Komatsu WA65-3 Manual

WA65-3
VEAM940200
Operation & Maintenance
Manual
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept inside the cab for reference
and periodically reviewed by all personnel who will come
into contact with the machine.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth de-
fects and other reproductive harm.
WARNING
SERIAL NUMBER
:$
VEAM940200
:+((//2$'(5
+$
and up
©1999 Komatsu Hanomag Aktiengesellschaft
All Rights Reserved
Printed in Europe
03.99

Operation & Maintenance
Manual
This material is proprietary to Komatsu Hanomag Aktiengesellschaft and is not to be reproduced, used, or dis-
closed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurringany obligation to install such changes onproducts sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
March 1999 Copyright 1999 Komatsu Hanomag Aktiengesellschaft
SERIAL NUMBER
:$
VEAM940200
:+((//2$'(5
+$
and up

PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUC-
TION. EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND
SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP
MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Engine and Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VZPB179401
PARTS BOOK - MICROFICHE:
Engine and Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VZPM179401
OPERATION & MAINTENANCE MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEAM940200
SHOP MANUAL:
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YMHINSHI-H8013
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEBM950101
SAFETY MANUAL: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN
ONLY
BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIB-
UTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESS-
ING SYSTEM (PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM
KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ——>
SHIP TO ——————>
TYPE or PRINT
ONLY ———————>
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
KDC91D 121296 CURRENT PRICES WILL BE CHARGED
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
QTY. PUBLICATION FORM NO. PARTS BOOK
P-PAPER
M-MICROFICHE
PUBLICATION
DESCRIPTION MODEL NUMBER SERIAL NUMBER
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. [phone]
Tel No. [phone]
COMPANY NAME
ATTN.
STREET ADDRESS
CITY. STATE. ZIP CODE
COUNTRY
PURCHASE ORDER NO.
ORDRER DATE
➥

0-1
TABLE OF CONTENTS
INTRODUCTION
1. FORWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 • FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 • BREAKING IN A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR . . . . . . . . . . . . 5
4.1 • MACHINE SERIAL NO. PLATE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 • ENGINE SERIAL NO. PLATE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 • TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. WHY YOU SHOULD READ THESE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 6
6. NOTES ON SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 • CORRECT USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 • SAFETY NOTES IN THE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOADING AND TRANSPORTING THE MACHINE
8. LOADING AND TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.1 • SECURING THE ARTICULATED STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.2 • LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.3 • DRIVING MACHINE ONTO LOADING AREA OF TRANSPORT VEHICLE . . . . . . . . . . . . . . . . 14
8.4 • SECURING THE MACHINE DURING TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.5 • AFTER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SAFETY
9. GENERAL SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.1 • SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.2 • SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3 • EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.4 • CLOTHING AND PERSONAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.5 • MACHINE MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.6 • BEFORE YOU LEAVE THE DRIVER'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.7 • MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.8 • FIRE PREVENTION AND FIRE FIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.8.1 • • FIRE EXTINGUISHER AND FIRST-AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.9 • PROTECTION AGAINST ASBESTOS DUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.10 • PROTECTION AGAINST INJURIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.11 • WORKING AT HIGH TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.12 • ROLL-OVER PROTECTION SYSTEM (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.13 • ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS) . . . . . . . . . . . . . . 24
9.14 • ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.15 • BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10. SAFETY MEASURES DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1 • BEFORE YOU START THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1.1 • • WORKPLACE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1.2 • • IN THE DRIVER'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1.3 • • IN-DOOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1.4 • • GAS, DUST, AND INFLAMMABLE VAPOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

0-2
10.1.5 • • MIRRORS, WINDOWS, AND LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2 • MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2.1 • • BEFORE YOU START THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2.2 • • REVERSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2.3 • • DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2.4 • • DRIVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2.5 • • EMERGENCY LOWERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.2.6 • • WORKING CLOSE TO OVERHEAD POWER TRANSMISSION LINES . . . . . . . . . . . . . . . . . . 30
10.2.7 • • LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2.8 • • GOOD VISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2.9 • • WORKING ON SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2.10 • • HEIGHT LIMITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2.11 • • BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.2.12 • • WORKING ON LOOSE SOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.2.13 • • WORKING WITH THE FORKLIFT TRUCK ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.2.14 • • PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.3 • TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3.1 • • LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3.2 • • TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11. SAFETY MEASURES DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.1 • PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2 • PRIOR TO START OF MAINTENANCE MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.1 • • WARNING SIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.2 • • TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.3 • • SAFETY-RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.4 • • PRIOR TO START OF INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.2.5 • • SECURING THE ARTICULATED STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.2.6 • • SUPPORTING THE WORK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
11.3 • DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.3.1 • • ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.3.2 • • WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.3.3 • • KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
11.3.4 • • SPECIFIC MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.3.5 • • REFUELING AND TOPPING OFF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3.6 • • COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3.7 • • USE OF LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3.8 • • HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3.9 • • HANDLING HIGH-PRESSURE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3.10 • • FAN AND BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.3.11 • • WASTE MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.4 • TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.4.1 • • STORING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12. LABELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.1 • POSITION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
12.2 • POSITION OF STANDARD LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

0-3
CONTROLS AND INDICATORS
13. GENERAL VIEW OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14. CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14.1 • GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14.1.1 • • SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14.2 • INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14.3 • WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
14.4 • CONTROL LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
14.5 • MEASURING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
14.6 • SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.7 • CONTROL LEVERS, PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
14.8 • ARTICULATED STEERING CATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.9 • TRACTION DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.10 • SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.11 • DOOR UNLOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14.12 • ALARM HORN FOR REVERSE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
OPERATION
15. RUNNING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
16. PREPARING THE MACHINE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.1 • VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.1.1 • • BEFORE YOU START THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.1.2 • • BEFORE STARTING WORKING WITH THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
17. ADJUSTMENTS PRIOR TO MACHINE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
17.1 • ADJUSTING THE DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
17.2 • ADJUSTING THE STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.3 • ADJUSTING THE ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.4 • ADJUSTING THE REAR-VIEW MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.5 • ADJUSTING THE HEATING AND VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
17.5.1 • • ADJUSTING THE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
17.5.2 • • ADJUSTING THE HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
17.6 • PUTTING ON THE SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
17.6.1 • • PUTTING ON THE SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
17.6.2 • • TAKING OFF THE SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
18. STARTING AND SWITCHING OFF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
18.1 • STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
18.1.1 • • WARMING UP THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
18.2 • SWITCHING OFF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
19. DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
19.1 • START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
19.1.1 • • STARTING THE MACHINE ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
19.2 • CHANGING THE DRIVING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
19.3 • REVERSE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
19.4 • TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
19.4.1 • • TURNING ON SLOPES, EMBANKMENTS OR HILL FLANKS . . . . . . . . . . . . . . . . . . . . . . . . . 86
19.5 • BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
19.5.1 • • PULLING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
19.5.2 • • RELEASING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
19.5.3 • • BRAKING WITH THE SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
19.5.4 • • IF THE SERVICE BRAKE BREAKS DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

0-4
19.5.5 • • BRAKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
19.6 • STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
19.6.1 • • PARKING THE MACHINE ON A SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
19.7 • LONGER-DISTANCE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
20. OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
20.1 • PREPARING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
20.1.1 • • SELECTING A WORK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
20.1.2 • • PICKING UP THE WORK UNIT (EXCEPT MULTI-PURPOSE BUCKET) . . . . . . . . . . . . . . . . . 90
20.1.3 • • REMOVING THE WORK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
20.1.4 • • PICKING UP THE MULTI-PURPOSE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
20.1.5 • • REMOVING THE MULTI-PURPOSE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
20.2 • TIRE SERVICE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20.2.1 • • LEVEL INDICATOR FOR THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20.3 • LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20.3.1 • • REMOVING PILED UP SOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20.3.2 • • EXCAVATION WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
20.4 • TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
20.5 • DUMPING / UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
20.5.1 • • LOADING IN DIAGONAL DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
20.5.2 • • V-SHAPED LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
20.5.3 • • PILING UP MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
20.6 • PLANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
20.6.1 • • FILLING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
20.6.2 • • TAKING OFF SOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
20.6.3 • • CUTTING THE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
20.7 • WORKING WITH THE FORKLIFT TRUCK ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
20.7.1 • • PICKING UP THE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
20.8 • PRECAUTIONS FOR SPECIAL OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.8.1 • • WORKING IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.8.2 • • WORKING ON SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.8.3 • • DUMPING ON STEEP SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.8.4 • • WORKING IN THE VICINITY OF ELECTRICAL OVERHEAD LINES . . . . . . . . . . . . . . . . . . . . 102
20.8.5 • • OPERATION ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.8.6 • • WORKING ON LOOSE SOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.9 • AFTER THE WORK IS FINISHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.10 • INSTRUCTIONS FOR WINTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.10.1 • • BEFORE THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.10.2 • • AFTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.10.3 • • AFTER THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.11 • LONGER STANDSTILL PERIODS OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.11.1 • • BEFORE THE STANDSTILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.11.2 • • DURING THE STANDSTILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
20.11.3 • • AFTER THE STANDSTILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
TROUBLESHOOTING
21. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
21.1 • WARNING LIGHTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
21.2 • ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
21.3 • ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
21.4 • HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

0-5
21.5 • BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
21.6 • AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
21.7 • EMERGENCY STEERING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
21.8 • EMERGENCY LOWERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
21.9 • STARTING THE ENGINE WITH A BATTERY JUMPER CABLE . . . . . . . . . . . . . . . . . . . . . . . . 116
21.9.1 • • CONNECTING THE JUMPER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
21.10 • STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
21.10.1 • • DISCONNECTING THE BATTERY JUMPER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
21.11 • TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
21.12 • TOWING A MACHINE WITH DEFECTIVE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
MAINTENANCE
22. MAINTENANCE BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
22.1 • PREPARING THE MACHINE FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
22.2 • CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
22.2.1 • • PRECAUTIONARY MEASURES WHEN CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . 123
22.2.2 • • FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
22.3 • WORKING-AREA-DEPENDENT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
22.3.1 • • MUDDY OR WET WORKING AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
22.3.2 • • DUSTY WORKING AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
22.4 • LUBRICANTS AND OPERATING AGENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.1 • • DRAINING HOT LUBRICANTS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.2 • • CHECKING THE OIL LEVEL AND CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.3 • • CHANGING FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.4 • • REFUELLING AND TOPPING OFF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.5 • • OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
22.4.6 • • LUBRICATING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
22.4.7 • • BIODEGRADABLE HYDRAULIC OIL AND LUBRICATING GREASE . . . . . . . . . . . . . . . . . . . 125
22.4.8 • • FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
22.4.9 • • STORAGE OF OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
22.4.10 • • COOLANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
22.4.11 • • WINDSCREEN WASHER LIQUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
22.4.12 • • TABLE OF LUBRICANTS AND OPERATING AGENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
22.4.13 • • LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
22.5 • REPLACING SAFETY-RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
22.5.1 • • WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
22.6 • SPARE PARTS AND CONSUMABLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
22.7 • ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
22.7.1 • • FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
22.7.2 • • FUSE ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
22.7.3 • • SLOW-BLOWING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
22.8 • TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
22.8.1 • • TIRE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
22.8.2 • • CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
22.8.3 • • CHECKING THE TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
22.9 • TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
22.10 • TORQUE FOR STANDARD NUTS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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23. MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
24. MAINTENANCE PRIOR TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
24.1 • VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
24.2 • COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING OFF COOLANT . . . . . . . 141
24.3 • ENGINE, CHECKING THE OIL LEVEL, TOPPING OFF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
24.4 • ENGINE, DRAINING OFF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
24.5 • CHECKING THE FUEL LEVEL, REFUELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
24.6 • CHECKING THE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
24.7 • CHECKING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
24.7.1 • • TEST CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
24.7.2 • • TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
24.8 • CHECKING THE SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
24.9 • CHECKING THE ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
24.10 • OTHER MAINTENANCE MEASURES PRIOR TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
25. MAINTENANCE EVERY 10 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
25.1 • LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
26. MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
26.1 • ENGINE, CHANGING OIL AND REPLACING THE OIL FILTER CARTRIDGE . . . . . . . . . . . . . . 149
26.1.1 • • REPLACING THE OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
26.2 • V-BELT, CHECKING THE CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
26.3 • V-BELT, CHECKING AND ADJUSTING THE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
26.4 • HYDRAULIC SYSTEM, REPLACING THE FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
26.5 • CHECKING AND TIGHTENING THE WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
26.6 • FRONT AND REAR AXLE, CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
26.6.1 • • PLANET GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
26.6.2 • • DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
26.7 • TRANSFER GEAR - CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
27. MAINTENANCE EVERY 50 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
27.1 • CHECKING THE COOLING SYSTEM, COOLANT LEVEL IN THE RADIATOR AND
EXPANSION TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
27.2 • DRAINING OFF WATER AND DIRT DEPOSITS FROM THE FUEL TANK . . . . . . . . . . . . . . . . . 157
27.3 • CHECKING THE SERVICE BRAKE AND OIL LEVEL, REFILLING OIL . . . . . . . . . . . . . . . . . . . . 157
27.4 • CHECKING THE BATTERY AND ACID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
27.4.1 • • RE-CHARGING A BUILT-IN BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
27.5 • LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
27.5.1 • • LUBRICATING POINTS OF THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
28. MAINTENANCE EVERY 100 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
28.1 • DRAINING THE WATER SEPARATOR, REMOVING WATER AND DIRT DEPOSITS . . . . . . . . 161
29. MAINTENANCE EVERY 250 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.1 • CHANGING THE ENGINE OIL AND OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.2 • CHECKING THE V-BELT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.3 • CHECKING AND ADJUSTING THE V-BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.4 • LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.4.1 • • LUBRICATING POINTS OF THE STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
29.5 • FRONT AND REAR AXLE, CHECKING THE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
29.5.1 • • PLANET GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
29.5.2 • • DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
29.6 • AIR FILTER, REMOVING AND RE-INSTALLING THE FILTER INSERT, CHECKING AND
CLEANING THE FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
29.6.1 • • STRUCTURE OF THE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
29.6.2 • • MAINTENANCE DEMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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29.6.3 • • REMOVING THE FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
29.6.4 • • CLEANING OR EXCHANGING THE FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
29.6.5 • • CHECKING THE FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
29.6.6 • • ASSEMBLING THE AIR FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
29.7 • CLEANING THE RADIATOR SEGMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
30. MAINTENANCE EVERY 500 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
30.1 • CHANGING THE FUEL FILTER AND FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
30.1.1 • • BLEEDING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
30.2 • CHANGING THE FILTER CARTRIDGE OF THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . 169
30.3 • CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
30.4 • LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
30.5 • TRANSFER GEAR, CHECKING THE OIL LEVEL AND REFILLING OIL . . . . . . . . . . . . . . . . . . . 170
30.6 • AIR FILTER, REPLACING THE FILTER INSERT, REPLACING THE SAFETY FILTER . . . . . . 171
30.6.1 • • REPLACING THE FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
30.6.2 • • REPLACING THE SAFETY FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
31. MAINTENANCE EVERY 1000 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
31.1 • COOLING SYSTEM, EXCHANGING COOLANT AND CLEANING THE SYSTEM . . . . . . . . . . 172
31.1.1 • • DRAINING OFF THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
31.1.2 • • CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
31.1.3 • • FILLING OFF COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
31.2 • FRONT AXLE, OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.3 • REAR AXLE, OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.4 • TRANSFER GEAR, OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.5 • SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.5.1 • • CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.5.2 • • CHECKING TUBES AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.5.3 • • CHECKING THE BRAKE DISKS FOR WEAR AND TEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.5.4 • • ADJUSTING THE CLEARANCE OF THE BRAKE DISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.6 • CHECKING AND ADJUSTING SYSTEM PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.7 • CHECKING AND ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
31.8 • CHECKING AND ADJUSTING THE INJECTION NOZZLES, NOZZLE PRESSURE AND
FUEL-JET PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
32. MAINTENANCE EVERY 2000 OPERATING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
32.1 • HYDRAULIC SYSTEM, OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
32.2 • BLEEDING THE HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
32.3 • COOLING SYSTEM, CHECKING THE ANTIFREEZE CONTENT OF THE COOLANT . . . . . . . 176
32.4 • CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
32.5 • CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
32.6 • CHECKING THE FUEL AND COOLANT TUBES, REPLACING THE TUBES (IF REQUIRED) . 176
32.7 • CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
32.8 • CHECKING AND ADJUSTING THE FUEL INJECTION AND INJECTION TIME . . . . . . . . . . . . 177
32.9 • ENGINE, INTAKE VALVES AND OUTLET VALVES - GRINDING IN THE VALVE BASES . . . . 177
TECHNICAL DATA
33. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
33.1 • NOISE EMISSION LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
33.2 • VIBRATION LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
33.3 • LIMIT VALUES FOR SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
33.3.1 • • MAXIMUM SLOPE ANGLE FOR OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . 182
33.3.2 • • TILTING/TIPPING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

0-8

INTRODUCTION

FORWORD
2
1. FORWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It
will help the operator and maintenance personnel realize peak performance through effective, economical and
safe machine operation and maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can
not be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected
in this manual. Consult your local distributor or Komatsu America International Company for the latest available
information on your machine or for questions regarding information in this manual.
• Improper operation and maintenance of this machine can be hazardous and could result in serious in-
jury or death.
• Operators and maintenance personnel must read this manual thoroughly before operating or maintain-
ing this machine.
• This manual should be kept near the machine for reference and periodically reviewed by all personnel
who come across it.
• Some actions involved in operation and maintenance can cause a serious accident, if they are not per-
formed in the 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 should you or others engage in prohibited uses or actions
as described in this manual.
• Komatsu America International Company delivers machines that comply with all applicable regulations
and standards of the country to which it has been shipped. If this machine has been purchased in an-
other country or purchase from someone in another country, it may lack certain safety features and
specifications that are necessary for use in your country. If there is any question about whether your
product complies with the applicable standards and regulations or your country, consult your local dis-
tributor or Komatsu America International Company before operating the machine.
• The description of safety is given in "2. Safety Information" and in chapter "Safety".

SAFETY INFORMATION
3
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on
the machine before performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used.
• This word is used on safety messages and product graphics where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages and product graphics usually describe precautions that must be taken
to avoid the hazard. Failure to avoid this hazard may also result in serious damage
to the machine.
• This word is used on safety messages and product graphics where there is a po-
tentially dangerous situation, which could result in serious injury or death if the
hazard is not avoided. These safety messages and product graphics usually de-
scribe precautions that must be taken to avoid the hazard. Failure to avoid this
hazard may also result in serious damage to the machine.
• This word is used on safety messages and product graphics for hazards, which
could result in minor or moderate injury if the hazard is not avoided. These safety
messages and product graphics might also use this word for hazards where the
only result could be damage to the machine.
• This word is used for precautions that must be taken to avoid actions, which could
shorten the life of the machine.
• This word is used for important additional information.
Safety precautions are described in chapter "Safety".
Komatsu America International Company cannot predict every circumstance that might involve a potential hazard
in operation and maintenance. Therefore the safety message in this manual and on the machine may not include
all possible safety precautions. If any procedures, tools, actions, work method, or operating technique not specif-
ically recommended or allowed in this manual are used, you must be sure that you and others can do such proce-
dures and actions safely and without damaging the machine. If you are unsure about the safety of some
procedures, contact your local distributor or Komatsu America International Company.
☞
☞

INTRODUCTION
4
3. INTRODUCTION
3.1 FEATURES
• Maximum flexibility of usefulness.
• Improved sealing for reduced noise, low vibration cab.
• Console and adjustable steering column with unencumbered foot area provides a comfortable feeling.
• Light touch lever operations through use of electrical transmission control lever.
• Pleasant operators compartment with low vibration and noise levels.
• Excellent view from the cabin to all sides.
• Engine hood opens fully for ease of maintenance.
• Safety lock lever for work equipment.
• New engine that meets exhaust gas emission of 96 EPA & carb.
3.2 BREAKING IN A NEW MACHINE
Your machine has been thoroughly adjusted and tested before shipment. However, operating the machine under
severe conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours.
During breaking in:
• After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation.
• Avoid operation with heavy loads or at high speeds.
• Avoid sudden starts or acceleration, unnecessarily abrupt stops and sharp steering except in cases of emer-
gency.
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply
when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this
manual, Komatsu America International Company cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstance.

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
1 - POSITION OF PLATE
On the center right of the front frame.
2 - POSITION OF STAMP
4.2 ENGINE SERIAL NO. PLATE POSITION
1 - POSITION OF PLATE
2 - POSITION OF EPA - LABEL
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
REMARKS
Machine serial No.:
Engine serial No.:
Distributor name:
Address:
Service personnel for your machine:
Phone:
Fax:
2
1

WHY YOU SHOULD READ THESE OPERATING INSTRUCTIONS
6
5. WHY YOU SHOULD READ THESE OPERATING INSTRUC-
TIONS
The machine must be operated, cleaned, and maintained very carefully to ensure safe and troublefree operation.
If you operate the machine correctly, these operating instructions will help you to avoid injuries and damage to
property. To ensure this, these operating instructions take into account all applicable legal regulations and direc-
tives; the operating instructions comprise the following information:
• Notes on the Operating Instructions
• Notes on Transport
• Notes on Safety Regulations
• Operating Instructions
• Troubleshooting
• Maintenance Instructions
• Technical Data
• Notes on Lubricants and Operating Agents
The operating instructions are part of the machine and must always be available at hand in the machine. If the
operating instructions have been lost or if they have become unreadable, because they are dirty, you may receive
a new copy from Komatsu or your local Komatsu dealer. If the machine is resold, the operating instructions, and
the licence are to be handed over to the new owner.
The owner of the machine has to ensure that:
• all persons driving the machine have the legally required minimum age and are physically and mentally
fit to perform the tasks they are charged with.
• all persons in charge with operating or maintaining the machine are appropriately instructed before op-
eration or maintenance is started. They must have completely read and understood these operating in-
structions. In particular, this applies to the following section "6. Notes on Safety Regulations" and the
chapter "Safety".
• all persons driving the machine have read the accompanying leaflet "Notes on Operation of Komatsu
Construction Machines in Public Traffic".
• the machine is correctly operated.
• the machine is not improperly modified.
Please note:
If the owner modifies safety-related parts of the machine, the certificate of conformity of the manufacturer will
lapse and the person who has performed the modification has to issue a new certificate. Should you have any
questions concerning this point, please do not hesitate to ask your local Komatsu dealer.
Our continuous effort to improve the machine's design may lead to changes of machine details. However, the in-
troduction of these improvements does not oblige us to perform them on machines which have already been de-
livered and are already in use.
If these improvements result in minor changes, these minor changes will not be described in the operating in-
structions. Should you require new available information about your machine or have any questions concerning
the information given in the operating instructions, please do not hesitate to contact either Komatsu America In-
ternational Company or your local Komatsu dealer.
These operating instructions may refer to attachments and special equipment not available from your local Ko-
matsu dealer. Should you require attachments or special equipment, ask your local Komatsu dealer.