Komatsu Wheel Loader WA85-3 Operation & Maintenance Manual SN HA960051 and up – PDF DOWNLOAD

Description

Komatsu Wheel Loader WA85-3 Operation & Maintenance Manual

DESCRIPTION:

Komatsu Wheel Loader WA85-3 Operation & Maintenance Manual 

FOREWORD:

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize 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 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 in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

KOMATSU WHEEL LOADER WA85-3 OPERATION & MAINTENANCE MANUAL SN HA960051 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Wheel Loader WA85-3 Operation & Maintenance Manual 

MAIN MENU...............................................................................................................  0
COVER...................................................................................................................  1
Table of Contents.......................................................................................................  7
Introduction............................................................................................................ 15
	1. Forword.......................................................................................................... 16
	2. Safety Information............................................................................................... 17
	3. Introduction..................................................................................................... 18
		3.1 Features.................................................................................................... 18
		3.2 Breaking in a New Machine................................................................................... 18
	4. Location of Plates, Table to Enter Serial No. and Distributor.................................................... 19
		4.1 Machine Serial No. Plate position........................................................................... 19
		4.2 Engine Serial No. Plate Position............................................................................ 19
		4.3 Table to Enter Serial No. and Distributor................................................................... 19
	5. Why You Should Read these Operating Instructions................................................................. 20
	6. Notes on Safety Regulations...................................................................................... 21
		6.1 Correct Use................................................................................................. 21
		6.2 Safety Notes in the Operating Instructions.................................................................. 21
	7. Equipment........................................................................................................ 22
Loading and Transporting the Machine.................................................................................... 25
	8. Loading and Transporting the Machine............................................................................. 26
		8.1 Securing the Articulated Steering........................................................................... 26
		8.2 Lifting the Machine......................................................................................... 26
		8.3 Driving Machine Onto Loading Area of Transport Vehicle...................................................... 28
		8.4 Securing the Machine During Transport....................................................................... 29
		8.5 After Transport............................................................................................. 29
Safety.................................................................................................................. 31
	9. General Safety Measures.......................................................................................... 33
		9.1 Safety Instructions......................................................................................... 33
		9.2 Safety Devices.............................................................................................. 33
		9.3 Emergency Exit.............................................................................................. 33
		9.4 Clothing and Personal Protection............................................................................ 34
		9.5 Machine Modifications....................................................................................... 34
		9.6 Before You Leave the Driver's Seat.......................................................................... 34
		9.7 Mounting and Dismounting.................................................................................... 34
		9.8 Fire Prevention and Fire Fighting........................................................................... 35
			9.8.1 Fire Extinguisher and First-Aid Kit................................................................... 36
		9.9 Protection Against Asbestos Dust............................................................................ 36
		9.10 Protection Against Injuries................................................................................ 37
		9.11 Working at High Temperatures............................................................................... 37
		9.12 Roll-Over Protection System (ROPS)......................................................................... 38
		9.13 Attachment for Protection Against Falling Objects (FOPS)................................................... 38
		9.14 Attachments................................................................................................ 38
		9.15 Battery.................................................................................................... 39
	10. Safety Measures during Operation................................................................................ 40
		10.1 Before You Start the Engine................................................................................ 40
			10.1.1 Workplace Safety..................................................................................... 40
			10.1.2 In the Driver's Cab.................................................................................. 40
			10.1.3 In-Door Operation.................................................................................... 41
			10.1.4 Gas, Dust, and Inflammable Vapours................................................................... 41
			10.1.5 Mirrors, Windows, and Lighting....................................................................... 41
		10.2 Machine Operation.......................................................................................... 42
			10.2.1 Before You Start the Engine.......................................................................... 42
			10.2.2 Reversing............................................................................................ 42
			10.2.3 Driving.............................................................................................. 43
			10.2.4 Driving On Slopes.................................................................................... 43
			10.2.5 Emergency Lowering System............................................................................ 44
			10.2.6 Working Close to Overhead Power Transmission Lines................................................... 44
				1 - Do not leave the driver's cab. The driver's cab is a "Faraday cage" protecting you from elect....... 45
				2 - Warn other persons and tell them to stay far away from both the power line and your machine......... 45
				3 - Try to move the machine out of the range of influence of the overhead power transmission line....... 45
				4 - Have the power in the line switched off............................................................. 45
			10.2.7 Loading.............................................................................................. 45
				1 - First, dump a heap of earth in front of the hill.................................................... 45
				2 - Fill the bucket with earth again and drive the machine into the heap of earth. Dump the bucke....... 45
			10.2.8 Good Vision.......................................................................................... 45
			10.2.9 Working On Snow...................................................................................... 45
			10.2.10 Height Limitation................................................................................... 45
			10.2.11 Brakes.............................................................................................. 46
			10.2.12 Working On Loose Soil............................................................................... 46
			10.2.13 Working with the Forklift Truck Attachment.......................................................... 47
			10.2.14 Parking the Machine................................................................................. 48
		10.3 Transport.................................................................................................. 49
			10.3.1 Loading and Unloading the Machine.................................................................... 49
			10.3.2 Transport............................................................................................ 49
	11. Safety Measures During Maintenance.............................................................................. 50
		11.1 Personnel.................................................................................................. 50
		11.2 Prior to Start of Maintenance Measures..................................................................... 50
			11.2.1 Warning Sign......................................................................................... 50
			11.2.2 Tools................................................................................................ 50
			11.2.3 Safety-Related Parts................................................................................. 50
			11.2.4 Prior to Start of Inspection and Maintenance......................................................... 51
			11.2.5 Securing the Articulated Steering.................................................................... 51
			11.2.6 Supporting the Work Unit............................................................................. 51
				1 - Park the machine on even ground..................................................................... 51
				2 - Apply the parking brake............................................................................. 51
				3 - Place wheel chocks in front of the wheels to prevent the machine from rolling away.................. 51
				4 - Lower the cutting edge or the teeth of the completely empty bucket onto the ground.................. 51
		11.3 During Maintenance......................................................................................... 52
			11.3.1 Attachments.......................................................................................... 52
			11.3.2 Working Under the Machine............................................................................ 52
			11.3.3 Keeping the Machine Clean............................................................................ 52
			11.3.4 Specific Measures.................................................................................... 52
			11.3.5 Refueling and Topping Off Oil........................................................................ 53
			11.3.6 Coolant.............................................................................................. 53
			11.3.7 Use of Lighting...................................................................................... 54
			11.3.8 High-Pressure Hoses.................................................................................. 54
			11.3.9 Handling High-Pressure Oil........................................................................... 54
			11.3.10 Fan and Belts....................................................................................... 55
			11.3.11 Waste Material...................................................................................... 55
		11.4 Tires...................................................................................................... 56
			11.4.1 Storing Tires........................................................................................ 56
	12. Labeling........................................................................................................ 57
		12.1 Position of Safety Labels.................................................................................. 57
		12.2 Position of Standard Labels................................................................................ 59
			1 - Instrument panel........................................................................................ 63
			2 - Horn button............................................................................................. 63
			3 - Light switch............................................................................................ 63
			4 - Direction indicator lever............................................................................... 63
			5 - Inch-brake pedal........................................................................................ 63
			6 - Unlocking system of left door........................................................................... 63
			7 - Parking brake........................................................................................... 63
			8 - Safety lever for work hydraulic system.................................................................. 63
			9 - Steering column adjustment.............................................................................. 63
			10 - Driving direction switch............................................................................... 63
			11 - Multifunctional lever.................................................................................. 63
			12 - Control lever for special equipment.................................................................... 63
			13 - Accelerator pedal...................................................................................... 63
			14 - Socket................................................................................................. 63
			15 - Unlocking system of right door......................................................................... 63
			16 - Car radio (Option)..................................................................................... 63
			17 - Lever of emergency lowering system..................................................................... 63
			1 - Rocker arm.............................................................................................. 62
			2 - Bucket cylinder......................................................................................... 62
			3 - Bucket.................................................................................................. 62
			4 - Boom.................................................................................................... 62
			5 - Front wheel............................................................................................. 62
			6 - Lift cylinder........................................................................................... 62
			7 - Head lamp............................................................................................... 62
			8 - Rear wheel.............................................................................................. 62
Controls and InDicators................................................................................................. 61
	13. General View of Machine......................................................................................... 62
	14. Controls and Indicators......................................................................................... 63
		14.1 General View............................................................................................... 63
			14.1.1 SWITCHES AND CONTROLS................................................................................ 64
		14.2 Instrument Panel........................................................................................... 65
		14.3 Warning Lights............................................................................................. 66
			1 - Brake fluid warning light............................................................................... 66
			2 - Air filter warning light................................................................................ 66
			3 - Parking brake warning light............................................................................. 66
			4 - Charging current warning light.......................................................................... 66
			5 - Engine oil-pressure warning light....................................................................... 66
		14.4 Control Lamps.............................................................................................. 69
			1 - Driving direction switch indicator...................................................................... 69
			2 - Direction indicator control lamp........................................................................ 69
			3 - Air preheater control lamp.............................................................................. 69
			4 - Heated rear windscreen indicator........................................................................ 69
			5 - High beam control lamp.................................................................................. 69
			6 - Low beam control lamp................................................................................... 69
		14.5 Measuring Indicators....................................................................................... 72
			1 - Fuel level indicator.................................................................................... 72
			2 - Operating hour meter.................................................................................... 72
			3 - Coolant temperature indicator........................................................................... 72
		14.6 Switches................................................................................................... 74
			1 - Switch and control lamp of hazard flashers.............................................................. 74
			2 - Switch of front windscreen wiper and washer............................................................. 74
			3 - Switch of rear windscreen wiper and washer.............................................................. 74
			4 - Direction indicator lever............................................................................... 74
			5 - Horn button............................................................................................. 74
			6 - Light switch............................................................................................ 74
			7 - Driving direction switch................................................................................ 74
			8 - Start switch............................................................................................ 74
			9 - Fan rotary switch, for ventilation and heating.......................................................... 74
			10 - Heating temperature switch............................................................................. 74
			11 - Heated rear windscreen switch.......................................................................... 74
			12 - Switch and control lamp for driving range up to 12.43 mph (20 km/h).................................... 74
			13 - Working lights switch and control lamp................................................................. 74
			14 - Switch for inside lighting (without fig.).............................................................. 74
			15 - Battery main switch (option, without fig.)............................................................. 74
		14.7 Control Levers, Pedals..................................................................................... 80
			1 - Brake pedal............................................................................................. 80
			2 - Parking brake........................................................................................... 80
			3 - Safety lever to close or open the work hydraulic system................................................. 80
			4 - Steering column adjustment.............................................................................. 80
			5 - Accelerator pedal....................................................................................... 80
			6 - Multifunctional lever................................................................................... 80
			7 - Control lever for special equipment..................................................................... 80
			8 - Switching lever for bucket (without fig.)............................................................... 80
		14.8 Articulated Steering Catch................................................................................. 85
		14.9 Traction Device............................................................................................ 85
		14.10 Socket.................................................................................................... 85
		14.11 Door Unlocking System..................................................................................... 86
		14.12 Alarm Horn for Reverse Driving............................................................................ 86
			20 - Brake fluid warning light.............................................................................. 64
			21 - Air filter warning light............................................................................... 64
			22 - Parking brake warning light............................................................................ 64
			23 - Charging current warning light......................................................................... 64
			24 - Driving direction switch indicators.................................................................... 64
			25 - Engine oil-pressure warning light...................................................................... 64
			26 - Direction indicator control lamp....................................................................... 64
			27 - Air preheater control lamp............................................................................. 64
			28 - Heated rear windscreen indicator....................................................................... 64
			29 - Working lights switch and control lamp................................................................. 64
			30 - Driving range switch and control lamp for speed up to 12.43 mph (20 km/h).............................. 64
			31 - Coolant temperature indicator.......................................................................... 64
			32 - Operating hour meter................................................................................... 64
			33 - High beam control lamp................................................................................. 64
			34 - Low beam control lamp.................................................................................. 64
			35 - Fuel supply indicator.................................................................................. 64
			36 - Rear windscreen wiper switch and washer................................................................ 64
			37 - Front windscreen wiper switch and washer............................................................... 64
			38 - Hazard flasher switch and control lamp................................................................. 64
Operation............................................................................................................... 87
	15. Running in the Machine.......................................................................................... 88
	16. Preparing the Machine Start..................................................................................... 89
		16.1 Visual Checks.............................................................................................. 89
			16.1.1 Before you start the engine.......................................................................... 89
			16.1.2 Before starting working with the machine............................................................. 89
	17. Adjustments Prior to Machine Start.............................................................................. 91
		17.1 Adjusting the Driver’s Seat................................................................................ 91
		17.2 Adjusting the Steering Column.............................................................................. 92
			1 - Push down the locking lever (2)......................................................................... 92
			2 - Adjust it in such a way that you can reach the steering wheel from a comfortable seating posi........... 92
			3 - Pull up the locking lever again to lock the steering column in this position............................ 92
		17.3 Adjusting the Armrest...................................................................................... 92
			1 - Loosen the screw (2).................................................................................... 92
			2 - Either pull out or push back the armrest to reach the multifunctional lever. Your forearm sho........... 92
			3 - Re-tighten the screw.................................................................................... 92
		17.4 Adjusting the Rear-View Mirrors............................................................................ 92
		17.5 Adjusting the Heating and Ventilation System............................................................... 93
			17.5.1 Adjusting the ventilation system..................................................................... 93
			17.5.2 Adjusting the heating system......................................................................... 93
		17.6 Putting on the Safety Belt................................................................................. 94
			17.6.1 Putting on the safety belt........................................................................... 94
				1 - Sit down on the driver's seat....................................................................... 94
				2 - Slowly and continuously pull out the belt........................................................... 94
				3 - Insert the lock tongue into the lock socket until the lock engages.................................. 94
				4 - Then, pull the belt to check whether or not the lock tongue is fully engaged........................ 94
			17.6.2 Taking off the safety belt........................................................................... 94
	18. Starting and Switching Off the Engine........................................................................... 95
		18.1 Starting the Engine........................................................................................ 95
			1 - Ensure parking brake is engaged......................................................................... 95
			2 - Set the drive direction switch to its neutral position ‘N’.............................................. 95
			3 - Turn the ignition key into the operating position ‘I’. The fuel supply (1) is indicated. The ........... 95
			4 - Press down slightly the accelerator pedal............................................................... 95
			5 - If the control lamp of the air preheater has gone out, you can turn the ignition key to the s........... 95
			6 - Release the ignition key as soon as the engine started. It automatically returns to the opera........... 95
			7 - Check whether all warning lights have gone out.......................................................... 95
			18.1.1 Warming up the engine................................................................................ 96
				1 - Press down slightly the accelerator pedal and let the engine run without load at medium speed....... 96
				2 - Proceed as follows in order to heat up the hydraulic oil at low ambient temperatures: Allow t....... 96
				3 - While the engine is warming up, observe all measuring instruments and warning lights and elim....... 96
				4 - Let the engine run with lightweight load further until the engine coolant temperature indicat....... 96
				5 - Ensure that the exhaust gas colour is normal and that the exhaust pipe produces neither abnor....... 96
		18.2 Switching Off the Engine................................................................................... 97
			1 - Check the temperature of the engine with the help of the coolant temperature indicator (1).............. 97
			2 - If the engine is overheated, you must let it run at medium speed or 5 minutes before you swit........... 97
			3 - Lower the work unit..................................................................................... 97
			4 - Turn the ignition key into its stop position ‘0’ in order to switch off the engine...................... 97
			5 - Pull the ignition key from the start switch............................................................. 97
	19. Driving......................................................................................................... 98
		19.1 Start-Up................................................................................................... 98
			1 - Start up the engine as described in chapter "18.1 Starting the Engine".................................. 98
			2 - Release the work hydraulic system by setting the locking lever of the work hydraulic system t........... 98
			3 - Raise the work unit to its transport position. If the work unit is in transport position, the........... 98
			4 - Press down the brake pedal and hold it in this position................................................. 98
			5 - Release the parking brake. Press the celebration adjustment knob to this at the parking brake........... 98
			6 - Set the drive direction switch to the desired direction setting......................................... 98
			7 - Release the brake pedal and press down the accelerator pedal at the same time in order to sta........... 98
			19.1.1 Starting the machine on slopes....................................................................... 99
				1 - Start up the engine as described in chapter "18. Starting and Switching Off the Engine"............. 99
				2 - Make sure that the parking brake is pulled. The parking brake warning light lights up............... 99
				3 - Press down the brake pedal.......................................................................... 99
				4 - Release the parking brake........................................................................... 99
				5 - Set the drive direction switch to the desired direction setting..................................... 99
				6 - Press down the accelerator pedal and release slowly the brake pedal at the same time in order....... 99
		19.2 Changing the Driving Direction............................................................................. 99
		19.3 Reverse Driving............................................................................................100
		19.4 Turning....................................................................................................100
			19.4.1 Turning on slopes, embankments or hill flanks........................................................100
		19.5 Braking....................................................................................................101
			19.5.1 Pulling the parking brake............................................................................101
				1 - Press the locking button............................................................................101
				2 - Pull up the parking brake lever.....................................................................101
				3 - Release the locking button. The control lamp of the parking brake lights up.........................101
			19.5.2 Releasing the parking brake..........................................................................101
				1 - Lift up the parking brake lever a little............................................................101
				2 - Press the locking button............................................................................101
				3 - Push the parking brake lever down...................................................................101
				4 - Release the locking button. The control lamp of the parking brake goes out..........................101
			19.5.3 Braking with the service brake.......................................................................101
			19.5.4 If the service brake breaks down.....................................................................101
			19.5.5 Braking on slopes....................................................................................102
		19.6 Stopping...................................................................................................102
			1 - Release the accelerator pedal and press down the brake pedal............................................102
			2 - Set the drive direction switch into its neutral position ‘N’............................................102
			3 - Apply the parking brake.................................................................................102
			4 - Lower the work unit onto the ground.....................................................................102
			5 - Protect the work hydraulic system against unintentional activation by turning the locking lev...........102
			19.6.1 Parking the machine on a slope.......................................................................102
		19.7 Longer-Distance Driving....................................................................................103
	20. Operating the Machine...........................................................................................104
		20.1 Preparing the Work Equipment...............................................................................104
			20.1.1 Selecting a work unit................................................................................104
			20.1.2 Picking up the work unit (except multi-purpose bucket)...............................................104
				1 - Make sure that the change-over lever for the additional control unit is in position '2' (fig........104
				2 - Start the engine....................................................................................104
				3 - Unlock the quick-change unit by setting the control lever for special equipment into position.......104
				4 - Lift the boom slightly by setting the multi-function lever into position ‘H’ (fig. 75_016)..........104
				5 - Tilt the quick-change unit slightly to the front by setting the multi-function lever into pos.......104
				6 - Drive the machine to the work unit until the quick-change unit (3) is below the pickup hooks .......104
				7 - Tip in the quick-change unit until the work unit is connected to the limit stops on the the q.......104
				8 - Lock the quick-change unit by setting the control lever for special equipment into position ‘.......104
				9 - Check whether the work unit is completely locked in by tipping it in and then dumping it............104
			20.1.3 Removing the work unit...............................................................................105
				1 - Lower the work unit onto level ground...............................................................105
				2 - Unlock the quick-change unit by setting the control lever for special equipment into position.......105
				3 - Set the quick-change unit into the dumping position ‘A’ (fig. 75_016) using the multi-functio.......105
				4 - Make sure that nobody is behind the machine and drive the machine away from the work unit...........105
			20.1.4 Picking up the multi-purpose bucket..................................................................105
				1 - Set the change-over lever for the additional control unit into position '2' (fig. 75_160)...........105
				2 - Start the engine....................................................................................105
				3 - Unlock the quick-change unit by setting the control lever for special equipment into position.......105
				4 - Lift the boom slightly by setting the multi-function lever into position ‘H’ (fig. 75_016)..........105
				5 - Tilt the quick-change unit slightly to the front by setting the multi-function lever into pos.......105
				6 - Drive the machine to the work unit until the quick-change unit (1) is below the pickup hooks .......105
				7 - Tip in the quick-change unit until the work unit is connected to the limit stops on the the q.......105
				8 - Lock the quick-change unit by setting the control lever for special equipment into position ‘.......105
				9 - Connect the hydraulic hoses of the multi-purpose bucket to the quick attach couplers (2) (fig.......106
				10 - Lock the quick-change unit by setting the control lever for special equipment into position .......106
				11 - Set the change-over lever for the additional control circuit into position '1' (fig. 75_160).......106
				12 - Check whether the work unit is completely locked in by tipping it in and then dumping it...........106
			20.1.5 Removing the multi-purpose bucket....................................................................107
				1 - Lower the multi-purpose bucket onto level ground....................................................107
				2 - Turn the change-over lever for the additional control circuit to position ‘2’ (fig. 75_160).........107
				3 - Unlock the quick-change unit by setting the control lever for special equipment into position.......107
				4 - Loosen the hydraulic hoses of the multi-purpose bucket from the quick attach couplers...............107
				5 - Set the quick-change unit into the dumping position ‘A’ (fig. 75_016) using the multi-functio.......107
				6 - Make sure that nobody is behind the machine and drive the machine away from the work unit...........107
		20.2 Tire Service Life..........................................................................................108
			20.2.1 Level indicator for the bucket.......................................................................108
		20.3 Loading....................................................................................................109
			20.3.1 Removing piled up soil...............................................................................109
				1 - Drive in straight line to the piled up soil.........................................................109
				2 - While driving forward, lower the bucket rapidly until it reaches a height of approx. 11.8 in .......109
				3 - Then, proceed with slowly lowering the bucket onto the ground.......................................109
				4 - Brake right in front of the material to be removed using the service brake, while pressing do.......109
				5 - Press down the accelerator pedal and drive the bucket into the material to be removed. In ord.......110
				6 - To prevent that the bucket digs in too deep into the material to be removed, you must lift th.......110
				7 - Tip in the bucket...................................................................................110
				8 - If there is too much material inside the bucket, you must briefly tip it in, dump it and lowe.......110
			20.3.2 Excavation works.....................................................................................111
				1 - Drive up to the soil heap in a straight line........................................................111
				2 - Slow down the machine using the service brake while keeping the accelerator pedal pressed dow.......111
				3 - Bend the bucket edge slightly down..................................................................111
				4 - While driving forward, move slightly the multi-function lever of the boom in order to remove .......111
				5 - Move the multi-function lever of the boom slightly up and down to reduce the resistance durin.......111
		20.4 Transporting...............................................................................................112
		20.5 Dumping / Unloading........................................................................................112
			20.5.1 Loading in diagonal direction........................................................................112
			20.5.2 V-shaped loading.....................................................................................113
			20.5.3 Piling up material...................................................................................113
		20.6 Planing....................................................................................................114
			20.6.1 Filling up...........................................................................................114
			20.6.2 Taking off soil......................................................................................114
			20.6.3 Cutting the Ground...................................................................................114
		20.7 Working With the Forklift Truck Attachment.................................................................115
			20.7.1 Picking up the load..................................................................................115
				1 - Approach slowly the load to be picked up............................................................115
				2 - Drive so far under the load until it touches the fork back of the forklift truck attachment.........115
				3 - Tip in slightly the forklift truck attachment so that the load cannot fall down.....................115
				4 - Lower the boom to its transport position. The two red arrows of the transport position markin.......115
				5 - Then lift the load to the appropriate height only shortly before you reach the stacking surfa.......115
				6 - Set the load surface slowly and from above onto the stacking........................................115
				7 - Slowly lower the boom so far that you can pull out the fork tines below the load....................115
				8 - Make sure that nobody is behind the machine and drive off backwards from the deposit surface........115
		20.8 Precautions For Special Operations.........................................................................116
			20.8.1 Working in water.....................................................................................116
			20.8.2 Working on snow......................................................................................116
			20.8.3 Dumping on steep slopes..............................................................................116
			20.8.4 Working in the vicinity of electrical overhead lines.................................................116
			20.8.5 Operation on slopes..................................................................................116
			20.8.6 Working on loose soil................................................................................116
		20.9 After the work is finished.................................................................................116
			1 - Walk around the machine and visually inspect the work unit, the car body and the chassis. In ...........116
			2 - Fill up the fuel tank...................................................................................116
			3 - Remove highly flammable material from the engine room since it represents a fire risk...................116
			4 - Clean roughly the chassis landing gear..................................................................116
		20.10 Instructions for Winter Operation.........................................................................117
			20.10.1 Before the cold season..............................................................................117
			20.10.2 After Operation.....................................................................................117
			20.10.3 After the cold season...............................................................................117
		20.11 Longer Standstill Periods of the Machine..................................................................117
			20.11.1 Before the standstill...............................................................................117
			20.11.2 During the standstill...............................................................................118
			20.11.3 After the standstill................................................................................118
Troubleshooting.........................................................................................................119
	21. Troubleshooting.................................................................................................120
		21.1 Warning Lights and Indicators..............................................................................120
		21.2 Electrical System..........................................................................................121
		21.3 Engine.....................................................................................................122
		21.4 Hydraulic system...........................................................................................125
		21.5 Brakes.....................................................................................................127
		21.6 Axles......................................................................................................128
		21.7 Emergency Steering Characteristics.........................................................................129
		21.8 Emergency Lowering System..................................................................................129
			1 - Ensure that nobody is standing under the work unit......................................................129
			2 - Turn the lever of the emergency lowering system to position '2'. The work unit is lowered, or...........129
			3 - Turn the lever of the emergency lowering system back to position '1'....................................129
		21.9 Starting the Engine with a Battery Jumper Cable............................................................130
			21.9.1 Connecting the Jumper Cable..........................................................................130
				1 - Turn the start switch of the defective machine to '0' (OFF).........................................130
				2 - Connect one clamp of the battery jumper cable to the positive terminal (+) of the discharged .......130
				3 - Connect the other clamp of the battery jumper cable to the positive terminal (+) of the charg.......130
				4 - Connect one clamp of the battery jumper cable to the negative terminal (-) of the charged bat.......130
				5 - Connect the other clamp of the battery jumper cable to the engine block of the machine with t.......130
		21.10 Starting the Engine.......................................................................................131
			21.10.1 Disconnecting the Battery Jumper Cable..............................................................131
				1 - Disconnect one clamp of the battery jumper cable from the engine block..............................131
				2 - Disconnect the other clamp of the battery jumper cable from the negative terminal (-) of the .......131
				3 - Disconnect the clamp of the battery jumper cable from the positive terminal (+) of the charge.......131
				4 - Disconnect the other clamp of the battery jumper cable from the positive terminal (+) of the .......131
		21.11 Towing the Machine........................................................................................132
			1 - Set the driving-direction switch to position 'N'........................................................132
			2 - Loosen both screws (1) and remove the cover plate (2)...................................................132
			3 - Remove protecting caps from the valves..................................................................132
			4 - Hold the valve (3) in position, using a wrench..........................................................132
			5 - Loosen the counter-nut (4) an re-insert the threaded stud (5) clockwise, using a hexagonal so...........132
			6 - Re-tighten firmly the counter-nut (4). Perform these operations on both valves..........................132
		21.12 Towing a Machine with Defective Brakes....................................................................133
Maintenance.............................................................................................................135
	22. Maintenance Basics..............................................................................................136
		22.1 Preparing the Machine for Maintenance......................................................................136
			1 - Park the machine on solid and level ground..............................................................136
			2 - Set the machine to the specified position for maintenance and repair....................................136
			3 - Lower the work unit to the ground and position it as shown in the drawing...............................136
			4 - Set all control levers to either the neutral or the hold position '0'...................................136
			5 - Turn the safety lever of the work hydraulic system to position '1'......................................136
			6 - Take out the start key and store it in a safe place.....................................................136
			7 - Apply the parking brake.................................................................................136
			8 - Apply the warning sign you received together with the tools at the start switch.........................136
			9 - Put wheel chocks in front and behind the wheels.........................................................136
			10 - Secure the articulated steering with the articulated steering catch....................................136
			11 - If required, remove dirt...............................................................................136
		22.2 Cleaning the Machine.......................................................................................137
			1 - Park the machine on level ground........................................................................137
			2 - Apply the parking brake.................................................................................137
			3 - Place wheel chocks in front of the wheels to prevent the machine from rolling away......................137
			4 - With the bucket in its dumping position, lower the bucket onto the ground with either its cut...........137
			22.2.1 Precautionary Measures When Cleaning the Machine.....................................................137
			22.2.2 Fire Prevention......................................................................................137
		22.3 Working-Area-Dependent Maintenance.........................................................................137
			22.3.1 Muddy or Wet Working Areas...........................................................................137
			22.3.2 Dusty Working Areas..................................................................................137
		22.4 Lubricants and Operating Agents............................................................................138
			22.4.1 Draining Hot Lubricants and Fluids...................................................................138
			22.4.2 Checking the Oil Level and Changing Oil..............................................................138
			22.4.3 Changing Filters.....................................................................................138
			22.4.4 Refuelling and Topping off Oil.......................................................................138
			22.4.5 Oil..................................................................................................138
			22.4.6 Lubricating Grease...................................................................................139
			22.4.7 Biodegradable Hydraulic Oil and Lubricating Grease...................................................139
			22.4.8 Fuel.................................................................................................139
			22.4.9 Storage of Oil and Fuel..............................................................................139
			22.4.10 Coolants............................................................................................140
			22.4.11 Windscreen Washer Liquid............................................................................140
			22.4.12 Table of Lubricants and Operating Agents............................................................142
			22.4.13 Lubrication chart...................................................................................143
		22.5 Replacing Safety-Related Parts.............................................................................144
			22.5.1 Welding Instructions.................................................................................144
		22.6 Spare Parts and Consumable Components......................................................................145
		22.7 Electrical System..........................................................................................146
			1 - Checking the tension of the generator belt,.............................................................146
			2 - Checking the generator belt for damage and wear, and....................................................146
			3 - Checking the acid level in the battery..................................................................146
			22.7.1 Fuses................................................................................................146
			22.7.2 Fuse Assignment......................................................................................146
			22.7.3 Slow-Blowing Fuses...................................................................................147
		22.8 Tires......................................................................................................148
			22.8.1 Tire Components......................................................................................148
				1 - Steel Cord Belt.....................................................................................148
				2 - Radial Carcass......................................................................................148
				3 - Bead Core...........................................................................................148
				4 - Liner...............................................................................................148
				5 - Diagonal Carcass....................................................................................148
				6 - Bead Cores..........................................................................................148
			22.8.2 Checking the Tires...................................................................................148
			22.8.3 Checking the Tire Pressure...........................................................................148
		22.9 Tools......................................................................................................150
		22.10 Torque for Standard Nuts and Bolts........................................................................151
	23. Maintenance Schedule............................................................................................153
	24. Maintenance Prior to Start......................................................................................155
		24.1 Visual Checks..............................................................................................155
		24.2 Cooling System, Checking the Coolant Level, Topping off Coolant............................................155
			1 - Open the engine hood....................................................................................155
			2 - Check whether the coolant level in the expansion tank is between the FULL and LOW markings. I...........155
			3 - Remove the cover cap of the overflow tank...............................................................155
			4 - Top coolant until the level reaches up to the FULL marking..............................................155
			5 - After topping, firmly close the cover cap. If the expansion tank is empty again after a short...........155
		24.3 Engine, Checking the Oil Level, Topping off Oil............................................................156
			1 - Pull out the oil dipstick (1) and wipe off the oil with a clean cloth...................................156
			2 - Completely re-insert the oil dipstick and pull it out again after a few seconds. The oil leve...........156
			3 - If the oil level does not reach up to the (L) marking, top off engine oil...............................156
			4 - Wait three minutes before you check the oil level again. If the oil level is above the (H) ma...........156
			5 - Close the oil filler (2)................................................................................156
		24.4 Engine, Draining Off Oil...................................................................................157
			1 - Loosen the screw (1) at the bottom cover plate (2) and swivel the cover plate to the side...............157
			2 - Put the oil trough to pan...............................................................................157
			3 - Remove the cover cap (3) of the drain screw.............................................................157
			4 - Unscrew the drain screw (4).............................................................................157
			5 - Let the excess oil flow off.............................................................................157
			6 - Screw in the drain screw................................................................................157
			7 - Check the oil level again...............................................................................157
			8 - Put on the cover cap....................................................................................157
			9 - Fasten the bottom cover plate with the screw............................................................157
		24.5 Checking the Fuel Level, Refueling.........................................................................158
			1 - Turn the start switch to the operating position 'I' and check the fuel level indicated on the...........158
			2 - Then, return the start switch to the stop position '0'..................................................158
			3 - If required, refuel via the filler (1)..................................................................158
			4 - After refueling, firmly close the filler................................................................158
		24.6 Checking the Controls......................................................................................159
			1 - Turn the start switch to the operating position 'I'.....................................................159
			2 - Check that the following alarm and control indicators are on until the engine is started:...............159
			3 - Check that the fuel level indicator (5) indicates the fuel level in the fuel tank.......................159
		24.7 Checking the Parking Brake.................................................................................160
			24.7.1 Test Conditions......................................................................................160
			24.7.2 Test Procedure.......................................................................................160
				1 - Start the engine, set the machine to straight driving, and drive the machine with an empty bu.......160
				2 - Stop the machine with the service brake and do not release your foot again to keep the servic.......160
				3 - Lower the bucket....................................................................................160
				4 - Set the driving direction switch (1) to its neutral position 'N'....................................160
				5 - Switch off the engine...............................................................................160
				6 - Apply the parking brake (2) and slowly release the pedal of the service brake.......................160
		24.8 CHecking the Service Brake.................................................................................160
		24.9 Checking the Electrical Connections........................................................................161
		24.10 Other Maintenance Measures Prior to Start.................................................................161
	25. Maintenance Every 10 Operating Hours............................................................................162
		25.1 Lubrication................................................................................................162
			1 - Before you start maintenance work, park and secure the machine as described in the chapter "1...........162
			2 - Clean the grease nipples marked by arrows...............................................................162
			3 - Use a grease gun to fill the grease nipples with a sufficient volume of lubricating grease..............162
			4 - Remove the used lubricating grease that is pressed out of the bearings..................................162
	26. Maintenance After the First 50 Operating Hours..................................................................163
		26.1 Engine, Changing Oil and Replacing the Oil Filter Cartridge................................................163
			1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...........163
			2 - Loosen the screw (1) at the bottom cover plate (2) and swivel the cover plate to the side...............163
			3 - Put the oil trough under the drain screw (4)............................................................163
			4 - Remove the cover cap (3) of the drain screw.............................................................163
			5 - Screw the drain hose (5) onto the drain plug (4). This will at the same time cause the drain ...........163
			6 - Let the oil drain off into the oil trough...............................................................163
			7 - Check the removed oil for metal parts or undesired material. If the oil contains such particl...........163
			8 - Remove the drain hose (5), this will cause the drain valve (4) to close.................................163
			9 - Screw on the cover cap (3)..............................................................................163
			10 - Fasten the bottom cover plate with the screw...........................................................163
			26.1.1 Replacing the Oil Filter Cartridge...................................................................164
				11 - Turn the filter screwdriver counterclockwise to unscrew the filter cartridge (1)...................164
				12 - Clean the filter holder. Completely fill up the new filter cartridge with engine oil. Slight.......164
				13 - When installing the filter cartridge, make sure that the sealing surface of the cartridge sl.......164
				14 - After replacing the filter cartridge, fill in clean engine oil until the oil level reaches u.......164
				15 - Close the oil filler (2)...........................................................................164
				16 - Let the engine run in idle for about five minutes and check whether oil is leaking out.............164
				17 - Switch off the engine..............................................................................164
				18 - Wait about ten minutes, then check the oil level again. The oil level must be between the 'H.......164
		26.2 V-Belt, Checking the Condition.............................................................................165
		26.3 V-Belt, Checking and Adjusting the Tension.................................................................165
			1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...........165
			2 - Press down the V-belt in the middle of the longest straight part. You should be able to press...........165
			3 - Loosen the fastening screw (1) at the generator.........................................................165
			4 - Loosen the connecting screw (2) between the generator and the guide rail................................165
			5 - Loosen the fastening screw (3) at the guide rail........................................................165
			6 - Tilt the generator to adjust the tension of the V-belt..................................................165
			7 - Fasten the generator and the guide rail.................................................................165
			8 - Check the tension of the V-belt and re-adjust it, if required...........................................165
		26.4 Hydraulic System, Replacing the Filter Insert..............................................................166
			1 - Lower the work equipment onto the floor.................................................................166
			2 - Park the machine........................................................................................166
			3 - Turn the inlet and ventilation screw (1) several revolutions to let the pressure escape.................166
			4 - Clean the surface of the filter cap (2) and the area around the filter cap..............................166
			5 - Unscrew the filter cap..................................................................................166
			6 - Pull out the filter element (3) at the handle (4) ......................................................166
			7 - Pull the filter element off the handle and dispose of the filter element................................166
			8 - Clean the inner surface of the filter housing. Before you start cleaning, check that there is...........166
			9 - Put the handle onto the new filter element..............................................................166
			10 - Insert the new filter element into the housing.........................................................166
			11 - Screw on the filter cap and tighten it with 2.039 kgm (20 Nm)..........................................166
			12 - Ventilate the system at the tank according to the specification (see "32.2 Bleeding the Hydr...........166
			13 - Perform a test run and check that the system is tight..................................................166
		26.5 Checking and Tightening the Wheel Nuts.....................................................................167
		26.6 Front and Rear Axle, Changing Oil..........................................................................168
			26.6.1 Planet gear..........................................................................................168
				1 - Move the machine until the check drill hole (1) of the planet gear at the wheel that you want.......168
				2 - Put the oil trough under the oil discharge hole.....................................................168
				3 - Unscrew the screw plug (1) and let the oil flow off.................................................168
				4 - Turn the wheel to bring the drill hole of the planet gear into horizontal position..................168
				5 - Top up the planet gear with oil, until the oil reaches up to the bottom edge of the check dri.......168
				6 - Clean the screw plug and replace the gaskets........................................................168
				7 - Re-tighten firmly the screw plug....................................................................168
				8 - Change the oil in the planet gear for the other wheel as described under the points 3 through 7.....168
			26.6.2 Differential.........................................................................................168
				1 - Unscrew the screw plugs (1) and (2) at the front axle and let the oil flow off......................168
				2 - Clean the screw plugs and replace the gaskets.......................................................168
				3 - Re-tighten firmly the screw plug....................................................................168
				4 - Top up with oil, until the oil reaches up to the bottom edge of the check drill hole of screw.......168
				5 - Re-tighten firmly the screw plug (2)................................................................168
				6 - Unscrew the screw plugs (4) and (5) at the rear axle and let the oil flow off. Then, proceed .......168
		26.7 Transfer Gear - Changing Oil...............................................................................169
			1 - Before you start maintenance work, park and secure the machine as described in the chapter "2...........169
			2 - Clean the surfaces of the screw plugs (1) and (2) and the area around the screw plugs...................169
			3 - Unscrew the screw plugs.................................................................................169
			4 - Let the oil flow off....................................................................................169
			5 - Clean the screw plugs and replace the gaskets...........................................................169
			6 - Tightly screw in the screw plug (2).....................................................................169
			7 - Fill in oil via the check drill hole (1), until the oil reaches up to the bottom edge of the ...........169
			8 - Tightly screw in the screw plug (1).....................................................................169
	27. Maintenance Every 50 Operating Hours............................................................................170
		27.1 Checking the cooling System, coolant level in the radiator and expansion tank..............................170
			1 - Stop the engine and let it cool down....................................................................170
			2 - Open the engine cover...................................................................................170
			3 - Turn the radiator cap (arrow) slowly to the first stop and let the pressure escape. Then pres...........170
			4 - Check that the radiator is filled up to the overflow with coolant. If not then top off to the...........170
			5 - After topping off, fit the radiator cap and tighten.....................................................170
			6 - Check that the coolant level in the expansion tank is between the marks full and low....................170
			7 - Top off to the full mark if required....................................................................170
			8 - After topping off, refit the tank cap and tighten.......................................................170
		27.2 Draining Off Water and Dirt Deposits From the Fuel Tank....................................................171
			1 - Place a container under the drain plug of the fuel tank (see arrow).....................................171
			2 - Open the drain plug, drain off water and dirt...........................................................171
			3 - Close the drain plug when clean fuel starts to leak out.................................................171
		27.3 Checking the Service Brake and Oil Level, Refilling Oil....................................................171
			1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...........171
			2 - Check the brake fluid level at the expansion tank. The oil level must be 0.394 in (10 mm) to ...........171
			3 - If the oil level is too low, fill prescribed oil into the expansion tank................................171
			4 - If you detect a significant oil loss, inform your local Komatsu dealer..................................171
		27.4 Checking the Battery and Acid Level........................................................................172
			1 - For maintenance operations, park and secure the machine as described in chapter "22.1 Prepari...........172
			2 - Check the battery and pole terminals for proper fit.....................................................172
			3 - Clean the environment of the plugs......................................................................172
			4 - Remove all plugs and check whether the battery acid is at the acid level markings. Refill dis...........172
			5 - Measure the specific density of the battery acid and read off the battery charging using the ...........172
			6 - Recharge insufficiently charged batteries...............................................................172
			7 - Lock the cells with the cleaned plugs.Re-Charging the Battery...........................................172
			27.4.1 Re-charging a built-in battery.......................................................................173
				1 - The battery may be overheated.......................................................................173
				2 - Decrease in the battery acid volume.................................................................173
				3 - Damage of the electrode plates......................................................................173
		27.5 Lubrication................................................................................................174
			27.5.1 Lubricating points of the work equipment.............................................................174
				1 - Park and secure machine for the maintenance operations as described in chapter "22.1 Preparin.......174
				2 - Clean the grease nipples which are indicated by the arrows..........................................174
				3 - Use a grease gun to press sufficient grease into the grease nipples.................................174
				4 - Remove the old grease which is extruding at the bearings............................................174
	28. Maintenance Every 100 Operating Hours...........................................................................175
		28.1 Draining the Water Separator, Removing Water and Dirt Deposits.............................................175
			1 - Screw out the drain plug (2)............................................................................175
			2 - Let the water run off...................................................................................175
			3 - Screw in the drain plug and tight it....................................................................175
			4 - Check for tightness.....................................................................................175
	29. Maintenance Every 250 Operating Hours...........................................................................176
		29.1 Changing the Engine Oil and Oil Filter Cartridge...........................................................176
		29.2 Checking the V-Belt Condition..............................................................................176
		29.3 Checking and Adjusting the V-belt Tension..................................................................176
		29.4 Lubrication................................................................................................176
			29.4.1 Lubricating points of the steering cylinder..........................................................176
				1 - For maintenance operations, park the machine as described in chapter "22.1 Preparing the Mach.......176
				2 - Clean the grease nipples which are indicated by the arrows..........................................176
				3 - Use a grease gun to press sufficient grease into the grease nipples.................................176
				4 - Remove the old grease which is extruding at the bearings............................................176
		29.5 Front and Rear Axle, Checking the Oil Level................................................................177
			29.5.1 Planet gear..........................................................................................177
				1 - Move the machine until the oil level marking at the planetary gearing of the wheel which you .......177
				2 - Unscrew the locking screw (1) of the drill hole.....................................................177
				3 - Check the oil level. The oil level must reach up to the bottom edge of the check drill hole.........177
				4 - If the oil level is too low, top off oil via the check drill hole of the screw plug. For deta.......177
				5 - Tightly screw in the screw plug.....................................................................177
				6 - Check the oil level at the other wheel of the front and rear axle. For this purpose, proceed .......177
			29.5.2 Differential.........................................................................................177
				1 - Unscrew the locking screw (2) of the drill hole at the front axle. Check the oil level as des.......177
				2 - Unscrew the locking screw (2) of the drill hole at the rear axle. Check the oil level as desc.......177
		29.6 Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter I...............178
			29.6.1 Structure of the air filter..........................................................................178
			29.6.2 Maintenance demand...................................................................................178
			29.6.3 Removing the filter cartridge........................................................................178
				1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t.......178
				2 - Open the twistlocks on the cover of the air filter housing (2)......................................178
				3 - Remove the cover of air filter housing..............................................................178
				4 - Pull out the filter cartridge (3)...................................................................178
			29.6.4 Cleaning or exchanging the filter cartridge..........................................................179
			29.6.5 Checking the filter cartridge........................................................................180
			29.6.6 Assembling the air filter cartridge..................................................................180
				1 - Check the safety filter for proper fit..............................................................180
				2 - Insert the filter cartridge into filter housing in such a way that the seal of the insert loc.......180
				3 - Assemble the air filter cap.........................................................................180
		29.7 Cleaning the Radiator Segments.............................................................................180
	30. Maintenance Every 500 Operating Hours...........................................................................181
		30.1 Changing the Fuel Filter and Filter Element................................................................181
			1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...........181
			2 - Clean the area around the fuel filter (1)...............................................................181
			3 - Unscrew the filter element counterclockwise with the filter screwdriver.................................181
			4 - Clean the filter head...................................................................................181
			5 - Fill up the new filter element with clean fuel..........................................................181
			6 - Lubricate the sealing faces of the filter element lightly with engine oil...............................181
			7 - During reassembly, re-tighten the filter element manually, until the seal is fitting. Then re...........181
			8 - Then purge the fuel system..............................................................................181
			9 - Start the engine and check for leaks....................................................................181
			30.1.1 Bleeding the Fuel System.............................................................................182
				1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t.......182
				2 - Loosen the vent screw (1) at the water separator....................................................182
				3 - Unlock the fuel pump (2) by pressing the cover down and swivelling it out of the way................182
				4 - Operate fuel pump until bubble-free fuel leaks out at the vent screw................................182
				5 - Re-tighten the vent screw...........................................................................182
				6 - Loosen the vent screw (4) at the fuel filter (3)....................................................182
				7 - Operate the fuel pump until bubble-free fuel leaks out at the vent screw............................182
				8 - Re-tighten vent screw...............................................................................182
				9 - Re-lock the cover of the fuel pump..................................................................182
				10 - Start up the engine and bleed the lines, one after the other, while engine is running until .......182
		30.2 Changing the Filter Cartridge of the Hydraulic System......................................................183
		30.3 Cleaning the Water Separator...............................................................................183
			1 - Loosen the drain plug (2)...............................................................................183
			2 - Let the water and fuel run off..........................................................................183
			3 - Loosen the screw (4) at the bottom side.................................................................183
			4 - Remove the housing (5) from the cover...................................................................183
			5 - Remove the gasket (6)...................................................................................183
			6 - Remove the filter element (7), the gasket (8) and the spiral spring (9).................................183
			7 - Remove water and dirt from the housing..................................................................183
			8 - Clean the filter element and blow-dry it with compressed air............................................183
			9 - Check the filter element and replace it, if it is damaged...............................................183
			10 - Re-insert the spiral spring, the gasket (8) and the filter element.....................................183
			11 - Position the gasket (6) and the housing................................................................183
			12 - Insert a new o-ring (10)...............................................................................183
			13 - Re-tighten the drain plug at the bottom side...........................................................183
			14 - Remove the attachment screw (3)........................................................................183
			15 - Fill up the water separator with fuel..................................................................183
			16 - Re-tighten firmly the attachment screw.................................................................183
		30.4 Lubrication................................................................................................184
			1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...........184
			2 - Clean the grease nipples................................................................................184
			3 - Use a grease gun to press sufficient grease into the grease nipples.....................................184
			4 - Remove the old grease which is extruding at the bearings................................................184
		30.5 Transfer Gear, Checking the Oil Level and Refilling Oil....................................................184
			1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing t...........184
			2 - Clean the screw plug (1) and the adjacent environment...................................................184
			3 - Unscrew the screw plug..................................................................................184
			4 - Check the oil level. The oil level must be at the lower edge of the control drill hole of the...........184
			5 - If the oil level is too low, fill up with oil using the control drill hole of the screw plug............184
			6 - Clean the screw plug and insert a new packing ring......................................................184
			7 - Re-tighten firmly the screw plug........................................................................184
		30.6 Air Filter, Replacing the Filter Insert, Replacing the Safety Filter.......................................185
			30.6.1 Replacing the Filter Insert..........................................................................185
				1 - Open the air filter and remove the air-filter insert (1). Proceed as described in chapter "29.......185
				2 - Use a lamp to check the new air filter for damages..................................................185
				3 - Re-install the air-filter insert as described in chapter "29.6 Air Filter, Removing and Re-In.......185
			30.6.2 Replacing the Safety Filter..........................................................................185
				1 - Open the air filter and remove the air-filter insert (1). Proceed as described in chapter "29.......185
				2 - Pull out the safety filter (2)......................................................................185
				3 - In order to prevent that dust enters the interior of the engine, it is required to the air as.......185
				4 - Clean the interior of the air-filter enclosure and remove the cloth from the air aspiration o.......185
				5 - Use a lamp to check the new safety filter for damages. If it is in perfect condition, press i.......185
				6 - Re-install the air-filter insert as described in chapter "29.6 Air Filter, Removing and Re-In.......185
	31. Maintenance Every 1000 Operating Hours..........................................................................186
		31.1 Cooling System, Exchanging Coolant and Cleaning the System.................................................186
			31.1.1 Draining off the coolant.............................................................................186
				1 - Switch off the engine and let it cool down..........................................................186
				2 - Turn the radiator cap (arrow) slowly to the side, up to the first fixed stop, and let the pre.......186
				3 - Stretch a tube onto the drain opening (1) of the discharge cock and insert the other tube end.......186
				4 - Open the discharge cock and let the coolant run off.................................................186
				5 - Close the discharge cock............................................................................186
			31.1.2 Cleaning the Cooling System..........................................................................187
				6 - Fill up the cooling system slowly with cleaning fluid...............................................187
				7 - With the radiator cap opened, let the engine run for 5 minutes with a coolant temperature of .......187
				8 - After the cleaning, switch off the engine and open the drain valve to let the entire cooling .......187
				9 - Let the engine run for five minutes with a coolant temperature of approx. 176F (80 C).............187
				10 - Then, let the cooling system run empty again. If the extruding water is not clean, the cooli.......187
				11 - Close the drain valve..............................................................................187
			31.1.3 Filling off Coolant..................................................................................187
				12 - Empty and clean the expansion tank.................................................................187
				13 - Prepare the coolant as prescribed..................................................................187
				14 - Fill off the coolant slowly into the cooling system up to the overflow shoot of the radiator.......187
				15 - To bleed the cooling system while the radiator cap is removed, let the engine run idle for f.......187
				16 - Switch off the engine, wait approx. three minutes and then refill coolant up to overflow sho.......187
				17 - Fill off coolant into the expansion tank, until the coolant level is between the FULL and LO.......187
		31.2 Front Axle, Oil Change.....................................................................................188
		31.3 Rear Axle, Oil Change......................................................................................188
		31.4 Transfer Gear, Oil Change..................................................................................188
		31.5 Service Brake..............................................................................................188
			31.5.1 Changing oil.........................................................................................188
			31.5.2 Checking tubes and lines.............................................................................188
			31.5.3 Checking the brake disks for wear and tear...........................................................188
			31.5.4 Adjusting the clearance of the brake disks...........................................................188
		31.6 Checking and Adjusting System Pressures....................................................................188
		31.7 Checking and Adjusting the Valve clearance.................................................................188
		31.8 Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern.........................188
	32. Maintenance Every 2000 Operating Hours..........................................................................189
		32.1 Hydraulic System, Oil Change...............................................................................189
			1 - Park the machine on level ground........................................................................189
			2 - Lower the work unit onto the ground.....................................................................189
			3 - Switch off the engine...................................................................................189
			4 - Secure the articulated steering with the articulated steering lock (1)..................................189
			5 - Unlock the feeding and ventilation screw (2) by turning it slowly to let the pressure escape............189
			6 - Loosen the screw plug (4) of the hydraulic oil tank and let the oil run off.............................189
			7 - Re-tighten the screw plug with its seal being in perfect condition......................................189
			8 - Unscrew the feeding and ventilation screw...............................................................189
			9 - Fill up oil until the oil level is between the center and top edge of the inspection glass (3)..........189
			10 - Start up the engine....................................................................................189
			11 - Raise and lower the work equipment several times, while operating the bucket at the same time..........189
			12 - Lower the bucket onto the ground and bring it into mining position.....................................189
			13 - Check the oil level with the engine running idle in its low speed position.............................189
			14 - Ventilate the hydraulic oil tank (see section "32.2 Bleeding the Hydraulic Oil Tank")..................189
		32.2 Bleeding the Hydraulic Oil Tank............................................................................190
			1 - Loosen the feeding and ventilation screw by turning it a couple of rotations............................190
			2 - Start up the engine.....................................................................................190
			3 - Bring the boom into its highest position................................................................190
			4 - Bring bucket into its tip-in position (up to its limit stop)............................................190
			5 - Re-tighten the feeding and ventilation screw............................................................190
		32.3 Cooling System, Checking the Antifreeze Content of the Coolant.............................................190
		32.4 Checking the Cooling System................................................................................190
		32.5 Checking the Fuel Pump.....................................................................................190
		32.6 Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required).....................................190
		32.7 Checking the Water Pump....................................................................................191
		32.8 Checking and Adjusting the Fuel Injection and Injection time...............................................191
		32.9 Engine, Intake Valves and Outlet Valves - Grinding In the Valve Bases......................................191
Technical Data..........................................................................................................193
	33. Technical Data..................................................................................................194
		33.1 Noise Emission Levels......................................................................................195
		33.2 Vibration Level............................................................................................195
		33.3 Limit Values for Slopes....................................................................................196
			33.3.1 Maximum slope angle for operating the machine........................................................196
			33.3.2 Tilting/tipping angle................................................................................196

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