Komatsu WA800-1 Operation & Maintenance Manual Download

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Summary of Contents for WA800-1

Page 1: ...Operation Maintenance Manual SEAM042801 02 WA800 I WHEEL LOADER SERIAL NUMBERS wA80 10 1 and UP...

Page 2: ...should be carefully carried out and the safety must be given the first priority Safety precautions are in dicated with A marks and technical precautions with marks in this manual The safety informati...

Page 3: ...engine warm up prior to actual operation Avoid operation with heavy loads or at high speeds Sudden starting or acceleration unnecessarily abrupt braking and sharp turning should be avoided l At the fi...

Page 4: ...L FILLER AND LEVEL GAUGE POSITIONS 78 ADJUSTMENT OF WORK EQUIPMENT 54 EVERY 50 HOURS SERVICE 7g HANDLING THE TIRES 56 EVERY 100 HOURS SERVICE 80 TOWING 5g INITIAL 250 HOURS SERVICE 83 TRANSPORTATION 6...

Page 5: ...ift cylinder 8 Dump cylinder 9 Tilt lever PERFORMANCE 1 Bucket capacity Heaped 2 Travel speeds Forward Reverse l With cab and ROPS canopy 10 5 m3 Max 28 0 km h Max 28 3 km h OPERATING WEIGHT 86800 kg...

Page 6: ...alarm buzzer sounds for about 2 seconds Three figures 188 are displayed on the speedometer while the monitor system is being checked After that all lamps go off and the buzzer stops If any monitor lam...

Page 7: ...y occurs while the engine is running the appropri ate monitor lamp will flash and the alarm buzzer will sound intermittent ly at the same time However when the emergency steering is being operated onl...

Page 8: ...L LEVEL MONITOR 0 A This monitor indicates a low oil level in the engine oil pan If the monitor lamp flashes check the oil level in the engine oil pan and add oil as required 3 RADIATOR COOLANT LEVEL...

Page 9: ...is monitor indicates an abnor This monitor indicates there is mality in the charging system while less than 155 liters of fuel in the the engine is running tank If the monitor lamp flashes If the moni...

Page 10: ...ct that monitor lamp c CAUTION MONITOR GROUP Emergency stop items If any abnormality occurs while the engine is running the appropri ate monitor lamp and the warning lamp will flash and the alarm buzz...

Page 11: ...ity 3 COOLANT LEVEL MONITOR 8 This monitor indicates a low radiator coolant level Check the coolant level when the monitor lamp flashes stop engine and add water as required Park the machine on level...

Page 12: ...d run the engine with no load at midrange speed until the green range of the temperature gauge lights Sr Park the machine on level ground and check the monitor lamps Confirm that these monitor lamps l...

Page 13: ...switch is up to indi items are I J This lamp lights up when the parking brake is applied 2 PILOT LAMP FOR WORKING LAMP rl 0 hll This lamp lights up when the working lamps are switched on 3 ENGINE PRE...

Page 14: ...or lamp is ON and the left brake pedal is depressed the transmission will be returned to neutral 6 AIR PRESSURE GAUGE Redw Green Red This gauge indicates the air pres sure in the air tank The green ra...

Page 15: ...UGE Red Green This gauge indicates the tem perature of the torque converter oil If the temperature is normal during operation the green range will light If the red range lights during operation the al...

Page 16: ...ER This meter indicates the running speed of the machine A speedometer for MPH is also available This meter shows the total operation hours of the machine The service meter advances while the engine i...

Page 17: ...mal brake but also switches transmission to NEUTRAL If the switch is at ON the trans mission cut off selector pilot lamp will light up started on a slope always turn the transmission cut off selec tor...

Page 18: ...can be switched between two levels 0 ON The engine low idling speed is set to approx 850 rpm This is used on busy jobsites where it is necessary to reduce the cycle time OFF This sets the engine low...

Page 19: ...The parking brake is released If the directional lever is placed in F FORWARD or R EVERSE with the parking brake applied the warning lamp will flash and the alarm buzzer will sound When the starting...

Page 20: ...eat function is not working AUTO position When engine water temperature is below 13 C APS starts After starting maintain this posi tion until the lamp of the after heating monitor goes out Before star...

Page 21: ...ain on however when the switch is turned OFF START At this key position the starting motor will crank the engine Release the key immediately after starting and the key will return automatically to ON...

Page 22: ...lamp switch can be operated regardless of the position of the lever Turn signal lever This lever operates the turn signal lamps LEFT TURN Push lever FORWARD RIGHT TURN Pull lever BACK When the lever i...

Page 23: ...CT OFF The wiper is actuated at low When this switch is pulled to ON speed position wiper operates on rear The wiper works at high speed glass When this switch is turned When this switch is turned clo...

Page 24: ...LAMP SWITCH OFF a ON This is used to light cigarettes When this switch is moved to ON To use push the lighter in After the position room lamp will light few seconds it will spring back At that time r...

Page 25: ...brake pedal The left brake pedal operates the wheel brakes and if the transmis sion cut off selector switch is at ON it also returns the transmission to neutral If the transmission cut off selec tor...

Page 26: ...lever is used to change the direction of travel of the machine lever place your hand on a steer ing wheel and operate it by your fingers This lever controls the travel speed of machine This machine ha...

Page 27: ...Position Stopper released 6 STEERING COLUMN TILT This lever allows the steering Range of adjustment column to be tilted forward or 100 mm stepless backward Pull the lever up and move the A Stop the ma...

Page 28: ...lift arm is kept in the same position Lower d 1 I Float The lift arm moves freely under external force When the lift arm control lever is pulled further from 0 position the lever is stopped in this po...

Page 29: ...is stopped in this posi tion until bucket reaches the preset position of bucket positioner and the lever is backed to hold position 9 SAFETY LOCK This is used to lock the lift arm and bucket control...

Page 30: ...uated press the reset button to reset the system However if the cir cuit breaker is actuated again after the button is pressed or the circuit breaker is frequently actuated there may be a short circui...

Page 31: ...breakers in box at the same time button wilt the breaker a When resetting the breaker always turn off the electrical current before starting turn starting switch OFF Breaker arrangement and circuit C...

Page 32: ...20A APS automatic priming system 0 IOA APS automatic priming system 0 IOA Monitor panel 0 10A Bucket positioner Boom kick out 0 10A Rear working lamp 8 10A Front working lamp Circuit breaker IV No Br...

Page 33: ...up or down about 3 C Seat cushion adjustment Rotate grip 3 under the seat to adjust scale 4 on the cushion ad justment to your own weight 50 to 120 kg D Backrest adjustment Pull lever 51 move the bac...

Page 34: ...lever to release it When leaving the operator s seat release the seat belt and hang it over the arm rest Fasten belt along your body with out kinking it Adjust the lengths of the belt on both the buc...

Page 35: ...fol lowing steps I Loosen retainer mounting bolts 2 Loosen lock bolt 3 and remove on the bucket link pin part and cam 4 A Park the machine on level the bucket pin part then remove retainer 1 and shim...

Page 36: ...remove pin 6 on both sides of bucket Disconnect lift arm and bucket REMOVAL AND INSTALLATION OF BUCKET Installing the bucket 1 Assemble O ring 2 on flange 2 1 of bucket pin Assemble O ring after coat...

Page 37: ...Bushing Assemble mounting side of the flange the same way Assemble lift arm to bucket and insert hinge pin When attaching bucket to lift arm do not hit flange I with the bucket If the bucket hits the...

Page 38: ...secure the lock to bucket pin 5 plate with cam 4 Sr Adjust the thickness of the shim so that the clearance be tween the end surface of the re tainer and the hinge plate is re duced to less than 0 2 mm...

Page 39: ...ibutor to make the repairs Only Komatsu personnel and those licensed to service high pressure equipment may re charge an accumulator with nitrogen USING ACCUMULATORS Never strike a charged accumula to...

Page 40: ...s sure hose and high pressure hose joints W 04276 c CHECK AND REFILL COOLANT b CHECK MONITOR PANEL Turn the starting switch to ON Check that all the monitor lamps the gauges and the warning lamp light...

Page 41: ...stick G to check the oil level 3 The oil level should be between mark L and H if necessary add oil at oil filler F 1 Open the inspection window at t When checking the oil level park the machine on a l...

Page 42: ...full Fuel capacity 1200 II When adding fuel never let the fuel overflow This may cause a fire Open the battery box covers If the electrolyte level is lower than the prescribed level IO to 12 mm above...

Page 43: ...iately clogged the red piston of dust in drain valves 11 2 3 and drain wash with plenty of clean dicator I 2 points reaches service water out of the tank water level and g s locked A In that case clea...

Page 44: ...lubricant used de pends on the ambient tempera ture Select according to the table FUEL COOLANT AND LUBRICANTS A Never use the vegetable oil i CHECK BEFORE STARTING CHECK FOR SEDIMENT AND WATER IN THE...

Page 45: ...CHECK THAT ENGINE EXHAUST GAS COLOR AND SOUND ARE NORMAL r CHECK STEERING PLAY CHECK THAT STEERING WORKS PROPERLY s CHECK THAT BACK UP BUZZER SOUNDS PROPERLY t CHECK ELECTRICAL WIRING Check for any si...

Page 46: ...arking brake switch I in With your back against the back rest of the operator s seat adjust the seat position so that the brake pedals can be easily depressed ON position 45 4 5 Is the directional lev...

Page 47: ...or water level When there is a warning indicator in the monitor refer to item A check group explanation of each device 1 2 Depress accelerator pedal 1 lightly Turn the key of starting switch 2 to the...

Page 48: ...th no load at midrange speed for about 5 minutes After warm up run is completed check monitor lamps for proper operation Continue to run the engine at light load until the green ranges of the engine w...

Page 49: ...parking brake is applied with parking brake switch 2 put in OFF put switch 2 to ON and return it to OFF again 4 Set speed control lever 3 and directional lever 4 to the desired position 60 70cm 5 Rele...

Page 50: ...to stop the ma chine even when switching between FORWARD and REVERSE Place directional lever 1 in the desired position A Before changing direction check that it is safe A Never change between FOR WARD...

Page 51: ...as it turns When turning the steering wheel fully do not turn it beyond the end of the stroke A It is dangerous to turn the ma chine suddenly at high speed or to turn on steep hills A When the engine...

Page 52: ...round then lock the safety lock lever for work equipment lever A Stop the machine in a safe place on firm level ground If the machine has to be stopped on a slope put blocks under the wheels In additi...

Page 53: ...ng 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 Axle housinq IF WHEEL BRAKE DOES NOT...

Page 54: ...next lower gear speed to lower the oil temperature If the temperature gauge does not indicate the green range of the scale even with the lever in the 1st speed position stop the machine place the leve...

Page 55: ...ft arm control lever at HOLD and lock the lever in position Then stop the engine and adjust as follows Loosen two bolts I and adjust plate 2 so that the bottom edge is in line with the center of the s...

Page 56: ...3 Loosen two nuts 5 and to make a clearance of 3 to 5 mm be tween angle 2 and the sensing surface of proximity switch 3 Then tighten the nuts to hold in position Ir Tightening torque 1 75 2 0 25 kgm...

Page 57: ...hen the machine travels at high speed for a long distance the l tires become extremely hot This causes early wear of the tires so it should be avoided as far as possible If the machine must be driven...

Page 58: ...SSURE Measure the tire pressure before starting operations when the tires are cool If the inflation pressure is too low it causes overload on the tires if the inflation pressure is too high the tire m...

Page 59: ...ssure chart l Operations on sand operations not using much digging force Low end of range in air pressure chart If the deflection of the tire is excessive raise the inflation pressure within the limit...

Page 60: ...so that the steering and braking can be used 0 k No lubrication oil flows in the transmission so disconnect the front and rear drive shafts before moving the machine The steering cannot be used so dis...

Page 61: ...ot be used This is dangerous so always tow the machine at low speed Keep the engine running so that the steering can be used 4 Push the end of the hose on the tire valve and air will be supplied to th...

Page 62: ...ANSPORTATION When transporting this machine it is necessary to disassemble it for transportation Contact your Komatsu distributor for details of disassembly trans portation and assembly after transpor...

Page 63: ...and antifreeze Min atmospheric temperature 5 10 15 20 25 30 C Amount of antifreeze 73 95 114 130 146 158 5 Q Amount of water Q 244 222 203 187 171 158 5 Coolant capacity 3 17 R I 2 3 Cautions for usin...

Page 64: ...year at the beginning and at the end of the cold season Do not mix an antifreeze with one of different brand Absolutely avoid using any water leak preventing agent irrespective of whether it is used...

Page 65: ...difficult to start the engine normally use the following starting procedure 1 Open fuel valve 1 of the au tomatic priming system Sr Keep fuel valve I open when the temperature drops during the season...

Page 66: ...cannot be carried out If normal starting is difficult use the procedure given in Starting using manual preheating to start the engine Depress the accelerator pedal 5 about half way Pre heating finish...

Page 67: ...ut 20 C the after heating is automatically cancelled and the after heating monitor lamp goes out The time taken for the after heating lamp to go out depends on the ambient temperature Ambient Time tak...

Page 68: ...ng the engine there fore never use it CAUTIONS AFTER COMPLETION OF WORK 1 Mud and water on the machine body should be completely removed Park the machine on concrete or hard ground If this is impossib...

Page 69: ...r vari ous units with the ones specified for warm weather use l Drain antifreeze coolant except permanent type flush the inside of cooling system completely and fill with clean soft water such as city...

Page 70: ...machine operation and re duced operating cost All hourly figures given in the following descriptions are based on service meter readings In practice however it is recommended to rearrange all of them...

Page 71: ...sition for one minute For details contact your Komatsu Distribor BLEEDING AIR FROM BRAKE HYDRAULIC CIRCUIT After removing piping of brake 3 Repeat until air bubbles stop hydraulic circuit bleed air fr...

Page 72: ...n all plugs 3 places Loosen the connector at block 3 side of case drain hose 2 of the piston pump 3 The case drain hoses x 3 for each pump are connected to block 3 but loosen only the connector of cas...

Page 73: ...on pump bleed air from hydraulic circuit After replacing oil filter element or strainer bleed the air from the circuit To bleed the air from the hydrau lic cylinders or hydraulic piping run the engine...

Page 74: ...there is no ap parent abnormality It goes without saying that if any abnormality should be found these parts must be replaced or repaired even before the predetermined period expires The periodical r...

Page 75: ...nel Check 39 c I Coolant Check and supply 39 d Engine oil pan Check and supply 40 h Air tank Drain water and sediment 42 I i Brake oil tank Check and supply 43 j Water separator Check 43 k Parking bra...

Page 76: ...r pin Lubricate 4 points 82 6 Steering cylinder pin Lubricate 4 points 82 7 Rear axle pivot pin Lubricate 3 points 82 INITIAL 250 HOURS SERVICE a Fuel filter Replace cartridge 83 b Transmission oil fi...

Page 77: ...7 C Air conditioner filter Replace element 99 Hydraulic tank breather Replace element 99 e POC Pilot Operated Control circuit strainer Clean 100 I I f Engine breather Clean element 100 9 Turbocharger...

Page 78: ...2 Accelerator pedal linkage Lubricate 2 points 112 3 Steering column Lubricate 1 point 113 g Bucket teeth Replace 113 h Air conditioner Check 114 I Condenser of air conditioner Check and clean 115 i W...

Page 79: ...ling water drain plug 3 Engine oil pan drain plug 4 Final drive case drain plug 5 Final drive case level plug 6 Cooling water inlet 10 Hydraulic tank drain valve 7 Hydraulic tank oil filler 1 1 Rear a...

Page 80: ...n on CHECK a FUEL TANK b TIRE BEFORE STARTING afore Measure the inflation pressure mentioned before operations when the tires are cool Refer to HANDLING THE TIRES Loosen valve I on the right side of t...

Page 81: ...ller IF if necessary The type of lubricant used depends on the ambient temperature Select according to the table FUEL COOLANT AND LUBRICANTS A When removing the cap turn it slowly to relieve inner ore...

Page 82: ...direct it from outside along its folds and again from inside and check element A When using compressed air wear safety glasses and other things required to maintain safety W 04298 c LUBRICATING Apply...

Page 83: ...EVERY 100 HOURS SERVICE 5 Lift cylinder pin 4 points 6 Steering cylinder pin 4 points 7 Rear axle pivot pin 3 points 82 w 04299...

Page 84: ...tire wear will be increased ands acci dents may be caused If any hub nuts are loose tighten them to the specified tightening torque t Tightening torque 94 5 10 5 kgm If any wheel nut is broken replac...

Page 85: ...l level and ensure that it is correct Close the engine side cover Refill capacity 64 Q The type of lubricant used depends on the ambient tempera ture Select according to the table FUEL COOLANT AND LUB...

Page 86: ...ten bolts 1 and lock nut 3 securely After operating the machine for one hour with a newly exchanged V belt test and adjust the V belt again When adjusting the V belt do not attempt to push the compres...

Page 87: ...ustment tighten bolt I 1 and nut 2 securely After operating the machine for one hour with a newly exchanged V belt test and adjust the V belt again When adjusting the V belt do not attempt to push alt...

Page 88: ...rt time at idling speed then stop the engine Check that the oil is at the specified level for details see WHEN REQUIRED Use a genuine Komatsu element Replace the filter gasket and O rings with new par...

Page 89: ...led as an option carry out the following in spection and if there is any abnor mality contact your Komatsu distributor Open the air tank drain valve and check that nothing is drained Note that if the...

Page 90: ...out the plug slowly to prevent the oil spouting out 2 Loosen drain plugs 3 6 pieces of transmission oil filter to drain oil After draining off the oil tighten up drain plugs 3 90 3 4 5 Remove bolt 4...

Page 91: ...ubricant used depends on the ambient temperature Select according to the table FUEL COOLANT AND LUBRICANTS Check for oil leak at transmission case and filter Make an oil level check before starting en...

Page 92: ...OURS SERVICE c LUBRICATING Apply grease to the grease fit tings shown by arrows 1 Center hinge pin 2 points 2 Drive shaft center support I point 3 Front drive shaft 3 points 4 Rear drive shaft 3 point...

Page 93: ...ngine exhaust pipe will cause a lowering of oil pressure resulting in seizing of bearings Connect your Komatsu distribu tor for repairs or check as follows Tighten if necessary Turbine housing mountin...

Page 94: ...is loose tighten it Tightening torque 280 30 kgm Install cover The tightening torque is large so a power wrench is needed when tightening Please request your Komatsu distributor to carry out this work...

Page 95: ...then screw it up by hand about l 2 to 3 4 of a turn Be careful not to apply excessive torque 5 After replacement open valve I Be sure to use a genuine Komatsu cartridge After replacing the cartridge s...

Page 96: ...e drain plug 3 and loosen drain valve 2 to drain oil After draining off the oil tighten up them t After loosing drain valve 21 pull it out slowly to drain oil 4 Remove mounting bolt 5 of the filter co...

Page 97: ...the piston pump If the engine is started without the air being bled from the piston pump the piston pump may be broken Bleed the air of hydraulic circuit refer to BLEEDING AIR FROM HYDRAULIC CIRCUIT T...

Page 98: ...final drive is at the bottom Remove oil filler plug 5 and drain plug 41 and fit the tube of attached tool in hole of plug 4 and drain the oil 4 After draining the oil clean drain plugs 21 3 and 41 the...

Page 99: ...BRICANTS c AIR CONDITIONER FILTER EVERY 2000 HOURS SERVICE d HYDRAULIC TANK BREATHER 1 2 3 Open the cover located on the behind of the operator s seat Loosen nut 1 holding the filter element pull out...

Page 100: ...e POC Pilot Operated Control CIRCUIT STRAINER 1 Loosen bolts I 3 pieces 2 Remove strainer case and pull out the strainer then wash strain er with clean diesel fuel 3 Install the strainer in the strain...

Page 101: ...of normal charger performance and possible damage Have turbocharger cleaned by Komatsu distributor 1 Remove the turbocharger oil filler pipe and drain pipe then remove the intake air pipe connector an...

Page 102: ...CKET LINK PIN m HYDRAULIC TANK STRAINER 1 2 After removing plugs 1 and 21 refill gear oil SAE140 GL 5 from hole of plug I until new oil comes out from grease fitting inside Amount of refill oil Approx...

Page 103: ...t it from coming loose If bolt 5 be comes loose and drops out it will be sucked into the piston pump and will damage the pump Tightening torque of bolt 5 9 2 3 5 kgm 5 n INTERNAL PART OF AIR DRYER _y...

Page 104: ...lat If there is any ab water leakage normality contact your Komatsu If any fault is detected ask distributor for repair Komatsu distributor to disassemble and repair or replace b AIR COMPRESSOR Specia...

Page 105: ...ent type antifreeze of eltylene glycol base When not using antifreeze Every 6 months spring Every 1000 hours and when autumn cleaning the inside of the Change antifreeze only cooling system and when i...

Page 106: ...ater and close drain valves 3 4 and 5 After draining the water clean with a cleaning agent We recommend use of a Komatsu genuine cleaning agent For details of the cleaning method see the instructions...

Page 107: ...off Stop the engine wait for about 3 minutes add soft water to the specified level then tighten cap 2 Use city water for the cooling water If river water well water or other such water supply must be...

Page 108: ...element which has been cleaned 6 times repeat edly or used throughout a year Replace the inner element at the same time Replace both inner and outer ele ments when the dust indicator red piston appea...

Page 109: ...ng its folds then direct it from outside along its folds and again from inside and check element A When using compressed air wear safety glasses and other things required to maintain safety The follow...

Page 110: ...ng water 1 Use sight gauge G to check the oil level 2 If the oil level is not between the top and bottom marks on the sight gauge add engine oil through oil filler F The type of lubricant used depends...

Page 111: ...instead of compressed air e CHECK AND REFILL AXLE OIL Carry out this procedure if there is any sign of oil on the axle case Front The rubber hose should be checked at the same time If the Remove oil l...

Page 112: ...pedal linkage linkage 2 points 2 points If the work equipment control If the accelerator pedal is heavy lever is heavy or does not move or does not return properly apply smoothly apply grease grease T...

Page 113: ...vy or does not return properly 0 apply grease 1 Extract pin 2 fitted to the bucket and then remove tooth I When extracting pin 21 strike the part either the left or right part with a sharp object This...

Page 114: ...ndi tion of cooler Normal High pressure pipe is High pressure pipe is hot warm Low pressure pipe is Low pressure pipe is cold cold Clear difference in Little dirrerence in temperature temperature Almo...

Page 115: ...ser 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 A Do not wash the conde...

Page 116: ...nt and rear axles in the same way Do not let dirt get into the port while breather is removed If dust sticks to area around breather clean with a brush I CHECKING OF GLOW PLUG OF APS Automatic priming...

Page 117: ...ing surface with engine oil and install When installing be careful not to overtighten When the cartridge comes in contact with the pack ing face tighten l 2 to 314 of a turn by hand n WHEN REQUIRED DR...

Page 118: ...retainer 1 4 5 Restore bolt retainer I to the original position and confirm that the retainer is in locking position to bolt 2 There are two calipers in the parking brake so adjust the other caliper...

Page 119: ...ONER Method of replacement Loosen lock nut 2 then loosen bolt 3 Push the tension pulley I in the direction of arrow to a position where the belt can be removed then replace the belt When changing belt...

Page 120: ...keeps going in and out l Charge the battery Starting motor turns the engine sluggishly l Charge the battery l Replace the starting motor The starting motor disengages before the engine starts up l Ch...

Page 121: ...valve Engine oil temperature monitor flashes Replace the monitor Repair where air is leaking into fuel system Replace the injection pump or the nozzle Check the valve clearance Check engine compressio...

Page 122: ...eed Check engine Abnormal noise is produced l Add oil to transmission case to the specified level Axle Abnormal noise is produced l Add oil to axle case to the specified level Disc brake Brake does no...

Page 123: ...s slow l Addoil 0 Replace filter in hydraulic tank Many bubbles from in oil l Replace with specified oil l Addoil l Bleed air from oil line Oil pressure is too low l Add oil and bleed air Cylinder vib...

Page 124: ...ical maintenance is due It also indicates the integrated working hours when machine problems are encountered How the meter progresses The service meter progresses by 1 when the engine is operated for...

Page 125: ...r the ma chine and engine serial numbers as well as the service meter reading before mentioned These numbers are founds on the plates shown in the photos below l Location of the machine serial l Locat...

Page 126: ...TEMPERATURE CAPACITY II RESERVOIR KIND OF FLUID 22 4 14 32 50 68 86 104 122 F 30 20 10 0 10 20 30 40 50 C Specified Refill Engine oil pan Brake Transmission case Hydraulic system Axle Front and rear...

Page 127: ...e day time Use API classification CD as engine oil and if API classification CC reduce the engine oil change in terval to half For axle oil use only recommended oil as follows SHELL DONAX TT or TD CAL...

Page 128: ......

Page 129: ...SAFETY AND OPERATION...

Page 130: ......

Page 131: ...HINTS a PRECAUTIONS FOR MAINTENANCE BUCKET OPERATION OPERATING THE AIR CONDITIONER OPERATING THE CAR HEATER LOCKING CAP RADIO HANDLING OF BATTERY STORAGE COOLANT AND LUBRICANTS I 2 8 12 18 21 23 24 26...

Page 132: ...he control devices gauges and warning devices Be sure you understand the meaning of the caution plates l Confirm that all gauges and l Fuel or oil are dangerous warning devices are functioning substan...

Page 133: ...t take the machine in water exceeding the allowable depth up to the underside of the axle housing l The overall height of the machine is restricted by tunnels roof height or overhead electric wires SO...

Page 134: ...getting on or off the machine use the handrail and step provided Do not jump up onto or down from the machine l If a seat belt is provided always use it If the belt is damaged or worn replace it with...

Page 135: ...many factors Changes in the gauges sound vibration exhaust gas color or re sponse of the control levers can indicate the occurrence of some disorder If any disorder occurs park the machine immediatel...

Page 136: ...ake im mediately to stop the machine l When traveling on hills with a loaded bucket travel forward up the hill and in reverse down the hill l The machine should always be operated at a speed where it...

Page 137: ...e machine Start the ma chine slowly to take up the slack in the wire rope Then start towing carefully Do not tow any machine whose brakes or steer ing have broken down l When parking the machine park...

Page 138: ...hod of oper ation of fire extinguishers Always stop the engine before cleaning the machine or adding fuel Flame should never be used in stead of lamps Never use a naked flame to check leaks or the lev...

Page 139: ...k filler cap If this is done immediately after using the machine there is a danger that boiling water or oil may spurt out l Always release the pressure in the circuit before checking or ser vicing th...

Page 140: ...machine In particular be careful to clean the filler caps grease fittings and the area around the dipsticks Be careful not to let any dirt or dust into the system When check an open cover there is a...

Page 141: ...talkie or citizen band con tact your Komatsu distributor l When washing the machine take care not to splash water over the electrical equipment If it is soaked with water it may not operate normally...

Page 142: ...perating jobsite flat and remove any fallen rocks When working with stockpiles operate the machine in 1 st or 2nd operate the machine in 1st when loading blasted rock When driving the machine for ward...

Page 143: ...bucket the load will be unbalanced 4 At the same time as thrusting the 5 Check that there is enough mate bucket into the material raise the rial loaded into the bucket then lift arm to prevent the bu...

Page 144: ...and drive the machine forward Always be careful not to load the bucket on one side and cause an unbalanced load This operation should be carried out in 1St gear Set the edge of the bucket facing sligh...

Page 145: ...ire s life 1 2 3 Scoop soil into the bucket Move the machine backward while A If leveling by forward travel spreading soil from the bucket can not be avoided do not little by little dump the bucket be...

Page 146: ...ground conditions CROSS DRIVE LOADING When a wheel loader is operated the digging should be made at a right angle toward accumulated soil When the scooping is completed the machine should be traveled...

Page 147: ...n of the wheel loader After scooping the soil back the wheel loader in such a way that it makes a right angle to the truck The loading on the truck is made by the wheel loader going forward The smalle...

Page 148: ...rator EQUIPMENT ON CONTROL PANEL 3 Fan switch l This controls the air flow when the air conditioner is used for cooling or heating o There are 3 levels L Low M Medium and H High aAir conditioner switc...

Page 149: ...ing air conditioner When cooling change the air occasionally l Smoking in the air conditioned cab will cause your eyes to get sore While smoking open the window to let the smoke out of the cab l While...

Page 150: ...frost Defrosting H ON quickly or to prevent the window from misting up move the lever FRE to the top Ventila tion or pres H L OFF surizing COOL move fully to COOL side FRE The effectiveness of the air...

Page 151: ...e car heater is used for heating 0 There are 3 levels L Low M Medium and H High Temperature control lever l This lever regulates the tempera ture when heating o The closer the lever is to WARM the hig...

Page 152: ...g the most suitable vent position This will pressurize the Do not turn the fan switch on cab and prevent the dust from when all the vents are closed entering OPERATION OF CONTROL PANEL Temperature con...

Page 153: ...nto place Insert the key as far as it 2 Turn the key clockwise and When the cap is locked against will go If the key is turned vandalism it rotates freely take the key out before it is inserted all th...

Page 154: ...CH VOLUME CONTROL Press this knob to turn on or off I the radio When it is turned to the right the sound level will increase STATION SELECTOR BUTTONS and vice versa 5 buttons By pressing these buttons...

Page 155: ...In particular close the window during rain or when washing the machine Do not wipe the dial plate or knobs with benzine or paint thin ners etc Always use a dry soft cloth if the radio is particularly...

Page 156: ...ger as soon as the battery is charged Overcharging the battery may cause followings I Overheating the battery 2 Decreasing the quantity of electrolyte 3 Damaging the electrode plate 5 If the electroly...

Page 157: ...oster cable do as follows 1 Before connecting the booster cable 1 2 3 4 5 Size of booster cable and clip should be suitable for the bat tery size Check cables and clips for breaks corroded surfaces et...

Page 158: ...the battery on the left the negative 1 terminal of side of the failed machine using the running engine A the same procedure When connecting the cables never contact the positive I A and negative 1 ter...

Page 159: ...e on the wood plates and cover it with canvas etc Completely fill fuel tank lubricate and change oil before storage l Apply a thin coat of grease to metal surface hydraulic piston rods and splined sha...

Page 160: ...made you shall apply the following treatment before operation l Wipe off the grease on the hy draulic piston rod l Loosen the drain plugs on oil pan and other cases and drain mixed water l You should...

Page 161: ...BP Vanellus C 3 Hypoidgear EP Energrease 2 Gear Oil EP Enerqrease LS2 Antifreeze 5 CALTEX RPM Delo 300 Multipurpose Thuban EP Marfak Multipurpose RPM Delo 400 Universal Thuban Marfak All Purpose AF En...

Page 162: ...per Mobilube GX Mobilgrease 532 Mobilux EP2 Supreme Duty Fleet No 4092 12 PENNZOIL Multi Purpose Gear No 4096 Multi Purpose No 705 Anti Freeze Multi Duty No 4140 Wheel Bearing No 707L Summer Coolant 1...

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Page 164: ...A Attn Technical Publications PROPOSAL FOR MANUAL REVISION Fax No 847 9704186 PFMRI 081696 FOR INTERNAL USE ONLY No PMR NAME OF COMPANY LOCATION 1 AACHINE MODEL i N IF APPLICABLE AGE NO ROBLEM Wach ph...

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