Preview
Preview
Manual
WA420-ILC
WHEEL LOADER
MACHINE MODEL NAME 8 MACHINE SERIAL NO. ENGINE MODEL NAME 8 ENGINE SERIAL-NO.
DELIVERY
. PERIODIC
PERIODIC
PERIODIC
PERIODIC
FORWARD
This manual describes procedures for operation, handling, lubrication, maintenance,
checking, and adjustment. It will help the operator or anyone realize peak performance
through effective, economical and safe machine operation and maintenance.
Please ,continue studying this manual until proper operation is completely reinforced
into personal habit.
This manual describes the basic techniques. Skill is performed as the operator or
anyone get the correct knowledge and performance of the machine.
Operation, inspection, and maintenance should be carefully carried out, and the
safety must be given the first priority. Safety precautions are indicated with A marks
and technical precautions with + marks in this manual. The safety information
contained in this manual is intended only to supplement safety codes, insurance
requirements, local laws, rules and regulations.
Some photographs and illustration pictures are different from your machine as
technical improvement is continuously reflected on it. Revision to up-to-date manual’s
content is performed in later editions.
This operation & maintenance manual may contain attachments and optional
equipment that are not available in your area. Please consult your local distributor
for those items you may require.
If a machine is subjected to unreasonably hard use at the initial operation stage, the
potential of performance will prematurely deteriorate and the service life will be reduced.
A new machine must be operated with care, particularly with regard to the following
items.
. After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior
to actual operation.
l At the first 250 hours of operation, the machine should be maintained in the
following manner in addition to usual 250 hours service:
* When replacing oil filter elements (cartridges), check their interiors for dirt and dust.
If heavily collected, check for possible cause before starting operation.
CONTENTS
DESCRIPTION PAGE
OPERATION
CONTENTS-Continued
PAGE
DESCRIPTION
CHECKBEFORESTARTING ..................................... ;;
WALK-AROUNDCHECK ......................................
CHECKMONITOR PANEL.........................._ ..........
CHECK AND REFILLCOOLANT ................................. z
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN .................. g
CHECK FUEL LEVEL AND REFILL FUEL ............................
CHECK AIR CLEANER SERVICE INDICATOR ........................ z
DRAIN WATERFROMAIRTANK .................... .‘. ..........
CHECK FOR SEDIMENT AND WATER IN II-lE WATER SEDIMENTOR ........ 34
FUEL-WATER SEPARATOR - DRAINING WATER AND SEDIMENT ........... 35
DRIVE BELT - INSPECTlON ................................... g
FAN -INSPECTION .........................................
CONTENTS
DESCRIPTION
TOSTARTTHEENG~E...................................... 38
SPECIAL STARTING 38
CHECKsAFTERSTARTIN’G’::::::::::::::::::::::::::::::::::: 39
TO MOVE THE MACHINE OFF . . . . . . . . . . . . . . . . . . . . . .‘: . . . . . . . . . . 39
CHANGINGGEARSPEED..~.................................. 40
CHANGING DlRECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TURNING 41
TOSTOPTHE’MACHINE’::::::::::::::::::::::::::::::::::::: 42
TO STOP THE ENGINE 43
MAXIMUM DEPTH OF W/+&i : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 43
IF WHEEL BRAKE DOES NOT WORK . . . . . . _ . _ . . . _ . . . . . . . . . . . . . . . . -43
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . 44
LOWER THE CENTER OF GRAVITY WHEN TURNING 44
BRAKING ON DOWNHILL SLOPES . . . . . . . . . . . _ . : : : : : : : : : : : : : : :: 44
IF ENGINE STOPS 44
PROPERBUCKETANDjidE’:::::::::::.:::::::::::::::::::::::: 45
HANDLlNGTHETlRES ......................................... 48
PRECAUTlONS WHEN HANDUNG TIRES ........................... 48
PRECAUTlONS WHEN DRIVING MACHINE .......................... 49
TIREPRESSURE ............................................ 50
INFLATING TIRES ........................................ 50
TOWING .................................................. 52
TOWINGTHE MACHINE.. .................................... 52
WHEN ENGINECAN BE USED ............................... 52
..
WHEN ENGINECANNOT BE USED ............................ 52
RELEASING PARKING BRAKE .................................. 53
CONTENtS
DESCRIPTION . PAGE
MAINTENANCE
MAINTENANCETABLE .......................................... 5‘
CONTENTS
DESCRIPTION PAGE
ADJUSTMENT ................................................ 54
ADJUSTING PARKING BRAKE ................................... 54
ADJUSTING LENGTH OF LEVER .................................. 55
CONTENTS
DESCRIPTION PAGE
ENGINE .......... 57
CHASSIS:::::::::::::::::::::::::::::::::::::: .......... 58
TRANSMISSION ......................................... 58
AXLE ..... .._........................;> .............. 58
DISCBRAKE : ........................................... 58
PARKlNG BRAKE ........................................ 59
STEERING.. ........................................... 59
HYDRAUUC SYSTEM ..................................... 59
MEMORANDA . . . . _ . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 64
BUCKETOPERATlON................_...._.._:’...: ............. 19
EXCAVATION ............................................. 19
PRECAUTIONS WHEN SCOOPING UP MATERIALS .................. 22
LEVELING ...............................................
LOAD AND CARRY OPERATIONS ................................ z
LOADING.. .............................................. 23
CROSSDRIVELOADING ........................... .........
V-SHAPE LOADING .......................................
Page 9
CONTENTS
DESCRIPTION PAGE
METHODOFOPERATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSPORTATION . .._........._.............._.............. 32
...............
...............
34
AFTER STORAGE .................. ....... ............... 34
..
COOLANT AND LUBRICANTS ............ . . . . . . . . . . . . . . . 35
MEMORANDA .. . ............................................ 36
SECTION 1
OPERATION
A
WARNING ! REFER TO AND READ ALL
..
SAFE+ PRECAUTIONS IN SECTION 3.
SECTION 1 OPERATION
Page 2
GENERAL LOCATIONS AND SPECIFICATIONS
GENERAL LOCATIONS
_ - . _ : _.__....___.
_- .__.-.-. . --. _ _._- - -
PERFORMANCE
Travel speeds:
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum of 24.1 mph (38.8 km/h)
Reverse . . . . . . . . . . . . . . _ . . . . . . . . . . . _ Maximum of 26.5 mph (42.6 km/h)
ENGINE
Thii monitor panel consists of monitor lamp groups (A, 6, C), mater group (D) and warning
np (0
l To check the monitor system, turn the starting switch to ON before starting the engine.
Then all the monitor lamps, the gauges and the warning lamp light up for about 3
seconds and the Alamobuzzer sounds for about 1 second. Three figures, 133, are
:
diiptayad on tha speedometer while tha monitor system is being chacked. After that, all
lamps go off and the buzzer stops. If any monitor lamp does not light up, ask your
diiutor to inspect that monitor lamp.
* When the starting switch is turned to ON, if the directional lever is not at neutral, the
warning lamp willflash and the alarm buzzer will continue to sound. lf this happens, return
the lever to neutral. The lamp will go out and the buzzer will stop.
* To check the monitor immediately when tha engine is stopped, waft for at least 30
seconds after the engine is stopped.
* When the engine is started, these monitor lamps will go off even if there are abnormalities.
SECTION 1
Page 4
If any abnormalityoccurs while the engine is running, the appropriate monitor lamp will flash to
indicate the abnonnalii.
* Even if any monitor lamp flashes, the machine can operate, but it should be repaired as
soon as possible. ’
If any abnorrMi occurs while the engine is running, the appropriatemonitor lamp will ilash and
thealarmbuzzarwiilsoundintermittenUyatthesarnatima.
* lf any monitor lamp flashes, stop the engine or run it at a low idling speed, and repair it
Immediately-
METER GROUP
Thii group consists of air pressure gauge, engine water temperature gauge, torque converter
oil temperature gauge, fuel gauge, speedometer, service meter and pilot display.
WARNING LAMP
The warning lamp will flash when there is an abnormalityin any (B) group item.
Tha warning lamp will flash and the alarm buzzer will sound when there is an abnormalii in any
(C) group item or when the parking brake is applied, but the diiectional lever is not at neutral.
OPERATION SECTION 1
Page 5
* Do not raly on ‘CHECK MONITOR GROUP (Check before starting)” only for the check
before starting. Always make the check by referring to the section on CHECK BEFORE’
STARTING.
lf any abnormality occurs while the engine is running, the appropriate monitor lamp and the
warning lamp will flash to indicate the abnormalii at the same time.
Charge Monttor
lf any abnom-talii occurs while the engine is running, the appropriate monitor lamp and tha
warning lamp will ffash and the alarm buzzer will sound intermittentlyat the same time.
* Thismonitorlampflashesandthealarm
buzzer sounds, when the starting switch
is turnad to ON immediately after the
engine is started or immediately before
the angina is stopped. lt does not
indicate an abnomlalii.
e
temperature.
When the monitor iamp flashes, run the engine
with no load at midrange speed until the green
range of tha angine water temperature gauge
lights.
* Park the machine on level ground and che& the monitor lamps.
* Confirm that these monitor lamps light for about 3 seconds after turning the starting
switch to ON. If any monitor lamp does not light, ask your distributor to inspact that
monitor lamp.
OPERATION SECTION 1
Page 9
When the starting switch is turned to on, this lights up to indicate that the display items are
working. (
9 10 9
11
12
04k
Air Pressure Gauge
* lf the air pressure drops even lower, the parking brake will tk autcimaticallyapplied.
OPERATION SECTION 1
Page 11
Fuel Gauge
This gauge indicates the amount of fuel in the
fuel tank. ffthere is enough fuel in the tank while
the engine is running, the green range lights. If
yhyhz&gkM, there is less than 21 liirs
Speedometer
__-_.._ . .
This meter indiies the running speed of the __.-
machii.
I[aTzi==Tr>ll
* A speedometer for MPH is also available.
serviceMeter
This meter shows the total operation hours of 1
the machine. The service met& advances while
th0 engine is running - even if the machine is
not traveling.
* ”
While engine is running, green pilot lamp on [JINGFS&u]
theservicemeterflashestoshowtheservice
meter advances.
OPERATION SECTION 1
Page 13
SWITCHES
ON:
Depressing the left brake pedal operates the
wheel brakes, and also returnsthe transmis-
sion to NEUTRAL
* if the switch is at Oti, the transmission cut-off selector pilot lamp will,light up.
A
WARNING! tf the machine has to be started on a slope, always turn the
transmission cut-off selector switch to OFF and depress the left brake pedal.
Then depress the accelerator pedal while releasing the left brake pedal to start
the machine off slowly.
SECTION 1 OPERATCON
Page 14
(c) ON:
A fixed amount of ether (approx. 3 cc each time)
is injected into the engine air intake to make it
easier to start the engine in cold weather.
(d) OFF:
Whentheswitchisr&ased,it~
retumstotheOFFpos&ion.
A WARNING! Do not keep the switch at the ON position for more than 5 seconds.
HORN BUrrON
(1) ON position:
The parking brake is applied, and the parking
brake pilot lamp lights up.
A
WARNING! Always apply the
parking brake when leavng the
machine or parking it.
If the directional lever is placed in F (FORWARD) or R (REVERSE) with the parking brake
applied, the warning lamp will flash and the alarm buzzer will sound.
When the starting switih ‘is turned to OFF, the parking brake is automaticallyapplied.
Before starting the engine, turn the parking brake switch to ON, then turn it to OFF.
The machine does not start when the directional lever is operated with parking brake
applied.
SECTION 1 OPERATION
Page 16
STARTINGSWITCH
LAMP SWITCHES
(for lamps, turn signal lamps, dimmer switch)
Lamp switch
Position (1):
Parking lamp lights up.
Position OFF (2):
Lamps-go off.
Position (3):
Cfearance iamps, tail lamps and machine
monitor fiihting light up.
Position (4):
Head lamps light up in addition to the lamps
in position (3):
* The lernp switch can be operated regardless of the position of the lever. ..
OPERATION SECTION 1
Page 17
CIGARETTELIGHTER
KEKDOWN SWITCH
DIRECTIONAL LEVER
lt is possible to change the length of the lever. For details of changing the length, see
ADJusThENT.
OPERATION SECIION 1
Page 21
Posii (1)
Stopper actuated.
Position (2)
Stopper released.
A
WARNING! Stpp the machine
before adjusting the angle of the
steering wheel.
ACCELERATOR PEDAL
This padal controls the engine speed and output. The engine speed can be freely controlled
between low idling and full speed.
SECTION 1 OPERATION
Page 22
BRAKE PEDALS
The right brake pedal operates the wheel brakes, and is used for normal braking.
A WARNING! On downhill slopes, apply the engine brake, and also use the right
brake pedal.
The left brake pedal operates the wheel brakes, and if the transmissii cut-off selector switch
is at ON, it also returns the transmission to neutral.
If the transmission cut-off selector switch is at OFF, the left brake pedal acts in the same way”
as the right brake pedal.
A WARNING! Do not use the brake pedals as footrests. Use them only when
applying the brakes.
* When the accelerator is being used for operating the work equipment, always use the left
brake pedal to slow or stop the machine after putting the transmission cut-off selector switch
in ON.
OPERATION SECTION 1
Page 23
(1) Tilt:
(2) Hold:The bucket is kept in the same
position.
(3) Dump:
SAFETY LOCK
T&G&i; ~IJ.SJ.S~
to lock the lii an-n and bucket
A
WARNING! When parking or
leaving the machine, or when
performing maintenance, always
lower the bucket to the ground,
put the work equipment levers in
hold position and check that
safety lock lever is locked.
SAFETY BAR
:
The safety bar is used during maintenance or
when transporting the machine. It locks the
front frame and rear frame, and prevents the
front and rear frames from bending.
A
WARNING1 Always us8 the safety
bar for maintenance or when
transporting the machine.
(1) Raise:
(2) Hold: The lift arm and the bucket are kept
in the same position.
(3) Lower:
(4) float: The Iii arm moves freely under
external force.
(5) Tilt:
(6) Dump:
DOOR-OPEN LOCK
r
HOOD TILT LOCK
L
Open the engine hood fi~liyand apply the lock.
A
WARNING! When carrying out
inspection or maintenance with
the engine hood raised, always
use the lock.
..
FUSE SQX
A
WARNING! Before replacing a
fuse, be sure to turn off the
starting switch.
SECTION 1 OPERATION
Page 28
Fuse
No. capacity circuit
1 2QA Woiking lamp
2 1OA Parking brake
3 1OA Monitor lamp
4 1OA Bucket positioner
6oom kick-out
5 1oA _
6 1OA _
7 20A Air condiioner
(Fan outside room)
‘s 20A Air conditioner
(Fan inside room)
9 1OA Radii, Room lamp
10 1OA Cigarette lighter
11 1OA Rear wiper
12 1OA Front wioer
OPERATOR’S SEAT
The seat adjustmant should ba checked at the
beginning of each shii and when operators
change.
FORWARD-BACKWARD ADJUSTMENT
Move lever (1) to the rig& move the seat to the
best position and releasathe lever. The seat
can be moved forward or backward within a
range of 140 mm in 7 stages.
SEAT ANGLE ADJUSTMENT
Move lever (2) up, sat the seat to the desired
angle, and release the lever.
The seat can be tilted up or down about 3”.
SEAT CUSHION ADJUSTMENT
Rotate grip (3) under the seat to adjust scale
(4) on the cushion adjustmentto your own weight. (50 to 120 kg)
BACKREST ADJUSTMENT
Pull lever (5), move the backrest to the best position and release the lever. The backrest can
ba set to 11 steps.
..
A WARNING! Park the machine in a safe place and stop the engine when carrying
out adjustment of the operator’s seat.
FORWARD-BACKWARD ADJUSTMENT
ANGLE ADJUSTMENT
SEAT BELT
A
WARNING! Before fastening the
seat belt, inspect the securing
brackets and belt for abnormal
conditions.
Fasten the belt and remove it in the following
manner.
1. Adjusttheseatsothatthebrakepedalcan
be depressed all the way with the
operato&backagainstthebackrest
2. After po&ioning the seat, install the tether
belt (1). Wti the seat unoccupied, tense the
belt slightly across the seat and install.
3. Si in the seat. Hold buckle (2) and insert (3) into the buckle (2). Check that the belt has
focked by pulling it.
4. When removing the belt, raise the tip of the buckle lever to release it.
* When leaving the operator’s seat, release the seat belt and hang it over the arm rest.
* Fasten belt along your body without kinking it_Adjust the lengths of the belt on both the
buckle and the insert sides so that the buckle is located at the mid-point of your body front.
_ ..__-.
Adjust the belt length in the following manner. 1 1
To shorten the belt, pull the free end of the
belt on either the buckle body or insert side.
To lengthen, pull the belt while holding it at
a right angle to buckfe or insert
When operating a machine equipped with
ROPS. be sure to use the seat belt.
lf the seat is scratched or frayed or if any of the fittings are broken’or deformed from long
service, replace the seat belt immediately. /
OPERATION SECTION 1
-Page 31
Always make the check by referring to this section on CHECK BEFORE STARTING.
SECTION 1 0PERATI:ON
Page 32
A
WARNING! Do not open the radia-
tor cap unless necessary. Always
check the coolant level of the sub-
tank when engine is cold.
FAN - INSPECTlON
F. CHECK THAT ENGINE EXHAUST GAS COLOR AND SOUND +RE NORMAL
G. CHECK THAT GAUGES AND INSTRUMENTS WORK PROPERLY.
H. CHECK STEERING PLAY; CHECK THAT STEERING WORKS PROPERLY.
I. CHECI( THAT BACK-UP BUZZER SOUNDS PROPERLY.
J. CHECK ELECTRICAL WIRING
Che& for any sign of disconnection or short circuit in the electricw@g. Check also for loose
terminals and tighten any loose parts.
check the following points cart3flJlly.
l -v
. StaRingmotor
0 Alternator
OPERATION SECTION 1
Page 37
SPE&AL STAFITING
When statingafter running out of fuel, fill with fuel, then fill the fuel filter cartridge with fuel and
bleed the air from the fuel system before starting.
A
WARNING! It me machine has to
be started on a slope, always turn
‘me transmission cut-off selector
switch to OFF and depress me left
brake pedal. Then depress me
accelerator
.. ._~. pedal while releasing
me left brake pedal to start me machine off slowly.
CHANGING DIRECTION
A
WARNING! Never change between
FORWARD and REVERSE at high
speed-
TURNING
A
WARNINGI If the engine stops when the machine is traveling, the steering
cannot be used.
This is particularly dangerous on hills, so the engine must never be stopped
when traveling.
If the engine should stop, stop the machine immediately in a safe place.
SECTION 1 OPERATION
Page 42
A
WARNING! Stop the machine in a
safe place on firm level ground. If
the machine has to be stopped on
a slope, put blocks under the
wheels. In addiion, dig the bucket
into the ground to increase safety.
OPERATION
TO STOP THE ENGINE
Runtheengineatlowidliispeedforabout
5 minutes to allow it to graduallycool down.
Ifi& 3p
____--
1.
: I .r
If the machine is not stopped by depressing brake pedal, use the parking brake to stop the
machine.
SECTION 1 OPERATION
Page 44
lf the speed control lever is not placed in a proper speed position, the torque converter oil may.
ovemeat.nit~~,pbcethespeedcontrdleverintheneJd:rOwergearspeedtolowerthe
oil temperature.
if the temperature gauge does not indicate the green range of the scale even with tha lever in
tha 1st speed position, stop the machii, place the lever in neutral, and run the angina at
medium speed until the gauge indicates the green range.
IF ENGINE STOPS
If tha engine stops on a slope, depress the right brake pedal fully. Next, lower the work
equipment to the ground and apply the parking brake. Then put the directional and speaci
control levers in neutral, and start the engine again. (If the directionallever is not in neutral, the
engine will not start).
SECTION 1
Page 45
Selectthe mostsuitablebucket and tires for the type ofwc~rkand the ground conditions on the
BLoading materials
Loading and carry-
ing materials
lading blast+
rock side steel breaker)
(A) and (B) at the top rear of the bucket are the
level indii. so the bucket angle can be
checked during operations.
B: 9CPtocuttingedge
SECTION 1 OPERATION
Page 48
when the machine travels at high speed for a long dii, the tires becoma extremely hot
Thiscausesearfywearofthetires,so1shouMbeavoidedasfaraspossible_Ifthemachine
must be driven for a long distance, take tha following precautions.
The most suitable tire pressure, travel speed, or tire typa diier according to the condii of
the travel surface. Contact your diiutor or tire dealer for information.
The following is a guide to suitable tire pressures and speeds when traveling on a paved
surface with standard tires.
Check tha tire pressure before starting, when the tire is cool.
After traveling for 1 hour, stop for 30 minutes. Check the tires and other parts for damage;
also chack the oil and coolant levels.
Never put calcium chloride or dry ballast in the tires when traveling.
SECTION 1 OPERATlOlr)
Page so
TIRE Pressure
Measure the tire pressure before starting operations, when the fires are cool.
If the inflation pressure is too low, it causes overload on the tires: if the inflation pressure is too
high, the tire may be cut or may’ burst under shock. Therefore adjust the inflation pressure to
the values in the following tabte.
INFLATtNG TIRES
-1 2.4-3-6
2.6 - 3.6 2.6 - 3.6
Rear tire: 3.5
26.5 - 25 16
(S Rock) 20 3.5 - 4.0 3.5 - 4.0
OPERATION SECTION i
Page Si
Stockpiiao~onEoftgtoUndz . . . . . . . . . . AveragepressureinakpressuredrPrt
tf the dafktlon of the the is axcaasivf3,raise the inflatbn ptesslrte wtIhir(the ri ghtenM ttto
table to give asuitable deflection (see d&action tatio).
stockpile opetations Inean the bding of sartd and othar loose materials.
H-h
- - xial
H
H: Free height
h: Haight when loaded
2 &g;fgr visual checks, thb deflection ratio (dektiorl/ftea height) of the ftont the should
.
Normal kxxling and battying operations (Iii arm horizontal): approx. 1525%
* When checking tha tire pressure, check also fot small ctacks and damage, and for wire Or
small pieces of metal which may cause punctures. Check also fot abnormal wear.
.- * Oparakg costs earl ba reduced and tire tie increased by icwpklg the operating ataa in good
condition and free from fallen todcs.
SECTION 1 OPERATION
Page 52
TOWING
TOWING THE MACHINE
This machine must not b& towed except in emergencies. When towing the machine, take the
folkWing precautions.
A WARNING! If there is a failure in the brake line, the brakes cannot be used, so
be extremely careful when towing.
l Always keep the engine running when towing the machiie, so that the steering and braking *
canbeused.
No lubrication oil flows in the transmission, so disconnect the front and rear drive shafts
before moving the machine.
The steering cannot be used, so disconnect the steering cylinder and steering linkage.
The machine should be towed only to the nearest place for inspection and maintenance. Do
not tow the machine for long distances.
If leakage in the air circuit has caused the pressure inside the air tank to drop, the parking
brake will be applied. When towing the machine, release the parking brake.
OPERATION SECTION 1
Page 53
A
WARNING! If there is a failure in
the air circuit, the brakes cannot
be used. This is dangerous, so
always tow the machine at low speed. Keep the engine running so that the
steering can be used.
4. Push the end of the hose on the tire valve, and +r will be supplied to’the brake chamber to
release Uk brake.
5. When tha parking brake is released, removti the air charge hose. Tow the machine
immediily to a safe place.
A
WARNING! Stop the machine on a fiat surface when releasing the parking brake,
and check that the surroundings are safe. In emergencies or when the parking
brake must be released on a hill, block the tires carefully before releasing the
brake.
SECTION 1 OPERATION
Page 54
ifthetemperaturebecomeSlow,itbecomesdiffiadttostarttheengine,andthecoohntmay
freeze,
so do asfollows.
changetofuelandoilwithlowviscosityforallcomponents.Fordetailsofthespecifiedviscosity,
see the TABLE OF FUEL, COOLANT AND LUBRICANTS.
COOLANT
Use antifreeze during all saasons to protact the cooling system from corrosion as well as’
~fraazingdamaga.
A mixture of 5096water and 50% ethylene-glycolbase antifreeze is required for operation of the
engine in temperature environments above -3X. A mixture of 40% water and 60% antifreeze
is recommended for temperatures below -3X.
MlTERY
* Measure specific gravity of fluid and obtain rate of charge from the following convsrsion
table:
Tamp. of fluid
0°C -10°C -20°C -30°C
Rata of charge
100% 1.20 1.29 1.30 1.31 1.32
1.26 1.27 1.28 1.23 1.30
1.24 1.25 1.26 1.27 1.28
75% 1.23 1.24 1.25 1.26 1.27
* when electrolyte level is low, add distilled water in the morning before work instead of after
the day’s work. This is to prevent fluid frorr!freazhg at night
WARNING! To avoid gas explosions, do not bring fire or sparks near the
A battery-
* lftheenginedoesnotstart,repeatthis23
times.
3. When the engine starts, release the key in
: starting switch (1) to return it to the ON
position.
A
WARNING! Never operate ether
injection switch (2) pxcept when
starling the engine.
Park the machine on concrete or hard ground. If this is impossible, park the machine on
wooden boards. This will prevent the accessories from freezing to the ground thereby
preventingmachiie movementthe next morning. Particular attention should be given to water
drops collected on the surface of the hydraulic cylinder piston rods. Such droplets must be
fullywiped off because if water is frozen to the rod when the cylinder is utilized, the cylinder
oil seals may be damaged.
2. Drain water collected in the air tanks and fuel system so that such water may not be frozen
at night.
3. As battery capacity drops at low ambient temperature, cover the battery or remove it from
the machine to be kept warm at night.
* Replace lubricating oils for various units with the ones specitied for warm-weather use.
* Drain ‘antifreeze coolant (without corrosion inhibitor), flush the inside of cooling system
completely, and fill with dean soft water (such as city water).
SECTION 2
MAINTENANCE
A
WARNING ! REFER TO AND READ ALL
All hourly figures given in the following descriptions are based on service meter readings. In
practice, however, it is recommended to rearrange all of them into units of days, weeks and
months to make the maintenance schedule more convenient. Under rough job site or operating
conditions, it is necessary to somewhat shorten the maintenance intervals stated in this manual.
l After replacing oil, fiker element or strainer, bleed the air from the circuit.
l To bleed the air from the hydraulic cylinders or hydraulic piping, run the engine at low idling
and do as follows.
1. Operate each hydraulic cylinder (of steering, bucket and lift am-r) 4 to 5 times, stopping
100 mm from stroke end.
2. Next, operate each cylinder3 to 4 times to the end of its stroke, then stop the engine and
loosen the air bleeding plug (1) of the hydraulic tank to bleed the air.
3. Increase the engine speed, and repeat step 2 to bleed the air until no more bubbles
come out from plug (1).
* If the engine is run at high speed at first, or if the cylinder is moved to the end of its
stroke, the air in the cylinder may damage the piston packing, etc.
4. After bleeding the air, tighten air bleed/ng _
plug (1).
* Tightening torque of the plug:
1.15 + 0.15 kgm
MAINTENANCE SECTION 2
Page 3
8mrn :
17 mm
A
WARNING! Do not bleed a hot
engine as this could cause fuel to
r
spill onto a hot exhaust manifold
creating a danger of fire.
These parts with the passage of time may have a tendency to deteriorate in quality and to wear
or deform. These parts must be replaced with new ones after a predetermined replacement
interval even though there is no apparent abnonnalii.
If any abnonnali should be found, these parts must be replaced or repaired even before the
predetermined period expires.
Periodical part replacement cost does not imply reimbursement under the manufacture’s .
warranty policy. Refer to the warranty manual for further details.
Replacement
Part Description Remarks
Interval
1 Wheel brake hose Every year
Replace with
2 Rubber parts for wheel brake power clusters Every year
repair kii
3 Packings, seals, O-rings of steering cylinders Every 2 years
4 Rubber hoses for steering cylinders Every 2 years
5 Fuel hoses Every 2 years
Replace with
6 Rubber parts for wheel brake valves Every year
repair kit
Rubber parts for parking Replace with
7 Every year
brake spring cylinder repair kit
Replace with
I 8 I Rubber parts for wheel brake slack adjusters I Every year I reoair kit I
MAINTENANCE SECTION 2
Page 5
.’ MAINTENANCE TABLE
ITEM : I SERVICE PAGE
CHECK BEFORE STARTING
FUEL TANK
TIRE
Measure the tire pressure before operationswhen the tires are cool. (Referto HANDLING TIRES)
MAINTENANCE SECTION 2
Page 11
HYDRAULIC TANK
LUBRICATING
inner pressure.
For details of the method of replacing or maintaining,see the section on EVERY 500 HOURS
SERVICE.
MAINTENANCE SECTION 2
Page 13
LUBRICATING
A WARNING! To avoid gas explosions, do not bring fire or sparks near the battery.
MAINTENANCE SECTION 2
Page 19
FUEL FILTERS
* Replace the filter gasket and O-rings with new parts. Coat the gasket and O-rings with clean
engine oil before installing.
* When tightening center bolt (3). install so that chamfered surface of the washer faces the
hexagonal head of the center bolt.
LUBRICATING
AIR DRYER
If the air dryer is installed as an option, carry out the following‘&&tion, and if there is any
abnormality, contact your distributor.
l Open the air tank drain valve and check that nothing is drained. Note that if the temperature
around the tank is lower than 16”C, a small amount of water may be collected in the drain.
l Check that there is no abnormal inclusion of oil in the water drain from the.exhaust port of
the air dryer.
MAINTENANCE SECTION 2
Page 21
COOLANT FILTER
A
WARNING! Do not remove the cap ’
while cooling water Is hot. Hot water may spout out.
When removing radiator cap, lilt the lever to relieve inner pressure.
MAINTENANCE SECTION 2
Page 23
EVERY
, . 1000 HOURS SERVICE
* Maintenance for eveiy 50,100,250 and 500 hours should be carried out at the same
time.
* Thatypaoflubricantuseddepandsontha
ambiant tamparature. 6alect according to
tha tabla “FUEL, COOLANT AND LUBRI-
CANTS’.
* Refiucapaay47
LUBRICATING
ENGINE VALVES
Screwdriver
13 and 18 mm
15 mm
FeelerGauge
15 mm
13 and 18 mm
A
WARNING! ‘When removing the
cap, turn it slowly to relieve Inner
pressure.
A
WARNING! The cover is pushed
by a spring, so hold the cover
when removing the bolts.
Check the oil level,and ensure that is correct. (Refer to EVERY 100 HOURS OF SERVICE.)
Refillcapacity:‘103e
Check that there is no oil leaking from the filter cover mount.
A
WARNING! When removing the
cap, turn it slowly to relieve inner
pressure.
* lt is possible to replace the element with the breather installed in the tank. However, if the
breather is removed, do not wrap the taper thread of the breather with seal tape when
assembling again, and be careful not to tighten too much.
MAINTENANCE SECTION 2
‘Page 35
DRIVE AXLES
Front
1. Fbnove front and r&r oil filler plugs (1),
then r?move drain plugs (2) to drain the oil.
After draining the oil, tighten drain plugs.
Rear
r
SECTION 2 MAINTENANCE
Page 36
3. Stopthemachiisothatdrainplug(6)of
the final drive is at tha bottom. Remove oil
filter plug (5) and drain plug (6) and drain
the oil.
4. After draining the oil, dean drain plugs (3),
(4) and (6) then instatlthem.
5. Add oil to the specified level through the oil
filler ports (1). (5) of the axle housing and
iaftandrightfinafdrives.
6. Chack the oil level and ensure that is
correct (Refer to WHEN REQUIRED.)
* Use the same procedure to change the oil for the front and rear axles.
* The type cjf lubricant used depends on the ambient temperature. Select according to the
tabte “FUEL, COOLANT AND LUBRICANTS’.
BRAKE DISC
If the air dryer is installed as an option, replacethe following internal parts of the air dryer:
Desiccant, oil filter, filter, and all rubber parts.
Contact your diibutor to have these parts replaced.
MAINTENANCE SECTION 2
Page 37
coolANT
Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze, and
supplemental coolant additive (DCA4). Supplemental coolant additive recommendations are
included in this Section.) Drain and replace the mixture every 2 years.
DCA4 is recommended to inhibit corrosion in the cooling system.
Antifreeze.concentration level in coolant should not exceed required protection levels.
l A XI/!50 antifreeze/water mix provides protection to -34°F. This is more than adequate for
most geographic locations.
l Never exceed a 70/30 antifreeze/water mix ratio.
l Never use 100 percent antifreeze for makeup coolant.
Use the supplemental coolant additive to protect the engine cooling system from corrosion.
Antiieeze alone does not provide enough corrosion protection for a heavy-duty diesel engine.
Supplemental corrosion protection must be supplied through periodic additions of the coolant
additive to the coolant.
DCA4 can be used for in service engines provided the cooling systems are drained and flushed,
and the old coolant is disposed of prior to installationof new coolant and the appropriate DCA4
filter.
Ming of DCA4 and other supplemental coolant additives is not recommended because there
is currently no test kit available to measure concentration levels with mixed chemical solutions.
With the use of DCA4 or the continued use of other supplemental coolant additives, Cummins
Engine Company recommends the following steps to prevent overconcentration and gel
formation:
. l Antifreeze concentration level in coolant must not exceed the required protection levels.
l Maintain proper supplemental coolant additive levels (do not overconcentrate)
l Wnh the use of any supplemental coolant additive,we recommend an antifreeze containing
less than 0.1 percent of silicate (measured as anhydrous alkali metasilicate).
To protect against corrosion, a new coolant charge must be brought up to one DCA4 unit per
3.8 litres [l.OO U.S. gallon] of coolant (initial charge).
Each time the coolant is drained and replaced, the coolant must be recharged with DCA (or
equivalent). New coolant can be correctlycharged with supplemental coolant add&es by using
liquid DCA4 concentrates or DCA4 filters listed in the following table.
If coolant is added between drain intervals, additional DCA4 will be required. See Maintenance
Guidelines (Section 2) or Engine Specif=tions (Section 5) for the correct test kit to check DCA
concentration.Check the coolant periodically.The DCA4 concentration must not fall below 1.0
unit per 3.8 lies [l.OClU.S. gallon] or exceed 2 units per 3.8 liires [l.OClU.S. gallon]
SECTION 2 MAINTENANCE
Page 38
DCA4 Liquid
DCMOL 3315459 4f
DCA4 Filter
WF-2070 3318157 2
WF-2071 3315116 4
W-2072 3316201 6 *
WF-2073 3315115 8
WF-2077 Nona 0
1
* If DCASOL is used, do not usa a filter that contains coolant addiies. The combination of
liquid and filter coolant addiies will result in overconcentration.
Notes:
A Total cooling system capacity: 50
B. After draining and replacing the coolant, install the initialper charge coolant filter to provide
the recommended level of DCA4 concant3ation.
1. stoptheengine.
A
WARNING! Wait until the
temperature Is below 50°C
[12o”FJ before removing the cool-
ant system pressurecap. Failure
to do-so can-cause persdnal injury
lrom heated coolant spray.
11. Use a mixture of 50 percent water and 50 percent ethylene giycol antifreezeto fill tha cooling
System
CooiantCapabty .Litre
(Engin W) [U.S. Quafts]
Note: Use the correct amount of DCA4 corrosion inhibitor to protectthe cooling ~yst8m.
12 Run the engine for 5 minutes at low idling to eliminateair trapped in the cooling system, and
run th8 engine for 5 minutes at high idling. (t8avt3water fillercap (1) off during thii operation.)
A
WARNING! Do not remove the cap
while coolant Is hot. Hot coolant
may spout out. When removing
radiator cap, lift the lever to relieve Inner pressure.
MAINTENANCE SECTION 2
Page 41
VlBRATlON DAMPER - INSPECTION.
NoWAUaircompmssorshaveasmallamount
of oil carryoverwhii lubricatesthe piston rings
alldrlWVingpattSWhWlthisoilisexposedto
normal air compressor operating temperatures
over a period of time, it will form varnish or
carbon deposits. tfthe followinginspectionsare
* not done, the air compressor piston rings will
be affwted by high operatingtemperaturesand
pressures and will not seal cwrecUy.
SECTION 2 MAINTENANCE
Page 42
0
Vialiy inspect the unloader valve for carbon
buildup. If carbon or heavy varnish is present,
remove, clean, and inspect the compressor OK
head and the valve assembly. Replace parts as
necessary. Contact your nearest authorized
. repair location for procedures.
SECTION 2 MAINTENANCE
Page 44
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CHECKING
Whenever the red piston in service indicator (1)
appears, clean the air cleaner outer element.
Stop the engine when cleaning the element.
1. Fust remove the cover and the outer element, and then remove the inner element.
2. Place the cover o&r the air intake part to prevent dust entering.
Clean the air cleaner body interior, then remove the cover from the air intake port
4. install the outer element and the cover. Push the dust indicator reset button.
WARNING! Do ,not clean or replace the air cleaner element wlth the engine ’
A running.
A
WARNING! When using com-
pressed air, wear safety glasses
and otherthings required to mai*
tain safety.
withwater
Dash city water (less than 3 kg/crn2) on element from inside along folds, then from outside and
againfrominside.Dyandcheckit.
For removing oils and fats as well as carbon etc. attached on the element, the element may be
cleaned in lukewarm solution of mild detergent, then rinsed in c&an water and left to drip dry.
* Drying can be speeded up by blowing dried compressed air less than 7 kg/cm2) from the
insids to the outside of the element.
* Using warm water (about 40%) instead of soapy water may also be effective.
MAINTENANCE SECTION 2
Page 47
lfelementisusable,vwapitandstoreitin
dryPla=
Do not use element whose folds or gasket
orsealaredamaged.
1
When cleaning element, do not hit it or beat
it against something.
Removeoillevelplug(1),andcheckthattheoil
levelreacbesthebcsttomoftheplughole.If
mcesmy,addoilthroughtheholeofplug(2).
Rear
MAINTENANCE SECTION 2
Page 49
Canyoutthiiprocedureifthereisanymudor Front.
dirt stuck around ttwj breather.
* lfthewaterpressureistoohgh,thefins
may get defonwd. When washing with a
Mt&~~~r~d~~kwHy the
A
WARNING! Do not wash the
condenser with a steam cleaner.
Otherwise, the condenser will get
hot and may break down.
SECTION 2 MAINTENANCE
Page 50
Cperata the cooler of the air conditioner for 5-10 minutes, then touch the high pressure portion
and tow pressure portion and low pressure portion of the compressor (or high pressure hose
and low pressure hosa jbint) by hand. At the same time, inspect the flow of refrigerant gas
(freon 12) through the sight glass to check the gas level.
The sight glass is installed at the side of the window washer tank inside the cover at the top
behind the operator3 seat.
1.
I-
Normal Abnormal
condition
Tamp. of high High pressure pipe is Hgh pressure pipe is Almost no difference in
andlow hot. warm. temperature batwaen
pressure pipes Low pressurs pipe is Low pressure pipe is high and low pressure
cold. cold. pipes.
Clear difference in Little difference in
temperature tamperature
Bight glass AJmost transparent. Bubbles are always Misty substance is
Any bubbles disappea flowing. Sometimas flowing.
if the angine speed is becomes transparent,
raisad or lowered. or whiie bubbles
..- =
appear-
0
z
0 0
0 -__z_
-0 -. 3 ---
0 0
z-_o_ .- -_-_=
---=--
-o-o_-
0 .- _ =:
-_-
connections Propertyconnected
fJfP4= ~p*dimm
Gewral condi- Coolant level correct, Maybe a leak some- Almost all coolant has
tion of cooler no abnormaiiies. where. Call service leaked out.
Readjrfor use repair shop for Contact service repair
inspection. shop immadiataly.
A
WARNING! The cooler refrigerant is colorless and ocioriti and does not cause
pollution of the atmosphere. However it may cause injury if it gets in the eyes
or on the hands, so never loosen any par@of the refrigerant circuit.
MAINTENANCE SECTION 2
Page 51
LUBRICATING
steeringcolumn (1 point)
If the play of the steering column is heavy or
does not return properly, apply grease.
WATER SEDIMENTOR
3. Exchange cutting edges (3) and (4) and install edge (5) in the opposite direction.
ADJUSTMENT
. ADJUSTING PARKING BRAKE
.a WARNING! When adjusting, always put blocks under the tires to prevent
the wheels from moving.
A
WARNING! To prevent the parking from being applied automatically
during adjustment, raise the air pressure, and put a warning tag on the
parking brake switch to prevent other people from touching it.
MAINTENANCE SECTION 2
Page 55
8mm
ELECTRICAL SYSTEM
Lamp does not glow biightly even when engine runs at high speed.
Lamp fllckera while engine runs.
0 Check for toose terminals and open-circuit wiring.
. Adjustbefttension.
Charge monltor does not go out even when engine runs at high speed.
. Replscetllealternator.
0 inspect and repair wiring.
Starting motor does not turn when starting switch is turned on.
0 Inspect and repair the wiring.
l Chargethe battery.
The engine oil pressure monitor does not light up when engine ls .stationary (when the
starting swttch ls ln ON posltion.)
l Replace the monitor.
l Replawthemonitorswitch.
Charge monltor does not light up when the engine is stationary. (When the starting switch
is in ON position.)
l Replacethemonitor.
0 InsDect and rewir the wirina
MAINTENANCE SECTION 2
Page 57
Outside the eiectrkai intake air heater is not warm when toudwd with the hand.
0 Checkandre@airting.
l Replace the ektrkai intake air heater.
0 Check and repair.the heater switch.
ENGINE
The engine oil pressure monitor flashes when engine speed is raised after completion
of w8mwp.
l Add the oii to the specked level.
l Repiacetheoileiement.
0 Cbckoiiieakagefromthepipeorthejoint.
0 Repiace the monitor.
Steam is emitted from the top part of the radiator (the pressure valve).
The radiator cooling water level monitor flashes,
0 Suppiy the cooling water and check leakage.
l Adjust fan beit tension.
0 Wash out inside of cooling system.
l Ciean or repair the radiator fin.
l Repiacethetbrmostat.
l Tighten the radiator cap firmly or replace the gasket of it.
l Replace the monitor.
The engine does not start when the starting motor is turned over.
Add fuel.
Repair where air is &king into fuel system.
Replace the injection pump or the nozzie.
Ch0cktheMhreciearance.
Check engine compression pressure.
Refer to the section of eiectrical system.
CHASSIS
RIANSMIBBION
Engine k running but machine will not move.
0 Release parking brake.
l Put directional lever in position properly.
l Add oil to transmission case to th? specified level.
oil overheats
l Addoiltotrans- case to the speciiied if3velor drain oil.
0 Usaasuitablegearspeed.
0 Reducetimeusingtorquf3wnverteratstaUspeed.
0 Checkengine.
DISC BBAKE
Brake does not work when pedal Is depressed.
0 Raise air pressure to specified level.
0 Replacedisc.
l Bleed air from brake system.
Brake slips
0 Replacedi.
MAINTENANCE SECTION 2
Page 59
PAFlKlNG BRAKE
STEERING
HYDRAUUC SVSTEM
SERVICE METER
This meter indicates the integratedwork hours.
So, use it according to the following in-
0
-
wiu
-
l&Q
25
-
75
lath
See NOTE 3 24
Specified capacity:Total amount of oil including oil for components end oil in piping.
Refillcapacity:Amount of oil needed to refillsystem during normal inspection and maintenance.
NOTES:
1. ENGINE OIL
Normal Opeqtion
The use of a qualii engine lubricating oil combinad with appropriate oil and filter change
intervals are critical factors in maintainingengine performance and durability.
SAE 15W4 mufti-visc&ity oil meeting the American Petroleum Institute (API) Classification
of CE/SF is recommeMed. CD/SF oil may be used in areas where CE/SF oil is not available.
A sutfated ash limit of.l.0 mass percent is suggested for optimum valve and piston deposit
and oil consumption control. The sulfated ash must not exceed 1.65 mass percent. The
sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils
recommended for use in the engine. Higher ash oils can cause valve and/or piston damage
and lead to excess& oil consumption. .
The API service symbol displays the following information.The upper half of the symbol
displays the appropriate oil categories; the lower half may contain words to describe oil
energy conserving features. The center section identifiesthe SAE oil vixosky grade. *
The use of a multi-graded lubricatingoil has been.found to improve oil consumption control
and improve engine crank@g in cold temperatures while maintaining lubrication at high
operating temperatures.
While SAE 15W-40 multi-viscosityoil is recommended for most operating climates, refer to
the previous chart for oil viscosity recommendationsfor extreme cliites.
Limited use of low viscosity oils, such as SAE lOW-30 may be used for easier starting and
providingsufficientoil flow at ambienttemperaturesbelow + 23°F (-SC). However, continuous
use of low viscosity oils can decrease engine life due to wear.
Do not use special ‘break-in’ lubricatingoils for a new or rebuilt engine, Use the same type
of oil during the ‘break-in’ as specifredfor normal operation.
Arctlc Operation
ff an engine is operated in ambient temperatures consistently below -10°F (-23%) and there
are no provisionsto keep the engine warm when jt is not in operation, use a synthetic CE/SF
or CD/SF engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-
30.
The oil supplier must be responsible for meeting the performance service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals.
Extended oil change intervals can decrease engine lii due to. factors such as; corrosion,
deposits and wear.
2. ENGINE OIL
Use API ciassiicatbn CD engine oil. If API ciassiticationCC is:used, reduce the oil change
intarvaito half.
3. AXLE OIL
SHELL: DONAXlTOTTD
CALTEX: RPM TRACTOR HYDRAULiC FLUID
CHEVRON: TRACTOR HYDRAUUC FLUID
TEXACO: TDH OIL
MOBI1: MOBIL AND SUPER UNIVERSAL
* lt is possible to substituteengine oil SAE 30W API classificationCD for axfeoil. lf noise comas
from the brake, it is no problem of durabilii.
4. DIESEL FUEL
A WARNING! Do not mlx gasoline or alcohol with diesal fuel. This mixture can
cause an explosion.
The usa of ASTM No. 2-D dii fuel with a minimum Catane number of 40 is recommendad.
The usa of No. 2-D diesel fuel will resuft in optimum engine perfonanca under most
operating condiions. Fuels wfth Cetane numbers higher than 40 may be naadad in high
akkudas or extremely low ambient temperatures to prevent misfiresand excessive smoke.
Use a iow sulfur content fuel having a cioud point that is at least 10 degrees below tha lowest
x$fuei temperature. Cloud point is the temperature at which crystals begin to fwm
The viscosii of the fuel must be kept above 1.3 cSt to provide adequate fuel system
lubriqation.
5. COOLANT
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and
supplementalcoolantadditives.Supplementalcoolantadditiverecommendationsare included
in the s&on entitled ‘CHANGE THE COOLANT AND FLUSH THE COOUNG SYSTEM’. The
coofant should ba changed at the specified service interval shown in the ‘MAINTENANCE
TABLE’.
SECTION 2 MAINTENANCE
Page 64
In climates where tha temperature is above -34°F (-3X), usa a coolant mixturethat contains
50 percent anweeze Antifreeze is essential in any climate. It broadens the operating
temperature range ‘b; lowering the coolant freezing point and by raising its boiling point. Do
not use more than 50 percent antifraeza in the mixture unless additionalfraeze protectionis
required. Never usa more than 58 parcant antifreeze under any condii.
Low silii ethytane giycol antifraaze is recommended. The antifmaze should contain no
more than 0.1% anhydrous alkali metasiliie. Low skate antifreeze is recommended to
avoid ths fom@ion of silica-gel (hydra-gel). This gel formation can cxcur when the cooling
systemcorwnsanover concentrationof high silicateantifraezeand/or supplementalcoolant
additive.DONOTusemethandoralcoholasansntiireetebecauseofitslowboilingpoint.
Antifmeze may retain its freeze protectionfor more than one season but coolant conditioners *
must lx added to maintain corrosion protection.
Check the solution periodically‘and at normal operating tamparature,to be sure the cooling
system has wfficient protection against freezing.
Usa water which has a low mineralcontent. Water usad in conjunctionwith antifreeze,coolant
filters and inhibited water must maat the followingstandards:
Totat Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to
prevent state deposits. Water containing dissolved magnesium and calcium (the usual
reason for water hardness) above the specSed amount will cause scale deposits to
develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent
CorrOSiOtl.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent
corrosion.
Dissohfed 6cWs - Not to exceed 340 parts per million (20 gmins/gallon maximum) to
minimize sludge deposii, scale deposits, corrosion or a combination of these.
lf any of the above requirements cannot be met, use distilled, de-ionized, or de-mineraliied
water. To datermine if tocal water supplies meat these standards, water samples can ba
tested by water treatment laboratories.Softened’ water that is prepared using common salt
(sodium chtorfde)contains excessive amounts of chloridas and should not be used.
NOTE: Never use water alone in the cooling systembecause corrosion will occur’.
MAINTENANCE SECTION 2
Page 66
Maintain supplemental coolant additive levels at 1 unit DCA4 par I U.S. gal (3.8 liters) of
coolant.
Use antifreeze during all seasons to protect the cooling system from corrosion as well as
freezing damage.
A rn-ktureof 5096watk and 60% ethylene glycol bass antifreeze is required for operation of
the angina in temperature environments above -34.VF (-37%). A mixture of 4096 water and
60% antifreeze is recommended for temperatures below -34.6”F (-37%).
MEMORANDA
SECTION 3
SAFETY AND OPERATION
A WARN’
NG ! REFER TO AND READ ALL
SECTION.
SECTION 3 ’ SAFETY AND OPERATION
Page 2
SAFETY HINTS. . . A
Protect yourself and ofhers. Safety is ahmys first.
OPERATION
GENERAL
Examinetheiayofthelandandthekindof
soilattheworksitetodeterminethedan-
gerous points and the best mettM of
opera&n.
Donotworkwhenvisibilityisreducedby
smoke, fog or dust. If the jobsii is dark,
instalilightingifrKaSaly.
0 whenoperatingamachinein wateror 1
fording streams, sun7ey the water depth,
‘groundcondiiandvelocityofthewater
inadvance.Donottakethemachinein
water exceedii the allowable depth (up to
the underside of the axle housing).
0 Carryoutchecksbefores@itingthema-
chine.lfanyproblemisfound,donotstart
the engine, but informthe foreman immedi-
2-m keep the machii in good
SECTION 3 SAFETY AND OPERATION
Page 6
Ifaseatbeltisprovidad,alwaysu~it. lfthe
bakisdamagadorwom,replaa3itwitha
rlewona.
DURING OPERATION
AJws-~ti=a- seatwhen
.
Do not allow anyone except.the operator on
themachine.
Themachinetxmdith&bejudgedfrom r
many factors.changes in the FJW,
sound, vibration, exhaust gas color or
responseoftheaw7trollt3verscanindicate
the ocasrence of some disorder. If any
diso&roccurs,parkthemachineimmedi-
atelyinasafeplaceandtakeappropriate
action.
SAFETY AND O.PERATION SECTION 3
Page 9
AlTENTlON TO SURROUNDINGS
AIwaysoperateslowlyinorowdedplaoes.
onhaulroedsorinnarrowpleces,givewey I ‘G
toloadedmachines.
lf the engine stops when the machine is traveling, it is impossible to use the steering. This
is dangerous, so apply the brake immediatalyto stop the machine.
Whentraveling&hiUswithaloadedbucket,
travel forward up the hi and in reverse
downthehiu.
SAFETY AND OPERATION SECTION 3
Page 11
mlemaohineshouldatwaysbeoperatedal
aspeedwhereltcanbec4mcttyoontrolled.
Never do the follow&g:
SpeedinS
snaking
Q=ting
Ah3ystraveldirectfyupordownsfopes.
Whentrawhgdownaslope,usethesame
g~speed=~goeluptheslope.
Whentravelingdownaslope,neverputtM
transmissioninneutral.
Becar&dwhentravehgonphnksorsteel
pkt9S,sSth8S8CanCWS6Siippge.
Besuretoarrangeanaclequetelighting
system.
Atnightitisveryeasytomakemistakesin
assumingthediiancih0ightofobjects
andlanci.
SAFETY AND OPERATION SECTION 3
Page 13
PARKING
When oarkincl the machine. oark it in a safe I
place butsid the wok& Korea,or in the
specified place. The following factors should
be WISid8red when choosing a parking
place: it should be on flat, firm ground
where there is no danger of rockfalis, land-
slides or floods.
‘
l when working with others, choose a group I
leader and work according to his instruc-
tions. Do not perform any mainunance
beyond the agreed work.
Alwayskwptheworkshopingoodcondi-
tion. Make sure there is ti mud or oil on
the floor.
BEFORE MAINTENANCE
Alwav!slockthefrontandrearframasbefore I
insphng and servicing the machine.
Whengatingonoroffthemachine,usethe
steps,[email protected]
onoroffthemachine.lfthesteps,hand
grfpsorJaddercannotbelJ&,useastand
togivaiimIfooting.
ovethecabksfromthe
EF2E!!Z-
MISCELIANEOUS
0 lhorougNyw&h themachine, particularfythe oiling and greasing parts and the Wnity,
thereof, in order to prevent the ingress of dust.
a Usegenuinerepl&mentpartsspecibdinthepartslii 1 _
b Use specified oil and grease. Use oil and grease having the recommended bcosity for the
pal%aWambieflttemperatWe.
b Inspect or replace oil in a dust free location to prevent the ingress of dirt
l Drain off used oil after heating it to a &able temperature (about Xl to 40%).
b After greasing up, always wipe off the old grease that was forced out.
l When changing the oil or fitter, check the drained oil and filter for any signs of excessive
metal panicles or other foreign materials.
. When removing parts crx&Mng C-rings, gaskets cr seals, clean the mounting surface and
replace with new sealing parts.
b When washing the machii, ensure that water does not get onto the altemator.
0 lhoroughty wash the machii. In particular,be careful to clean the filler caps, grease Gttings
andtheareaaroundtfiedipsticks.Becarefulnottoletanydirtordustintothe~~m.
b a
When checking an open cover there is risk of dropping things in. Before removing the
covers WWex stpty everything from your pockets. Be panicularty careful to
0 When wcrking on the sea shore, carefullyclean all elect&al equipment to ensure that it does
notcorrode.
b Before working in muddy water, rain or snow, check that the various~plugs, valves, are
properly screwed up. Upon completion of work, wash the machine, then check the varbs
parts of the machine for cracking, scratching, loose or missing nuts and b&s. Also, oil and
greasetflevarious parts of the machine.
l When working on rocky ground, be careful of damage to the undercamage, loose nuts and
bolts, cracks;wear and other damage.
SAFETY AND OPERATION SECTION 3
Page 19
. Whanworkinginadustylocation,becarefulofthefoUowing:
1) lnspecrtheservice~~toseewhethertheairdeaner$~edup.cleantheak
deanerassoonasitbecomesdirty.
2) Cleanther8diat&coresothatitdoesnotbecomeMockedup.
31 Cleanorreplacethefuelfitterassaonasitbecomesdirly.
4) Cleantheelectricalequipment,partiarlartythestartingmotorand~mator,toprevent
aa%mulation of dust.
l When,installingcarradioandawalkie-tslkieorcithenband,contactyourdistriknor.
l When washing the machine, take care not to splash water over the electrM equipment. if
it is soaked with water, it may not operate normally.
l Afterdisconnectingthecormedor,wveritwithavinylbagtopteventoilordustfromsticking
toitscontactsecGon.
0 When welding, be ca&ul of the following:
BUCKET OPERATION
Various types of attachments8re availableto extend the range of application beyond the
applk8tions described below.
EXCAVATION
Always keep the operating jobsiie ftat, and remove any fallen rocks.
SECTION 3 SAFETY AND OPERATION
Pago 20
.2. Shiftdownimmediiinfrontofthemater-
ialtobaloadf3d.whencompletingtheshi
down, depress the accelerator pedal at the
sametimeandthrustthebucketintothe
load.
5. Checkthattherelsenoughmaterialloaded
into the bucket, then operate the bucket
controllevertotiltthebucketandloadthe
bucket fully.
* lftflebucketedge.ismovedilpanddown
wbii pushing in ,tie bucket and digging, the
front tiras will come off the ground and this
will cause the tires to slip.
A
WARNING! Never dig or scoop
when the machine body b
articulated.
When scooping up materials, ba careful not to let the counterweight at the rear touch the
ground.
* Do not allow tires slipping to oaw during operation. Tres slipping shortens tire’s Me.
LEVELING
1. ScoopsoiiintothebucketMovethema-
chine backward while spreading soil from
thebucketliibylii.
2. Goovarthespraadsoilwiththebucket
teeth touching tha ground and level tha
ground by back-dragging.
3. Scoopsomemoresoilintothebucket,put ‘.’
the lift arm in fioat. level the bucket at
ground level, and smooth the ground by
movingbackward.
* Ahwaysmove the machine backward during
leveling operations.
A
WARNING! lf leveling by forward travel can not be avoided, do not dump the
bucket beyond 2fP. This will prevent quick wear and damage of the work
equipment and frame.
SAFETY AND OPERATION SECTION 3
Page 23
A
WARNING! Lower the bucket to
bring down the center of gravity
when carrying material.
LOADING
select and proceed effectiveoperationwhich avails lessturning and the shortest hauling distance
according to ground csndwns.
CROSS DRIVE LOADING
When 8 wheel loader is operated, the digging
should be mada at a right angle toward
acwmulatedsoil.Whenthescoopingiscom-
pleted,themachineshouldbetraveledback-
wardsasitis.Then,bringthebuckbetween
theaccumulatedsoilandthewheeiloaderfor
thepuqxseofioadinguponthedumptruck.
A
WARNING! Provide a flat road
free of rocks and hollows. When
theboomkraisedwtththebucket
loaded, do not make quick turns
or quick brakingbecause It is very
dangerous.
*A
WARNING! Do not load the
bucket by thrusting into a pile of
soil or gravel at high speed
because it is dangerous.
V-SHAPE LOADING
Stop the truck with the angle of about 60”
toward the scooping’ direction of the wheel I
loader. After scooping the soil, back the wheel
ioaderinsuchawaythatitmakesarightangle
tothetruck.Theloadingonthetruckismade
by the wheel loader going farward.
* ThefarthertheieverismovedtotherigM,
the hiiher~the temperature ofthe air blown
out from the vent.
I
AIR INTAKE SELECTOR LEVER
This switches the air intake port when heating.
Fresh air is taken in from outside in additionto the air inside the compartment. m is used
for ordinary heating, and when pressurizing ,?heinside of tha cab.)
Only the air @side the compartment is used. (This is mainly used for quick heating.)
SAFETY AND OPERATION SECTION 3
Page 25
METHOD OF OPERATlOfl
OPERATION OF CONTROL PANEL
Leverswitca Airintake
. Fanswitch Temperature control lever
sektorlever
* lf the outside air is extremely dusty, set the fan switch to the H position. This will preswrize
the cab and prevent the ,dust from entering.
Vent
FACE FDDT DEF
Purpose
Heating Openorclosed Open Open or dosed
Defrosting Closed Openorclos6d Open
VMltilation Open Open
* The effectiveness ofthe heating system can be increased by selecting the most suitable vent
* Donot~mthefanswitchonwhenalltheventsaredosed.
SECTION 3 SAFETY AND OPERATION
Page 26
TEMPERATURECONTROL LEVER
0 Thisis used to control the temperature for coolii or heating.
.
* The farther the lever is moved to the left, the lower the temperature of the air blown out from
thevent.
* ThefartherthelevefismovedtotherigM,thehigherthstemperatureoftheairblownout
fromthevent.
METHOD OF OPERATION
OPERATION OF CONTROL PANE&
Air
Airintake
Lever
switchFanswitch condii ~emperaturecontrollever
Selectof level
SWibh
I
- thick HI ON MoveJullyto left Left
Normal HI-LO ON From left side to near center Riht
Dehumidifying,
HI-LO ON From center to near right side lwht
hsatingI 1 ,
Heating Ouick HI OFF Move fully to near right side Left
* gtheoutsideairisextremelydusty,setthefanmvitchtotheHposition.Thiswillpresswize
the cab and prevent the dust from entering.
SECTION 3 SAFETY AND OPERATION
Page 28
IkIlt
’ purpose FACE FOOT DEF
* The effectiveness of the air condiioning system can be increased by sei&ng the most
witablevent.
* Donottumthefanswitchonwhenalltheventsareclosed. .
Smoking in tha air-condiion6d cab will cause your eyes to get sore. While smoking, open
thewindowtolstthesrnokeoutofthecab.
While using the air condii, open the window once every hour.
The cab should feel cool when entering there from outside (5% or 6°C lower than the
outside temperature). It is not good for the health to have the temperature in the cab too low.
Ahuays give careful consideration to temperature regulati6n.
To use the air conditioner comfortably during its season, ask your @stributor to check the air
co&tMerandaddtherefrigerantifnecessary.
l ThesCendarddeaningcycleforthefreshairfi~erisNERYlWHOURS,butrtbecomes
clogged, it will be impossibleto pressurizethe inside of the cab, and in addition, it may Cause
failures, so check and dean the filter immediately.
For detailsof cleaning,
see PERIODIC MAINTENANCE.
l Ifalargeamountofdir!Mdustcdlectsonthecondenser,thecoolingcapacitydrops,so
check and clean &en neceswy. For details, see WHEN REOUIRED.
To l&&ate each part 6f the compressor during the off-seasons, operate the air condiioner for
afewminutestwoorthreetimesamonth.
SAFETY AND OPERATION SECTION 3
Page 29
LOCKING CAP
A locking cap is available as an optional fuel tank &p or hydraulic tank cap. Open and dose
f
locking caps as follows:
1. Toopenthecap I
1) Insert the key into the cap.
Q5izP
6
* lnsertthekeyasfarasitwillgo.Ithe
.I i
key is turned before it is inserted all the
way, it may break.
I “2/: d’ Opn
2) Turn the key counterclockwiseand bring
--I;’ lao’
2. Tolockthecap
Aligningrtwk
1) Turn the cap into place.
2) Tum the key counterclockwiseand take
thakeyout.
* when the cap is locked (against van- shwldrr
dalism), it rotates freely. I
lhefueltankfillerportisequippedwithalock.
* Usethestartingkeytoopenanddosethecap.
. Tolockthecap
1. Tumthecapintoplace.
2. Turn the key counterdockwise and take the K ..
key out. shouldor
HANDLING OF BAlTERY
PRECAUYONS FOR CHARGING BATIERY
1. Wore charging, d&conn& the cable from the negative (-) terminal of the battery.
Othewise; an unusually hiih voltage will damage the alternator.
2 While charging the battery, remove all battery plugs for satisfactoryventilation.
To avoid gas explosions, do not bring fire or sperks near the battery.
3. lf the electrolytetemperature exceeds 45°C. stop charging for a while:
4. Turn off the charger as soon as the battery is charged.
Overcharging the battery may cause the following:
1) Overheating the battery.
2) Decreasing the quantity of electrolyte.
3) Damaging the electrode plate.
5. lf the elecWyW gets on your skin or clothes, immediatelywash with plenty of dean water.
6. Do not mix up cables (posiie (+) to negative (-) or negative (-) to positive (+)), as it will
damage the alternator.
7. When inspecting or servicing a battery, be sure to stop the engine and turn the starting
switch key to “OFF” position.
8. When performingany service to battery besides checking the electrolyte level or measuring
the speci6c gravity, d&connect cables from the battery.
REMOVAL AND INSTALLATION OF BATIERY
When removing battery, first disconnect the cable from the ground (normally, from the
negative (-) tetinal). ff a tool touches a cable connecting the positive terminal and the
chassis, there is danger of sparks being emitted.
When installingbattery, the ground cable should be connected to the ground terminal as the
last step.
The batteries are mounted on both side of the machine. The groundktg cable is connected
to the left side battery.
SAFETY AND OPERATION SECTION3
P8ge 31
STARTING ENGINE WITH A BOOSTER CABLE f
When starting up the engine with a booster
cable, do as fokwx~ . A
dl
1. Beforeconnectingthe‘boostercable: 1
8
1) SizeofbobstercabIeanddipshoukJbe
suiweforthebattetysize.
2) chedccablesanddipsforbreaks,cor- lknory for
roded surfaces, etc.
3) Make sure cables and dips are firmly Engina blodr to b starad -
4)
5)
WARNING! When connecting the cables, never contact the positive (+) and
negathre (-) termlnab.
A WARNING! Make sure that the booster cable connections are correct. Connect
the booster cable to the engine block as far as possible from the battery.
3. Startiq engine
1) Tumthe~switchtoSTARTpositionandstartuptheeng~.
2) Iftheenginedoesn’tstartatfrst,tryagainafter2minuteswso.
SECTION 3 SAFETY AND OPERATION
Page 32
Aftertheenginehas!stamd,theboostercaMes
shouid be discmnected in the reverse order in
which they were connected.
1. oisconnectingtheboostercabl8s
1) DiithedipofboostercabieB
fromtheengineblockwhiiwasstatted.
. -
2) &cowwct the other dip from the nega-
tive (-) terminal of the running engine.
31 Disawwt the dip of booster cable A from the positive (+) terminal of the running
engine.
4) Disconne~ the other dip from the positive (+) terminal of the engine which was started.
TRANSPORTATION
When transporting the machine, observe the various road rules, road transportation
vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain a special
platfofm for loading and unloading the machine. When it is unavoidably n- rytouse
a gangplank, however, at the very least observe the following for the Sake of safety.
1.
* 2 Determine the direction of the gangplank, then slowly load or unload the machine.
* When transmission cut-off switch is put in OFF, the I&t brake pedal and acxxWator pedal
areoperaWatthesametirn+
A WARNING! Remove the mud from the undercarriage to prevent the machine
from slipping to the slde on slopes.
WARNING! Do not on any account change the dikctio~ of the machine while
it is on the gangplank. To change the direction of the machine, first take it down
A from the gangplank.
SAFETY AND OPERATION SECTION 3
3.
4.
5.
6.
A WARNING! when loading fhe machine, park the frailer on a fiat, firm roadbed.
Keep a fairly long distance between the road shoulder and fhe machine. .
STORAGE
BEFORE STORAGE
To place the machine in storage for an extended period of time, the following measures must
be taken to insure that it can be returned to operation with minimum of service.
In case it is indispensable to leave it outdoors, lay wood plates on the ground, and park the
m8chineonthewoodplatesandwveritwithcanvasetc.
Completely fill fuel tank, lubricate end change oil before storage.
Apply a thin coat of grease to metal surface (hydraulic piston rods and splined shaft).
As to better&, remove the terminals and cover them, or remove them from the machii end
store separately.
When the ambient temperature is anticipated to drop below 0°C. always add antifreeze in
the cooling water.
Set C+I control lever to neutral or hold position, lock them and apply the parking brake.
SECTION 3 SAFETY AND OPERATION
Page 34
DURING STORAGE
l Operate the engine and move the machine for a short distance once a month so the new oil
film will be coated over movable parts and component surfaces.
l Before opeiating the work equipment, wipe off the grease on the hydraulic piston rod.
A
WARNING! If it is unavoidably necessary to carry out r&preventive operation
,while the machine is indoors, open up doors and windows to improve
ventilation and prevent the gas poisoning.
AFTER STORAGE
After storage (when it is,kept without cover or the rust-preventiveoperation once a month is not
made), you shall apply the followingtreatment before operation.
Loosen the drain plugs on oil pan and other cases and drain mixed water.
Remove the cylinder head cover and lubricate sufficiently valves and rocker arms. And
inspect the valve operation.
SAFETY AND OPERATION SECTION 3
‘Page 35
Performance 3c
SECTION 3 SAFETY AND OPERATION
Page 36
MEMORANDA
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-6112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 9704186
: PHONE NO:
; DEPARTMENT: DATE:
i NAME:
AANUAL NAME:
AANUAL NO:
AACHINE MODEL:
i/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
PFMRI 081696