling down slopes of a grade of more than 6°, never depress the accelerator pedal fully, regardless of whether the torque converter lock-up switch is ON or OFF. It is extremely dangerous to drive fast. ★ To prevent overrunning when traveling at high speed in the following cases, do not downshift. ★ When traveling in F3 at a speed of more than 25 km/h (15.5 mph), do not downshift to F2. ★ When traveling in F4 at a speed of more than 36 km/h (22.4 mph), do not downshift to F3.

When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct drive. To prevent overrun, the lock-up is automatically canceled to prevent the travel speed from going above 40 km/h (24.9 mph).

GENERAL LOCATIONS

1.

2.

Torque converter lock-up switch Torque converter lock-up pilot lamp

3.

4.

Shift indicator (displays actual speed range) Character display

TORQUE CONVERTER LOCK-UP SWITCH This switch (1) is the control switch for the torque converter lock-up function.

Position (a): ON The pilot lamp inside the switch lights up and the lock-up is actuated according to the travel speed. While the lock-up is engaged, the lock-up pilot lamp on the machine monitor lights up.

Position (b): OFF The lock-up does not function.

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WA480-5L

OPTIONS, ATTACHMENTS TORQUE CONVERTER LOCK-UP PILOT LAMP This monitor (2) lights up when the torque converter lock-up is engaged and the transmission actually enters direct drive.

For details of (3) and (4), see “SHIFT INDICATOR” on page 2-24 and “FAILURE CODE DISPLAY” on page 2-12.

METHOD OF OPERATION 1.

2.

Press the top (a) of the torque converter lock-up switch to turn it ON. The pilot lamp inside the switch lights up.

When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct drive.

Remark When 4th is selected in auto-shift mode, the lock-up is not actuated in 3rd. The lock-up is actuated only in the selected 4th gear.

When the lock-up is actually actuated, the lock-up pilot lamp on the machine monitor lights up.

3.

To cancel the lock-up, press the bottom (b) of the torque converter lock-up switch to turn it OFF. The lock-up is canceled.

★ The travel speed for actuation and cancellation of the lock-up is as shown below. ★ 4th speed range not used in Waste Handler applications.

Lock-ups

FORWARD travel speed (km/h (mph))

REVERSE travel speed (km/h (mph))

Speed range

Actuated

Canceled

Actuated

Canceled

3rd

11 to 14 (6.8 to 8.7)

10 to 12 (6.2 to 7.5)

16 (9.9)

13 (8.1)

4th

21 to 24 (13.0 to 14.9)

19 (11.8)

22 to 25 (13.7 to 15.5)

20 (12.4)

WA480-5L

5-23

OPTIONS, ATTACHMENTS

WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED TRAVEL SPEED WARNING FUNCTION This functions even when the torque converter lock-up switch is OFF.

When the travel speed goes above 38.0 km/h (23.6 mph), the central warning lamp lights up and the alarm buzzer sounds.

At the same time, “E00 OVERRUN PROTECT” is displayed on the character display.

If the alarm buzzer sounds, depress the brake immediately to slow the machine down.

When the travel speed goes below 36.0 km/h (22.4 mph), the alarm buzzer stops.

TRAVEL SPEED LIMIT FUNCTION This functions only when the torque converter lock-up switch is ON.

To prevent the travel speed from going above 40.0 km/h (24.9 mph), the lock-up is automatically canceled.

The lock-up cancel continues until the travel speed goes below 38.0 km/h(23.6 mph).

5-24

WA480-5L

OPTIONS, ATTACHMENTS

WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM With the waste handler application the method of reversing the cooling fan is different than the engine cooling fan reverse mode on the standard machine.This is due to the environment this machine will be used in.

1.

2.

3.

4.

5.

6.

Mode selector switch FORWARD/REVERSE timer Forward indicator lamp Reverse indicator lamp Forward setting knob Reverse setting knob

7.

8.

9.

10.

11.

12.

Forward time unit selector switch Reverse time unit selector switch Scale figure selector switch Direction selector switch Reverse pilot lamp Control box

FAN SYSTEM OPERATION Control panel (1) is used to operate the fan reverse mode. Outlined below are the procedures for the operation of this system.

WA480-5L

5-25

OPTIONS, ATTACHMENTS MODE SELECTOR SWITCH ★ This switch is used to select automatic or manual change of the direction of rotation of the cooling fan AUTO: The direction of the fan can change automatically, this is controlled with a timer MANUAL: The direction of the fan is controlled manually

Remark If an immediate reversal of the fan is needed, select this MANUAL mode.

FORWARD/REVERSE TIMER ★ Set this timer with the ignition switch in the “OFF” position This timer is used to set the forward and reverse revolution time of the cooling fan. The cooling fan repeats the directional changes when the selector switch is set in the AUTO position.

REVERSE/FORWARD INDICATOR LAMPS Remark Reverse direction is only for removing debris from the surface of the radiator core, always operate machine in the forward mode.

REVERSE: This orange timer lamp lights up while the system is in the reverse cycle

FORWARD: This green timer lamp lights up while the cooling fan is in the forward (normal operation) mode

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WA480-5L

OPTIONS, ATTACHMENTS FORWARD SETTING KNOB ★ This knob is used to set the forward rotation time of the cooling fan If outer larger knob (5) is turned, the green pointer moves. Set the pointer to the desired time with the knob first

If the time unit is set to h, and the scale to 3 and the green pointer to 0.5, the fan will revolve in the forward direction continuously for 1/2 hour.

Normally set the forward revolution time to 1/2 hour. Shorten the time if the radiator core surface is blocked more often than normal.

If the forward setting knob (5) (green pointer) is set to 1/2 hour and the reverse setting knob (6) (orange pointer) is set to 15 seconds and then the cycle is initiated, the cooling fan starts revolving forward. After the fan revolves forward for 1/2 hour it then revolves in reverse for 15 seconds, then revolves forward for 1/2 hour and in reverse for 15 seconds again.

If the ignition switch is turned off, the timer is reset. If the ignition switch is turned on again, the cooling fan starts revolving forward again and repeats the above cycle.

Remark Before changing direction, the fan is allowed to slow (coast) for 8 seconds. This action lowers the impact caused by the change in direction.

❥ ❥

When the engine is started, there will be an 8 second delay before the cooling fan starts rotation. This is normal When the cooling fan FORWARD/REVERSE switch is switched, there will be an 8 second delay before the cooling fan starts rotation. This is also normal

REVERSE SETTING KNOB ★ This knob is used to set the reverse direction of the cooling fan If inner smaller knob (6) is turned, the orange pointer moves. Set the pointer to a desired time with this knob.

If the time unit is set to 10s, the scale figure to 3 and the orange pointer to 1.5, the cooling fan will revolve in reverse for 15 seconds continuously.

Normally, set the reverse revolution time to 15 seconds. If the reverse time is set too long, then overheating may result.

WA480-5L

5-27

OPTIONS, ATTACHMENTS FORWARD TIME UNIT SELECTOR SWITCH ★ This switch is used to change the unit of time in the forward direction. Use a screwdriver to set this switch.

This switch is effective while only in the AUTO/MANUAL selector switch (1) is in the AUTO position. Set it to h, normally, and do not change it unless necessary

REVERSE TIME UNIT SELECTOR SWITCH ★ This switch is used to change the unit of time in the reverse direction. Use a screwdriver to set this switch.

This switch is effective while only in the AUTO/MANUAL selector switch (1) is in the AUTO position. Set it to 10s, normally, and do not change it unless necessary

SCALE FIGURE SELECTOR SWITCH ★ This switch is used to select the scale figure in unit of time to 1.2, 3, 12, or 30. Use a screwdriver to set this switch.

This switch is effective while in the AUTO/MANUAL selector switch (1) is in the AUTO position. Set it to 3, normally. Under this condition, the forward time can be set to 0.3 - 3 hours and the reverse time to 3 - 30 seconds.

★ Setting range of forward and reverse times under each combination of unit of time and scale figure.

Unit of time

s

10s

min

h

1.2

0.05 - 1.2

1.2 - 12

0.12 - 1.2

3

0.3 - 3

3 - 30

0.3 - 3

12

1.2 - 3

12 - 120

1.2 - 12

30

3 - 30

30 -300

3 - 30

Scale figure

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WA480-5L

OPTIONS, ATTACHMENTS DIRECTION SELECTOR SWITCH â&#x2DC;&#x2026; This switch is used to change the direction of the cooling fan. This switch is only effective in the manual mode FORWARD: Normal direction of rotation (or machine will overheat) REVERSE: Used for cleaning debris from the surface of the radiator core

Set this switch to the FORWARD position normally. If the cooler inlet is clogged with debris, set this switch to the REVERSE position to blow off the debris.

REVERSE PILOT LAMP â&#x2DC;&#x2026; This lamp will keep flashing while the cooling fan is running in reverse.

You may hear a ticking sound while this system is operating. This is normal

CONTROL BOX This box houses the electrical components which control the cooling fan direction function. Do not open this box and change any settings. They have been pre-set at the factory.

Remark When the fan is in reverse, the cooling fan control box (12) signals the transmission controller to maximize the fan rotation speed. It does this by using the T/C temperature signal. The transmission controller receives the signal and maximizes the angle of the swash plate on the cooling fan pump.

The reading on the T/C gauge may climb during the reversal period and not display a true reading. The needle should however, still remain in the white area.

The gauge should return to a true reading as soon as the fan returns to the forward direction. This is no indication of trouble.

Engine speed must be 1800 RPM or above to get the cooling fan speed for maximum cleaning ability.

WA480-5L

5-29

OPTIONS, ATTACHMENTS CLEANING RADIATOR AND COOLER FINS

Never open the engine side cover when the engine is running. Stop the engine completely before starting the cleaning operation.

If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury. Always wear safety glasses, dust mask, or other protective equipment. ★ Perform this procedure if there is any trash or paper stuck to the radiator.

Remark When rotating the fan in reverse, be careful of flying dust and take steps to prevent cloth or other objects from getting caught in the fan.

In waste handling locations where trash accumulates on to the radiator or cooler, rotate the fan in the reverse direction and blow out any trash stuck to the radiator or cooler. This can be used to extend the cleaning interval. ★ Method Of Rotating The Fan In Reverse 1. Set cooling fan AUTO/MANUAL switch (2) to MANUAL mode.

2. Set cooling fan FORWARD/REVERSE switch (3) to REVERSE mode.

3. Check to be sure the cooling fan reverse rotation pilot lamp (4) is blinking.

Remark When the fan is running in reverse, the pilot lamp on the fan control box lights up. For normal operations, always use the fan rotating in the normal direction (forward).

4.

5.

6.

7.

8.

Run the engine at high idle, (at or above 1800 RPM) to get fan rotating full speed.

After completing the cleaning, run the engine at low idle for approximately 10 seconds.

If manual cleaning is to follow, turn the ignition switch to the “OFF” position and stop the engine.

Set cooling fan AUTO/MANUAL switch (2) to AUTO mode.

Set cooling fan FORWARD/REVERSE switch (3) to FORWARD mode.

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WA480-5L

OPTIONS, ATTACHMENTS 9.

When the fan rotation stops, loosen wing bolts (2), use hook (3) to slide cleaning covers (4), and open the left and right covers.

10. Insert the air nozzle and blow the dirt out to the front of the machine.

Remark Steam or water may be used instead of compressed air.

11. After blowing out the dirt, install the left and right cleaning covers (4).

12. Check the radiator hose. Replace with a new one if the hose is found to have cracks or to be hardened by ageing. Further, check hose clamps for looseness.

WA480-5L

5-31

OPTIONS, ATTACHMENTS

HANDLING JOYSTICK STEERING SYSTEM To enable you to use the joystick steering safely and efficiently, please read the following before using it.

EXPLANATION OF COMPONENTS

1.

2.

3.

4.

5.

6.

Shift up switch Shift down switch FNR switch Joystick steering lever Joystick ON/OFF switch HI/LOW selector switch

7.

8.

9.

10.

11.

Horn switch Console lock lever Height adjustment lock lever Angle, fore/aft adjustment lock lever Console.

SHIFT UP, SHIFT DOWN SWITCHES These switches (1) and (2) are used when shifting up or down, regardless of whether the transmission is in the manual shift mode.

Press (1): Shift up Press (2): Shift down

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WA480-5L

OPTIONS, ATTACHMENTS FNR SWITCH The F/N/R switch (3) at the top of the joystick steering lever is used to switch the transmission between FORWARD and REVERSE.

(F) position: FORWARD (N) position: Neutral (R) position: REVERSE

Use the shift up and shift down switches at the top of the joystick steering lever to change the speed range.

JOYSTICK STEERING LEVER Use this lever (4) to steer the machine to the left or right. When traveling, operate this lever in the direction to turn the machine.

(a): Left turn (b): Right turn (N): Neutral

JOYSTICK ON/OFF SWITCH When this switch (5) is turned ON, the joystick steering is switched ON. Position (a): ON (possible to steer with joystick) Position (b): OFF (impossible to steer with joystick)

HI/LOW SELECTOR SWITCH This switch (6) is used to switch the steering speed between HIGH and LOW. Position (a): HI The articulating speed of the machine is high in relationship to the operation of the joystick steering lever. Therefore, this setting is suitable for comparatively fast cycle times.

Position (b): LOW The articulating speed of the machine is low in relationship to the operation of the joystick steering lever, so this setting is suitable for operations loading loose materials and materials that easily spill.

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OPTIONS, ATTACHMENTS HORN SWITCH Press this switch (7) at the top of the joystick steering lever to sound the horn. By using this switch, it is possible to sound the horn without taking your hand off the lever.

CONSOLE LOCK LEVER For details of this lever (8), see “GETTING IN OR OUT OF THE OPERATOR'S CAB” on page 5-36.

HEIGHT ADJUSTMENT LOCK LEVER For details of this lever (9), see “JOYSTICK CONSOLE ADJUSTMENT” on page 5-37.

ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER For details of this lever (10), see “JOYSTICK CONSOLE ADJUSTMENT” on page 5-37.

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OPTIONS, ATTACHMENTS

STRUCTURE AND FUNCTION OF JOYSTICK STEERING The joystick steering system is used instead of a steering wheel. The joystick reduces operator fatigue by allowing light-touch steering operation with short joystick movement.

If the joystick ON/OFF switch (1) is turned ON, electric current flows to the joystick controller and makes it possible to operate the steering with the joystick.

When the joystick steering is in use, the joystick pilot lamp on the machine monitor lights up.

With the joystick steering system, selecting the steering and transmission is shown below. Also with the joystick steering, the transmission auto-shift is included.

The differences between operating a joystick steering and a steering wheel are as follows.

Selection

Operation using joystick lever

Operation using steering wheel

Joystick ON/OFF switch

ON

OFF

Steering

Steering using joystick lever (steering with steering wheel is also possible)

Steering using the steering wheel

F/N/R

Operation using FNR switch at top of joystick lever

Transmission type Transmission

Operation using transmission directional lever

Auto

Auto

Shift mode Manual selector switch

Auto (L, M, H)

Selection of speed range

Automatic gear shift- Operation using ing according to travel gearshift lever speed

Speed range selection using shift up, shift down switches at top of joystick lever *

Manual

Auto (L, M, H) Automatic gearshifting according to travel speed

*: Does not shift up above speed range of gearshift lever.

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OPTIONS, ATTACHMENTS JOYSTICK AND STEERING WHEEL OPERATION

If the directional lever and joystick FNR switch are not at the neutral position, the neutral interlock circuit makes it impossible to switch the transmission directional control (when the joystick ON/OFF switch is ON, it is switched from the directional lever to the joystick FNR switch; when the joystick ON/OFF switch is OFF, it is switched from the joystick FNR switch to the directional lever).

Do not use the joystick when traveling on public roads.

Select the joystick lever or steering wheel according to the work.

â?Ľ

Steering using the joystick lever.

The joystick is suited for continuous loading operations on jobsites with ample space where the loading operation can be carried out with a comparatively relaxed cycle time. Because operations can be performed with small movements and light operating effort, this is also suitable for reducing operator fatigue when operating continuously.

â?Ľ

Steering using the steering wheel.

The steering wheel provides excellent fine control and the ability to travel straight, so it is suitable for travel between jobsites and for load and carry operations. In addition, it is also suitable for short cycle loading operations because it holds the upper part of the operator's body when frequently switching between FORWARD and REVERSE.

GETTING IN OR OUT OF THE OPERATOR'S CAB

Always spring the joystick console up before getting in or out of the operator's cab. If the console is sprung up, the safety switch is turned OFF and the joystick is automatically stopped from operating.

The joystick console is a spring-up type, allowing the operator to get in and out of the operator's cab easier.

If the joystick lever is moved accidentally when the engine is running, the machine may articulate unexpectedly. To prevent this danger, always spring the joystick console up when not using the joystick for operations and when getting in or out of the operator's cab.

1.

2.

3.

Set the lock lever (1) to the FREE position.

Spring the console (2) up. Turn it at least 90 degrees. The safety switch is turned OFF and the joystick cannot be operated.

When operating, lower the joystick console (2) and push lock lever (1) down to the LOCK position. The safety switch is turned ON and the joystick can be selected.

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OPTIONS, ATTACHMENTS JOYSTICK CONSOLE ADJUSTMENT

When adjusting the console, park the vehicle on a level and safe place. Adjust the console before starting operation or when the operator changed. Before adjusting the console, adjust the operator's seat so that the operator can fully press the brake pedal while his back is to the seat back.

Height Adjustment 1.

2.

3.

Operate lever (1) in the cancel direction and loosen the lock.

Adjust the height of the console and set joystick lever (2) to the desired position. Amount of adjustment: 30 mm (1.2 in.)

After setting, operate lever (1) to the LOCK position to lock it securely in position.

Angle Adjustment, fore/aft position 1.

Operate lever (1) in the cancel direction and loosen the lock.

2. Adjust the height of the console and set joystick lever (2) to the desired position. Amount of adjustment: 30 mm (1.2 in.)

3.

After setting, operate lever (1) to the LOCK position to lock it securely in position.

JOYSTICK OPERATION

It is dangerous to turn the machine suddenly at high speed, or to turn on steep hills. Do not operate the steering in such conditions.

When turning, the articulation stops at the position where the steering wheel is turned to, but if the joystick is held in an operated position, the body will articulate fully.

The feeling when operating the steering with the joystick is different from when operating with the steering wheel, so be extremely careful until you have become use to operating the joystick.

Check the adjustment and operation before starting the engine. For details, see â&#x20AC;&#x153;START-UP PROCEDURESâ&#x20AC;? on page 2-83.

1.

Before starting the engine, check the operation of the joystick lever steering, check that the transmission directional lever is at N, and that the surrounding area is safe.

Remark Under the following conditions, a warning may be given when the engine is started.

If the joystick control lever FNR switch is at F or R, the joystick pilot lamp flashes, the central warning lamp lights up, and the alarm buzzer sounds.

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OPTIONS, ATTACHMENTS At the same time, “E00 J/S SW NEUTRAL” is displayed on the character display. In this condition, the engine will not start, so set the FNR switch to N. If the joystick is not at the N position, the joystick pilot lamp flashes, the central warning lamp lights up, and the alarm buzzer sounds.

At the same time, “E00 J/S LEVER POSI” is displayed on the character display. In this condition, the engine will not start. Therefore, set the joystick lever to the N position.

2.

Press the (a) part of the joystick ON/OFF switch to turn it ON.

3.

Operate the joystick lever in the direction (b) to turn the machine to the right; operate it in direction (a) to turn the machine to the left.

The greater the angle of operation, the faster the articulating speed becomes.

4.

It is possible to switch the articulating speed with the HI/LOW selector switch. Select the speed to match the operation.

When the machine has articulated to the desired angle, return the joystick lever to the N position. The joystick lever will return automatically to the N position.

To return the direction of travel of the machine so that it travels in a straight line, operate the joystick lever in the opposite direction from the N position (for example, when the machine is articulated to the right, operate the joystick lever to the left).

Use the FNR switch at the top of the joystick lever to set the transmission to the direction of travel.

5.

6.

7.

N position: Neutral F position: FORWARD R position: REVERSE

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OPTIONS, ATTACHMENTS Remark If the position of the directional lever and the FNR switch are different, the joystick pilot lamp flashes, the warning lamp lights up, and the alarm buzzer sounds.

At the same time, “E00 SHIFT LEVER NEUTRAL” is displayed on the character display. In this condition, the machine will travel in the direction set by the directional lever, so set the directional lever to N.

8.

To change the speed range, use shift up switch (1) or shift down switch (2) on the joystick lever.

Remark The joystick steering is unstable and dangerous to operate at high speeds, so it is set so that the machine cannot travel in 4th.

When joystick operation is selected, if the gear shift lever is moved to 4th, or the joystick ON/OFF switch is turned ON when the gear shift lever is at 4th, the central warning lamp lights up and the alarm buzzer sounds.

At the same time, “E00 SHIFT LEVER” is displayed on the character display.

Set the gear shift lever within the range from 1st to 3rd.

In addition, when the joystick operation is selected, machines equipped with a torque converter lock up, the system is designed so that the machine does not travel at a high speed even if the torque converter lock-up switch is turned ON.

9.

Press part (b) of the joystick ON/OFF switch to turn it OFF. The joystick operation is then canceled.

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5-39

OPTIONS, ATTACHMENTS

EPC WORK EQUIPMENT LEVER EPC (Electronic Pilot Control) work equipment levers are offered as an option.

To improve the operating efficiencies, the following three functions are provided. ❥ ❥ ❥ ❥ ❥ ❥

Modulation function to prevent shock when stopping the bucket Function to set the bucket stop position at two places - Tope and Bottom (remote positioner) It’s possible to set the stop position from the operators seat.

Semiautomatic digging bucket - control function Bucket tilt operation can be automatically done when digging.

Semiautomatic digging offers two selectable modes - Soft and Hard.

SWITCHES

1.

2.

5-40

(Not used in North America) Remote positioner raise mode switch

3.

4.

Remote positioner mode switch Remote positioner raise/lower set switch

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OPTIONS, ATTACHMENTS

AUTO-GREASING SYSTEM With this system, the grease is automatically supplied through the computer controls.

If any abnormality occurs in the lubrication controller, please inform your Komatsu distributor of the symptoms and ask for repairs to be carried out.

OPERATING AUTO-GREASING SYSTEM 1. Turn the switch ON. Remark Immediately after the power is turned on, all the display lamps on the lubrication controller inside the box under the step, on the left side of the machine light up for several seconds. This is a self check for the lamps, and does not indicate any abnormality.

The display portion for starting the calibration of the greasing interval will flash, but all other displays will go out after a few seconds.

However, even if the greasing interval has not been reached, if the switch is ON/OFF repeatedly, grease will automatically start due to the function of the supplemental circuit, immediately after starting switch is turned on. After display of the 7-segment LED and greasing-in-progress LED, as shown in the â&#x20AC;&#x153;LUBRICATION CONTROLLER DISPLAY TABLEâ&#x20AC;?, the above condition will be returned.

2. Centralized greasing is carried out in accordance with the set time and frequency limit for greasing.

Remark If the starting switch is turned ON/OFF frequency before the greasing interval is reached, the warning for the remaining time is displayed earlier, but this does not indicate any abnormality.

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OPTIONS, ATTACHMENTS

1.

2.

3.

4.

5.

7-segment LED Cancel key Level selector key blade-type fuse Power source LED

6.

7.

8.

9.

10.

Greasing LED Warning LED Setting LED Starting key Item selector key

REMAINING NUMBER OF TIMES OF GREASE If the remaining number of times of greasing is less than 10, remaining number is displayed and it flashes. If the remaining number of times is 10 or more, only the flashing is shown without displaying the number.

OPERATION AS DESIRED If auto-greasing switch (1) on the right switch panel or the start button on the lubrication controller inside the box under the step on the left side of the machine are pressed, one cycle of greasing will be carried out regardless of the hours of operation. The time count of the greasing interval will be cancelled, and when the electric pump automatically stops, the count will start again.

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OPTIONS, ATTACHMENTS PILOT LAMP DISPLAY ON MACHINE MONITOR The display of pilot lamp (2) on the machine monitor lights up or flashes according to the following conditions.

Lighted up: Normal operation1 flash per sec: Grease cartridge empty 1 flash per 0.5 sec: Defective decompression, pump pressurized, pressure detected, fuse blown

SETTING GREASE TIME The set time and greasing frequency limit differs according to the operation condition and greasing plan for the machine, so set the following items to carry out suitable centralized greasing. ❥

Greasing interval (Hr.): Greasing interval for automatic operation ❥ Greasing time (min): Length of time pump is operated for each greasing operation ❥ Greasing frequency limit (times): No of times for operating pump before the 1000 cc cartridge becomes empty.

The settings when shipped from the factory are as follows.

Greasing interval: 3 hours Greasing time: 7 minutes Greasing frequency limit: 100 times The grease level alarm is set to sound after 300 hours on the hourmeter (when normal operation).

Remark Be careful since the life of grease cartridge will be shortened if the greasing interval becomes shorter. Also if the greasing interval becomes shorter, the amount of grease dripping from the tip of the machine increases. It may make the machine and surrounding area dirty.

SETTING GREASING TIME IN COLD AREAS In cold temperatures, the viscosity of the grease rises, so it is necessary to increase the grease time.

For example, if the machine is used at temperature below -20 degrees, set the greasing time to 20 minutes (code No 7). In addition, use the lithium-based grease No. 0.

When changing the set value, please consult your Komatsu dealer.

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OPTIONS, ATTACHMENTS METHOD OF SETTING When setting the various items, the values is not input directly. Select the code number from the set code table below, and set as follows.

Setting Code Table

Remark When using the machine at ambient temperatures of below -4 degrees Fahrenheit, set to greasing time 9b) at code No. 7.

Procedure For Setting 1.

Stop the working machine on the flat and hard ground, and stop the engine.

2. Set the safety lock lever at LOCK position and set the starting switch at the ON position.

3. Turn the starting switch to the START and start the engine.

4. Press the level and item keys at the same time to set the setting mode 5. Press the ITEM key one or more times to select the item to be set.

Remark Each time the ITEM key is pressed, the setting item is changed: a->b->c->a.

6. When the item to be set flashes, press the LEVEL key.

7. Refer to the setting code table and press the ITEM key one or more times to select Remark Each time the ITEM key is pressed, the code number (numeric portion) goes up by 1.

8.

When the code number that is to be set flashes, press the SET key to carry out the setting.

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OPTIONS, ATTACHMENTS 9.

Repeat steps 6 to 8 to set all the items a, b and c. After completing the setting, press the ESC key to leave the setting mode.

Remark Even if it is desired to change only one item, always carry out the setting according to steps 4 to 8. After completing the setting, always press the ESC key to leave the setting mode.

If the power is then turned ON, the count for the grease interval will start immediately after the ESC key is pressed.

Part of the display segment flashes to indicate that the system is counting. After setting, the set value is retained in the memory even if the power is turned OFF.

CHECK THE AMOUNT OF GREASE 1.

Turn the starting switch ON

2.

Check the display of the pilot lamp on the machine monitor. If the pilot lamp is flashing at 1-second intervals, it means that the grease cartridge is empty. Replace the grease cartridge with a new cartridge.

REPLACEMENT OF GREASE CARTRIDGE

Air bleed of the pump involves danger because of high pressure. Ask your Komatsu distributor for air bleeding.

Be careful of the force applied by spring (2) install inside the cover.

Remark After replacing cartridge, be sure to reset number on controller.

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OPTIONS, ATTACHMENTS Replace grease cartridge according to procedure below.

1.

Remove cover by turning cartridge cover 91) approx. 60 degrees to the left.

2.

Remove grease cartridge (3) by turning it to the left. Do not detach seal cap (4) at this time.

3.

Detach cap (5) and middle plug (6) from new grease cartridge and tightly screw it in. Screw in tightly to ensure that no air enters.

When fixing, if grease cartridge is pressed slightly and grease comes out and deposits in a heaped shape, and if grease cartridge is screwed into suction port connector under above conditions, no air will enter. (Max No. of turns is approx. 5) Turn the cover to right and tighten it until securely fixed. If not tightened well, there is a possibility that it will work loose due to machine vibration.

4.

5.

Use the grease cartridge shown below.

Part No.

Part name

Qâ&#x20AC;&#x2122;ty

Capacity

421-S95-3340

Cartridge

1

1000cc

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OPTIONS, ATTACHMENTS PRECAUTIONS WHEN HANDLING AUTO GREASING SYSTEM ❥ ❥

❥

❥

Basically, the power source input to the lubrication controller should be DC24V, but use a max of 30V. The grease nipple installed to the service port used for initial charging of the divider valve has a ball check structure, so it may leak if it gets stuck in it. Check it from time to time, and replace the grease nipple immediately if any grease is leaking.

When carrying out initial operation or when the grease tank is empty, air may get into the piston portion of the pump. If the pressure does not rise within the specified time when running the pump, and an error is displayed for the controller, bleed the air. i the divider valve or grease piping are removed when replacing the attachment on the machine, handle carefully to prevent any damage. When storing or installing again, be extremely careful to prevent the entry of any air or dirt. If there is air in the system, bleed immediately.

TROUBLESHOOTING If any abnormality occurs in the greasing system, the error codes will flash alternately to display the type of abnormality.

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OPTIONS, ATTACHMENTS

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Komatsu America Corp.

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