Komatsu Wheel Loader WA30 Repair Service Manual
Komatsu Wheel Loader WA30 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA30-5, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA30-5 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,052 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM016503 - Wheel Loader WA30-5 avance Shop Manual.pdf
SEAM010700 - Wheel Loader WA20-2, WA30-5, WA40-3, WA50-3 Operation & Maintenance Manual.pdf
SEAM034300 - Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.pdf
SEAM03610102 - Wheel Loader WA20-1 Operation & Maintenance Manual.pdf
TEN00071-00 - Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.pdf
MAIN SECTIONS
SEAM010700 - Wheel Loader WA20-2, WA30-5, WA40-3, WA50-3 Operation & Maintenance Manual.....2
COVER.....2
1. FOREWORD.....3
2. SAFETY INFORMATION.....4
3. INTRODUCTION.....5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....6
5. CONTENTS.....8
SAFETY.....11
6. GENERAL PRECAUTIONS.....12
7. PRECAUTIONS DURING OPERATION.....17
7.1 BEFORE STARTING ENGINE.....17
7.2 OPERATING MACHINE.....19
7.3 TRANSPORTATION.....24
7.4 BATTERY.....25
7.5 TOWING.....26
8. PRECAUTIONS FOR MAINTENACE.....27
8.1 BEFORE CARRYING OUT MAINTENANCE.....27
8.2 DURING MAINTENANCE.....31
8.3 TIRES.....35
9. POSITION FOR ATTACHING SAFETY LABELS.....37
OPERATION.....41
10. GENERAL VIEW.....42
10.1 GENERAL VIEW OF MACHINE.....42
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....43
11. EXPLANATION OF COMPONENTS.....44
11.1 METER, LAMPS.....44
11.2 SWITCHES.....48
11.3 CONTROL LEVERS, PEDALS.....50
11.4 CAP WITH LOCK.....54
11.5 SAFETY BAR.....54
11.6 TILT HOOD.....55
11.7 TOWING PIN.....55
11.8 FUSE.....55
11.9 FUSIBLE LINK.....56
11.10 MANUAL POCKET.....57
11.11 CONNECTORS.....57
12. OPERATION.....58
12.1 CHECK BEFORE STARTING ENGINE.....58
12.2 STARTING ENGINE.....69
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....72
12.4 MOVING MACHINE OFF.....74
12.5 CHANGING DIRECTION.....76
12.6 TURNING.....76
12.7 STOPPING MACHINE.....77
12.8 OPERATION OF WORK EQUIPMENT.....78
12.9 WORK POSSIBLE USING WHEEL LOADER.....79
12.10 PRECAUTIONS FOR OPERATION.....83
12.11 ADJUSTING WORK EQUIPMENT POSTURE.....85
12.12 PARKING MACHINE.....86
12.13 CHECKS AFTER COMPLETIONOF OPERATION.....87
12.14 STOPPING ENGINE.....88
12.15 CHECK AFTER STOPPING ENGINE.....88
12.16 LOCKING.....88
12.17 HANDLING THE TIRES.....89
13. TRANSPORTATION.....92
13.1 LOADING, UNLOADING WORK.....92
13.2 PRECAUTIONS FOR LOADING.....93
13.3 LIFTING MACHINE.....93
13.4 PRECAUTIONS FOR TRANSPORTATION.....96
13.5 REMOVING AND INSTALLATION OF CANOPY.....96
14. COLD WEATHER OPERATION.....98
14.1 PRECAUTIONS FOR LOW TEMPERATURE.....98
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....100
14.3 AFTER COLD WEATHER.....100
15. LONG-TERM STORAGE.....101
15.1 BEFORE STORAGE.....101
15.2 DURING STORAGE.....101
15.3 AFTER STORAGE.....101
16. TROUBLESHOOTING.....102
16.1 WHEN MACHINE RUNS OUT OF FUEL.....102
16.2 TOWING THE MACHINE.....103
16.3 IF BATTERY IS DISCHARGED.....106
16.4 OTHER TROUBLE.....110
MAINTENANCE.....115
17. GUIDES TO MAINTENANCE.....116
18. OUTLINES OF SERVICE.....119
18.1 OUTLINE OF OIL, FUEL, COOLANT.....119
18.2 OUTLINE OF ELECTRIC SYSTEM.....122
19. WEAR PARTS LIST.....123
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....124
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....128
21.1 INTRODUCTION OF NECESSARY TOOLS.....128
21.2 TORQUE LIST.....130
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....131
23. MAINTENANCE SCHEDULE CHART.....138
23.1 MAINTENANCE SCHEDULE CHART.....138
24. SERVICE PROCEDURE.....141
24.1 INITIAL 250 HOURS SERVICE.....141
24.2 WHEN REQUIRED.....142
24.3 CHECK BEFORE STARTING.....156
24.4 EVERY 50 HOURS SERVICE.....162
24.5 EVERY 250 HOURS SERVICE.....163
24.6 EVERY 500 HOURS SERVICE.....168
24.7 EVERY 1000 HOURS SERVICE.....171
24.8 EVERY 2000 HOURS SERVICE.....174
SPECIFICATIONS.....177
25. SPECIFICATIONS.....178
OPTIONS, ATTACHMENTS.....179
26. OPTIONAL PARTS AND ATTACHMENTS.....180
27. SEAT BELT.....181
27.1 FASTENING AND REMOVING BELT.....181
27.2 ADJUST BELT LENGTH.....182
27.3 CHECK SEAT BELT AND MOUNTS.....182
28. EQUIPMENT WITH CAB.....183
28.1 SWITCHES.....183
28.2 REAR WINDOW.....187
28.3 CHECK AND MAINTENANCE.....188
SEAM034300 - Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.....197
COVER PAGE.....197
1. FOREWORD.....198
2. SAFETY INFORMATION.....199
3. INTRODUCTION.....200
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....201
5. CONTENTS.....202
SAFETY.....205
6. GENERAL PRECAUTIONS.....206
7. PRECAUTIONS DURING OPERATION.....211
7.1 BEFORE STARTING ENGINE.....211
7.2 OPERATING MACHINE.....213
7.3 TRANSPORTATION.....218
7.4 BATTERY.....219
7.5 TOWING.....220
8. PRECAUTIONS FOR MAINTENANCE.....221
8.1 BEFORE CARRYING OUT MAINTENANCE.....221
8.2 DURING MAINTENANCE.....225
8.3 PRECAUTIONS WITH TIRES.....229
9. POSITION FOR ATTACHING SAFETY LABELS.....230
OPERATION.....235
10. GENERAL VIEW.....236
10.1 GENERAL VIEW OF MACHINE.....236
10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....237
11. EXPLANATION OF COMPONENTS.....239
11.1 METER, LAMPS.....239
11.2 SWITCHES.....242
11.3 CONTROL LEVERS, PEDALS.....244
11.4 CAP WITH LOCK.....248
11.5 SAFETY BAR.....248
11.6 TILT HOOD.....249
11.7 TOWING PIN.....249
11.8 FUSE.....249
11.9 FUSIBLE LINK.....250
11.10 MANUAL POCKET.....251
11.11 CONNECTORS.....251
12. OPERATION.....252
12.1 CHECK BEFORE STARTING ENGINE.....252
12.2 STARTING ENGINE.....265
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....268
12.4 MOVING MACHINE OFF.....270
12.5 CHANGING DIRECTION.....272
12.6 TURNING.....272
12.7 STOPPING MACHINE.....273
12.8 OPERATION OF WORK EQUIPMENT.....274
12.9 OPERATING FRONT ATTACHMENT SERVICE HYDRAULIC CIRCUIT.....275
12.10 WORK POSSIBLE USING WHEEL LOADER.....277
12.11 PRECAUTIONS FOR OPERATION.....281
12.12 ADJUSTING WORK EQUIPMENT POSTURE.....283
12.13 PARKING MACHINE.....284
12.14 CHECKS AFTER COMPLETION OF OPERATION.....285
12.15 STOPPING ENGINE.....286
12.16 CHECK AFTER STOPPING ENGINE.....286
12.17 LOCKING.....286
12.18 HANDLING THE TIRES.....287
13. TRANSPORTATION.....290
13.1 LOADING, UNLOADING WORK.....290
13.2 PRECAUTIONS FOR LOADING.....291
13.3 LIFTING MACHINE.....291
13.4 PRECAUTIONS FOR TRANSPORTATION.....294
14. COLD WEATHER OPERATION.....295
14.1 PRECAUTIONS FOR LOW TEMPERATURE.....295
14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....297
14.3 AFTER COLD WEATHER.....297
15. LONG-TERM STORAGE.....298
15.1 BEFORE STORAGE.....298
15.2 DURING STORAGE.....298
15.3 AFTER STORAGE.....298
16. TROUBLESHOOTING.....299
16.1 WHEN MACHINE RUNS OUT OF FUEL.....299
16.2 TOWING THE MACHINE.....300
16.3 IF BATTERY IS DISCHARGED.....303
16.4 OTHER TROUBLE.....307
MAINTENANCE.....312
17. GUIDES TO MAINTENANCE.....313
18. OUTLINES OF SERVICE.....316
18.1 OUTLINE OF OIL, FUEL, COOLANT.....316
18.2 OUTLINE OF ELECTRIC SYSTEM.....318
19. WEAR PARTS LIST.....319
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....320
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....324
21.1 INTRODUCTION OF NECESSARY TOOLS.....324
21.2 TORQUE LIST.....326
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....327
23. MAINTENANCE SCHEDULE CHART.....328
23.1 MAINTENANCE SCHEDULE CHART.....328
24. SERVICE PROCEDURE.....331
24.1 INITIAL 250 HOURS SERVICE.....331
24.2 WHEN REQUIRED.....332
24.3 CHECK BEFORE STARTING.....345
24.4 EVERY 50 HOURS SERVICE.....351
24.5 EVERY 250 HOURS SERVICE.....352
24.6 EVERY 500 HOURS SERVICE.....357
24.7 EVERY 1000 HOURS SERVICE.....361
24.8 EVERY 2000 HOURS SERVICE.....364
SPECIFICATIONS.....366
25. SPECIFICATIONS.....367
SEAM03610102 - Wheel Loader WA20-1 Operation & Maintenance Manual.....370
COVER.....370
FOREWORD.....371
BREAKING IN YOUR NEW MACHINE.....372
CONTENTS.....373
SAFETY HINTS.....374
GENERAL LOCATIONS AND SPECIFICATIONS.....379
INSTRUMENTS AND CONTROLS.....380
CHECK BEFORE STARTING.....390
OPERATING YOUR MACHINE.....394
BUCKET OPERATION.....401
HOW TO USE INCHING PEDAL.....405
TIRE REPLACEMENT.....407
HANDLING THE TIRES.....408
HANDLING OF BATTERY.....409
MACHINE MOVEMENT.....411
COLD WEATHER OPERATION.....412
TRANSPORTATION.....415
PERIODIC MAINTENANCE.....416
PRECAUTIONS FOR MAINTENANCE.....417
PERIODIC REPLACEMENT OF PARTS FOR SAFETY.....421
MAINTENANCE TABLE.....422
OIL FILLER AND LEVEL GAUGE POSITIONS.....425
EVERY 50 HOURS SERVICE.....426
EVERY 250 HOURS SERVICE.....426
EVERY 500 HOURS SERVICE.....433
EVERY 1000 HOURS SERVICE.....437
EVERY 2000 HOURS SERVICE.....440
WHEN REQUIRED.....441
ADJUSTMENT.....446
STORAGE.....448
SERVICE METER.....450
MACHINE AND ENGINE SERIAL NUMBERS.....451
FUEL,COOLANT AND LUBRICANTS.....452
SEBM016503 - Wheel Loader WA30-5 avance Shop Manual.....456
COVER.....456
CONTENTS.....457
01 GENERAL.....480
GENERAL ASSEMBLY DRAWING.....481
SPECIFICATIONS.....483
WEIGHT TABLE.....486
LIST OF LUBRICANT AND WATER.....487
10 STRUCTURE AND FUNCTION.....489
POWER TRAIN.....490
POWER TRAIN SYSTEM.....491
RADIATOROIL COOLER.....493
DAMPER COUPLING.....494
HST PIPING.....495
HST HYDRAULIC SYSTEM DIAGRAM.....496
HST HYDRAULIC CIRCUIT DIAGRAM.....497
MAIN PISTON PUMP.....498
HIGH-PRESSURE RELIEF VALVE.....500
LOW-PRESSURE RELIEF VALVE.....502
WORK EQUIPMENTSTEERING PUMP, HST CHARGE PUMP.....503
CHARGE PUMP OIL FILTER.....504
SPEED RELATED VALVE (DA VALVE).....505
PISTON MOTOR.....506
DIRECTIONAL SHUTTLE VALVE.....508
SERVO VALVE.....509
INCHING VALVE.....510
TRANSFER.....511
HST CONTROL.....512
DRIVE SHAFT.....513
AXLE.....514
DIFFERENTIAL.....516
FINAL DRIVE.....519
AXLE MOUNT.....521
TIREWHEEL.....522
CENTER HINGE PIN.....523
STEERING PIPING.....524
STEERING COLUMN.....525
PRIORITY VALVE.....526
STEERING VALVE (ORBIT-ROLL).....530
BRAKE, PARKING BRAKE CONTROL.....538
BRAKE (ALSO USED AS PARKING BRAKE).....539
WORK EQUIPMENT PIPING.....540
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....541
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....542
WORK EQUIPMENT LEVER LINKAGE.....543
HYDRAULIC TANK.....544
HYDRAULIC FILTER.....545
MAIN CONTROL VALVE.....546
WORK EQUIPMENT LINKAGE.....553
BUCKET.....554
BUCKET POSITIONER.....555
PROXIMITY SWITCH.....556
ROPS CANOPY.....557
CENTRAL PANEL (CLUSTER GAUGE).....558
ENGINE START CIRCUIT.....559
ENGINE STOP CIRUIT.....559
PREHEATING CIRCUIT.....560
PARKING BRAKE CIRCUIT.....561
20 TESTING AND ADJUSTING.....562
STANDARD VALUE TABLE FOR ENGINE.....563
STANDARD VALUE TABLE FOR CHASSIS.....565
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....570
ADJUSTING VALVE CLEARANCE.....571
MEASURING COMPRESSION PRESSURE.....574
TESTING AND ADJUSTING FUEL INJECTION TIMING.....575
BLEEDING AIR FROM FUEL CIRCUIT.....581
TESTING AND ADJUSTING FAN BELT TENSION.....582
TESTING FOR ABNORMALITY IN FUEL LEVEL SENSOR.....584
MEASURING ACCELERATOR PEDAL.....585
MEASURING OPERATING EFFORT, TRAVEL OF DIRECTIONAL LEVER.....587
MEASURING STALL SPEED.....588
MEASURING HST OIL PRESSURE.....589
TESTING AND ADJUSTING STEERING WHEEL.....590
MEASURING OPERATING TIME FOR STEERING WHEEL.....591
MEASURING STEERING PRESSURE.....592
TESTING AND ADJUSTING BRAKE PEDAL.....593
MEASURING OPERATING EFFORT, TRAVEL OF BRAKE PEDAL.....595
MEASURING BRAKE PERFORMANCE.....596
MEASURING PARKING BRAKE PERFORMANCE.....597
MEASURING BRAKE DISC WEAR.....598
TESTING AND ADJUSTING INCHING VALVE LINKAGE.....599
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.....600
MEASURING TRAVEL OF MAIN CONTROL VALVE SPOOL.....602
MEASURING WORK EQUIPMENT PRESSURE.....603
TESTING AND ADJUSTING BUCKET POSITIONER.....605
TROUBLESHOOTING.....607
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....608
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....609
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....610
CHECKS BEFORE TROUBLESHOOTING.....618
TROUBLESHOOTING OF ELECTRICAL SYSTEM.....619
E-1 ENGINE DOES NOT START.....620
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE).....625
TROUBLESHOOTING.....626
CHECKING MACHINE BEFORE TROUBLESHOOTING.....626
CHECKING HST BEFORE TROUBLESHOOTING.....627
H-1 IMPOSSIBLE TO TRAVEL IN EITHER DIRECTION (FORWARD OR REVERSE).....629
H-2 IMPOSSIBLE TO TRAVEL IN ONE DIRECTION ONLY (EITHER FORWARD OR REVERSE).....630
H-3 LACKS SPEED IN BOTH DIRECTIONS (FORWARD AND REVERSE).....631
H-4 LACKS SPEED IN ONE DIRECTION ONLY (FORWARD OR REVERSE).....632
H-5 LACKS DRAWBAR PULL IN BOTH DIRECTIONS (FORWARD AND REVERSE).....632
H-6 LACKS DRAWBAR PULL IN ONE DIRECTION ONLY (FORWARD OR REVERSE).....633
H-7 ENGINE SPEED IS HIGH WHEN STARTING IN BOTH DIRECTIONS (FORWARD AND REVERSE).....633
H-8 ENGINE SPEED IS HIGH WHEN STARTING IN ONE DIRECTION ONLY (FORWARD OR REVERSE).....633
30 DISASSEMBLY AND ASSEMBLY.....634
HOW TO READ THIS MANUAL.....635
PRECAUTIONS WHEN CARRYING OUT OPERATION.....637
SPECIAL TOOLS LIST.....639
FUEL INJECTION PUMP.....640
REMOVAL.....640
INSTALLATION.....641
ENGINE.....642
REMOVAL AND INSTALLATION.....642
RADIATOR.....672
REMOVAL AND INSTALLATION.....672
FUEL TANK.....681
REMOVAL AND INSTALLATION.....681
MAIN PISTON PUMP.....682
REMOVAL.....682
INSTALLATION.....687
DISASSEMBLY AND ASSEMBLY.....691
PISTON MOTOR.....697
REMOVAL.....697
INSTALLATION.....699
DISASSEMBLY.....701
ASSEMBLY.....702
ENGINE AND TRANSFER.....703
REMOVAL AND INSTALLATION.....703
TRANSFER.....731
DISASSEMBLY.....731
ASSEMBLY.....734
DRIVE SHAFT.....738
DISASSEMBLY.....738
ASSEMBLY.....739
FRONT AXLE.....740
REMOVAL.....740
INSTALLATION.....741
REAR AXLE.....742
REMOVAL.....742
INSTALLATION.....745
DIFFERENTIALS.....748
DISASSEMBLY.....748
ASSEMBLY.....751
AXLE HOUSINGS.....762
DISASSEMBLY.....762
ASSEMBLY.....767
CENTER HINGE PIN.....773
REMOVAL.....773
INSTALLATION.....780
STEERING VALVE.....790
REMOVAL AND INSTALLATION.....790
DISASSEMBLY.....791
ASSEMBLY.....794
RELIEF VALVE HOUSING SIDE OF STEERING VALVE.....799
DISASSEMBLY.....799
ASSEMBLY.....800
STEERING CYLINDER.....801
REMOVAL AND INSTALLATION.....801
PARKING BRAKE.....802
REMOVAL.....802
INSTALLATION.....804
HYDRAULIC TANK.....807
REMOVAL AND INSTALLATION.....807
WORK EQUIPMENT VALVE.....808
REMOVAL AND INSTALLATION.....808
DUMP CYLINDER.....809
REMOVAL AND INSTALLATION.....809
LIFT CYLINDER.....810
REMOVAL AND INSTALLATION.....810
HYDRAULIC CYLINDER.....811
DISASSEMBLY.....811
ASSEMBLY.....813
WORK EQUIPMENT.....815
REMOVAL.....815
INSTALLATION.....818
COUNTERWEIGHT.....821
REMOVAL AND INSTALLATION.....821
INSTRUMENTS PANEL.....822
REMOVAL AND INSTALLATION.....822
40 MAINTENANCE STANDARD.....823
TRANSMISSIONENGINE MOUNT.....824
WORK EQUIPMENTSTEERING PUMP, HST CHARGE PUMP.....825
TRANSFER.....826
HST INCHING VALVE.....828
DRIVE SHAFT.....829
DIFFERENTIAL (1/2).....830
DIFFERENTIAL (2/2).....831
FINAL DRIVE.....833
AXLE MOUNT.....834
STEERING COLUMN.....835
PRIORITY VALVE.....836
STEERING CYLINDER MOUNT.....837
BRAKE.....838
HYDRAULIC CYLINDER.....839
CENTER HINGE PIN.....841
WORK EQUIPMENT LINKAGE.....842
BUCKET POSITIONER.....844
BUCKET.....845
90 OTHERS.....846
ELECTRICAL CIRCUIT DIAGRAMSERIAL NO. 22005-26000.....847
ELECTRICAL CIRCUIT DIAGRAM (1/2)SERIAL NO. 26001 AND UP.....848
ELECTRICAL CIRCUIT DIAGRAM (2/2)SERIAL NO. 26001 AND UP.....849
BACKHOE.....850
CONTENTS.....851
GENERAL.....852
GENERAL ASSEMBLY DRAWING.....852
SPECIFICATIONS.....853
WEIGHT TABLE.....855
STRUCTURE AND FUNCTION.....856
VALVE CONTROL.....856
HYDRAULIC CIRCUIT DIAGRAM.....857
BACKHOE CONTROL VALVE.....858
CHECK VALVE.....860
WORK EQUIPMENT.....862
ACTUAL ELECTRICAL WIRING DIAGRAM.....863
ELECTRICAL CIRCUIT DIAGRAM.....864
TESTING AND ADJUSTING.....865
ADJUSTING BACKHOE SWING.....865
TEN00071-00 - Wheel Loader WA30-5, WA50-3 Operation & Maintenance Manual.....866
COVER.....866
FOREWORD.....867
FOREWORD.....868
SAFETY INFORMATION.....871
INTRODUCTION.....873
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....873
NECESSARY INFORMATION.....874
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....874
ENGINE SERIAL NO. PLATE AND POSITION.....874
POSITION OF SERVICE METER.....874
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....875
CONTENTS.....876
SAFETY.....879
SAFETY.....880
SAFETY LABELS.....882
LOCATION OF SAFETY LABELS.....883
SAFETY LABELS.....884
GENERAL PRECAUTIONS.....888
SAFETY RULES.....888
IF ABNORMALITIES ARE FOUND.....888
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....888
FIRE EXTINGUISHER AND FIRST AID KIT.....888
SAFETY FEATURES.....888
KEEP MACHINE CLEAN.....889
INSIDE OPERATOR'S COMPARTMENT.....889
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....889
HANDRAILS AND STEPS.....890
MOUNTING AND DISMOUNTING.....890
NO PEOPLE ON ATTACHMENTS.....890
DO NOT GET CAUGHT IN ARTICULATED PORTION.....891
PREVENTION OF BURNS.....891
FIRE PREVENTION.....892
ACTION IF FIRE OCCURS.....893
WINDOW WASHER LIQUID.....893
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).....893
PRECAUTIONS FOR ATTACHMENTS, OPTIONS.....893
UNAUTHORIZED MODIFICATION.....893
SAFETY AT WORKSITE.....894
WORKING ON LOOSE GROUND.....894
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....894
ENSURE GOOD VISIBILITY.....895
VENTILATION FOR ENCLOSED AREAS.....895
CHECKING SIGNALMAN'S SIGNALS AND SIGNS.....895
EMERGENCY EXIT FROM OPERATOR'S CAB.....895
BE CAREFUL ABOUT ASBESTOS DUST.....896
PRECAUTIONS FOR OPERATION.....897
STARTING ENGINE.....897
CHECKS BEFORE STARTING ENGINE.....897
PRECAUTIONS WHEN STARTING.....897
PRECAUTIONS IN COLD AREAS.....898
OPERATION.....899
CHECKS BEFORE OPERATION.....899
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE.....899
PRECAUTIONS WHEN TRAVELING.....900
PRECAUTIONS WHEN USING A SMOKE POT.....900
TRAVELING ON SLOPES.....901
PROHIBITED OPERATIONS.....902
PRECAUTIONS WHEN OPERATING.....902
METHODS OF USING BRAKE.....903
OPERATE CAREFULLY ON SNOW.....903
PARKING MACHINE.....904
TRANSPORTATION.....905
LOADING AND UNLOADING.....905
SHIPPING.....905
BATTERY.....906
BATTERY HAZARD PREVENTION.....906
STARTING WITH BOOSTER CABLES.....907
TOWING.....908
WHEN TOWING.....908
PRECAUTIONS FOR MAINTENANCE.....909
WARNING TAG.....909
KEEP WORK PLACE CLEAN AND TIDY.....909
APPOINT LEADER WHEN WORKING WITH OTHERS.....909
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.....910
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.....911
PROPER TOOLS.....911
PERSONNEL.....912
ATTACHMENTS.....912
WORK UNDER THE MACHINE.....912
NOISE.....912
PRECAUTIONS WHEN USING HAMMER.....913
REPAIR WELDING.....913
REMOVING BATTERY TERMINAL.....913
PRECAUTIONS WITH HIGH-PRESSURE OIL.....913
HANDLING HIGH-PRESSURE HOSES.....914
WASTE MATERIALS.....914
COMPRESSED AIR.....914
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....914
PRECAUTIONS WITH TIRES.....915
HANDLING TIRES.....915
PRECAUTIONS WHEN STORING TIRES.....915
OPERATION.....916
GENERAL VIEW.....917
GENERAL VIEW OF MACHINE.....917
GENERAL VIEW OF CONTROLS AND GAUGES.....918
EXPLANATION OF COMPONENTS.....920
MACHINE MONITOR.....920
SWITCHES.....929
CONTROL LEVERS, PEDALS.....931
CAP WITH LOCK.....935
FRAME LOCK BAR.....936
TILT HOOD.....936
TOWING PIN.....936
FUSE.....937
FUSIBLE LINK.....938
MANUAL POCKET.....938
POWER OUTLET.....938
OPERATION.....939
CHECK BEFORE STARTING ENGINE, ADJUST.....939
STARTING ENGINE.....950
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....953
STOPPING ENGINE.....954
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....955
TURNING.....959
OPERATION OF WORK EQUIPMENT.....960
HANDLING FRONT ATTACHMENT SERVICE HYDRAULIC CIRCUIT (IF EQUIPPED).....961
WORK POSSIBLE USING WHEEL LOADER.....962
PRECAUTIONS FOR OPERATION.....966
ADJUSTING WORK EQUIPMENT POSTURE.....968
PARKING MACHINE.....970
CHECKS AFTER COMPLETION OF OPERATION.....972
LOCKING.....972
HANDLING THE TIRES.....973
TRANSPORTATION.....976
TRANSPORTATION PROCEDURE.....976
LOADING, UNLOADING WORK WITH TRAILERS.....976
LIFTING MACHINE.....979
REMOVAL, INSTALLATION OF CANOPY.....983
COLD WEATHER OPERATION.....985
PRECAUTIONS FOR LOW TEMPERATURE.....985
PRECAUTIONS AFTER COMPLETION OF WORK.....986
AFTER COLD WEATHER.....987
LONG-TERM STORAGE.....988
BEFORE STORAGE.....988
DURING STORAGE.....988
AFTER STORAGE.....988
TROUBLESHOOTING.....989
WHEN MACHINE RUNS OUT OF FUEL.....989
TOWING THE MACHINE.....989
IF BATTERY IS DISCHARGED.....991
OTHER TROUBLE.....994
MAINTENANCE.....999
GUIDES TO MAINTENANCE.....1000
OUTLINES OF SERVICE.....1002
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....1002
OUTLINE OF ELECTRIC SYSTEM.....1004
WEAR PARTS.....1005
WEAR PARTS LIST.....1005
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO .....1006
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....1006
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....1010
TORQUE LIST.....1010
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....1011
MAINTENANCE SCHEDULE CHART.....1012
MAINTENANCE SCHEDULE CHART.....1012
SERVICE PROCEDURE.....1014
INITIAL 250 HOURS SERVICE OR INITIAL 3 MONTHS (ONLY AFTER THE FIRST 250.....1014
WHEN REQUIRED.....1015
REPLACE AIR CLEANER ELEMENT.....1015
CLEAN INSIDE OF COOLING SYSTEM.....1016
DRAIN WATER AND SEDIMENT FROM FUEL TANK.....1018
CLEAN WATER SEPARATOR ELEMENT.....1019
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL.....1020
CHECK AXLE OIL LEVEL, ADD OIL.....1021
CLEAN TRANSFER CASE BREATHER.....1022
CLEAN AXLE CASE BREATHER.....1022
CLEAN AND CHECK RADIATOR FINS.....1023
TURN, REPLACE BOLT-ON CUTTING EDGE.....1023
CHECK PARKING BRAKE.....1024
ADJUST PARKING BRAKE RELEASE LEVER.....1024
CHECK BRAKE PEDAL.....1024
SELECTION AND INSPECTION OF TIRES.....1025
CHECK BEFORE STARTING.....1027
EVERY 50 HOURS SERVICE OR EVERY 1 MONTH.....1028
CLEAN AIR CLEANER DUST CUP.....1028
EVERY 250 HOURS SERVICE OR EVERY 3 MONTHS.....1029
LUBRICATING.....1029
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....1030
CLEAN AIR CLEANER ELEMENT.....1031
CHECK FAN BELT TENSION, ADJUST.....1032
CHECK BATTERY ELECTROLYTE LEVEL.....1033
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.....1035
EVERY 500 HOURS SERVICE OR EVERY 6 MONTHS.....1036
LUBRICATE REAR AXLE PIVOT PIN (2 PLACES).....1036
REPLACE FUEL FILTER CARTRIDGE.....1036
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....1038
EVERY 1000 HOURS SERVICE OR EVERY 1 YEAR.....1039
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE AND HST.....1039
LUBRICATING.....1040
EVERY 2000 HOURS SERVICE OR EVERY 2 YEARS.....1041
CHANGE OIL IN TRANSFER CASE.....1041
CHANGE AXLE OIL.....1042
CHECK ALTERNATOR, STARTING MOTOR.....1042
CHECK ENGINE VALVE CLEARANCE, ADJUST.....1042
SPECIFICATIONS.....1043
SPECIFICATIONS.....1044
ATTACHMENTS, OPTIONS.....1045
HANDLING SEAT BELT.....1046
FASTENING AND REMOVING BELT.....1046
ADJUST BELT LENGTH.....1046
CHECK SEAT BELT AND MOUNTS.....1047
HANDLING SERVICE HYDRAULIC CIRCUIT.....1048
CONNECTING HYDRAULIC CIRCUIT.....1048
ROUTE OF HYDRAULIC CIRCUIT.....1049
INDEX.....1050
