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KOMATSU GALEO WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA400-5L A40001 and UP) – PDF DOWNLOAD
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- KOMATSU GALEO WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:WA400-5L A40001 and UP
- PUBLICATION NUMBER:CEAM009601
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Description
KOMATSU GALEO WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA400-5L A40001 and UP)
KOMATSU GALEO WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA400-5L A40001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA400-5L A40001 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 WA400-5L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA400-5L A40001 and UP)
MAIN MENU.......................................................................... 0 COVER.............................................................................. 1 INTRODUCTION....................................................................... 2 FOREWORD....................................................................... 3 SAFETY INFORMATION............................................................. 4 APPROVED AND NON-APPROVED USES................................................. 5 NON-APPROVED............................................................... 5 PRODUCT IDENTIFICATION......................................................... 6 MACHINE SERIAL NUMBER...................................................... 6 ENGINE SERIAL NUMBER AND EMISSION LABEL.................................... 7 SERVICE METER LOCATION..................................................... 7 SERIAL NUMBERS AND DEALER INFORMATION.......................................... 8 CONTENTS........................................................................... 9 SAFETY............................................................................. 22 GENERAL SAFETY RULES AND PRECAUTIONS........................................... 23 GENERAL SAFETY RULES....................................................... 23 SAFETY FEATURES............................................................ 24 PERSONAL PROTECTIVE EQUIPMENT.............................................. 24 UNAUTHORIZED MODIFICATIONS................................................. 25 LEAVING OPERATOR’S COMPARTMENT............................................. 25 MOUNTING AND DISMOUNTING................................................... 26 WASTE HANDLER APPLICATIONS............................................. 26 FIRE PREVENTION FOR FUEL AND OIL........................................... 27 DUST HAZARD PRECAUTIONS.................................................... 27 CRUSH OR PINCH POINT DANGERS............................................... 28 FIRE EXTINGUISHER AND FIRST AID KIT........................................ 28 INSIDE OPERATOR’S COMPARTMENT.............................................. 29 PRECAUTIONS WHEN USING ROPS................................................ 29 PRECAUTIONS FOR ATTACHMENTS................................................ 29 STARTING YOUR WORK OPERATIONS.................................................. 30 WORK SITE HAZARDS.......................................................... 30 AVOIDING DANGEROUS SITUATIONS.............................................. 30 WORKING CLEARANCES......................................................... 32 RULES FOR ROAD TRAVEL.......................................................... 33 TRAVELING IN REVERSE....................................................... 33 TRAVELING ON ICY OR SNOW-COVERED SURFACES.................................. 33 WORKING ON LOOSE OR UNSTABLE GROUND........................................ 33 TRAVEL ON SLOPES........................................................... 34 PARKING THE MACHINE........................................................ 35 PRECAUTIONS DURING MAINTENANCE OPERATIONS...................................... 36 WARNING TAGS............................................................... 36 EQUIPMENT STORAGE.......................................................... 36 WORKING UNDER THE MACHINE.................................................. 37 USING DROP LAMPS........................................................... 37 KEEPING THE MACHINE CLEAN.................................................. 38 RUNNING THE MACHINE DURING MAINTENANCE..................................... 38 RULES FOR REFUELING THE MACHINE............................................ 39 COOLING SYSTEM PRECAUTIONS................................................. 39 BATTERY PRECAUTIONS........................................................ 40 STARTING THE MACHINE....................................................... 40 HIGH PRESSURE HOSES........................................................ 41 HIGH TEMPERATURES AREAS.................................................... 41 DISPOSAL OF WASTE MATERIALS................................................ 41 INFLATING TIRES............................................................ 42 ACCUMULATOR................................................................ 42 CRITICAL PARTS............................................................. 42 VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED................................ 42 SAFETY AND WARNING DECALS...................................................... 43 LOCATION OF THE SAFETY DECALS.............................................. 43 LOCATION OF SAFETY LABELS.................................................. 44 SAFETY LABELS.......................................................... 44 OPERATION.......................................................................... 52 GENERAL VIEW OF MACHINE........................................................ 53 OUTSIDE VIEW OF THE MACHINE................................................ 53 INSIDE VIEW OF THE CAB..................................................... 54 DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS............................. 55 INSTRUMENT BEZEL........................................................... 55 SWITCH PANELS.............................................................. 56 DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM............................... 57 INSTRUMENT BEZEL........................................................... 57 TYPES OF WARNING....................................................... 58 MACHINE ELECTRONIC MONITORING DISPLAY.......................................... 59 MONITOR MODE SELECTOR SWITCHES............................................. 59 MODE SELECTOR SWITCH 1................................................. 60 MODE SELECTOR SWITCH 2................................................. 60 MONITOR DISPLAY INFORMATION................................................ 60 HOUR METER AND ODOMETER DISPLAY........................................ 60 ADJUSTING MONITOR BRIGHTNESS........................................... 61 PROGRAMMING TELEPHONE NUMBER........................................... 61 ACTION CODE DISPLAY.................................................... 61 FAILURE CODE DISPLAY................................................... 62 SERVICE DISPLAY........................................................ 63 SELECTING LANGUAGE..................................................... 64 EMERGENCY STOP WARNING SYSTEM.............................................. 65 BRAKE PRESSURE WARNING LAMP............................................ 65 ENGINE OIL PRESSURE WARNING LAMP....................................... 66 BATTERY CHARGE WARNING LAMP............................................ 66 STEERING OIL PRESSURE WARNING LAMP..................................... 66 CAUTION ALERT WARNING SYSTEM............................................... 67 AXLE OIL TEMPERATURE CAUTION LAMP...................................... 67 TORQUE CONVERTER CAUTION LAMP.......................................... 68 COOLANT TEMPERATURE CAUTION LAMP....................................... 68 HYDRAULIC OIL TEMPERATURE CAUTION LAMP................................. 68 FUEL LEVEL CAUTION LAMP................................................ 68 INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM............................ 69 ENGINE OIL LEVEL CAUTION LAMP.......................................... 69 RADIATOR COOLANT LEVEL CAUTION LAMP.................................... 70 AIR CLEANER CLOGGING CAUTION LAMP...................................... 70 MAINTENANCE CAUTION LAMP............................................... 70 MODE ALERT LAMPS........................................................... 71 PARKING BRAKE PILOT LAMP............................................... 71 COOLING FAN REVERSE ROTATION PILOT LAMP................................ 72 EMERGENCY STEERING PILOT LAMP.......................................... 72 OUTPUT MODE PILOT LAMP (POWER MODE).................................... 72 PREHEATING PILOT LAMP.................................................. 73 JOYSTICK PILOT LAMP.................................................... 73 SHIFT INDICATOR........................................................ 73 AUTO-SHIFT PILOT LAMP.................................................. 73 LOCKUP PILOT LAMP...................................................... 74 SHIFT HOLD PILOT LAMP.................................................. 74 SHIFT LEVER POSITION PILOT LAMP........................................ 74 TURN SIGNAL PILOT LAMP................................................. 74 HEAD LAMP HIGH BEAM PILOT LAMP......................................... 75 GAUGE DISPLAY.............................................................. 76 TORQUE CONVERTER OIL TEMPERATURE GAUGE................................. 76 ENGINE TEMPERATURE GAUGE............................................... 77 HYDRAULIC TEMPERATURE GAUGE............................................ 77 FUEL GAUGE............................................................. 77 SPEEDOMETER............................................................ 77 METER DISPLAY PILOT LAMP............................................... 78 MACHINE MONITOR............................................................ 78 DISPLAYING ODOMETER.................................................... 78 RESET FOR FILTER, OIL REPLACEMENT TIME................................. 78 ENTERING A TELEPHONE NUMBER............................................ 79 SELECTING A LANGUAGE................................................... 80 ADJUSTING MONITOR BRIGHTNESS........................................... 81 MACHINE SWITCHES AND CONTROLS.................................................. 82 SWITCH LOCATION............................................................ 82 IGNITION SWITCH........................................................ 83 POWER MODE SELECTOR SWITCH............................................. 83 TRANSMISSION MODE SELECTOR SWITCH...................................... 84 TRANSMISSION CUT-OFF SWITCH............................................ 84 TRANSMISSION CUT-OFF SET SWITCH........................................ 85 LAMP SWITCH............................................................ 85 TURN SIGNAL LEVER...................................................... 85 DIMMER SWITCH.......................................................... 86 HORN BUTTON............................................................ 86 HAZARD LAMP SWITCH..................................................... 86 PARKING BRAKE SWITCH................................................... 86 FRONT WORKING LAMP SWITCH.............................................. 87 REAR WORKING LAMP SWITCH............................................... 87 MONITOR PANEL MODE SELECTOR SWITCH 1................................... 88 MONITOR PANEL MODE SELECTOR SWITCH 2................................... 88 KICKDOWN SWITCH........................................................ 88 HOLD SWITCH............................................................ 89 FRONT WIPER SWITCH..................................................... 89 REAR WIPER SWITCH...................................................... 89 CIGARETTE LIGHTER...................................................... 90 CAB LAMP SWITCH........................................................ 90 REAR DEFROSTER SWITCH.................................................. 90 E.C.S.S. SWITCH........................................................ 91 EMERGENCY STEERING SWITCH.............................................. 91 COOLING FAN REVERSE ROTATION SWITCH.................................... 92 TORQUE CONVERTER LOCK-UP SWITCH........................................ 92 LOAD METER CANCEL SWITCH............................................... 92 LOAD METER SUBTOTAL SWITCH............................................. 92 SOUND SYSTEM................................................................... 93 DIGITAL ESPERIA RADIO COMPONENTS........................................... 93 POWER SWITCH/VOLUME.................................................... 93 TONE CONTROL KNOB...................................................... 94 DISPLAY................................................................ 94 CLOCK BUTTON/DISPLAYING FREQUENCY...................................... 94 AST.................................................................... 94 PRESET BUTTON.......................................................... 95 SEEK................................................................... 95 BAND SELECTOR SWITCH................................................... 95 TUNING SWITCH.......................................................... 95 LISTENING TO THE RADIO................................................. 96 AUTOMATIC TUNING....................................................... 96 MANUAL TUNING.......................................................... 96 SETTING THE PRESET BUTTONS............................................. 96 AUTOMATIC MEMORY....................................................... 97 AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO....................... 97 ADJUSTING THE TIME..................................................... 97 BLAUPUNKT CALAIS RADIO COMPONENTS.......................................... 98 POWER SWITCH/MUTE...................................................... 98 VOLUME CONTROL......................................................... 99 FMT CONTROL............................................................ 99 IR REMOTE CONTROL (OPTIONAL)........................................... 99 RDS CONTROL............................................................ 99 ML CONTROL.............................................................100 EJECT CASSETTE.........................................................100 CASSETTE COMPARTMENT...................................................100 FF AND RW BUTTONS......................................................100 GEO BUTTON.............................................................101 SRC BUTTON.............................................................101 AUDIO BUTTON...........................................................101 MULTIFUNCTION ROCKER SWITCH............................................101 MENU BUTTON............................................................102 KEYPAD 1-5.............................................................102 TRAFFIC................................................................102 DISPLAY................................................................102 THEFT PROTECTION.......................................................103 PRECAUTIONS WHEN USING.................................................103 AIR CONDITIONER CONTROL PANEL..............................................104 FAN SWITCH.............................................................104 AIR CONDITIONER SWITCH.................................................105 MODE SELECTOR SWITCH...................................................105 FRESH/RECIRC SELECTOR SWITCH...........................................105 EXTERNAL AIR INTAKE....................................................105 TEMPERATURE CONTROL SWITCH.............................................106 METHOD OF OPERATION....................................................106 WHEN NOT USING THE AIR CONDITIONER REGULARLY...........................107 COOL BOX...............................................................108 PRECAUTIONS WHEN USING THE AIR CONDITIONER.............................108 CONTROL LEVERS, PEDALS.....................................................109 SPEED CONTROL LEVER....................................................109 DIRECTIONAL LEVER......................................................111 SPEED CONTROL LEVER STOPPER............................................111 SAFETY LOCK LEVER......................................................112 BUCKET CONTROL LEVER...................................................112 LIFT ARM CONTROL LEVER.................................................113 BRAKE PEDAL............................................................113 ACCELERATOR PEDAL......................................................114 STEERING TILT LOCK LEVER...............................................114 SECURITY AND LOCKS.............................................................115 IGNITION KEY LOCKED AREAS..................................................115 CAB DOOR LOCKS.........................................................115 ENGINE ACCESS DOORS....................................................115 REAR GRILL.............................................................116 FUEL CAP...............................................................116 PADLOCKED AREAS............................................................117 BATTERY AND TOOL BOX...................................................117 TRANSFER CASE..........................................................117 UPPER HOOD ACCESS PANEL................................................117 SAFETY FEATURES................................................................118 PASSIVE SAFETY FEATURES....................................................118 ROLL-OVER PROTECTIVE STRUCTURE (ROPS)..................................118 CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY).....................118 BACKUP WARNING ALARM...................................................118 ACTIVE SAFETY FEATURES.....................................................119 SAFETY BAR.............................................................119 SEAT BELT..............................................................119 EQUIPMENT LOCK LEVER...................................................120 MACHINE FEATURES...............................................................121 CAB DOORS..................................................................121 OPEN LOCK..............................................................121 ELECTRICAL.................................................................121 FUSE...................................................................121 FUSE CAPACITY AND NAME OF CIRCUIT......................................122 SLOW BLOW FUSE.........................................................123 AUXILIARY POWER........................................................123 MACHINE CAB AND CHASSIS....................................................124 SEAT ADJUSTMENT........................................................124 HANDLING CAB WIPER.....................................................126 DUST INDICATOR.........................................................126 GREASE PUMP............................................................126 PRECAUTIONS BEFORE STARTING WORK OPERATIONS....................................127 PRE-OPERATIONAL CHECKS.....................................................127 PERFORM A WALK AROUND CHECK OF YOUR MACHINE............................127 UNDER THE HOOD.........................................................127 CHECK COOLANT LEVEL....................................................128 CHECK ENGINE OIL LEVEL, ADD OIL........................................129 REAR-VIEW MIRROR ADJUSTMENT............................................129 IN THE OPERATOR’S CAB..................................................130 SEAT BELT ADJUSTMENT...................................................130 LEVER STAND ADJUSTMENT.................................................131 LEVER STAND ANGLE ADJUSTMENT...........................................131 START-UP PROCEDURES........................................................132 CHECK FUEL LEVEL, ADD FUEL.............................................132 CHECK THE BRAKE PEDALS.................................................133 CHECK THE PARKING BRAKE................................................133 STARTING THE ENGINE....................................................134 OPERATIONS AND CHECKS AFTER STARTING ENGINE....................................137 BREAKING IN THE MACHINE....................................................137 NORMAL START-UP AND WARM-UP............................................137 STOPPING THE ENGINE....................................................138 TRAVELING, STOPPING AND PARKING THE MACHINE....................................139 TRAVELING..................................................................139 TURNING ON SLOPES......................................................141 CHANGING GEAR SPEED RANGES.............................................141 CHANGING DIRECTION.....................................................142 WHEN USING AUTO-SHIFT..................................................143 STOPPING AND PARKING THE MACHINE...........................................144 TRANSMISSION CUT-OFF SWITCH............................................146 ADJUSTING THE TRANSMISSION CUT-OFF.....................................146 STOPPING WHEN TRANSMISSION CUT-OFF IS ON...............................147 TURNING................................................................147 EMERGENCY STEERING.............................................................148 USING THE EMERGENCY STEERING...............................................148 EMERGENCY STEERING SELF-CHECK FUNCTION.................................149 STARTING YOUR WORK OPERATIONS..................................................150 WORK EQUIPMENT.............................................................150 LIFT ARM LEVER.........................................................150 BUCKET LEVER...........................................................151 SCOOPING A LOAD OR CUTTING A GRADE.........................................152 LOADING PILED SOIL OR BLASTED ROCK.....................................152 CUTTING A GRADE ON LEVEL GROUND........................................154 LEVELING OPERATIONS........................................................155 PUSHING OPERATION..........................................................155 LOAD AND CARRY OPERATIONS..................................................155 LOADING OPERATIONS.........................................................156 CROSS DRIVE LOADING....................................................156 V-SHAPE LOADING........................................................156 PRECAUTIONS WHEN PILING UP LOADS.......................................156 LOADING TRUCKS OR HOPPERS..............................................157 PRECAUTIONS DURING OPERATION...................................................158 PERMISSIBLE WATER DEPTH....................................................158 IF WHEEL BRAKE DOES NOT WORK...............................................158 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.................................158 BRAKING ON DOWNHILL SLOPE..............................................158 IF THE ENGINE STOPS....................................................158 PRECAUTIONS WHEN DRIVING THE MACHINE.......................................159 PRECAUTIONS REGARDING BRAKE FUNCTION.......................................159 WORK EQUIPMENT AND MACHINE POSTURE.............................................160 ADJUSTING BUCKET...........................................................160 BOOM KICKOUT ADJUSTMENT................................................160 BUCKET POSITIONER ADJUSTMENT...........................................161 BUCKET LEVEL INDICATOR.................................................161 TRANSPORTING THE MACHINE.......................................................162 LOADING AND SECURING THE MACHINE...........................................162 LIFTING THE MACHINE............................................................163 LIFTING LOCATIONS AND PROCEDURES...........................................163 USING WIRE ROPE............................................................164 PRE LIFTING PROCEDURES.................................................164 TOWING THE MACHINE.............................................................166 COLD WEATHER OPERATION.........................................................167 FUEL AND LUBRICANTS........................................................167 COOLANT....................................................................167 PRECAUTIONS AFTER COMPLETION OF WORK.......................................167 AFTER COLD WEATHER.........................................................167 WARMING UP THE STEERING....................................................167 MAINTENANCE........................................................................168 GUIDES TO MAINTENANCE..........................................................169 CHECK SERVICE METER........................................................169 KOMATSU GENUINE REPLACEMENT PARTS..........................................169 KOMATSU GENUINE OILS.......................................................169 ALWAYS USE CLEAN WASHER FLUID..............................................169 ALWAYS USE CLEAN OIL AND GREASE............................................169 CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...............169 FUEL STRAINER..............................................................169 WELDING INSTRUCTIONS.......................................................169 DO NOT DROP THINGS INSIDE THE MACHINE......................................170 DUSTY WORKSITES............................................................170 AVOID MIXING OIL...........................................................170 LOCKING INSPECTION COVERS..................................................170 BLEEDING AIR FROM HYDRAULIC CIRCUIT........................................170 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES................................170 CHECKS AFTER INSPECTION AND MAINTENANCE....................................171 SYSTEMS TROUBLESHOOTING CHARTS.................................................172 ELECTRICAL SYSTEM..........................................................172 CHASSIS....................................................................173 ENGINE.....................................................................177 OUTLINES OF SERVICE............................................................179 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................179 OIL....................................................................179 FUEL...................................................................179 COOLANT................................................................179 GREASE.................................................................180 PERFORMING KOWA (Komatsu Oil Wear Analysis)................................180 KOWA ANALYSIS ITEMS........................................................181 OIL SAMPLING...........................................................181 STORING OIL AND FUEL...................................................181 FILTERS................................................................182 OUTLINE OF ELECTRIC SYSTEM.................................................182 WEAR PARTS LIST................................................................183 FUEL, COOLANT AND LUBRICANTS...................................................184 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...........................184 STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES............................186 TORQUE LIST................................................................186 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................188 MAINTENANCE SCHEDULE CHART.....................................................189 GENERAL MAINTENANCE AND INSPECTION.............................................191 INITIAL 250 HOURS SERVICE..................................................191 CHANGE TRANSMISSION OIL FILTER CARTRIDGE...............................191 REPLACE HYDRAULIC TANK FILTER ELEMENT..................................191 WHEN REQUIRED..............................................................191 CLEANING THE MACHINE...................................................191 ENGINE AIR FILTER......................................................193 CLEANING THE COOLING SYSTEM............................................196 WATER SEPARATOR........................................................198 TRANSMISSION OIL LEVEL.................................................200 AXLE OIL LEVEL.........................................................201 CHECK AXLE VENT........................................................203 AIR CONDITIONER CONDENSER..............................................203 WINDOW WASHING FLUID LEVEL.............................................204 CLEAN RADIATOR FINS....................................................205 CHECK ELECTRICAL INTAKE AIR HEATER.....................................208 REPLACE BOLT-ON CUTTING EDGE...........................................208 REPLACE BUCKET TEETH...................................................209 REPLACING SLOW-BLOW FUSE...............................................210 INSPECTION OF TIRES....................................................211 EVERY SPECIFIC HOURS SERVICE...................................................213 EVERY 50 HOURS OF SERVICE..................................................213 DRAIN SEDIMENT FROM FUEL TANK..........................................213 EVERY 100 HOURS SERVICE....................................................213 LUBRICATE THE REAR AXLE PIVOT PIN......................................213 CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL...................213 CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT..................214 EVERY 250 HOURS OF SERVICE.................................................215 CHECK BATTERY ELECTROLYTE LEVEL........................................215 CHECK PARKING BRAKE....................................................217 ALTERNATOR BELT TENSION................................................217 AIR CONDITIONER COMPRESSOR BELT TENSION................................217 WHEEL HUB NUTS.........................................................218 AIR CONDITIONER RECIRCULATION FILTER...................................218 LUBRICATING POINTS.....................................................219 EVERY 500 HOURS SERVICE....................................................220 CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE.........220 REPLACING FUEL FILTER CARTRIDGE........................................221 EVERY 1000 HOURS SERVICE...................................................222 CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER...........222 CLEAN THE TRANSMISSION CASE VENT.......................................223 LUBRICATING POINTS.....................................................224 CHECKING PARTS OF TURBOCHARGER.........................................224 REPLACE CORROSION RESISTOR CARTRIDGE...................................224 EVERY 2000 HOURS SERVICE...................................................225 CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT.............225 HYDRAULIC TANK VENT ELEMENT............................................227 CHANGE THE AXLE OIL....................................................228 AIR CONDITIONER RECIRCULATION FILTER...................................228 CLEAN PPC CIRCUIT STRAINER.............................................229 CLEAN THE ENGINE VENT ELEMENT..........................................229 CHECK ALTERNATOR, STARTER MOTOR........................................230 CHECK ENGINE VALVE CLEARANCE...........................................230 CHECK TURBOCHARGER.....................................................230 CHECK INJECTOR.........................................................230 CHECK ACCUMULATOR GAS PRESSURE.........................................230 CHECK VIBRATION DAMPER.................................................230 CHECKING BRAKE DISC WEAR...............................................231 EVERY 4000 HOURS SERVICE...................................................232 LUBRICATING POINTS.....................................................232 CHECK WATER PUMP.......................................................233 CHECK AIR CONDITIONER COMPRESSOR.......................................233 REPLACE INJECTOR NOZZLE TIP............................................233 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.....233 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....233 EVERY 8000 HOURS SERVICE...................................................234 REPLACE HIGH-PRESSURE PIPING CLAMP.....................................234 REPLACE FUEL SPRAY PREVENTION CAP......................................234 LONG-TERM STORAGE..............................................................235 BEFORE STORAGE.............................................................235 DURING STORAGE.............................................................235 AFTER STORAGE..........................................................235 TROUBLESHOOTING EMERGENCY PROBLEMS.............................................236 WHEN MACHINE RUNS OUT OF FUEL..............................................236 PROCEDURE FOR BLEEDING AIR.............................................236 TOWING THE MACHINE.............................................................237 WHEN ENGINE CAN BE USED....................................................238 WHEN ENGINE CANNOT BE USED.................................................238 RELEASING THE PARKING BRAKE................................................238 RELEASE PARKING BRAKE WITH EMERGENCY PARKING BRAKE RELEASE VALVE.......238 MECHANICAL RELEASE.....................................................240 EMERGENCY TRAVEL OPERATION.................................................241 SPECIFICATIONS.....................................................................242 SPECIFICATIONS.................................................................243 MACHINE DIMENSIONS AND WEIGHTS.............................................243 TIRES..................................................................243 WORK EQUIPMENT.........................................................244 WEIGHT CHANGES.........................................................244 MACHINE SYSTEMS SPECIFICATIONS.................................................245 ENGINE.....................................................................245 OPTIONS, ATTACHMENTS...............................................................246 MONITOR WITH LOAD METER........................................................247 LOAD METER.................................................................247 SWITCHES...................................................................247 LOAD METER CANCEL SWITCH...............................................248 LOAD METER SUB TOTAL SWITCH............................................248 LOAD METER FUNCTIONS.......................................................249 LOAD METER ADDITION MODE...............................................249 LOAD METER REMAIN MODE.................................................250 SELECTION OF DISPLAY FOR TYPE OF LOAD..................................250 METHOD OF CALIBRATION (ADJUSTING 0 POINT)..............................251 DELETING LOAD METER DISPLAY............................................251 SPEED DISPLAY..........................................................251 USING LOAD METER DISPLAY...................................................252 SETTING ADDITION MODE..................................................252 SETTING THE REMAIN MODE................................................253 TOTAL LOAD DATA DISPLAY................................................255 STOPPING THE CALCULATION...............................................256 PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..................257 PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.................258 SUBTRACTION FUNCTION...................................................260 SETTING THE TIME ON THE CLOCK..........................................263 PRINTER OUTPUT.............................................................265 PRINTOUT MODE..........................................................265 SELECTING THE PRINTOUT MODE............................................266 TORQUE CONVERTER LOCK-UP.......................................................267 GENERAL LOCATIONS..........................................................267 TORQUE CONVERTER LOCK-UP SWITCH........................................267 TORQUE CONVERTER LOCK-UP PILOT LAMP....................................268 METHOD OF OPERATION....................................................268 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...................................269 TRAVEL SPEED WARNING FUNCTION..........................................269 TRAVEL SPEED LIMIT FUNCTION............................................269 WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM................................270 FAN SYSTEM OPERATION.......................................................270 MODE SELECTOR SWITCH...................................................271 FORWARD/REVERSE TIMER..................................................271 REVERSE/FORWARD INDICATOR LAMPS........................................271 FORWARD SETTING KNOB...................................................272 REVERSE SETTING KNOB...................................................272 FORWARD TIME UNIT SELECTOR SWITCH......................................273 SCALE FIGURE SELECTOR SWITCH...........................................273 DIRECTION SELECTOR SWITCH..............................................274 REVERSE PILOT LAMP.....................................................274 CONTROL BOX............................................................274 CLEANING RADIATOR AND COOLER FINS......................................275 HANDLING JOYSTICK STEERING SYSTEM..............................................277 EXPLANATION OF COMPONENTS..................................................277 SHIFT UP, SHIFT DOWN SWITCHES..........................................277 FNR SWITCH.............................................................278 JOYSTICK STEERING LEVER................................................278 JOYSTICK ON/OFF SWITCH.................................................278 HI/LOW SELECTOR SWITCH.................................................278 HORN SWITCH............................................................279 CONSOLE LOCK LEVER.....................................................279 HEIGHT ADJUSTMENT LOCK LEVER...........................................279 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER..................................279 STRUCTURE AND FUNCTION OF JOYSTICK STEERING................................280 JOYSTICK AND STEERING WHEEL OPERATION..................................281 GETTING IN OR OUT OF THE OPERATOR'S CAB................................281 JOYSTICK CONSOLE ADJUSTMENT............................................282 JOYSTICK OPERATION.....................................................282 SELECTING BUCKET AND TIRES.....................................................285
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