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KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA380-5L A52001 and UP) – PDF DOWNLOAD
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- KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:WA380-5L A52001 and UP
- PUBLICATION NUMBER:CEAM009301
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Description
KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA380-5L A52001 and UP)
KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA380-5L A52001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA380-5L A52001 and UP)
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
- If this manual is lost, damaged or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.
- Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require.
TABLE OF CONTENTS:
KOMATSU GALEO WA380-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA380-5L A52001 and UP)
MAIN MENU.......................................................................... 0 COVER.............................................................................. 1 INTRODUCTION....................................................................... 7 FOREWORD....................................................................... 8 SAFETY INFORMATION............................................................. 10 APPROVED AND NON-APPROVED USES................................................. 11 NON-APPROVED............................................................... 11 PRODUCT IDENTIFICATION......................................................... 12 MACHINE SERIAL NUMBER...................................................... 12 ENGINE SERIAL NUMBER AND EMISSION LABEL.................................... 13 SERVICE METER LOCATION..................................................... 13 SERIAL NUMBERS AND DEALER INFORMATION.......................................... 14 CONTENTS........................................................................... 15 SAFETY............................................................................. 27 GENERAL SAFETY RULES AND PRECAUTIONS........................................... 28 GENERAL SAFETY RULES....................................................... 28 SAFETY FEATURES............................................................ 29 PERSONAL PROTECTIVE EQUIPMENT.............................................. 29 UNAUTHORIZED MODIFICATIONS................................................. 30 LEAVING OPERATOR’S COMPARTMENT............................................. 30 MOUNTING AND DISMOUNTING................................................... 31 WASTE HANDLER APPLICATIONS............................................. 31 FIRE PREVENTION FOR FUEL AND OIL........................................... 32 DUST HAZARD PRECAUTIONS.................................................... 32 CRUSH OR PINCH POINT DANGERS............................................... 33 FIRE EXTINGUISHER AND FIRST AID KIT........................................ 33 INSIDE OPERATOR’S COMPARTMENT.............................................. 34 PRECAUTIONS WHEN USING ROPS................................................ 34 PRECAUTIONS FOR ATTACHMENTS................................................ 34 STARTING YOUR WORK OPERATIONS.................................................. 35 WORK SITE HAZARDS.......................................................... 35 AVOIDING DANGEROUS SITUATIONS.............................................. 35 WORKING CLEARANCES......................................................... 37 RULES FOR ROAD TRAVEL.......................................................... 38 TRAVELING IN REVERSE....................................................... 38 TRAVELING ON ICY OR SNOW-COVERED SURFACES.................................. 38 WORKING ON LOOSE OR UNSTABLE GROUND........................................ 38 TRAVEL ON SLOPES........................................................... 39 PARKING THE MACHINE........................................................ 40 PRECAUTIONS DURING MAINTENANCE OPERATIONS...................................... 41 WARNING TAGS............................................................... 41 EQUIPMENT STORAGE.......................................................... 41 WORKING UNDER THE MACHINE.................................................. 42 USING DROP LAMPS........................................................... 42 KEEPING THE MACHINE CLEAN.................................................. 43 RUNNING THE MACHINE DURING MAINTENANCE..................................... 43 RULES FOR REFUELING THE MACHINE............................................ 44 COOLING SYSTEM PRECAUTIONS................................................. 44 BATTERY PRECAUTIONS........................................................ 45 STARTING THE MACHINE....................................................... 45 HIGH PRESSURE HOSES........................................................ 46 HIGH TEMPERATURES AREAS.................................................... 46 DISPOSAL OF WASTE MATERIALS................................................ 46 INFLATING TIRES............................................................ 47 ACCUMULATOR................................................................ 47 CRITICAL PARTS............................................................. 47 VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED................................ 47 SAFETY AND WARNING DECALS...................................................... 48 LOCATION OF THE SAFETY DECALS.............................................. 48 LOCATION OF SAFETY LABELS.................................................. 49 SAFETY LABELS.......................................................... 49 OPERATION.......................................................................... 57 GENERAL VIEW OF MACHINE........................................................ 58 OUTSIDE VIEW OF THE MACHINE................................................ 58 INSIDE VIEW OF THE CAB..................................................... 59 DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS............................. 60 INSTRUMENT BEZEL........................................................... 60 SWITCH PANELS.............................................................. 62 DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM............................... 63 INSTRUMENT BEZEL........................................................... 63 TYPES OF WARNING....................................................... 64 MACHINE ELECTRONIC MONITORING DISPLAY.......................................... 65 MONITOR MODE SELECTOR SWITCHES............................................. 65 MODE SELECTOR SWITCH 1................................................. 66 MODE SELECTOR SWITCH 2................................................. 66 MONITOR DISPLAY INFORMATION................................................ 66 HOUR METER AND ODOMETER DISPLAY........................................ 66 ADJUSTING MONITOR BRIGHTNESS........................................... 67 PROGRAMMING TELEPHONE NUMBER........................................... 67 ACTION CODE DISPLAY.................................................... 67 FAILURE CODE DISPLAY................................................... 68 SERVICE DISPLAY........................................................ 69 SELECTING LANGUAGE..................................................... 70 EMERGENCY STOP WARNING SYSTEM.............................................. 71 BRAKE PRESSURE WARNING LAMP............................................ 71 ENGINE OIL PRESSURE WARNING LAMP....................................... 72 BATTERY CHARGE WARNING LAMP............................................ 72 STEERING OIL PRESSURE WARNING LAMP..................................... 72 CAUTION ALERT WARNING SYSTEM............................................... 73 AXLE OIL TEMPERATURE CAUTION LAMP...................................... 73 TORQUE CONVERTER CAUTION LAMP.......................................... 74 COOLANT TEMPERATURE CAUTION LAMP....................................... 74 HYDRAULIC OIL TEMPERATURE CAUTION LAMP................................. 74 FUEL LEVEL CAUTION LAMP................................................ 74 INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM............................ 75 ENGINE OIL LEVEL CAUTION LAMP.......................................... 75 RADIATOR COOLANT LEVEL CAUTION LAMP.................................... 76 AIR CLEANER CLOGGING CAUTION LAMP...................................... 76 MAINTENANCE CAUTION LAMP............................................... 76 MODE ALERT LAMPS........................................................... 77 PARKING BRAKE PILOT LAMP............................................... 77 COOLING FAN REVERSE ROTATION PILOT LAMP................................ 78 EMERGENCY STEERING PILOT LAMP.......................................... 78 OUTPUT MODE PILOT LAMP (POWER MODE).................................... 78 PREHEATING PILOT LAMP.................................................. 79 JOYSTICK PILOT LAMP.................................................... 79 SHIFT INDICATOR........................................................ 79 AUTO-SHIFT PILOT LAMP.................................................. 79 LOCKUP PILOT LAMP...................................................... 80 SHIFT HOLD PILOT LAMP.................................................. 80 SHIFT LEVER POSITION PILOT LAMP........................................ 80 TURN SIGNAL PILOT LAMP................................................. 80 HEADLAMP HIGH BEAM PILOT LAMP.......................................... 81 GAUGE DISPLAY.............................................................. 82 TORQUE CONVERTER OIL TEMPERATURE GAUGE................................. 82 ENGINE TEMPERATURE GAUGE............................................... 83 HYDRAULIC TEMPERATURE GAUGE............................................ 83 FUEL GAUGE............................................................. 83 SPEEDOMETER............................................................ 83 METER DISPLAY PILOT LAMP............................................... 84 MACHINE MONITOR............................................................ 84 DISPLAYING ODOMETER.................................................... 84 RESET FOR FILTER, OIL REPLACEMENT TIME................................. 84 ENTERING A TELEPHONE NUMBER............................................ 85 SELECTING A LANGUAGE................................................... 86 ADJUSTING MONITOR BRIGHTNESS........................................... 87 MACHINE SWITCHES AND CONTROLS.................................................. 88 SWITCH LOCATION............................................................ 88 IGNITION SWITCH........................................................ 89 POWER MODE SELECTOR SWITCH............................................. 89 TRANSMISSION MODE SELECTOR SWITCH...................................... 90 TRANSMISSION CUT-OFF SWITCH............................................ 90 TRANSMISSION CUT-OFF SET SWITCH........................................ 91 LAMP SWITCH............................................................ 91 TURN SIGNAL LEVER...................................................... 91 DIMMER SWITCH.......................................................... 92 HORN BUTTON............................................................ 92 HAZARD LAMP SWITCH..................................................... 92 PARKING BRAKE SWITCH................................................... 92 FRONT WORKING LAMP SWITCH.............................................. 93 REAR WORKING LAMP SWITCH............................................... 93 MONITOR PANEL MODE SELECTOR SWITCH 1................................... 94 MONITOR PANEL MODE SELECTOR SWITCH 2................................... 94 KICKDOWN SWITCH........................................................ 94 HOLD SWITCH............................................................ 95 FRONT WIPER SWITCH..................................................... 95 REAR WIPER SWITCH...................................................... 95 CIGARETTE LIGHTER...................................................... 96 CAB LAMP SWITCH........................................................ 96 REAR DEFROSTER SWITCH.................................................. 96 E.C.S.S. SWITCH........................................................ 97 EMERGENCY STEERING SWITCH.............................................. 97 COOLING FAN REVERSE ROTATION SWITCH.................................... 98 DIRECTIONAL SELECTOR SWITCH............................................ 98 DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH........................... 99 TORQUE CONVERTER LOCK-UP SWITCH........................................ 99 LOAD METER CANCEL SWITCH............................................... 99 LOAD METER SUBTOTAL SWITCH............................................. 99 SOUND SYSTEM...................................................................100 DIGITAL ESPERIA RADIO SERIAL NUMBER A52001 - A52189........................100 POWER SWITCH/VOLUME....................................................100 TONE CONTROL KNOB......................................................101 DISPLAY................................................................101 CLOCK BUTTON/DISPLAYING FREQUENCY......................................101 AST....................................................................101 PRESET BUTTON..........................................................102 SEEK...................................................................102 BAND SELECTOR SWITCH...................................................102 TUNING SWITCH..........................................................102 LISTENING TO THE RADIO.................................................103 AUTOMATIC TUNING.......................................................103 MANUAL TUNING..........................................................103 SETTING THE PRESET BUTTONS.............................................103 AUTOMATIC MEMORY.......................................................104 AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO.......................104 ADJUSTING THE TIME.....................................................104 BLAUPUNKT CALAIS RADIO SERIAL NUMBER A52190 AND UP.........................105 POWER SWITCH/MUTE......................................................105 VOLUME CONTROL.........................................................106 FMT CONTROL............................................................106 IR REMOTE CONTROL (OPTIONAL)...........................................106 RDS CONTROL............................................................106 ML CONTROL.............................................................107 EJECT CASSETTE.........................................................107 CASSETTE COMPARTMENT...................................................107 FF AND RW BUTTONS......................................................107 GEO BUTTON.............................................................108 SRC BUTTON.............................................................108 AUDIO BUTTON...........................................................108 MULTIFUNCTION ROCKER SWITCH............................................108 MENU BUTTON............................................................109 KEYPAD 1-5.............................................................109 TRAFFIC................................................................109 DISPLAY................................................................109 THEFT PROTECTION.......................................................110 PRECAUTIONS WHEN USING.................................................110 AIR CONDITIONER CONTROL PANEL..............................................111 FAN SWITCH.............................................................111 AIR CONDITIONER SWITCH.................................................112 MODE SELECTOR SWITCH...................................................112 FRESH/RECIRC SELECTOR SWITCH...........................................112 EXTERNAL AIR INTAKE....................................................112 TEMPERATURE CONTROL SWITCH.............................................113 METHOD OF OPERATION....................................................113 WHEN NOT USING THE AIR CONDITIONER REGULARLY...........................114 COOL BOX...............................................................115 PRECAUTIONS WHEN USING THE AIR CONDITIONER.............................115 CONTROL LEVERS, PEDALS.....................................................116 SPEED CONTROL LEVER....................................................116 DIRECTIONAL LEVER......................................................118 SPEED CONTROL LEVER STOPPER............................................118 SAFETY LOCK LEVER......................................................119 BUCKET CONTROL LEVER...................................................119 LIFT ARM CONTROL LEVER.................................................120 BRAKE PEDAL............................................................120 ACCELERATOR PEDAL......................................................121 STEERING TILT LOCK LEVER...............................................121 SECURITY AND LOCKS.............................................................122 IGNITION KEY LOCKED AREAS..................................................122 CAB DOOR LOCKS.........................................................122 ENGINE ACCESS DOORS....................................................122 REAR GRILL.............................................................123 FUEL CAP...............................................................123 PADLOCKED AREAS............................................................124 BATTERY AND TOOL BOX...................................................124 TRANSFER CASE..........................................................124 UPPER HOOD ACCESS PANNEL...............................................124 SAFETY FEATURES................................................................125 PASSIVE SAFETY FEATURES....................................................125 ROLL-OVER PROTECTIVE STRUCTURE (ROPS)..................................125 CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY).....................125 BACKUP WARNING ALARM...................................................125 ACTIVE SAFETY FEATURES.....................................................126 SAFETY BAR.............................................................126 SEAT BELT..............................................................126 EQUIPMENT LOCK LEVER...................................................127 MACHINE FEATURES...............................................................128 CAB DOORS..................................................................128 OPEN LOCK..............................................................128 ELECTRICAL.................................................................128 FUSE...................................................................128 FUSE CAPACITY AND NAME OF CIRCUIT......................................129 SLOW BLOW FUSE.........................................................130 AUXILIARY POWER........................................................130 MACHINE CAB AND CHASSIS....................................................131 SEAT ADJUSTMENT........................................................131 HANDLING CAB WIPER.....................................................133 DUST INDICATOR.........................................................133 GREASE PUMP............................................................133 PRECAUTIONS BEFORE STARTING WORK OPERATIONS....................................134 PRE-OPERATIONAL CHECKS.....................................................134 PERFORM A WALK AROUND CHECK OF YOUR MACHINE............................134 UNDER THE HOOD.........................................................134 CHECK COOLANT LEVEL....................................................135 CHECK ENGINE OIL LEVEL, ADD OIL........................................136 REAR-VIEW MIRROR ADJUSTMENT............................................136 IN THE OPERATOR’S CAB..................................................137 SEAT BELT ADJUSTMENT...................................................137 LEVER STAND ADJUSTMENT.................................................138 LEVER STAND ANGLE ADJUSTMENT...........................................138 START-UP PROCEDURES........................................................139 CHECK FUEL LEVEL, ADD FUEL.............................................139 CHECK THE BRAKE PEDALS.................................................140 CHECK THE PARKING BRAKE................................................140 STARTING THE ENGINE....................................................141 OPERATIONS AND CHECKS AFTER STARTING ENGINE....................................144 BREAKING IN THE MACHINE....................................................144 NORMAL START-UP AND WARM-UP............................................144 STOPPING THE ENGINE....................................................145 TRAVELING, STOPPING AND PARKING THE MACHINE....................................146 TRAVELING..................................................................146 TURNING ON SLOPES......................................................148 CHANGING GEAR SPEED RANGES.............................................148 CHANGING DIRECTION.....................................................149 WHEN USING AUTO-SHIFT..................................................150 STOPPING AND PARKING THE MACHINE...........................................151 TRANSMISSION CUT-OFF SWITCH............................................153 ADJUSTING THE TRANSMISSION CUT-OFF.....................................153 STOPPING WHEN TRANSMISSION CUT-OFF IS ON...............................154 TURNING................................................................154 EMERGENCY STEERING.............................................................155 USING THE EMERGENCY STEERING...............................................155 EMERGENCY STEERING SELF-CHECK FUNCTION.................................156 STARTING YOUR WORK OPERATIONS..................................................157 WORK EQUIPMENT.............................................................157 LIFT ARM LEVER.........................................................157 BUCKET LEVER...........................................................158 SCOOPING A LOAD OR CUTTING A GRADE.........................................159 LOADING PILED SOIL OR BLASTED ROCK.....................................159 CUTTING A GRADE ON LEVEL GROUND........................................161 LEVELING OPERATIONS........................................................162 PUSHING OPERATION..........................................................162 LOAD AND CARRY OPERATIONS..................................................162 LOADING OPERATIONS.........................................................163 CROSS DRIVE LOADING....................................................163 V-SHAPE LOADING........................................................163 PRECAUTIONS WHEN PILING UP LOADS.......................................163 LOADING TRUCKS OR HOPPERS..............................................164 PRECAUTIONS DURING OPERATION...................................................165 PERMISSIBLE WATER DEPTH....................................................165 IF WHEEL BRAKE DOES NOT WORK...............................................165 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.................................165 BRAKING ON DOWNHILL SLOPE..............................................165 IF THE ENGINE STOPS....................................................165 PRECAUTIONS WHEN DRIVING THE MACHINE.......................................166 PRECAUTIONS REGARDING BRAKE FUNCTION.......................................166 WORK EQUIPMENT AND MACHINE POSTURE.............................................167 ADJUSTING BUCKET...........................................................167 BOOM KICKOUT ADJUSTMENT................................................167 BUCKET POSITIONER ADJUSTMENT...........................................168 BUCKET LEVEL INDICATOR.................................................168 TRANSPORTING THE MACHINE.......................................................169 LOADING AND SECURING THE MACHINE...........................................169 LIFTING THE MACHINE............................................................170 LIFTING LOCATIONS AND PROCEDURES...........................................170 USING WIRE ROPE............................................................171 PRE LIFTING PROCEDURES.................................................171 TOWING THE MACHINE.............................................................173 COLD WEATHER OPERATION.........................................................174 FUEL AND LUBRICANTS........................................................174 COOLANT....................................................................174 PRECAUTIONS AFTER COMPLETION OF WORK.......................................174 AFTER COLD WEATHER.........................................................174 WARMING UP THE STEERING....................................................174 MAINTENANCE........................................................................175 GUIDES TO MAINTENANCE..........................................................176 CHECK SERVICE METER........................................................176 KOMATSU GENUINE REPLACEMENT PARTS..........................................176 KOMATSU GENUINE OILS.......................................................176 ALWAYS USE CLEAN WASHER FLUID..............................................176 ALWAYS USE CLEAN OIL AND GREASE............................................176 CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...............176 FUEL STRAINER..............................................................176 WELDING INSTRUCTIONS.......................................................176 DO NOT DROP THINGS INSIDE THE MACHINE......................................177 DUSTY WORKSITES............................................................177 AVOID MIXING OIL...........................................................177 LOCKING INSPECTION COVERS..................................................177 BLEEDING AIR FROM HYDRAULIC CIRCUIT........................................177 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES................................177 CHECKS AFTER INSPECTION AND MAINTENANCE....................................178 SYSTEMS TROUBLESHOOTING CHARTS.................................................179 ELECTRICAL SYSTEM..........................................................179 CHASSIS....................................................................180 ENGINE.....................................................................184 OUTLINES OF SERVICE............................................................186 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................186 OIL....................................................................186 FUEL...................................................................186 COOLANT................................................................186 GREASE.................................................................187 PERFORMING KOWA (Komatsu Oil Wear Analysis)................................187 KOWA ANALYSIS ITEMS........................................................188 OIL SAMPLING...........................................................188 STORING OIL AND FUEL...................................................188 FILTERS................................................................189 OUTLINE OF ELECTRIC SYSTEM.................................................189 WEAR PARTS LIST................................................................190 FUEL, COOLANT AND LUBRICANTS...................................................191 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...........................191 LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS.............................193 STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES.............................195 TORQUE LIST................................................................195 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................196 MAINTENANCE SCHEDULE CHART.....................................................197 INITIAL 250 HOURS SERVICE..................................................197 WHEN REQUIRED..............................................................197 EVERY 50 HOURS SERVICE.....................................................197 EVERY 100 HOURS SERVICE....................................................197 EVERY 250 HOURS SERVICE....................................................197 EVERY 500 HOURS SERVICE....................................................198 EVERY 1000 HOURS SERVICE...................................................198 EVERY 2000 HOURS SERVICE...................................................198 EVERY 4000 HOURS SERVICE...................................................198 EVERY 8000 HOURS SERVICE...................................................198 GENERAL MAINTENANCE AND INSPECTION.............................................199 INITIAL 250 HOURS SERVICE..................................................199 CHANGE TRANSMISSION OIL FILTER CARTRIDGE...............................199 REPLACE HYDRAULIC TANK FILTER ELEMENT..................................199 WHEN REQUIRED..............................................................199 CLEANING THE MACHINE...................................................199 ENGINE AIR FILTER......................................................201 CLEANING THE COOLING SYSTEM............................................204 WATER SEPARATOR........................................................206 TRANSMISSION OIL LEVEL.................................................208 AXLE OIL LEVEL.........................................................209 CHECK AXLE VENT........................................................211 AIR CONDITIONER CONDENSER..............................................211 WINDOW WASHING FLUID LEVEL.............................................212 CLEAN RADIATOR FINS....................................................213 CHECK ELECTRICAL INTAKE AIR HEATER.....................................216 REPLACE BOLT-ON CUTTING EDGE...........................................216 REPLACE BUCKET TEETH...................................................217 REPLACING SLOW-BLOW FUSE...............................................218 INSPECTION OF TIRES....................................................219 EVERY SPECIFIC HOURS SERVICE...................................................221 EVERY 50 HOURS OF SERVICE..................................................221 DRAIN SEDIMENT FROM FUEL TANK..........................................221 EVERY 100 HOURS SERVICE....................................................221 LUBRICATE THE REAR AXLE PIVOT PIN......................................221 CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL...................221 CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT..................222 EVERY 250 HOURS OF SERVICE.................................................223 CHECK BATTERY ELECTROLYTE LEVEL........................................223 CHECK PARKING BRAKE....................................................225 ALTERNATOR BELT TENSION................................................225 AIR CONDITIONER COMPRESSOR BELT TENSION................................225 WHEEL HUB NUTS.........................................................226 AIR CONDITIONER RECIRCULATION FILTER...................................226 LUBRICATING POINTS.....................................................227 EVERY 500 HOURS SERVICE....................................................228 CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE.........228 REPLACING FUEL FILTER CARTRIDGE........................................229 EVERY 1000 HOURS SERVICE...................................................230 CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER...........230 CLEAN THE TRANSMISSION CASE VENT.......................................231 LUBRICATING POINTS.....................................................232 CHECKING PARTS OF TURBOCHARGER.........................................232 REPLACE CORROSION RESISTOR CARTRIDGE...................................232 EVERY 2000 HOURS SERVICE...................................................233 CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT.............233 HYDRAULIC TANK VENT ELEMENT............................................235 CHANGE THE AXLE OIL....................................................236 AIR CONDITIONER RECIRCULATION FILTER...................................236 CLEAN PPC CIRCUIT STRAINER.............................................237 CLEAN THE ENGINE VENT ELEMENT..........................................237 CHECK ALTERNATOR, STARTER MOTOR........................................238 CHECK ENGINE VALVE CLEARANCE...........................................238 CHECK TURBOCHARGER.....................................................238 CHECK INJECTOR.........................................................238 CHECK ACCUMULATOR GAS PRESSURE.........................................238 CHECK VIBRATION DAMPER.................................................238 CHECKING BRAKE DISC WEAR...............................................239 EVERY 4000 HOURS SERVICE...................................................240 LUBRICATING POINTS.....................................................240 CHECK WATER PUMP.......................................................241 CHECK AIR CONDITIONER COMPRESSOR.......................................241 REPLACE INJECTOR NOZZLE TIP............................................241 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.....241 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....242 EVERY 8000 HOURS SERVICE...................................................243 REPLACE HIGH-PRESSURE PIPING CLAMP.....................................243 REPLACE FUEL SPRAY PREVENTION CAP......................................243 LONG-TERM STORAGE..............................................................244 BEFORE STORAGE.............................................................244 DURING STORAGE.............................................................244 AFTER STORAGE..........................................................244 TROUBLESHOOTING EMERGENCY PROBLEMS.............................................245 WHEN MACHINE RUNS OUT OF FUEL..............................................245 PROCEDURE FOR BLEEDING AIR.............................................245 TOWING THE MACHINE.............................................................246 WHEN ENGINE CAN BE USED....................................................247 WHEN ENGINE CANNOT BE USED.................................................247 RELEASING THE PARKING BRAKE................................................247 RELEASE PARKING BRAKE WITH EMERGENCY PARKING BRAKE RELEASE VALVE.......247 MECHANICAL RELEASE.....................................................249 EMERGENCY TRAVEL OPERATION.................................................250 SPECIFICATIONS.....................................................................251 SPECIFICATIONS.................................................................252 MACHINE DIMENSIONS AND WEIGHTS.............................................252 TIRES..................................................................252 WORK EQUIPMENT.........................................................253 WEIGHT CHANGES.........................................................253 MACHINE SYSTEMS SPECIFICATIONS.................................................254 ENGINE.....................................................................254 TRANSMISSION...............................................................255 AXLES AND FINAL DRIVES.....................................................255 BRAKES.....................................................................255 STEERING SYSTEM............................................................255 SERVICE REFILL CAPACITIES..................................................255 OPTIONS, ATTACHMENTS...............................................................257 MONITOR WITH LOAD METER........................................................258 LOAD METER.................................................................258 SWITCHES...................................................................258 LOAD METER CANCEL SWITCH...............................................259 LOAD METER SUB TOTAL SWITCH............................................259 LOAD METER FUNCTIONS.......................................................260 LOAD METER ADDITION MODE...............................................260 LOAD METER REMAIN MODE.................................................261 SELECTION OF DISPLAY FOR TYPE OF LOAD..................................261 METHOD OF CALIBRATION (ADJUSTING 0 POINT)..............................262 DELETING LOAD METER DISPLAY............................................262 SPEED DISPLAY..........................................................262 USING LOAD METER DISPLAY...................................................263 SETTING ADDITION MODE..................................................263 SETTING THE REMAIN MODE................................................264 TOTAL LOAD DATA DISPLAY................................................266 STOPPING THE CALCULATION...............................................267 PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..................268 PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.................269 SUBTRACTION FUNCTION...................................................271 SETTING THE TIME ON THE CLOCK..........................................274 PRINTER OUTPUT.............................................................276 PRINTOUT MODE..........................................................276 SELECTING THE PRINTOUT MODE............................................277 TORQUE CONVERTER LOCK-UP.......................................................278 GENERAL LOCATIONS..........................................................278 TORQUE CONVERTER LOCK-UP SWITCH........................................278 TORQUE CONVERTER LOCK-UP PILOT LAMP....................................279 METHOD OF OPERATION....................................................279 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...................................280 TRAVEL SPEED WARNING FUNCTION..........................................280 TRAVEL SPEED LIMIT FUNCTION............................................280 WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM................................281 FAN SYSTEM OPERATION.......................................................281 MODE SELECTOR SWITCH...................................................282 FORWARD/REVERSE TIMER..................................................282 REVERSE/FORWARD INDICATOR LAMPS........................................282 FORWARD SETTING KNOB...................................................283 REVERSE SETTING KNOB...................................................283 FORWARD TIME UNIT SELECTOR SWITCH......................................284 SCALE FIGURE SELECTOR SWITCH...........................................284 DIRECTION SELECTOR SWITCH..............................................285 REVERSE PILOT LAMP.....................................................285 CONTROL BOX............................................................285 CLEANING RADIATOR AND COOLER FINS......................................286 HANDLING JOYSTICK STEERING SYSTEM..............................................288 EXPLANATION OF COMPONENTS..................................................288 SHIFT UP, SHIFT DOWN SWITCHES..........................................288 FNR SWITCH.............................................................289 JOYSTICK STEERING LEVER................................................289 JOYSTICK ON/OFF SWITCH.................................................289 HI/LOW SELECTOR SWITCH.................................................289 HORN SWITCH............................................................290 CONSOLE LOCK LEVER.....................................................290 HEIGHT ADJUSTMENT LOCK LEVER...........................................290 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER..................................290 STRUCTURE AND FUNCTION OF JOYSTICK STEERING................................291 JOYSTICK AND STEERING WHEEL OPERATION..................................292 GETTING IN OR OUT OF THE OPERATOR'S CAB................................292 JOYSTICK CONSOLE ADJUSTMENT............................................293 JOYSTICK OPERATION.....................................................293 SELECTING BUCKET AND TIRES.....................................................296
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