Komatsu Wa70-7 User manual

Errors in the operation and maintenance may be

dangerous and cause personal injury. Be sure to read

and understand this manual thoroughly before operating

the machine or performing maintenance. Keep this

manual accessible at all times and have all personnel

read it periodically.

Operation and

Maintenance Manual

VENAM02003

DANGER

Komatsu has had this Operation and Maintenance

Manual translated into some other languages used in the

European Union. Please contact your Komatsu

distributor if you need a manual in another language.

NOTE

Printed in Europe 11.2016

ORIGINAL INSTRUCTIONS

-7

SERIAL NUMBERS H62051 and up

WHEEL LOADER

Foreword

WA70-7 – VENAM02003 1-1

1. Foreword

1.1 Foreword Foreword

1-2 WA70-7 – VENAM02003

1.1 Foreword

This manual provides rules and guidelines to help you use this

machine safely and effectively. The precautions in this manual

must be followed at all times during the operation and mainte-

nance of the machine. The majority of accidents are caused by a

failure to follow fundamental safety rules for the operation and

maintenance of machines. Accidents can be prevented by know-

ing beforehand the conditions that may create hazards during

operation or maintenance.

WARNING

Operators and maintenance personnel must always do as

follows before beginning operation or maintenance.

Be sure to read and understand this manual thoroughly

before operating the machine or performing maintenance.

Read the safety messages given in this manual and the

safety labels affixed to the machine thoroughly and be sure

that you understand them fully.

Keep this manual at the storage location for the Operation

and Maintenance Manual given below.

Have all personnel read the manual periodically. If this man-

ual is lost or has become so dirty as to be illegible, immedi-

ately request a replacement manual from Komatsu or your

Komatsu distributor.

If you sell the machine, be sure to hand over this manual to

the new owners together with the machine.

Komatsu delivers machines that comply with all applicable

regulations and standards of the country to which it has

been shipped. If this machine was purchased in another

country, safety devices and specifications may not be com-

pliant with the requirements applicable in the country of use.

If there is any question about whether your product complies

with the applicable standards and regulations of your coun-

try, consult Komatsu or your Komatsu distributor before

operating the machine.

Foreword 1.1 Foreword

WA70-7 – VENAM02003 1-3

The operating manual is to be considered part of the machine

and should be stored in the lid of the hinged panel in the left side

of the operator's cab.

Any safety-relevant modification to the machine by the owner

voids the manufacturer's declaration of conformity.

Our continuous efforts to improve the machine's design may

result in minor changes to the machine.

The introduction of these improvements however does not con-

stitute an obligation on our part to implement the same changes

in machines already delivered and operating. Minor changes

due to improvements are not covered by this manual.

1.1 Foreword Foreword

1-4 WA70-7 – VENAM02003

EU Directives

Machines delivered by Komatsu are compliant with the Machine

Directive 2006/42/EEC and its amendments. If the machine is

used in another country, it is possible that certain safety devices

and specifications may not be compliant with the requirements

applicable in the country of use. For example, warning beacons

may be used in some countries while being prohibited in others.

If there is any question about whether your product complies

with the applicable standards and regulations of your country,

consult your Komatsu distributor before operating the machine.

Notes on subsequent installation of electrical and electronic

equipment and components

Electrical and electronic equipment and/or components installed

after delivery emit electromagnetic radiation which may possibly

influence the function of the electronic components and assem-

blies of the machine. This may affect the safety of the machine

or endanger persons. For this reason, please ensure that the fol-

lowing safety instructions are observed.

If you are installing electrical or electronic equipment and/or

components in the machine and connect them to the vehicle's

electrical system, you are obliged to have the installation verified

for not interfering with vehicle's electronic system or other com-

ponents. In particular, please ensure that any subsequently

installed electrical and electronic components comply with the

EMC Directive 2004/108/EC in their currently valid version and

that they have CE labels.

The following requirements also have to be met for subsequent

installation of mobile communication systems (e.g. radio, tele-

phone):

Only equipment approved by national legislation (e.g. BZT

approval for Germany) may be installed.

The unit must be fixed in position.

Portable or mobile units may only be used inside the vehi-

cles if they are connected to a fixed outside antenna.

The transmitter unit must be spatially separated from the

vehicle’s electronic system.

Ensure that the antenna is installed properly with a good

earthing connection between the antenna and the vehicle

earth.

Also observe installation instructions by Komatsu or the manu-

facturer for wiring, installation and maximum permitted power

consumption.

Foreword 1.2 Safety information

WA70-7 – VENAM02003 1-5

1.2 Safety information

In order to ensure the safe operation of the machine, this man-

ual contains safety instructions, and there are safety labels

affixed to the machine. They are intended to inform the operator

of situations that may pose an injury hazard and to point out

ways to avoid such situations.

1.2.1 Signal words

The following signal words are used to inform you that there is a

potentially hazardous situation that may lead to personal injury

or damage.

In this manual, the following signal words are used to express

the potential level of hazard.

DANGER

Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

ATTENTION

Indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury. This word is also used to

indicate unsafe practices that may cause property damage.

1.2 Safety information Foreword

1-6 WA70-7 – VENAM02003

Example of safety message using a signal word.

WARNING

Engage the work equipment lock lever before leaving the

operator's cab.

Accidentally touching the control levers when they are not

locked may result in serious injury or death.

Other signal words

In addition to the above, the following signal words are used to

provide useful information or indicate precautions that should be

followed to protect the machine.

NOTICE

This word is used to indicate precautions that must be taken to

avoid actions which could shorten the life of the machine.

REMARK

This word is used for information that is useful to know.

Foreword 1.2 Safety information

WA70-7 – VENAM02003 1-7

1.2.2 Safety labels

Safety labels are affixed to the machine to inform the operating

or maintenance personnel immediately of hazards in the opera-

tion or maintenance of the machine.

For details see “Safety labels (2-2)”.

Safety labels using pictograms

Safety pictograms use a picture to express a hazard level that

corresponds to the signal word. The pictures used are intended

to help the operating and maintenance personnel understand

the level and type of hazard at all times. Safety pictograms show

the type of hazardous condition at the top or on the left side, and

the method of avoiding the hazardous condition at the bottom or

on the right side. In addition, the type of hazardous condition is

displayed inside a triangle, and the method of avoiding the haz-

ardous condition is shown inside a circle.

Komatsu cannot predict every circumstance that might involve a

potential hazard in operation and maintenance. Therefore, the

safety messages in this manual and on the machine may not

include all possible safety precautions.

If any procedures or actions not specifically recommended or

allowed in this manual are used, it is your responsibility to take

the necessary steps to ensure safety.

Never perform any type of work or use the machine in any way

that is expressly prohibited in this manual.

The explanations, values, and illustrations in this manual were

prepared based on the latest information available at the time.

Continuous improvements to the machine's design may result in

minor changes to the machine that may not be reflected in this

manual. Consult Komatsu or your Komatsu distributor for the lat-

est information available on your machine or for questions

regarding the information in this manual.

GK032002

Part no.

1.3 Introduction Foreword

1-8 WA70-7 – VENAM02003

1.3 Introduction

This loader is an independently powered machine moving on

wheels. Using the equipment (e.g., a bucket or fork) installed to

its front, the loader can be used to load or dig material while

moving forwards.

This Komatsu machine is designed to be used mainly for the fol-

lowing work:

Digging

Smoothing

Pushing

Loading

1.3.1 Intended use

If you use the machine for any other purpose than those speci-

fied above, we will not accept any responsibility for its safety.

Any considerations regarding safety will then be up to the owner

or the operating and maintenance personnel. In any case, nei-

ther you nor any other person are/is authorised to perform work

and functions explicitly prohibited in these operating instructions.

The transport of persons in the work equipment is strictly forbid-

den!

For details of the operating procedure, see

chapter 3.3.10 “Working with the wheel loader” (3-77).

Foreword 1.3 Introduction

WA70-7 – VENAM02003 1-9

1.3.2 Breaking in the machine

Every machine has been thoroughly tested and set up before

shipping. However, a new machine needs to be handled care-

fully during the first 100 hours of service.

If the machine is worked excessively hard during the breaking-in

period, this will cause premature deterioration of performance

and shorten the machine's service life. A new machine needs to

be broken in and serviced carefully.

Particularly observe the following points:

Let the engine run at idle for 5 minutes after starting.

Avoid operation with heavy loads or at high engine speeds.

Avoid sudden starts and stops, hard acceleration and sud-

den steering movements, except in emergencies.

The precautions for operation and maintenance in this manual

as well as the safety information apply only as long as the prod-

uct is used according to the specified intended use. If the

machine is used for any purpose not listed in this manual,

Komatsu cannot accept any responsibility for safety. In such

cases, any safety considerations are the sole responsibility of

the operator.

Never perform any type of work or use the machine in any way

that is expressly prohibited in this manual.

1.4 Key data of the machine Foreword

1-10 WA70-7 – VENAM02003

1.4 Key data of the machine

1.4.1 Product identification number (PIN)/Machine serial no. plate and

its position

Position of the serial no. plate (1)

Serial number stamp (2)

The plate is on the right side of the machine's front frame.

The design of the serial no. plate differs depending on the coun-

try.

Foreword 1.4 Key data of the machine

WA70-7 – VENAM02003 1-11

1.4.2 Engine serial no. plate

Engine serial no. plate

1.4.3 Axle serial no. plate

Axle serial no. plate (1)

Rear axle: Left

Front axle: Right

1.4.4 Transmission serial no. plate

Transmission serial no. plate (1)

1.4 Key data of the machine Foreword

1-12 WA70-7 – VENAM02003

1.4.5 ROPS/FOPS cab serial no. plate

ROPS/FOPS cab serial no. plate

In the cab beneath the operator's seat.

1.4.6 Operator's seat serial no. plate

Operator's seat serial no. plate

Under the bellows at the front of the seat, or on the rear lower

frame (arrow mark).

1.4.7 Fluorinated greenhouse gases

Product contains fluorinated greenhouse gases.

GJ2K4590

HFC-134a

GWP

1430 CO2 eq.

09971-10121

Product contains

fluorinated

greenhouse gases

1.2

1.72

Foreword 1.4 Key data of the machine

WA70-7 – VENAM02003 1-13

1.4.8 Serial number and distributor

1.4.9 Retrofitting by third-party suppliers

In the case of wheel loaders with equipment and tools that were

not part of a complete delivery straight from the factory, the

responsibility for compliance with applicable laws and guide-

lines, in particular the European Machine Directive, lies with the

customer that commissions the retrofit of the machine.

In the case of tools (e.g., load buckets) retrofitted by a third-party

supplier, the technical specifications of the manufacturer must

be observed. To this end, or for further information, please con-

tact Komatsu or your local Komatsu distributor.

Machine serial number

Engine serial number

Product identification number (PIN)

Manufacturer name

Address

Komatsu Germany GmbH

Hanomag Straße 9

30449 Hanover

Germany

Dealer name

Address

Service personnel

Phone/fax

1.4 Key data of the machine Foreword

1-14 WA70-7 – VENAM02003

1.4.10 Declaration of Conformity

The manufacturer:

Komatsu Germany GmbH

Hanomag Straße 9

30449 Hanover

Germany

declares that this machine:

WA70-7*

is in conformity with the applicable provisions of the following EU

Directives:

*:explanation of machine category

Machinery Directive 2006/42/EC

Electro Magnetic Compatibility Directive 2004/108/EC until 19 April 2016

2014/30/EU after 20 April 2016

Outdoor Noise Directive 2000/14/EC amended 2005/88/EC

Radio Equipment and Telecommunications Terminal

Equipment Directive 1999/5/EC until 12 June 2016

Radio Equipment Directive 2014/53/EU after 13 June 2016

Machine category Stand for:

WA Wheel loader

Foreword 1.5 Table of contents

WA70-7 – VENAM02003 1-15

1.5 Table of contents

1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

EU Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.2.1 Signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.2.2 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.3.1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.4 Key data of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.4.1 Product identification number (PIN)/Machine serial no. plate and its position . . . . . . . 1-10

1.4.2 Engine serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.4.3 Axle serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.4.4 Transmission serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.4.5 ROPS/FOPS cab serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.4.6 Operator's seat serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.4.7 Fluorinated greenhouse gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.4.8 Serial number and distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.4.9 Retrofitting by third-party suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.4.10 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.5 Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.6 Dimensions, weights, and operating data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1.7 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1.7.1 Equipment – part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1.7.2 Equipment – part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Position of the safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 Precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.3.1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.3.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.3.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.4 Precautions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2.5 Precautions when handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.5 Table of contents Foreword

1-16 WA70-7 – VENAM02003

3.1.1 General view of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.1.3 Machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.1.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3.2 Descriptions of the individual elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2.1 Machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Caution lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Pilot lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3.2.2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.2.3 Control levers and pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3.2.4 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.2.5 Tow hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.2.6 Power outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.2.7 Door unlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.2.8 Back-up alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3.2.9 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.2.10 Slow-blow fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.2.11 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.2.12 Setting the heating and ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.2.13 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3.3.1 Checks before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Checks before starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Adjustments before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3.3.2 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

Ambient temperature for operation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Checks after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3.3.3 Driving the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Limiting the maximum speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

3.3.4 Changing direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

3.3.5 Turning and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

3.3.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Engaging the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Disengaging the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Braking with the service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

If the service brake fails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

Braking on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

3.3.7 Stopping and parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

3.3.8 Operating the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Multi-function lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

3.3.9 Return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3.3.10 Working with the wheel loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Foreword 1.5 Table of contents

WA70-7 – VENAM02003 1-17

Saving the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Engaging the 100 % differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Working with the forklift attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

3.3.11 Operating precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Permissible water depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Working on snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Dumping on steep slopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Working near high-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Working on road shoulders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Working on loose ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

If the service brake fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Precautions for driving uphill or downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Precautions when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

3.3.12 Adjusting the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Selecting the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Attaching the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Removing the work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Removing the multi-purpose bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

Bucket level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

3.3.13 Switching off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

3.3.14 Checks after switching off the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

3.3.15 Locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

3.3.16 Handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Precautions when handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Standard tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

3.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

3.4.1 Transporting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

Ensure steady positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

3.4.2 Loading the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

Loading the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Securing the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

Unloading the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

3.4.3 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

3.5 Operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

3.5.1 Precautions for operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

3.5.2 Precautions after work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

3.5.3 After the cold weather period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

3.6 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

3.6.1 Before storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

3.6.2 During storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

3.6.3 After storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

1.5 Table of contents Foreword

1-18 WA70-7 – VENAM02003

3.7 Machines equipped with KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3.7.1 Basic precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

4. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Starting the engine with booster cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3 In case of insufficient brake power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.1 Checking the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.2 Checking the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.4 Emergency steering properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.5 Emergency lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.6 Other troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.6.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.6.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.6.3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.6.4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.6.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.6.6 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.6.7 Operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Maintenance guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.1 Tipping up the operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.1.2 Tipping down the operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.2 Basic maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.2.1 Fuel, coolant and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Storing oil and fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Biodegradable hydraulic oil and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.2.2 Outlines of the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.3 Wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.3.1 Wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.4 Fuel, lubricants, and coolants; quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.4.1 Lubrication table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.4.2 Recommended brands, recommended quality for products other than Komatsu genuine oil . . . 5-21

5.5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22