Komatsu WA20-2 Operation & Maintenance Manual Download

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3-22

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

No.

Safety critical parts for periodic replacement

Q’ty

Replacement interval

Fuel hose (fuel tank - water separator)

Fuel hose (water separator - feed pump)

Fuel hose (feed pump - fuel filter)

Fuel hose (fuel filter - injection pump)

Fuel return hose (injection pump - fuel filter)

Fuel return hose (fuel filter - fuel tank)

Fuel return hose (nozzle - injection pump)

Fuel hose (between nozzle)

Steering hose (pump - priority valve)

Steering hose (orbitrol valve - steering cylinder)

Steering cylinder packing, seal, O-ring

SAFETY CRITICAL PARTS (WA40)

Every 2 years or
every 4000 hours,
whichever comes
first

Summary of Contents for WA20-2

Page 1: ...your local distributor for availability Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintain ing this machine This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it WA20 11270 WA30 18970 WA40 13530 WA50 20642 SEAM010700 ...

Page 2: ...me actions involved in operation and maintenance of the machine can cause a serious accident if they are not done in a manner described in this manual The procedures and precautions given in this manual apply only to intended uses of the 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 shoul...

Page 3: ...ed These safety messages or labels usually describe precautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage to the machine CAUTION This word is used on safety messages and safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided This word might also be word for hazards where the only result could...

Page 4: ...machine life Be sure to break in the machine for the initial 100 hours as indicated by the service meter During breaking in 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 The precautions given in this manual for operating maintenance and safet...

Page 5: ...ront frame on the right side of the machine 4 1 2 WA30 40 50 Position of plate This plate is on the center of the front frame on the right side of the machine Position of stamp This is stamped on the center of the front frame on the right side of the machine 4 2 ENGINE SERIAL NO PLATE POSITION Position of plate This plate is on top of the engine cylinder head cover Position of stamp This is stampe...

Page 6: ...ne serial No Engine serial No Distributor name Address Phone Service personnel for your machine 4 3 TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 4 LOCATION OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR REMARKS ...

Page 7: ...ns for maintenance 1 17 8 1 Before carrying out maintenance 1 17 8 2 During maintenance 1 21 8 3 Tires 1 25 9 Position for attaching safety labels 1 27 OPERATION 10 General view 2 2 10 1 General view of machine 2 2 10 2 General view of controls and gauges 2 3 11 Explanation of components 2 4 11 1 Meter lamps 2 4 11 2 Switches 2 8 11 3 Control levers pedals 2 10 11 4 Cap with lock 2 14 11 5 Safety ...

Page 8: ...topping engine 2 48 12 15 Check after stopping engine 2 48 12 16 Locking 2 48 12 17 Handling the tires 2 49 13 Transportation 2 52 13 1 Loading unloading work 2 52 13 2 Precautions for loading 2 53 13 3 Lifting machine 2 53 13 4 Precautions for transportation 2 56 13 5 Removing and installation of canopy 2 56 14 Cold weather operation 2 58 14 1 Precautions for low temperature 2 58 14 2 Precautions...

Page 9: ...schedule chart 3 24 23 1 Maintenance schedule chart 3 24 24 Service Procedure 3 27 24 1 Initial 250 hours service 3 27 24 2 When required 3 28 24 3 Check before starting 3 42 24 4 Every 50 hours service 3 48 24 5 Every 250 hours service 3 49 24 6 Every 500 hours service 3 54 24 7 Every 1000 hours service 3 57 24 8 Every 2000 hours service 3 60 SPECIFICATIONS 25 Specifications 4 2 OPTIONS ATTACHMEN...

Page 10: ...1 1 SAFETY WARNING Read and follow all safety precautions Failure to do so may result in serious injury or death This safety section also contains precautions for optional equip ment and attachments ...

Page 11: ...AROUND CHECK Use safety features such as the safety lock lever and seat belts properly NEVER remove any safety features ALWAYS keep them in good operating condition Safety lock lever See 12 12 PARKING MACHINE Improper use of safety features could result in serious bodily injury or death CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewelry and loose long hair They can catch on contro...

Page 12: ... injury or damage When leaving the machine lower the work equipment completely to the ground set the safety lock lever to the LOCK position then stop the engine and use the key to lock all the equipment Always take the key with you Work equipment posture See 12 12 PARKING MACHINE Locks See 12 16 LOCKING MOUNTING AND DISMOUNTING NEVER jump on or off the machine NEVER get on or off a moving machine ...

Page 13: ...ngine oil and hydraulic oil are at high temperatures and are still under pressure Attempting to remove the cap drain the oil or water or replace the filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when carrying out these operations Before removing the radiator cap stop the engine and let the radiator cool Turn the cap slowly to relea...

Page 14: ... respirator if necessary CRUSHING OR CUTTING PREVENTION Do not enter or put your hand or arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machine and work equipment If the work equipment is operated the clearance will change and this may lead to serious damage or personal injury FIRE EXTINGUISHER AND FIRST AID KIT Be sure fire...

Page 15: ...ly display its performance if it is repaired or modified in the specified way When modifying or repairing the ROPS always contact your Komatsu distributor Even if the ROPS is installed it cannot show its full effect if the operator does not fasten the seat belt properly Always fasten the seat belt when operating PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment read the ...

Page 16: ...e depth and speed of flow of the water Be sure not to exceed the permitted water depth Permissible water depth See 12 10 PRECAUTIONS FOR OPERATION FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flam mable things accumulated in the engine compartment They could cause a fire Check fuel lubrication and hydraulic systems for leaks Have any leaks repaired Wipe up any excess oil fue...

Page 17: ...ly and in comfort If the operator s seat is not properly adjusted it will cause mistaken operation and fatigue with the danger that this will cause an accident Adjust the seat so that you can operate the control levers and pedals properly with your back against the seat back Adjustment of operator s seat See 12 1 3 ADJUSTMENT BEFORE OPERATION Before starting the engine check that the safety lock l...

Page 18: ...y designate a person to direct worksite traffic Do not allow any one to enter the line of travel of the machine This rule must be strictly observed even on machines equipped with a back up alarm or rear view mirror CHECK SAFETY 7 2 OPERATING MACHINE WHEN STARTING ENGINE Walk around your machine again just before mounting it checking for people and objects that might be in the way NEVER start the e...

Page 19: ...chine To avoid hitting other machines always keep a safe distance from other machines during operations an when traveling TRAVELING ON SLOPES Traveling on hills banks or slopes that are steep could result in the machine tipping over or slipping On hills banks or slopes carry the bucket closer to the ground approximately 20 to 30 cm 8 to 12 in above the ground In case of emergency quickly lower the...

Page 20: ...EN OPERATING Be careful not to approach too close to the edge of cliffs When making embankments or landfills or when dropping soil over a cliff dump one pile then use the next pile of soil to push the first pile Be careful not to let the bucket hit the dump truck or the side of the excavated ditch The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches th...

Page 21: ...lip DO NOT HIT WORK EQUIPMENT When working in places where there are height limits such as in tunnels under bridges under electric cables or in garages be extremely careful not to hit the work equipment METHOD OF USING BRAKES Do not put your foot on the brake pedal unless necessary Do not depress the brake pedal repeatedly unless necessary When traveling downhill use the engine as a brake and alwa...

Page 22: ...rom moving When parking on public roads park the machine so that the machine flags and fences do not obstruct traffic and provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see the machine clearly Parking procedure See 12 12 PARKING MACHINE When leaving the machine lower the work equipment completely to the ground set the safety lock lever ...

Page 23: ...the hauling vehicle and place blocks under both ramps before loading and unloading ALWAYS use ramps of adequate strength Be sure the ramps are wide and long enough to provide a safe loading slope Be sure that the ramps are securely positioned and fastened and that the two sides are at the same level as one another Be sure the ramp surface is clean and free of grease oil ice and loose materials Rem...

Page 24: ...tteries stop the engine and turn the starting switch to the OFF position Avoid short circuiting the battery terminals through accidental contact with metallic objects such as tools across the terminals When removing or installing check which is the positive terminal and negative terminal Tighten the battery cap securely Tighten the battery terminals securely Loosened terminals can generate sparks ...

Page 25: ...ng rope that has kinks or is twisted Do not stand astride the towing cable or wire rope When connecting a machine that is to be towed do not let any one come between the towing machine and the machine that is being towed Set the coupling of the machine being towed in a straight line with the towing portion of the machine and secure it in position Towing method See 16 TROUBLESHOOTING 7 PRECAUTIONS ...

Page 26: ...ch additional warning tags around the machine if necessary These tags are available from your Komatsu distributor Part No 09963 03000 PROPER TOOLS Use only tools suited to the task Using damaged low quality faulty or makeshift tools could cause personal injury Tools See 21 1 INTRODUCTION OF NECESSARY TOOLS A0055120 DO NOT operate When this plate is not being used keep it in the storage compartment...

Page 27: ...R MAINTENANCE WARNING For reasons of safety always follow these safety precautions AM089160 HEAT OFF ON START STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE When carrying out inspection and maintenance always stop on a flat firm road surface where there is no danger of falling rocks landslides or floods Then lower the work equipment to the ground set the safety lock levers to the L...

Page 28: ... add fuel and oil in a well ventilated place RADIATOR WATER LEVEL When checking the water level stop the engine and wait for the engine and regulator to cool down then check the water level in the sub tank When adding water add water through the sub tank Loosen the cap slowly to release the internal pressure before removing the cap USE OF LIGHTING When checking fuel oil coolant or battery electrol...

Page 29: ...el and batteries which may cause a fire To prevent fire do as follows Keep fuel and other flammable oil and fluids well away from fire Always use a non flammable oil for washing parts Put out any fires that may cause the fuel or oil to ignite Always have a fire extinguisher or other fire fighting equipment available Do not smoke when carrying out inspection and maintenance operations ...

Page 30: ...vice or repairs under the machine Always block the tires of the machine securely Never work under the machine if the machine is poorly supported KEEP THE MACHINE CLEAN Spilled oil or grease or scattered tools or broken pieces are dangerous because they may cause you to slip or trip Always keep your machine clean and tidy If water gets into the electrical system there is danger that the machine may...

Page 31: ...re PRECAUTIONS WITH HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out maintenance or inspection before completely releasing the internal pressure If oil is leaking under high pressure from small holes it is dangerous if the jet of high pressure oil hits your skin or enters your eyes Always wear safety glasses and thick ...

Page 32: ...CHECK BEFORE STARTING Checking hydraulic oil level adding oil see 24 5 PERIODIC MAINTENANCE Changing oil replacing filters see 24 6 8 PERIODIC MAINTENANCE ROTATING FAN AND BELT Keep away from rotating parts and be careful not to let anything get caught in them If your body or tools touch the fan blades or fan belt they may be cut off or sent flying so never touch any rotating parts WHEN OPERATING ...

Page 33: ...TE MATERIALS Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly on the ground Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and others INCORRECT A0055220 ...

Page 34: ...the type of tire and the condition under which they are used For details please contact your Komatsu distributor or tire maker If the tire is heated when installed to the wheel flammable gas is produced If this catches fire the tire may explode and cause serious injury or damage Unlike when a tire is punctured and burst if a tire explodes it produces a highly destructive force so the following ope...

Page 35: ...signs that even young children can understand Stand the tire on level ground and block it securely so that it cannot roll or fall over If the tire should fall over get out of the way quickly The tires for construction equipment are extremely heavy so trying to hold the tire may lead to serious injury Block A0060880 60 70 A0055130 8 PRECAUTIONS FOR MAINTENANCE WARNING For reasons of safety always f...

Page 36: ...gain or replace them with a new label There are other labels in addition to the safety labels listed as follows so handle them in the same way Safety labels may be available in languages other than English To find out what labels are available contact your Komatsu distributor 9 1 POSITION FOR ATTACHING SAFETY LABELS ...

Page 37: ...NEW ONES CONTACT YOUR NEAREST KOMATSU AGENT BEFORE LEAVING THE OPERATOR S SEAT BE SURE TO LOWER THE WORK EQUIPMENT TO THE GROUND AND SET THE SAFETY LOCK KNOB LOCATED AT RIGHT OF THE OPERATOR S SEAT IN THE LOCK POSITION FAILURE TO OBSERVE THE ABOVE MAY RESULT IN SERIOUS INJURY OR DEATH CAUSED BY UNEXPECTED MOVEMENT OF THE MACHINE DUE TO ACCIDENTAL CONTACT WITH THE UNLOCKED OPERATING LEVER BEFORE OP...

Page 38: ...ING THE MACHINE LOCK THE SAFETY BAR AS REQUIRED 6 Precautions when coolant is at high tem perature 7 Precautions when handling battery cable 5 Precautions for safety bar WARNING 8 Precautions when handling battery 235 53 31360 WARNING TAKE PRECAUTIONS AGAINST HOT COOLING WATER IN ORDER TO PREVENT HOT COOLING WATER FROM BLOWING OUT OBSERVE THE FOLLOWING PROCEDURE STOP THE ENGINE WAIT UNTIL THE WATE...

Page 39: ...1 30 MEMO ...

Page 40: ...2 1 OPERATION ...

Page 41: ...2 2 10 1 GENERAL VIEW OF MACHINE If directions are indicated in this section they refer to the directions shown by the arrows in the diagram below 10 GENERAL VIEW Machines equipped with canopy ...

Page 42: ...2 3 10 GENERAL VIEW 10 GENERAL VIEW 10 2 GENERAL VIEW OF CONTROLS AND GAUGES ...

Page 43: ...e oil temperature is normal When the pointer enters the red range stop the machine imme diately and run the engine with no load at midrange speed until the oil temperature drops to the normal value NOTICE If the engine water temperature gauge enters the red range frequently check and clean the radiator fins 2 HST OIL TEMPERATURE GAUGE This gauge indicates HST oil temperature When the pointer of th...

Page 44: ...he machine The service advances while the engine is running even if the machine is not traveling While the engine is running green pilot lam on the service meter flashes to show the service meter advances The service meter progresses by 1 when the engine is operated for one hour regardless of the engine speed 7 FUEL WATER SEPARATOR CAUTION PILOT LAMP WA30 40 50 This lamp indicates the water in fue...

Page 45: ...LAMP This lamp lights up when the parking brake is applied 10 ENGINE OIL PRESSURE CAUTION LAMP This lamp indicates lowering of the engine lubricating oil pres sure It is kept turned off during operation if the oil pressure is normal If the engine oil pressure lowers during operation this lamp lights up In this case stop the engine immediately and check the engine oil level If this lamp does not li...

Page 46: ...rator that the glow plug is heated This lamp lights up when the starting switch is turned to the HEAT position and goes out after 15 seconds 13 PARKING BRAKE REMINDER PILOT LAMP After stopping engine this lamp lights up with beep when the parking brake is not applied Apply the brake when lighting up A0061050 ...

Page 47: ...T position This is the engine start position Keep the key at this position during cranking Immediately after starting the engine release the key which will automatically return to the ON position HEAT preheat position When starting the engine in winter set the key to this position When the key is set to the HEAT position the pre heating monitor lights up Keep the key at this position until the mon...

Page 48: ...t panel lighting 1 OFF 2 q position Side clearance lamp tail lamps and gauge light ing light up 3 w position Head lamps light up in addition to lamps at q position REMARK The lamp switch can be operated regardless of the position of the lever 2 TURN SIGNAL LEVER This lever operates the turn signal lamps 1 LEFT TURN Push lever FORWARD 2 RIGHT TURN Pull lever BACK REMARK When the lever is operated t...

Page 49: ...his lever 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 Position 1 Forward Position N Neutral Position 2 Reverse 11 EXPLANATION OF COMPONENTS 11 EXPLANATION OF COMPONENTS ...

Page 50: ... This lever is used to operate the lift arm and the bucket 1 RAISE J 2 HOLD N The lift arm is kept in the same position 3 LOWER M 4 FLOAT The lift arm moves freely under external force A TILT U B DUMP When the bucket is in the dump position if the control lever is pulled to the TILT position the control lever will stop at this position and the bucket will continue to move When the bucket reaches t...

Page 51: ...LS WARNING Do not use the brake pedals repeatedly unless necessary Do not put your foot on this pedal unless necessary There are brake pedals on both the left and right sides Both the left and right pedals have the same function When the brake pedal is depressed the machine is stopped The brake pedal is interconnected with the HST inching valve so if the brake pedal is depressed lightly the HST pu...

Page 52: ...nal lever is oper ated with parking brake applied NOTICE Never use the parking brake lever to apply the brakes when traveling except in an emergency Apply the parking brake only after the machine has stopped 8 PARKING BRAKE RELEASE LEVER This is used to release the parking brake Pull the lever back to release the parking brake When the parking brake pedal returns to its original position the parki...

Page 53: ...rted all the way it may break 2 Turn the key clockwise align the match mark on the cap with the rotor groove then remove the cap TO LOCK THE CAP 1 Turn the cap into place 2 Turn the key counterclockwise and take the key out 11 5 SAFETY BAR WARNING Always use the safety bar for maintenance or when trans porting the machine Always remove the safety bar during normal travel opera tions The safety bar...

Page 54: ...own and set it in position When removing the towing pin carry out the above procedure in reverse 11 8 FUSE NOTICE Before replacing a fuse be sure to turn off the starting switch 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 Remove cover 1 then check or replace ...

Page 55: ...er Room lamp Patrol light 9 20A Working lamp Radio 0 20A Rear wiper 11 9 FUSIBLE LINK If the power does not come on when the starting switch is turned ON the fusible link may be blown so open the tilt hood at the rear of the machine and check or replace it FUSIBLE LINK 65A Chassis power source REMARK A fusible link is a large fuse wire installed in circuits where there is a large amount of electri...

Page 56: ...10 MANUAL POCKET The operator s seat has a manual pocket in the back of backrest This manual should be kept in it for reference and periodical reviewing 11 11 CONNECTORS Connectors 1 are in the right of the monitor panel Use as power source Yellow Black Max 10 A 120 W ...

Page 57: ...bnormality is found repair it or contact your Komatsu distributor Before starting the engine look around the machine and under the machine to check for loose nuts or bolts or leakage of oil fuel or coolant and check the condition of the work equipment and hydraulic system Check also for loose wiring play and collection of dust at places which reach high temperatures Always carry out the items in t...

Page 58: ... damage or wear to tires loose mounting bolts Check for cracks or peeling of the tires and for cracks or wear to the wheels Tighten any loose wheel nuts If any abnormality is found repair or replace the part If any valve caps are missing install new caps 6 Check for damage to handrail and steps loose bolts Repair any damage and tighten any loose bolts 7 Check for damage to lamps gauges loose bolts...

Page 59: ...ed When the parking brake is released the parking brake reminder caution lamp lights up and the alarm buzzer sounds CHECK COOLANT LEVEL ADD WATER WARNING Normally do not open the radiator cap Always wait for the engine to cool down before checking the water level and check using the sub tank 1 Open the engine side cover at the rear left side of the machine and check that the coolant level is betwe...

Page 60: ... fuel gauge G After checking return the starting switch to the OFF position 2 Upon completion of work add fuel through filler F until the fuel tank is full For details of the method for opening and closing the cap see 11 4 CAP WITH LOCK For details of the fuel to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 3 After adding fuel tighten the cap securely Fuel capacit...

Page 61: ...ngine oil through oil filler F For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 5 If the oil is above the H mark drain the excess engine oil from drain plug P and check the oil level again 6 If the oil level is correct tighten the oil filler cap securely then tighten the tilt hood REMARK When checking the oil level after the engine has been o...

Page 62: ...rake pedal 3 4 notches then pull the release lever and check that the parking brake pedal returns to its original position The travel of the lever after the brake is released should be 35 50 mm 1 4 2 in If the above value is not correct see 24 2 WHEN REQUIRED CHECK EFFECT OF BRAKE AND PEDAL STROKE The travel at the tip of the pedal should be 60 85 mm 2 4 3 4 in If the travel is not within the stan...

Page 63: ...t is clogged with dirt or dust wash the battery cap to clean the breather hole Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring Check also for loose terminals and tighten any loose parts Check the following points carefully Battery Starting motor Alternator When carrying out walk around checks or checks before starting always check if there is any ...

Page 64: ...r plate lamps option light up C Head lamps light up in addition to lamps lighting up at position B 3 Check for lighting of the reverse lamps by positioning the directional lever 3 in REVERSE Check for sound of buckup buzzer option 4 Check for lighting of brake lamps by depressing brake pedal 4 Check for flashing of turn signal lamps 1 Turn the starting switch 1 to ON 2 Check for function of turn s...

Page 65: ...2 26 12 OPERATION 12 OPERATION CHECK ENGINE EXHAUST COLOR AND SOUND CHECK OPERATION OF GAUGES CHECK DIRECTION OF REAR VIEW MIRROR CHECK FOR DIRT OR DAMAGE ...

Page 66: ... starting operations or when changing operators Check that you can depress the brake pedal fully with your back against the seat backrest Forward backward adjustment Move lever 1 to the right move the seat to the best position and release the lever Fore and aft adjustment 140 mm 5 5 in 8 stages ADJUST REAR VIEW MIRROR Sit in the operator s seat and adjust the rear view mirror so that you can see p...

Page 67: ...s at the LOCK position 2 Check that directional lever 2 is at the N position and that it is locked by safety lock 3 When starting the engine if directional lever 2 is not at the N position the engine will not start 3 Lower the bucket to the ground then check that work equipment control lever 4 is locked by safety lock 5 4 Insert the key in starting switch 6 turn the key to the ON position and chec...

Page 68: ...continuously for more than 20 seconds If the engine will not start wait for at least 2 minutes before trying to start the engine again 1 Depress accelerator pedal 1 lightly 2 Turn the key in starting switch 2 to the ON position 3 When engine is started release the key of starting switch 2 and the key will return automatically to ON 12 OPERATION 12 OPERATION AM090350 HEAT OFF ON STAR T AM090360 HEA...

Page 69: ... If the engine fails to start repeat from step 2 and after waiting for about 2 minutes 1 Hold the key in starting switch 1 at the HEAT position and check that preheating pilot lamp 2 lights up for 15 seconds The table shown below gives a guide to preheating time 12 OPERATION 12 OPERATION The preheating time in cold areas changes according to the water temperature when starting the engine 2 Depress...

Page 70: ... of starting switch 1 The key will return automatically to the ON position 5 When the engine speed rises depress accelerator pedal 3 lightly and hold it in position If the engine does not start wait for 2 minutes then repeat Steps 1 2 and 3 AM090360 HEAT OFF O N STA RT ...

Page 71: ... is 50 80 C but in order to extend the life of the machine the temperature must be raised to at least 20 C before starting work Do not suddenly operate the levers when the hydraulic oil temperature is below 20 C Do not suddenly accelerate the engine before the warming up operation is completed Do not run the engine at low idling or high idling continuously for more than 20 minutes If it is necessa...

Page 72: ...each in turn 5 After carrying out the warming up operation check that the gauges and pilot lamps are normal If any abnormality is found carry out repairs Operate the machine under light load until engine water tem perature gauge 4 and HST oil temperature gauge 5 are in the white range 6 Check that there is no abnormal exhaust gas color noise or vibration If any abnormality is found carry out repai...

Page 73: ...s not lighted up 2 Set safety lock 3 of work equipment control lever 2 to the FREE position 3 Operate work equipment control lever 2 to raise the bucket 25 45 cm 10 18 in from the ground then tilt the bucket back 4 Depress brake pedal 4 then pull parking brake release lever 5 back to release the parking brake If the parking brake is still locked the machine will not move even if the directional le...

Page 74: ...r 7 to the desired position 6 Release brake pedal 4 then depress accelerator pedal 8 to move the machine off REMARK When starting on a slope depress the left brake pedal then depress the accelerator pedal and slowly release the brake pedal to allow the machine to start 12 OPERATION 12 OPERATION ...

Page 75: ... the machine suddenly at high speed or to turn on steep hills If the engine stops when the machine is traveling the steer ing wheel becomes heavy so do not stop the engine This is particularly dangerous on hills so never stop the engine when the machine is traveling If the engine stops stop the machine immediately at a safe place When traveling use steering wheel 1 to turn the machine With this ma...

Page 76: ... compart ment always set the safety lock lever securely to the LOCK position NOTICE Never use the parking brake pedal to brake the machine when traveling except in an emergency Apply the parking brake only after the machine has stopped 1 Release accelerator pedal 1 and depress brake pedals 2 to stop the machine The left and right brake pedals are interconnected so the machine can be stopped by pre...

Page 77: ...lt U B Dump When the bucket has been operated to the DUMP position if the control lever is pulled to the TILT position it will be held at that position and the bucket will continue to move When the bucket reaches the position set by the bucket positioner the control lever is automatically returned to the HOLD position and the bucket movement stops If the lift arm is lowered in this condition the b...

Page 78: ...e machine forward as shown below If the tires begin slipping under heavy load raise the bucket slightly to reduce the load 1 Force the bucket into the pile of soil while moving the machine forward 2 After the bucket has fully penetrated into the soil place the work equipment control lever in raise position while moving the machine forward Move the work equipment control lever to tilt position from...

Page 79: ...or each digging pass is 5 10 cm 2 4 in 1 Set the edge of the bucket facing slightly down 2 Drive the machine forward and operate the work equipment control lever forward to cut a thin layer of the surface each time when excavating the soil 3 Operate the work equipment control lever slightly up and down to reduce the resistance when driving the machine forward When digging with the bucket avoid imp...

Page 80: ... leveling operations when traveling forward do not set the bucket dumping angle to more than 20 1 Scoop soil into the bucket Move the machine backward while spreading soil from the bucket little by little 2 Go over the spread soil with the bucket teeth touching the ground and level the ground by back dragging 3 Scoop some more soil into the bucket put the lift arm in float level the bucket at grou...

Page 81: ...ock pile and the wheel loader This method requires the least time for loading and is extremely effective in reducing the cycle time 12 OPERATION 12 OPERATION V SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx 60 from the direction of approach to the stockpile After loading the bucket drive the wheel loader in reverse then turn it to face the dum...

Page 82: ...L SLOPES If the foot brake is used too frequently when traveling downhill the brake may overheat and be damaged To avoid this problem operate the accelerator pedal and make full use of the braking force of the engine IF ENGINE STOPS If the engine stops on a slope depress the brake pedal immedi ately lower the work equipment to the ground then depress the parking brake pedal fully to hold the machi...

Page 83: ...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 12 OPERATION 12 OPERATION WA20 WA30 WA40 50 Air pressure All wheels All wheels All wheels MPa kgf cm2 0 18 1 8 0 2...

Page 84: ...fter adjusting start the engine and raise the lift arm Operate the work equipment control lever to the DUMP position then operate it to the TILT position and check that the work equipment control lever is automatically returned to HOLD when the bucket reaches the desired angle 12 11 2 BUCKET LEVEL INDICATOR A and B at the top rear of the bucket are the level indicators so the bucket angle can be c...

Page 85: ...erator s compartment always set the safety lock lever securely to the LOCK position NOTICE Never use the parking brake lever to brake the machine when traveling except in an emergency Apply the parking brake only after the machine has stopped 1 Release accelerator pedal 1 and depress brake pedals 2 to stop the machine The left and right brake pedals are interconnected so the machine can be stopped...

Page 86: ... with safety lock 7 12 13 CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature engine oil pressure HST oil temperature and fuel level with the meter and lamps If the engine has overheated do not stop it suddenly Run the engine at a midrange speed to allow the engine to cool down before stopping it 12 OPERATION 12 OPERATION ...

Page 87: ...starting switch 1 to the OFF position and stop the engine 3 Remove the key from starting switch 1 12 15 CHECK AFTER STOPPING ENGINE 1 Walk around the machine and check the work equipment body work and undercarriage and check also for leakage of oil and water If any leakage or abnormality is found carry out repairs 2 Fill the fuel tank 3 Remove any waste paper or dead leaves from inside the engine ...

Page 88: ...e is peeling there is separation fi When the bead is damaged fi For tubeless tires when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires It is dangerous to jack up the machine without taking due care 12 17 2 TIRE PRESSURE Measure the tire pressure before starting operations when the tires are cool If the tire inflation pressure is too low the...

Page 89: ... load lift arm horizontal Approx 15 25 When digging rear wheels off ground Approx 25 35 When checking the tire inflation pressure check also for small scratches or peeling of the tire for nails or pieces of metal which may cause punctures and for any abnormal wear Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and give improved econom...

Page 90: ...e tire jacked up off the ground tighten the wheel hub bolts lightly in the order shown in the diagram on the right 3 After tightening the wheel hub bolts partially lower the machine to the ground then tighten to the specified torque WA20 WA30 40 50 Tightening torque 168 15 441 49 N m kgf m 17 1 5 45 5 DIRECTION FOR INSTALLING TIRE The tire tread has a lug shape to provide strong rimpull and flotat...

Page 91: ...ose materials Never change the direction of travel when on the ramps If it is necessary to change direction drive off the ramps and correct the direction then drive on to the ramps again When loading or unloading always use ramps or a platform and carry out the operations as follows 1 Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move Then ...

Page 92: ...horizontal and that there is no looseness in the wire cable Before lifting the machine always stop the engine apply the parking brake and lock the frames with the safety bar to prevent the front frame from turning When lifting check that there is no looseness in counter weight mounting bolts 1 Tighten any loose bolts WA20 30 40 WA50 Bolt 2 4 Tightening torque 490 608N m 50 62 kgf m WARNING Never r...

Page 93: ...2 54 13 TRANSPORTATION 13 TRANSPORTATION 13 4 1 POSITION FOR ATTACHING HOOK MARK LABELS For details of the machine weight see 25 SPECIFICATIONS ...

Page 94: ...rake pedal fully to apply the parking brake 4 Stop the engine check that the area around the operator s compartment is safe then lock the frame with the safety bar so that the front and rear frames do not bend 5 Fit the lifting equipment to the following 3 places places with hook mark left and right front axle and towing pin 6 When the machine comes off the ground stop lifting and check carefully ...

Page 95: ...workers decide signals and always follow these signals during the operation Weight of parts Pole 9 kg 18 lb each roof 15 kg 30 lb When removing parts always check that the parts are prop erly supported before starting to remove When parts have been removed or when they are to be installed set them in a stable position so that they will not fall over When installing the canopy tighten the canopy mo...

Page 96: ...INSTALLATION 1 Install pole 1 with 8 bolts 2 and 8 washers Tightening torque 59 to 74 N m 6 to 7 5 kgf m Pole weight 9 kg 18 lb 2 Install roof 4 with 4 bolts 5 and 4 washers Tightening torque 59 to 74 N m 6 to 7 5 kgf m Roof weight 15 kg 30 lb ...

Page 97: ...tifreeze Do not mix one antifreeze with a different brand For details of the antifreeze mixture when changing the coolant see 24 2 WHEN REQUIRED Use a Permanent Antifreeze ethylene glycol mixed with corro sion inhibitor antifoam agent etc meeting the standard require ments as shown below With permanent antifreeze no change of coolant is required for a year If it is doubtful that an available antif...

Page 98: ...ge ratio is low the battery electro lyte may freeze Maintain the battery charge as close as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table 14 COLD WEATHER OPERATION 14 COLD WEATHER OPERATION Temp of fluid 20 C 0 C 10 C 20 C 30...

Page 99: ...n start next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing As the battery capacity drops markedly in low temperatures cover the battery or remove it from the machine keep it in a warm place and install it again the next morning 14 3 AFTER COLD WEATHER When season changes and the weather becomes warmer do as follows Replace the fuel and oi...

Page 100: ... to the work equipment control lever and directional lever then apply the parking brake 15 2 DURING STORAGE WARNING If it is unavoidably necessary to carry out the rust prevention operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning Operate the engine and move the machine for a short distance once a month so that a new film of oil will ...

Page 101: ...re starting the engine PROCEDURE FOR BLEEDING AIR Turn the key in the starting switch to the START position and crank the engine for 15 20 seconds Repeat this procedure 3 4 times to bleed the air Do not turn the starting motor continuously for more than 20 seconds Wait for 2 minutes before turning the starting motor again The air can be bled more quickly if the fuel tank is completely filled with ...

Page 102: ...locks under the wheels to prevent the machine from moving If the wheels are not blocked the machine may suddenly move When towing a machine tow it at a low speed of less than 2 km h 1 24 MPH and for a distance of a few meters to a place where repairs can be carried out The machine should be towed only in emergencies If the machine must be moved long distances use a transporter Fit a guard plate to...

Page 103: ...ple braking power weight and rimpull to allow it to control both machine on slopes or on the tow road When towing a machine downhill use a larger machine for towing to provide ample rimpull and braking power or connect another machine to the rear of the machine being towed In this way it is possible to prevent the machine from losing control and turning over Towing may be carried out under various...

Page 104: ... motor is not actuated so remove the front and rear drive shafts fi When short circuiting main HST circuit In this case it is always necessary to readjust the high pressure safety valve so please contact your Komatsu dis tributor 1 Remove the floor mat and plate and check the location of the 2 HST pump high pressure safety valves 2 Remove cap nut 1 from the high pressure safety valve then loosen l...

Page 105: ...und normally from the negative terminal When installing install the positive terminal first If a tool touches the cable connecting the positive terminal and the chassis there is danger that it will cause sparks If the terminals are loose there is danger that the defective contact may generate sparks that will cause an explosion When installing the terminals install them tightly When removing or in...

Page 106: ...e battery If the electrolyte temperature exceeds 45 C stop charging for a while Turn off the charger as soon as the battery is charged Overcharging the battery may cause the following 1 Overheating the battery 2 Decreasing the quantity of electrolyte 3 Damaging the electrode plate Do not mix the cables positive to negative or negative to positive as it will damage the alternator When performing an...

Page 107: ...rious injury Make sure that there is no mistake in the booster cable connections The final connection is to the engine block of the problem machine but sparks will be generated when this is done so connect to a place as far as possible from the battery Use care when removing the cables from the machine that has been started Do not allow the cable ends to contact each other or the machine to avoid ...

Page 108: ...ry terminals 2 Start the engine of the normal machine and keep it to run at high idling speed 3 Turn the starting switch of the problem machine to the START position and start the engine If the engine doesn t start at first try again after 2 minutes or so Disconnecting the booster cables After the engine has started disconnect the booster cables in the reverse of the order in which they were conne...

Page 109: ...icient battery charge Charge sluggishly Defective starting motor Replace Starting motor disengages before Defective wiring Check repair engine starts Insufficient battery charge Charge Preheating pilot lamp does not light Defective wiring Check repair up Defective glow relay glow Replace controller water temperature sensor Defective preheating pilot lamp Replace Even when engine is stopped Defecti...

Page 110: ...y See 250 HOURS SERVICE and lacks power Inching control linkage Connect linkage check brake disconnected control Hydraulic oil temperature is low Carry out warming up operation Oil overheats Too much oil or too little oil Add or drain oil to specified level See WHEN REQUIRED Clogged oil cooler core Clean oil cooler core Noise generated Lack of oil Add oil to specified level See WHEN REQUIRED Axle ...

Page 111: ...tem Lack of lifting power for bucket Lack of oil Add oil to specified level See EVERY 250 HOURS SERVICE Bucket takes time to rise Clogged hydraulic tank filter Replace filter See EVERY 1000 HOURS SERVICE Excessive bubbles in oil Low quality oil being used Replace with good quality oil Oil level is low Add oil to specified level See EVERY 250 HOURS SERVICE Air in oil line Bleed air See EVERY 1000 H...

Page 112: ...ce thermostat Loose radiator filler cap high Tighten cap or replace packing altitude operation Defective water level sensor Replace sensor Water temperature gauge is under Defective thermostat Replace thermostat white range C Defective monitor Replace Engine does not start when Lack of fuel Add fuel see CHECK starting motor is turned BEFORE STARTING Air in fuel system Repair replace where air is s...

Page 113: ...n above Combustion noise occasionally Defective nozzle Replace nozzle makes breathing sound Abnormal noise generated Low grade fuel being used Change to specified fuel combustion or mechanical Overheating Refer to Water temperature gauge is in red range as above Damage inside muffler Replace muffler Excessive valve clearance Adjust valve clearance 16 TROUBLESHOOTING 16 TROUBLESHOOTING ENGINE conti...

Page 114: ...3 1 MAINTENANCE ...

Page 115: ...placement 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 Al...

Page 116: ...cautions During the operation always obey the precautions on the safety label attached to the machine Welding instructions Turn off the engine starting switch Do not apply more than 200 V continuously Connect grounding the cable within 1 m 3 28 ft from the area to be welded Avoid seals or bearings from being between the area to be welded and the position of the grounding point Never weld any pipe ...

Page 117: ...re to lubricate work equipment pins daily if they are submerged in water On jobsites where heavy duty operations are common reduce the maintenance intervals and carry out greasing more frequently Dusty worksites When working at dusty worksites do as follows Inspect the air cleaner clogging portion pilot lamp to see whether the air cleaner is blocked up Clean the air cleaner at shorter intervals th...

Page 118: ...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 replace 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...

Page 119: ...LANT 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 anti freeze always observe the precautions given in the Operation and Maintenance Manual Komatsu machines are supplied with Komatsu original anti...

Page 120: ...utside 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 18 1 6 FILTERS Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace al...

Page 121: ...eck of damage or wear in the fan belt and 3 check of battery fluid level Never remove or disassemble any electric components installed in the machine Never install any electric components other than those specified by Komatsu Be careful to keep the electric system free of water when washing the machine or when it rains When working on the seashore carefully clean the electric system to prevent cor...

Page 122: ...090 11045 Bolt 6 09218 11614 Nut 6 362 972 1111 Edge 1 Cutting edge 02090 11050 Bolt 6 WA30 02205 11015 Nut 6 01643 31645 Washer 6 363 70 21190 Edge 1 Cutting edge 02090 11050 Bolt 7 WA40 50 02205 11015 Nut 7 01643 31645 Washer 7 19 WEAR PARTS LIST Wear parts such as the filter element air cleaner element bolt on edge etc are to be replaced at the time of periodic maintenance or before their abras...

Page 123: ... Rear 4 5 Rear 4 5 1 19 US gal 1 19 US gal 0 99 UK gal 0 99 UK gal Pins Grease WA20 25 0 6 6 US gal 5 5 UK gal Fuel tank Diesel fuel WA30 40 50 42 0 11 9 US gal 9 2 UK gal WA20 4 2 1 19 US gal 0 92 UK gal WA30 5 5 Cooling system Water 1 45 US gal 1 21 UK gal WA40 50 5 8 1 53 US gal 1 28 UK gal CAPACITY Specified Refill 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER S...

Page 124: ...al When starting the engine in an atmospheric temperature of lower than 0 C be sure to use engine oil of SAE10W SAE10W 30 and SAE15W 40 even though an atmospheric temperature goes up to 10 C more or less in the day time Use API classification CD as engine oil and if API classification CC reduce the engine oil change interval to half There is no problem if single grade oil is mixed with multigrade ...

Page 125: ... EP2 Antifreeze Hypogear EP RPM delo 400 Universal thuban Marfak all purpose 2 6 CALTEX AF engine coolant RPM delo 450 Universal thuban EP Ultra duty grease 2 EP Turbomax EPX MS3 7 CASTROL RX super Hypoy Anti freeze Spheerol EPL2 CRD Hypoy B Hypoy C 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 Universal gear 9 CONOCO Fleet motor oil Super sta grease lubricant Multiperformance 3C Tranself ...

Page 126: ...White bearing summer coolant grease FINA potonic N 15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor FINA potonic NE Spirax EP 16 SHELL Rimula X Alvania EP grease Spirax heavy duty Sunoco ultra prestige Sunoco antifreeze Sunoco GL5 17 SUN 2EP and summer gear oil Sun prestige 742 coolant Ursa super plus Multifak EP2 Code 2055 startex 18 TEXACO Multigear Ursa premium Starplex 2 antifreeze coo...

Page 127: ...driver 09033 00190 Crosshead flat head interchangeable type 6 Pliers 09036 00150 Grease pump 21R 98 11110 7 WA20 30 40 For greasing work Grease pump 07952 70004 WA50 Grease cartridge 21R 98 11120 8 WA20 30 40 Lithium base grease 400 g Grease cartridge 07950 90403 WA50 21 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 21 1 INTRODUCTION OF NECESSARY TOOLS The following tools are provided with the ma...

Page 128: ...all between the holder then fit the grease pump to the holder When doing this be careful of the following 1 Pull the grease pump chain to lock it If the chain is not pulled grease may ooze out 2 Fit a rubber band as shown in the diagram on the right to prevent the grease pump lever from moving 3 To prevent the grease pump chain from vibrating and making noise secure it with the pin as shown in the...

Page 129: ...at mm a b Nm kgm lbft 6 10 13 2 1 4 1 35 0 15 9 73 1 03 8 13 31 4 2 9 3 2 0 3 23 2 2 1 10 17 65 7 6 8 6 7 0 7 48 5 5 0 12 19 112 9 8 11 5 1 0 82 6 7 2 14 22 177 19 18 0 2 0 131 14 16 24 279 29 28 5 3 206 21 18 27 383 39 39 3 282 29 20 30 549 58 56 6 405 43 22 32 745 78 76 8 549 58 24 36 927 98 94 5 10 684 72 27 41 1320 140 135 15 973 100 30 46 1720 190 175 20 1270 140 33 50 2210 240 225 25 1630 18...

Page 130: ...wever 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...

Page 131: ...se injection pump fuel filter 1 5 Fuel return hose fuel filter fuel tank 2 6 Fuel return hose nozzle injection pump 1 7 Fuel hose between nozzle 2 8 Steering hose pump priority valve 1 9 Steering hose orbitrol valve steering cylinder 2 10 Steering cylinder packing seal O ring 1 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS WA20 Every 2 years or every 4000 hours whichever c...

Page 132: ...3 19 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...

Page 133: ...p 1 5 Fuel return hose injection pump fuel filter 1 6 Fuel return hose fuel filter fuel tank 2 7 Fuel return hose nozzle injection pump 1 8 Fuel hose between nozzle 2 9 Steering hose pump priority valve 1 10 Steering hose orbitrol valve steering cylinder 3 11 Steering cylinder packing seal O ring 1 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS WA30 WA50 Every 2 years or ev...

Page 134: ...3 21 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...

Page 135: ...fuel filter 1 4 Fuel hose fuel filter injection pump 1 5 Fuel return hose injection pump fuel filter 1 6 Fuel return hose fuel filter fuel tank 2 7 Fuel return hose nozzle injection pump 1 8 Fuel hose between nozzle 2 9 Steering hose pump priority valve 1 10 Steering hose orbitrol valve steering cylinder 2 11 Steering cylinder packing seal O ring 1 SAFETY CRITICAL PARTS WA40 Every 2 years or every...

Page 136: ...3 23 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...

Page 137: ...r case oil level add oil 3 34 Check axle oil level add oil 3 35 Clean transfer case breather 3 36 Clean axle case breather 3 36 Clean radiator fin 3 37 Replace bolt on cutting edge option for WA20 3 38 Adjust parking brake 3 39 Adjust parking brake release lever 3 40 Adjust brake pedal stroke 3 41 CHECK BEFORE STARTING Check bulb of pilot lamp 3 42 Check coolant level add water 3 42 Check fuel lev...

Page 138: ...250 HOURS SERVICE Lubricating 3 49 Bucket link pin 2 points 3 49 Bucket pin 2 points 3 49 Tilt lever pin 1 point 3 49 Lift cylinder pin 4 points 3 49 Dump cylinder pin 2 points 3 49 Lift arm pivot pin 2 points 3 49 Steering cylinder pin 2 points 3 49 Check oil level in hydraulic tank add oil 3 50 Check and clean air cleaner element 3 51 Check tension of fan belt adjust 3 52 Check battery electroly...

Page 139: ...nk replace hydraulic oil filter cartridge and HST filter element 3 57 Lubricating 3 59 Front drive shaft 3 points 3 59 Rear drive shaft 2 points 3 59 Center hinge pin 1 point 3 59 EVERY 2000 HOURS SERVICE Change oil in transfer case 3 60 Change axle oil 3 61 Check alternator starting motor 3 61 Check engine valve clearance adjust 3 61 ...

Page 140: ...CHANGE OIL IN ENGINE OIL PAN REPLACE ENGINE OIL FILTER CARTRIDGE REPLACE HYDRAULIC TANK FILTER ELEMENT AND HST FILTER ELEMENT CHECK ENGINE VALVE CLEARANCE ADJUST For details of the method of replacing or maintaining see the section on EVERY 500 HOURS 1000 HOURS and 2000 HOURS SERVICE 24 SERVICE PROCEDURE ...

Page 141: ...e of the case and the dust cup 1 Install a cover to the air intake after removing the element 2 When installing the element be sure to assemble the seal washer 3 When installing the dust cup install with the arrow mark on the dust cup pointing up 4 Replace the element if it has been cleaned six times or used for one year 5 Never remove the air cleaner element when the engine is running 6 If seal w...

Page 142: ...ent type of antifreeze If for some reason it is impossible to use permanent type antifreeze use an antifreeze containing ethylene glycol In areas where the water is hard always add Komatsu genuine corrosion resistor agent KI One packet of corrosion resistor agent contains 100g The standard density of the mixture should be 7g Clean the inside of the cooling system change the coolant and add the cor...

Page 143: ...f 3 2 2 9 2 7 2 5 2 3 2 1 water US gal 0 92 0 83 0 76 0 70 0 64 0 59 UK gal 0 71 0 64 0 59 0 54 0 50 0 46 WA30 WA40 50 Min C 5 10 15 20 25 30 atmospheric temperature F 23 14 5 4 13 22 Amount of 1 3 1 7 2 0 2 3 2 5 2 8 antifreeze US gal 0 33 0 44 0 52 0 60 0 67 0 73 UK gal 0 28 0 36 0 44 0 50 0 56 0 61 Amount of 4 2 3 8 3 5 3 2 3 0 2 7 water US gal 1 12 1 01 0 93 0 85 0 78 0 72 UK gal 0 93 0 85 0 7...

Page 144: ...lame Use city water for the cooling water If river water well water or other such water supply must be used contact your Komatsu distributor We recommend use of an antifreeze density gauge to control the mixing proportions 24 SERVICE PROCEDURE 24 SERVICE PROCEDURE ...

Page 145: ...ter clean with a flushing agent For details of the cleaning method see the instructions given with the cleaning agent 7 After cleaning open drain valve 2 and plug 3 to drain all the cooling water then close them and fill slowly with clean water 8 When the water comes up to near the water filler port open drain valve 2 and plug 3 run the engine at low idling and continue to run water through the sy...

Page 146: ...TER FROM WATER SEPARATOR WA30 40 50 Carry out this procedure if water separator caution pilot lamp lights on 1 Turn lever 1 up to close valve Turn the lever at least 90 2 Disconnect connector wiring to sensor and remove ring nut 2 cup 3 and element 4 3 Clean cup 3 and element 4 with diesel fuel or cleaning purpose oil 4 After cleaning and assembling separator turn lever 1 down to open valve 5 Open...

Page 147: ...er the machine has been operated Always wait for the temperature to go down before starting this operation Carry out this procedure if there is any oil leak from the transfer case 1 Open filler plug F and check the oil level If the level is correct the oil comes out from hole 2 If the oil level is not correct add engine oil through oil filler F For details of the oil to use see 20 USE OF FUEL COOL...

Page 148: ...the oil level cannot be checked correctly 1 Stop the engine and remove oil level plug 1 2 Wipe off any oil adhering to the oil level gauge G 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 fille...

Page 149: ... after removing the floor mat 2 Remove breather 2 after cleaning around the breather and soak in the cleaning agent 24 2 8 CHECK AXLE CASE BREATHER WARNING When cleaning apply the parking brake and lock the front and rear frames with the safety bar and pin Remove all mud and dirt from around the breather with a brush When cleaning the breather clean the breathers at two places front and rear 24 SE...

Page 150: ...d instead of com pressed air When using steam the radiator fins may be damaged if the steam nozzle is brought too close to the fins so stand well away from the radiator 2 The rubber hose should be checked at the same time If the hose is found to have cracks or to be hardened by ageing it should be replaced with a new one Further loosen hose clamps should also be tightened 24 SERVICE PROCEDURE 24 S...

Page 151: ...s horizontal 2 Remove nuts 2 and bolts 1 then remove cutting edge 3 3 Clean the mounting surface of cutting edge 3 4 Turn cutting edge 3 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 s...

Page 152: ... Remove the floor plate at the rear of the pedal 3 Loosen locknuts 1 and 2 Locknut 1 has a left hand screw and locknut 2 has a right hand screw so be careful of the direction of turning when loosening the locknuts 4 When adjustment screw 3 is turned clockwise rod 4 extends and when it is turned counterclockwise the rod retracts 5 Adjust the length of rod 4 with adjustment screw 3 so that the trave...

Page 153: ... mm 1 4 2 in when the lever is released adjust as follows Adjusting WARNING Before carrying out adjustment always block the tires and take action to prevent the machine from slipping Secure the front and rear frames with the safety bar and pin 1 Loosen locknut 1 of the cable 2 Adjust the position of the cable so that the travel is 30 50 mm 1 2 2 in 3 Secure with locknut 1 24 SERVICE PROCEDURE 24 S...

Page 154: ...he floor plate at the rear of the pedal 3 Loosen locknuts 1 and 2 Locknut 1 has a left hand screw and locknut 2 has a right hand screw so be careful of the direction of turning when loosening the locknuts 4 When adjustment screw 3 is turned clockwise rod 4 extends and when it is turned counterclockwise the rod retracts 5 Adjust the length of rod 4 with adjustment screw 3 so that the travel at the ...

Page 155: ... brake reminder caution lamp lights up and the alarm buzzer sounds 24 3 2 CHECK COOLANT LEVEL ADD WATER WARNING Normally do not open the radiator cap Always wait for the engine to cool down before checking the water level and check using the sub tank 1 Open the engine side cover at the rear left side of the machine and check that the coolant level is between the FULL and LOW marks on sub tank 1 If...

Page 156: ... level with fuel gauge G After checking return the starting switch to the OFF position 2 Upon completion of work add fuel through filler F until the fuel tank is full For details of the method for opening and closing the cap see 11 4 CAP WITH LOCK For details of the fuel to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 3 After adding fuel tighten the cap securely F...

Page 157: ...F For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 5 If the oil is above the H mark drain the excess engine oil from drain plug P and check the oil level again 6 If oil level is correct tighten the oil filler cap securely then tighten the tilt hood REMARK When checking the oil level after the engine has been operated wait for at least 15 minu...

Page 158: ...l the release lever and check that the parking brake pedal returns to its original position The travel of the lever after the brake is released should be 35 50 mm 1 4 2 in If the above value is not correct see 24 2 WHEN REQUIRED 24 3 8 CHECK EFFECT OF BRAKE AND PEDAL STROKE The travel at the tip of the pedal should be 60 85 mm 2 4 3 4 in If the travel is not within the standard range or the brakin...

Page 159: ...e breather hole Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring Check also for loose terminals and tighten any loose parts Check the following points carefully Battery Starting motor Alternator When carrying out walk around checks or checks before starting always check if there is any accumulation of flammable material around the battery and remov...

Page 160: ...ition B 3 Check for lighting of the reverse lamps by positioning the directional lever 3 in REVERSE Check for sound of buckup buzzer option 4 Check for lighting of brake lamps by depressing brake pedal 4 Check for flashing of turn signal lamps 1 Turn the starting switch 1 to ON 2 Check for function of turn signal lever 2 at A and B positions A Left turn signal lamps front and rear flashes B Right ...

Page 161: ...50 0 18 MPa 1 8 kgf cm2 WA30 0 2 MPa 2 0 kgf cm2 NOTICE The appropriate tire inflation pressure differs according to the type of work so see 12 17 HANDLING THE TIRES 24 4 2 CLEAN AIR CLEANER DUST CUP 1 Remove clip 1 and dust cup 2 2 Throw out the dust inside the cup then clean the inside Install so that the arrow mark on the cup is at the top 24 SERVICE PROCEDURE 24 SERVICE PROCEDURE ...

Page 162: ...tion then stop the engine and apply the locks securely to the work equipment control lever 1 Using a grease pump pump in grease through the grease fittings marked by the arrows 2 After greasing wipe off any old grease that is pushed out 1 Bucket link pin 2 points 2 Bucket pin 2 points 3 Tilt lever pin 1 point 4 Lift cylinder pin 4 points 5 Dump cylinder pin 2 points 6 Lift arm pin 2 points 7 Steer...

Page 163: ...ucket horizontally to the ground and stop the engine Wait for 5 minutes then check sight gauge G NOTICE When removing or installing the oil filler cap use a tool which matches the width of the cap groove It is dangerous to use a tool which does not match the groove width because it will slip 2 Add oil through oil filler port F For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS...

Page 164: ... When installing the dust cup install with the arrow mark on the dust cup pointing up 4 Replace the element if it has been cleaned six times or used for one year 5 Never remove the air cleaner element when the engine is running 6 If seal washer 4 is damaged or the thread of wing nut 3 is damaged replace with new parts 7 Remove evacuator valve 5 and clean with compressed air NOTICE If small holes o...

Page 165: ...or 3 2 Check each pulley for damage wear of the groove and wear of the belt In particular be sure to check that the belt is not touching the bottom of the groove 3 Replace the belt if it has stretched leaving no allowance for adjustment or if there is any cut or crack on belt 4 When fixing insert a piece of wood between the bar and alternator to prevent damage to the alternator 5 When replacing th...

Page 166: ...te is spilled have dilute sulphuric acid added 2 Clean the air hole in the battery cap then tighten the cap securely NOTICE When adding distilled water in cold weather add it before starting operations in the morning to prevent the electrolyte from freezing 24 5 6 CHECK FOR LOOSE WHEEL HUB BOLTS TIGHTEN If wheel hub bolts 1 are loose tire wear will be increased and accidents may be caused 1 Check ...

Page 167: ...he starting switch to the START position without depressing the accelerator pedal and run the starting motor for 15 20 seconds to crank the engine and bleed the air from the system Do not run the starting motor continuously for more than 20 seconds Wait for 2 minutes before turning the starting motor running it again WARNING When cranking the engine confirm the safety around the en gine as the eng...

Page 168: ...Open oil filler F 3 Place a container to catch the oil under drain plug P 4 Loosen drain plug P and drain the oil 5 Check the drained oil and if there are excessive metal particles or foreign material please contact your Komatsu distributor 6 Install drain plug P 7 Using the filter wrench turn filter cartridge 1 counterclockwise to remove it In particular if this operation is carried out immediate...

Page 169: ...ge must be replaced when the machine has been operated for 6 months In the same way even if the machine has not been operated for 6 months the oil and filter cartridge must be replaced when the machine has been operated for 500 hours Use API category CD class oil If CC class oil must be used change the oil and replace the oil filter at half the usual interval 250 hours 24 6 3 GREASE REAR AXLE PIVO...

Page 170: ... WA20 Min 15 capacity WA30 40 50 Min 28 capacity Refill capacity WA20 15 4 0 US gal 3 3 UK gal WA30 40 50 28 7 4 US gal 6 2 UK gal 1 Lower the bucket horizontally to the ground and apply the parking brake then stop the engine 2 When removing the oil filler cap 2 turn it slowly to release the internal pressure then remove it carefully 3 Set a container under drain plug P to catch the oil 4 Remove d...

Page 171: ...bleed the air from the HST circuit 13 Check that the hydraulic oil is at the specified level For details see 24 5 EVERY 250 HOURS SERVICE 14 Run the engine at low idling then extend and retract the steer ing bucket and lift arm cylinders to a point approx 100 mm 4 in before the end of the stroke NOTICE If the engine is run immediately at high speed or the cylinder is operated to the end of its str...

Page 172: ...ocks securely to the work equipment control levers 1 Using a grease pump pump in grease through the grease fittings marked by the arrows 2 After greasing wipe off any old grease that is pushed out 1 Front drive shaft 3 points 2 Rear drive shaft 2 points 3 Center hinge pin 1 point REMARK Grease to the shafts and pin until the grease goes up from seal portion 24 SERVICE PROCEDURE 24 SERVICE PROCEDUR...

Page 173: ... P to catch the oil then remove drain plug P and drain the oil Be careful not to get the oil over yourself Loosen drain plug P gradually to prevent the oil from suddenly spurting out then remove it slowly 2 After draining the oil tighten drain plug P Tightening torque 59 10 N m 6 1 kgf m 3 Add engine oil through oil filler port F to the specified level For details of the oil to use see 20 USE OF F...

Page 174: ...lugs 1 then remove drain plug P to drain the oil 3 After draining the oil clean drain plug P then install it 4 Add axle oil through plug hole 1 at the specified level For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 5 After adding oil check that the oil is at the specified level For details see 24 2 WHEN REQUIRED 24 8 3 CHECK ALTERNATOR START...

Page 175: ...3 62 MEMO ...

Page 176: ...4 1 SPECIFICATIONS ...

Page 177: ...utside tire 2 950 mm WEIGHT Including 1 operator Operating weight 55 kg 110 lb and a canopy 1 735 kg 3 470 lb Including 1 operator 55 kg 110 lb and a cab 1 885 kg 3 770 lb ENGINE Model Komatsu 3D78AE 3A diesel engine Flywheel horsepower 16 2 kW 2 600 rpm Max torque 73 5 N m 1 500rpm 7 5 kgf m 1 500 rpm Starting motor 12 V 1 8 kW Alternator 12 V 40 A Battery 12 V 60 Ah x 1 piece 25 SPECIFICATIONS W...

Page 178: ...5 1 OPTIONS ATTACHMENTS ...

Page 179: ...fi STD fi STD Dumping fork Loading and transporting fi fi fi fi small diameter lumber Lumber fork Loading and transporting fi fi fi fi small diameter lumber Multi coupler Easy installation and removing fi fi fi fi for other work equipment Steel cab fi fi fi fi Heater Heating operator s cab fi fi fi fi 26 OPTIONAL PARTS AND ATTACHMENTS Available in the future The other attachments are also availabl...

Page 180: ... Sit on the seat depress the brake pedal fully and adjust the seat so that your back is pressed against the backrest 2 After adjusting the seat position adjust teaser belt 1 Tense the teaser belt and install it when there is no one sitting on the seat Machine equipped with suspection seat 3 Sit on the seat take buckle 2 and tongue in your left and right hands insert tongue into buckle 2 and pull t...

Page 181: ... end at right angles to the buckle or tongue and pull 27 3 CHECK SEAT BELT AND MOUNTS Check that the bolts for the seat belt mounts on the machine are not loose Tighten any loose bolts Tightening torque 24 5 5 N m 2 5 0 5 kgf m If the belt is damaged or frayed or the mounting clamps are damaged or deformed replace the seat belt 27 SEAT BELT 27 SEAT BELT AE061720 AE061730 ...

Page 182: ...5 5 28 EQUIPMENT WITH CAB 28 1 SWITCHES 1 ROOM LAMP SWITCH ON Lights up OFF Goes off OFF ON AD051820 ...

Page 183: ...switch out to operate the wiper Position 1 OFF Position 2 Wiper operates at low speed Position 3 Wiper operates at high speed Wiper and window washer Pull the switch out to the operating position for the wiper then turn the switch to the right to spray out water Be careful of the following when using the wiper and washer Do not spray out the washer fluid continuously for more than 10 seconds Do no...

Page 184: ...itch to the OFF position to spray out water Wiper only Press the switch to the ON position to operate the wiper Wiper and window washer Press the switch to the ON position for the wiper then keep the switch pressed to the ON position to spray out water Be careful of the following when using the wiper and washer Do not spray out the washer fluid continuously for more than 10 seconds Do not try to s...

Page 185: ...to ON 5 REAR WORKING LAMP SWITCH OPTION FOR MACHINE WITH CAB WARNING Always turn the working lamp off before traveling on public roads The rear working lamp lights on when pushing this switch to ON 6 ROTARY LAMP SWITCH OPTION FOR MACHINE WITH CAB The rotary lamp lights on when pushing this switch to ON 7 HEATER SWITCH Position 1 OFF Position 2 Lo Position 3 Hi AD051870 ON OFF AD051870 ON OFF AD051...

Page 186: ...n the stopper lever by hand to release the accelerator pedal 9 VENT SELECTOR LEVER This lever selects the vent for the hot air to warm the operator s cab Position A All hot air sent to the vent for the front glass defroster Position B Divided between vent for heat and vent for front glass defroster 28 2 REAR WINDOW Open the rear window of the cab when opening or closing the tilt hood Hold lever 1 ...

Page 187: ...WITH CAB 28 3 CHECK AND MAINTENANCE 28 3 1 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID Check the level of the window washer fluid in tank 1 If the level is low add automobile washer fluid Be careful not to let dust get in when filling the tank ...

Page 188: ...4 3 25 SPECIFICATIONS 25 SPECIFICATIONS ...

Page 189: ... tire 3 060 mm WEIGHT Including 1 operator Operating weight 55 kg 110 lb and a canopy 2 555 kg 5 110 lb Including 1 operator 55 kg 110 lb and a cab 2 705 kg 5 410 lb ENGINE Model Komatsu 3D84E 3D diesel engine Flywheel horsepower 21 3 kW 2 500 rpm Max torque 90 N m 1 600pm 9 2 kgf m 1 600 rpm Starting motor 12 V 2 kW Alternator 12 V 40 A Battery 12 V 60 Ah x 1 piece 25 SPECIFICATIONS 25 SPECIFICAT...

Page 190: ...4 5 25 SPECIFICATIONS 25 SPECIFICATIONS ...

Page 191: ...re 3 210 mm WEIGHT Including 1 operator Operating weight 55 kg 110 lb and a canopy 3 055 kg 6 110 lb Including 1 operator 55 kg 110 lb and a cab 3 205 kg 6 410 lb ENGINE Model Komatsu S3D84E 3B diesel engine Flywheel horsepower 27 2 kW 2 500 rpm Max torque 123 N m 1 600 rpm 12 5 kgf m 1 600 rpm Starting motor 12 V 2 kW Alternator 12 V 40 A Battery 12 V 60 Ah x 1 piece 25 SPECIFICATIONS 25 SPECIFIC...

Page 192: ...4 7 25 SPECIFICATIONS 25 SPECIFICATIONS ...

Page 193: ... 3 210 mm WEIGHT Including 1 operator Operating weight 55 kg 110 lb and a canopy 3 445 kg 6910 lb Including 1 operator 55 kg 110 lb and a cab 3 605 kg 7210 lb ENGINE Model Komatsu S3D84E 3B diesel engine Flywheel horsepower 27 2 kW 2 500 rpm Max torque 123 N m 1 600 rpm 12 5 kgf m 1 600 rpm Starting motor 12 V 2 kW Alternator 12 V 40 A Battery 12 V 60 Ah x 1 piece 75D31R 25 SPECIFICATIONS 25 SPECI...

Page 194: ...4 9 25 SPECIFICATIONS 25 SPECIFICATIONS ...

Page 195: ...4 10 MEMO ...

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Komatsu WA20-2, Operation & Maintenance Manual

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