Komatsu Utility 395F6001 Operation & Maintenance Manual Download Page 232

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MAINTENANCE PLAN

230

4.7.9.b

CHANGING THE HYDRAULIC TRANSMISSION OIL

ATTENTION

• Before warming up the machine to change the oil, thoroughly clean the transmission and the final reduc-

tion gear to remove any impurities from the areas involved in the operation.

DANGER

• Carry out this operation with the machine parked on level

ground, with boom fully retracted and lowered and with
parking brake applied.

• The hydraulic transmission oil must be drained at operat-

ing temperature, which is very high, and may cause severe
burns; wear insulating gloves, goggles and safety shoes.

• Immediately clean any area dirty with oil.
• Oil is considered special waste and must be collected and

disposed of according to the anti-pollution regulations in
force.

TRANSMISSION

When changing the transmission oil, also change the filter.
Proceed as follows:
1 - With the machine at operating temperature, stop the engine,

open the engine hood and extract the dipstick (1).

2 - Remove the drain plug (2) and let the oil flow into a container

with suitable capacity.

3 - Remove the filter (3) and change it. (See «4.7.9.c CHANG-

ING THE HYDRAULIC TRANSMISSION FILTER»).

DRIVING GEAR

4 - Remove the drain plug (4) and let the oil flow into a container

with suitable capacity.

5 - While the oil flows out, remove the filler cap (5).
6 - When the oil has been drained, clean the drain plug (4) and

put it back.

REFILLING

7 - Refill with the prescribed oil through the filler cap (5), up to

half the level gauge (6).
For the relevant specifications, see «4.3 FUEL, COOLANT
AND LUBRICANTS».

8 - Put back the driving gear filler cap (5).
9- Put back the transmission drain plug (2) and fill with oil until

reaching the MAX. mark on the dipstick (1).

10 - Start the engine and let it idle to fill the converter and the in-

ternal circuits.

11 - While the engine is idling, add oil until reaching the MAX.

mark again.

12 - When the oil reaches a temperature of approximately 85–

88°C, add oil until reaching the MAX. mark.

13 - Close the engine hood.

RKAA2010

MAX.

MIN.

RKAA2020

RKAA2100

RKAA2110

Summary of Contents for 395F6001

Page 1: ...5F70004 and up Operation Maintenance Manual Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine WARNING MODEL SERIAL NUMBER TELESCOPIC HANDLERS ...

Page 2: ......

Page 3: ...ions that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval Therefore it is advisable to consult either the hour meter and the maintenance plan frequently Over the years Komatsu Utility Dealers have gathered considerable experience in customer service If more information i...

Page 4: ... result in serious injury or even death These safety messages or labels usually describe the precautions that must be taken to avoid the haz ard Failure to take these precautions may also result in serious damage to the machine ATTENTION This word is used in safety messages and on safety labels to signal hazards which could result in minor or moderate injury or damage This kind of warning is used ...

Page 5: ...been tampered with by modifying the standard setting of the hydraulic system Before carrying out any electrical welding disconnect the battery the alternator and the connector of the gearshift unit installed under the steering wheel See 2 8 12 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR and 2 8 14 PRE CAUTIONS CONCERNING THE GEAR LEVER Install only authorized additional equipment The mac...

Page 6: ...closed to this manual The instructions regarding the assembly of the authorized equipment the controls requiring special machine configurations and the hydraulic couplings necessary for the operation of the equipment are grouped in the final section of this manual The Komatsu Utility TELESCOPIC HANDLERS are designed and built exclusively for handling and transporting inert materials the following ...

Page 7: ...n optional SLI Safe Load Indicator Axle frame lock that engages automatically when the boom inclination exceeds approximately 30 optional 1 3 4 RUNNING IN Every machine is scrupulously adjusted and tested before delivery A new machine however must be used carefully for the first 100 hours in order to ensure proper running in of the various components Every new machine must be used carefully paying...

Page 8: ...hours of operation change the hydraulic circuit drain filter After the first 500 hours of operation change the hydraulic circuit oil and the intake filter IMPORTANT When changing the oil filters cartridges check their innner part to make sure that there are no depos its If abundant deposits are observed find out what may have caused their accumulation before starting the machine The number of oper...

Page 9: ... AND PRODUCT IDENTIFICATION NUMBER PIN The machine bears the data required by the EC Directives as well as the Product Identification Number PIN 1 The PIN is a stamped on the front right part of the machine b indicated on the identification plate as alphanumeric stamping and as a bar code The identification plate 2 is fixed to the front right part of the frame in a protected place in such a way as...

Page 10: ...HINE IDENTIFICATION PLATE RKA02031 TYPE SERIAL No MANUFACTURING YEAR MASS ENGINE POWER kW kg 395 93 11570 MANUFACTURED BY KOMATSU UTILITY EUROPE S p A 36025 NOVENTA VICENTINA VI ITALY RATED CAPACITY kg Product Identification Number PIN ...

Page 11: ...is also stamped on the right side of the cyl inder block on the upper part of the oil cooling heat exchanger The engine class plate 4 and the engine details EPA Family engine model engine displacement engine power RPM idle speed quantity of fuel cycle valve clearance and U S EPA CARB conformity can be found on the plate positioned below the Manu facturer s plate Both plates 2 and 4 are applied to ...

Page 12: ...ed on the central body 1 4 6 TRANSMISSION SERIAL NUMBER The transmission serial number is stamped on the plate posi tioned on the transmission case on the engine coupling side 1 4 7 CAB SERIAL NUMBER The cab serial number is stamped on the plate positioned on the front right base crosspiece RKAA0450 RKAA0460 RKAA0470 ...

Page 13: ...TION 11 1 4 8 SERIAL NUMBERS AND DEALER S ADDRESS Machine No Model Engine No Front axle No Transmission No Dealer Address Tel Contact person NOTES Cab No Rear axle No Optional equipment Product identification number PIN ...

Page 14: ...20 2 1 1 POSITION OF THE SAFETY PLATES 20 2 1 2 PICTOGRAMS AND RELEVANT MEANINGS 24 2 1 3 POSITION OF THE NOISE PLATES 32 2 2 GENERAL PRECAUTIONS 33 2 2 1 GENERAL SAFETY RULES 33 2 2 2 SAFETY DEVICES AND GUARDS 33 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS 33 2 2 4 UNAUTHORIZED MODIFICATIONS 34 2 2 5 LEAVING THE OPERATOR S SEAT 34 2 2 6 GETTING ON AND OFF THE MACHINE 35 2 2 7 CHECKING THE REAR V...

Page 15: ...NG AND UNLOADING THE MACHINE 53 2 5 2 THE ROUTE 53 2 6 BATTERY 54 2 6 1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES 54 2 6 2 STARTING WITH BOOSTER CABLES 54 2 7 PRECAUTIONS FOR EMERGENCY RECOVERY 55 2 8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 56 2 8 1 WARNING PLATES 56 2 8 2 TOOLS 56 2 8 3 PERSONNEL 56 2 8 4 EQUIPMENT 57 2 8 5 WORKING UNDER THE MACHINE 57 2 8 6 KEEPING THE MACHINE CLEAN 57 2 8 7 U...

Page 16: ...IT FUSES AND RELAYS 112 3 4 1 1 CENTRAL UNIT FUSES 113 3 4 1 2 CENTRAL UNIT RELAYS 115 3 4 2 ENGINE LINE FUSES AND RELAYS 116 3 4 2 1 ENGINE LINE FUSES 116 3 4 2 2 ENGINE LINE RELAYS 117 3 5 GUARDS CAB AND DRIVER S SEAT 118 3 5 1 ENGINE HOOD 118 3 5 2 CAB 119 3 5 3 EMERGENCY EXIT 120 3 5 4 VENTILATION AND HEATING 121 3 5 5 AIR CONDITIONER optional 123 3 5 6 SEAT 124 3 5 6 1 STANDARD SEAT 124 3 5 6...

Page 17: ...ALE GRIPPERS ETC 147 3 12 4 ORGANIZING THE WORK AREA 148 3 12 5 OPERATING THE EQUIPMENT 148 3 12 6 OPERATING THE MACHINE FITTED WITH FORKS 149 3 12 6 1 FORKING A LOAD 149 3 12 6 2 TRANSPORTING THE LOAD 151 3 12 6 3 STACKING THE LOAD 151 3 12 7 PREPARING THE MACHINE FOR TRAVELLING ON ROADS 153 3 12 8 USING THE MACHINE AS A LOADER 154 3 12 8 1 ORGANIZING THE WORK AREA 154 3 12 8 2 LOADING HEAPED AND...

Page 18: ... SAFETY 181 4 6 1 1 FUEL SUPPLY SYSTEM 181 4 6 1 2 DELIVERY HYDRAULIC SYSTEM 182 4 6 1 3 CONTROL VALVE HYDRAULIC SYSTEM 183 4 6 1 4 BOOM HYDRAULIC SYSTEM 184 4 7 MAINTENANCE PLAN 185 4 7 1 WHEN REQUIRED 189 4 7 1 a CHECKING THE BATTERY ELECTROLYTE LEVEL INSPECTING TERMINALS AND CABLES 189 4 7 1 b CHECKING CLEANING OR CHANGING THE ENGINE AIR CLEANERS 190 4 7 1 c CHECKING AND CLEANING THE CAB AIR FI...

Page 19: ...ly for machines in which synthetic biodegradable oil HEES is used 213 4 7 8 MAINTENANCE EVERY 500 HOURS OF OPERATION OR EVERY 6 MONTHS 214 4 7 8 a CHANGING THE FUEL FILTER 214 4 7 8 b DRAINING THE FUEL TANK 215 4 7 8 c CHECKING THE HYDRAULIC OIL LEVEL 215 4 7 8 d CHANGING THE HYDRAULIC OIL DRAIN FILTER 216 4 7 8 e DRAINING CONDENSATE FROM THE OIL TANK Only for machines in which synthetic biodegrad...

Page 20: ... 5 1 TECHNICAL DATA 238 5 1 1 DIMENSIONS WITH FORKS 238 5 1 2 TECHNICAL CHARACTERISTICS 240 5 1 2 1 TECHNICAL CHARACTERISTICS WH609 Aspirated engine 240 5 1 2 2 TECHNICAL CHARACTERISTICS WH609 Turbo engine 241 5 1 2 3 TECHNICAL CHARACTERISTICS WH613 Aspirated engine 242 5 1 2 4 TECHNICAL CHARACTERISTICS WH613 Turbo engine 243 5 1 2 5 TECHNICAL CHARACTERISTICS WH713 244 5 1 2 6 TECHNICAL CHARACTERI...

Page 21: ...SAFETY DEVICES AND ACCIDENT PREVENTION MEASURES 19 ...

Page 22: ...with a solution made of water and detergent Do not use fuel petrol or solvents If the plates are damaged ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer In case of replacement of a component provided with a safety plate make sure that this plate is applied also to the new piece The machine can be provided with other plates in addition to those indicated below keep also to the...

Page 23: ...SAFETY NOISE AND VIBRATION PLATES 21 395 93 11391 RKAA0400 ...

Page 24: ...SAFETY NOISE AND VIBRATION PLATES 22 RKAA0740 RKAA0720 ...

Page 25: ...SAFETY NOISE AND VIBRATION PLATES 23 RKAA0710 ...

Page 26: ...ained in the picto grams perfectly the symbols and the relevant meanings are explained in the following list WORK AREA Do not stand within the operating range of the equipment when it is lifted and loaded DO NOT OPEN THE HOOD Do not open or remove the hood while the engine is running CONSULT THE MANUAL Carefully read the contents of the manual before using the ma chine or performing maintenance op...

Page 27: ...SAFETY NOISE AND VIBRATION PLATES 25 SAFETY DISTANCE Do not get near or stand within the machine operating area RISK OF ELECTROCUTION 395 93 11400 RKA00160 395 93 11920 RKA01670 RKA00170 395 93 11351 ...

Page 28: ...SAFETY NOISE AND VIBRATION PLATES 26 BEFORE LEAVING THE WORK POSITION DO NOT CLIMB ON THE ENGINE HOOD RISK OF CRUSHING 395 93 11341 RKA00180 395 93 11391 RKA00700 395 93 11380 RKA00690 ...

Page 29: ...ISE AND VIBRATION PLATES 27 EMERGENCY EXIT DO NOT USE AS A PLATFORM DO NOT OPEN THE RADIATOR AND THE HYDRAULIC OIL TANK WHEN THE ENGINE IS HOT RKA00520 20N 98 RB26101 RKA00790 395 93 11511 RKA00660 395 93 11320 ...

Page 30: ...ND UNDER THEM DO NOT WASH THE ENGINE CENTRAL UNIT WITH HIGH PRESSURE JETS FILLING THE HYDRAULIC SYSTEM WITH OIL Only for machines in which synthetic biodegradable oil type HEES is used PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY RKA00770 395 93 11471 RKA00780 395 93 11491 RKA00630 BIO OIL 395 93 11370 RKA00680 ...

Page 31: ... TOPPING UP HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER REFUELLING FUEL FILTER ENGINE LUBRICATING OIL FILTER RWA00620 20M 98 RB26221 RKA00560 20N 98 RB26041 RKA00550 20N 98 RB26051 RWA00610 20M 98 RB26231 D RWA00590 20M 98 RB26271 RWA00600 20M 98 RB26261 ...

Page 32: ...R ENGINE COOLANT PRESSURE TRANSMISSION OIL TOPPING UP TRANSMISSION OIL LEVEL TRANSMISSION OIL FILTER BRAKE OIL TOPPING UP RWA00580 20M 98 RB26281 RKA00570 20M 98 RB26331 RWA00730 395 93 11430 RWA00740 395 93 11440 RWA00720 395 93 11420 RWA00750 395 93 11450 ...

Page 33: ...RATION PLATES 31 BRAKE OIL LEVEL LUBRICATION POINTS POWER OUTLET ANCHORING POINT FOR TRANSPORT AND LIFTING OPERATIONS RWA00760 395 93 11460 RKA00710 395 93 11410 RKA00540 12V 20N 98 RB26061 RKA00530 2 0 M 9 8 R 8 2 6 0 8 1 ...

Page 34: ...r Komatsu Utility Dealer In case of replacement of the cab door to which the noise plates are fixed make sure that the plates are applied also to the new door NOISE OUTSIDE THE CAB This value indicates the noise level outside the machine and re fers to the noise perceived by the persons who are in the vicinity of the work area NOISE INSIDE THE CAB This value indicates the maximum noise level perce...

Page 35: ...he safety devices and always keep them in good operating conditions Carry out the prescribed functional checks respecting the indicated intervals Improper use of the safety devices may result in serious injury or even death 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS Do not wear large or loose clothes rings and watches and do not go near the machine with loose long hair since they can get entagle...

Page 36: ...EAT When leaving the operator s seat even if for a short time make sure that the machine is in a safe position See 3 7 PARKING THE MACHINE Before leaving the operator s seat carry out the following oper ations in the sequence indicated below 1 Lower the equipment to the ground 2 Apply the parking brake 3 Shift the gearshift reverse lever to the neutral position 4 Stop the engine See 3 8 STOPPING T...

Page 37: ...ey are loose and clean the handles and the steps if they are dirty with oil or grease Carefully clean the cab floor if it is dirty with oil grease mud or rubble 2 2 7 CHECKING THE REAR VIEW MIRRORS Working without checking the back of the machine is danger ous since the machine may hit persons who are incautiously standing in the work area fixed obstacles or manoeuvring vehi cles Make sure that th...

Page 38: ... and oil safety caps securely Do not fill the tank completely in order to leave room for the fuel to expand In case some fuel is spilled wipe it up immediately 2 2 9 PREVENTING BURNS If the engine coolant the engine oil and the hydraulic oil are hot use heavy cloths and wear gloves heavy clothing and safety goggles before carrying out any check or touching the hot parts Before checking the coolant...

Page 39: ...e air operate the machine with the wind to your back whenev er possible 4 Even if the cab provides suitable protection use an ap proved and homologated respirator 5 The powder gathered during the cleaning operations must be wet and put in a sealed and marked container so that it can be safely disposed of according to the regulations in force 2 2 11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT Do...

Page 40: ...he cab is inadvertently hit or the machine overturns during work the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator Contact Komatsu Utility or a Komatsu Utility Dealer to have the cab structure and resistance checked in case of impact or damage 2 2 14 PRECAUTIONS CONCERNING THE EQUIPMENT When installing and using optional equ...

Page 41: ...If these obstacles cannot be avoided be very careful and lower the speed as much as possible If it is necessary to cross rivers check the depth of the water and the force and direction of the current 2 3 2 FIRE PREVENTION Completely remove all wood chips rubbish paper and other flammable materials that may have accumulated inside the en gine compartment and on the radiator since they can cause fir...

Page 42: ...ssary replace any faulty bulbs with new ones making sure that the power is correct 2 3 6 CLEANING THE WINDOWS AND THE REAR VIEW MIRRORS CHECKING THE WINDSHIELD WIPER BLADES Remove any trace of dirt from the cab windows and clean the rear view mirrors in order to ensure perfect visibil ity on the work area Adjust the rear view mirrors that may have moved so that the operator seated in the driving p...

Page 43: ...ing the horn Turn the steering wheel in both directions and check the movements of the front wheels 2 4 2 RULES FOR TRAVELLING ON ROADS Before travelling on roads it is necessary to study and plan the route checking the road width the presence of tight curves the bearing capacity of the bridges the presence of ditches or of excavations filled with earth that isn t well compacted etc To travel on r...

Page 44: ...e ground is approximately 30 cm The machine must travel with the frame in horizontal positions in such a way as to be able to stand any inclina tion due to the unevenness of the ground When turning make sure that there is a suitable distance between the machine and any wall or obstacle when the machine is steering in fact the front equipment and therefore the load R1 and the rear part R2 of the ma...

Page 45: ... increase the bending of the tyre sidewalls and in limit conditions cause the tyres to slip 3 Check the area and in particular check if there are grass lay ers of leaves or recent excavations since in these conditions the machine may run the risk of slipping or overturning 4 Check the weather conditions since fog rain or wind may cause the machine to slip or overturn See 2 4 8 WORKING IN WINDY WEA...

Page 46: ...and transversal inclination 2 A B Machine with frame levelling system and stabilizers trans versal inclination 0 longitudinal inclination max 2 C A 2 4 7 UNAUTHORIZED OPERATIONS Do not use the machine equipped with front loader to remove soil when the inclination of the boom exceeds 10 since this may overload the rear axle and the transmission RKA02020 A Max 2 B RKA02380 C RKA02390 Max 2 0 RKA0175...

Page 47: ...eference to a surface of less than 1 m for each ton lifted if the exposed surface is larger than 1 m ton interrupt work WIND FORCE TABLE THE BEAUFORT SCALE Intensity of the wind Speed Effects Force Description m sec km h Land based specification 0 Calm 0 0 2 1 Smoke raises vertically 1 Light air 0 3 1 5 1 5 Direction of wind shown by smoke drift but not by wind vanes 2 Light breeze 1 6 3 3 6 11 Le...

Page 48: ...he must contact his supervisor or the supplier of the material to be handled Once the weight of the material has been determined consult the machine load chart corresponding to the conditions of use on tyres or stabilizers and to the equipment fitted this is important in order to en sure that the lifting transport and definitive positioning of the load are carried out within the safety range indic...

Page 49: ...nt completely to stabilize the load and maintain the center of gravity of the load in the pre scribed position with respect to the forks DANGER The load must be retained or released only through the movements of the boom do not move the machine to take hold of the load or release it Be extremely careful in order to avoid moving the load 7 Slowly lift the load a few centimeters and make sure that i...

Page 50: ...e right arm points upward with the palm facing forward and the hand slowly makes a circle 5 LOWER the right arm points downward with the palm facing forward and the hand slowly makes a circle 6 HORIZONTAL DISTANCE the hands indicates the relevant distance 7 MOVE FORWARD both arms are bent with the palms facing upward and the forearms make slow move ments toward the body several times 8 MOVE BACKWA...

Page 51: ...and to the equipment installed DANGER If the maximum extension and angle allowed are exceeded the machine isn t stable and this condition will be signalled by the acoustic alarm If the stability limit indicated and signalled by the SLI Safe Load Indicator is reached the machine can not get nearer the unloading area and the operation must be interrupted since the load exceeds the ca pacity of the m...

Page 52: ...scribed Ask the electricity company in advance what are the voltage of the cables and the minimum safety distance DANGER The minimum distances from overhead lines can vary in the different countries according to the climate and to the percentage of humidity in the air Indicatively the distances indicated in the table below should be respected 2 4 11 VISIBILITY Switch on the headlights or the work ...

Page 53: ... kept from the edges of ditches slopes excavations or sites when travelling and wishing to ensure the stability of the machine are the fol lowing a with compact ground distance X equal to the depth of the ditch fig A b with not compacted ground subject to landslides dis tance X twice the depth of the ditch fig B NOTE The safety distance must be measured at the upper edge of the ditch If it isn t p...

Page 54: ... to the left choosing the direction in which there are fewer obstacles 2 Stop the machine applying the parking brake 3 Lower the equipment to the ground 4 Stop the engine 5 Position wedges or safety blocks under the front and rear wheels When leaving the machine remove the ignition key and lock the door If it is necessary to park on public roads signal the presence of the machine according to the ...

Page 55: ... with a maximum inclination of 15 Make sure that the ramp surface is clean and there is no trace of grease oil soil and ice remove dirt from the wheels before starting to load the machine on the vehicle Do not correct the trajectory of the machine while it is on the ramps If necessary move it down the ramps and start the oper ation again When loading or unloading the machine make sure that no part...

Page 56: ... and remove the ignition key Avoid short circuiting the battery terminals through any contact even if accidental with metal objects or tools or through the in version of the terminals Tighten the battery terminals securely Loose terminals may generate sparks and even cause the explosion of the battery 2 6 2 STARTING WITH BOOSTER CABLES The booster cables must be connected to the battery DO NOT con...

Page 57: ...an be allowed to ap proach the machines or the cables Do not stand astride the cables Move the machine only as far as necessary to allow the re quired repairs to be carried out Do not remove the machine in any way other than that indicated in paragraph 3 14 2 REMOVING THE MACHINE IN CASE OF FAILURE ATTENTION The maximum force to be applied for towing the machine corresponds to 75 of the machine ma...

Page 58: ... tags also around the machine and in particu lar on the cab handles 2 8 2 TOOLS Use only the tools supplied together with the machine and high quality tools suitable for the tasks to be performed Do not use worn damaged low quality tools or tools that are not suitable for the tasks to be performed in order to avoid any personal injury After use always store the tools in the apposite compartment 1 ...

Page 59: ...s or broken pieces are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy Before carrying out any cleaning operation protect the areas where there are electric parts in particular the engine central unit identified by the apposite pictogram To clean the machine use a pressurized jet of warm water or steam and the specific detergents ...

Page 60: ...em fuel delivery and return pipes Hydraulic system main delivery pipes of the hydraulic pump Hydraulic system work circuit pipes from the distributor to the hydraulic cylinders Even if they seem to be in good conditions these components must be periodically changed with new ones In fact these components tend to deteriorate over time If one of these parts is defective change or repair it even if th...

Page 61: ...xplosions 2 8 12 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR When repairing the electric system disconnet the battery in or der to stop the flow of current IMPORTANT Disconnect first the negative earth cable and then the positive cable At the end of the operation reconnect first the positive ca ble and then the negative cable If electric welding operations are to be carried out on the ma...

Page 62: ...f the engine may be damaged and this may affect the reliability of the machine in critical conditions like low temperatures and the engine stop in case of emergency Do not start the engine with the booster cables connected to the starter 2 8 14 PRECAUTIONS CONCERNING THE GEAR LEVER If it is necessary to carry out any electric welding on the ma chine disconnect the gearshift connector 1 which can b...

Page 63: ... and the resulting jets are extremely dangerous since they can perforate the skin and penetrate in the blood circulation or injure the eyes For this reason always wear goggles and thick gloves during the inspections and use a piece of cardboard or a sheet of ply wood to check for oil leakages If you are struck by a jet of high pressure oil or are injured even if slightly consult a doctor without d...

Page 64: ...ton sealing rings Teflon rings piston seals made of fluoroelastomers electric cable insulating materials etc At room temperature and up to approximately 200 C these materials can be handled without taking any precautions since they are completely inert However if these materials are burnt they release highly toxic gases Once they have cooled down these materials must be collected into airtight bag...

Page 65: ...DABLE OIL TYPE HEES It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils since when the temperature increases insoluble compounds are generated which are deposited on the filters and clog them the maximum concentration of ordinary oil must not exceed 1 of the total quantity of oil Biodegradable oil can be used only in the hydraulic system it cannot be us...

Page 66: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 67: ...DESCRIPTION AND OPERATION OF THE MACHINE 65 ...

Page 68: ...FT FOR FORW WARD ARD FORWARD RKAA0391 11 14 12 13 4 2 1 1 Frame 2 Stabilizers 3 Front axle 4 Rear axle 5 Frame levelling cylinder optional 6 Boom 7 Intermediate boom section only for the 3 section boom version 8 Final boom section 9 Equipment carrier 10 Forks 11 Cab 12 Hydraulic oil tank 13 Fuel tank 14 Rear axle locking cylinder optional ...

Page 69: ...3 Steering mode selection unit 4 Frame levelling push button optional 5 Stabilizers push buttons optional 6 Boom control lever 7 SLI Safe Load Indicator 8 Parking brake 9 Service brake pedal 10 Accelerator 11 Steering wheel 12 Steering wheel position lock lever 13 Dashboard 14 Direction indicators dimmer switch horn front windshield washer 15 Water level spirit level ...

Page 70: ...ly and the general alarm warning light flashes intermittently see 3 2 2 WARNING LIGHTS pos 15 GENERAL ALARM WARNING LIGHT Red 2 SPEEDOMETER AND REVOLUTION COUNTER The speedometer indicates the travel speed of the machine The revolution counter indicates the number of engine revolu tions When the speed exceeds 50 km h the alarm buzzes and the general alarm warning light flashes intermittently see 3...

Page 71: ...urther details on the use and functions of this device see 3 2 5 MACHINE CONTROLS pos 7 SLI SAFE LOAD INDI CATOR 5 WATER LEVEL SPIRIT LEVEL This instrument makes it possible to check the levelling of the ma chine during the frame stabilization phase and during work For a correct levelling operation the water level must be centered transversally in the central circle that represents the optimal cen...

Page 72: ... when the engine is running at the normal operating speed this means that the alternator does not work and the battery is not charged correctly IMPORTANT If the warning light remains off when the ignition key is turned to position I this means that the alternator is faulty or broken 2 PREHEATING WARNING LIGHT Yellow This warning light comes on when the ignition key is turned to po sition to start ...

Page 73: ...ately and try to locate the trouble 4 AIR CLEANER CLOGGING WARNING LIGHT Red This warning light comes on when the engine air filter needs cleaning 5 LOW OIL PRESSURE OR BRAKING SYSTEM FAILURE WARNING LIGHT Red This warning light comes on to indicate that the brake oil pressure is low or that there is no oil in the reservoir due to leakages If it comes on repeatedly check the braking system and eli...

Page 74: ...g brake is applied 10 TRANSMISSION OIL TEMPERATURE WARNING LIGHT Red This warning light comes on and activates the acoustic alarm when the transmission oil exceeds the maximum temperature al lowed when it comes on immediately stop the machine put it in neutral and let it cool down with the engine idling at approximately 1200 rpm until the warning light goes out If this inconvenience occurs repeate...

Page 75: ...switch see 3 2 3 SWITCHES AND PUSH BUT TONS pos 21 DIRECTION INDICATORS DIMMER SWITCH HORN FRONT WINDSHIELD WIPER WASHER 14 REAR AXLE SWING LOCK WARNING LIGHT optional This warning light comes on when the rear axle is locked that is when the inclination of the telescopic boom exceeds approxi mately 30 or when WORK mode is selected WORK see 3 2 5 MACHINE CONTROLS pos 3 OPERATING MODE SELEC TION UNI...

Page 76: ... a for about 3 seconds during the general warning light check every time the machine is started b when the maximum temperature allowed for the engine cool ant is exceeded c when the travel speed exceeds 50 km h d when the engine rpm exceeds 3250 e when the engine oil pressure is low RKA00030 ...

Page 77: ...INSTRUMENTS AND CONTROLS 75 3 2 3 SWITCHES AND PUSH BUTTONS RKAA0550 RKAA0560 RKAA0570 RKAA0580 RKAA1140 1 3 4 5 6 10 11 12 13 14 15 16 17 18 20 19 2 8 7 9 23 22 ...

Page 78: ...it switches on also the rear work lights warning light 8 on the dashboard See 3 2 2 WARNING LIGHTS NOTE When the machine travels on roads the work lights must be off or covered by a screen 3 UPPER WINDSHIELD WIPER WASHER SWITCH optional With the first click it operates the windshield wiper while with two clicks with automatic return to the first click position it operates the rear and upper windsh...

Page 79: ... the cursor to its original position up or press the switch again 8 REVOLVING LIGHT SWITCH optional It switches on the revolving light IMPORTANT When the machine travels on roads the revolving light can be used only if this is required allowed by the local traffic regulations 9 12V OUTLET This is 12V outlet than can be used also to charge mobile phones to supply power to radios for service communi...

Page 80: ... position 12 FRAME LEVELLING PUSH BUTTON optional This is a rocker button that returns to the center whenever re leased It must be used to level the frame when it is necessary to work on uneven ground or in any case on a slope that is transversal with respect to the axis of the machine For details on how to use this button see 3 2 5 MACHINE CON TROLS 13 14 STABILIZERS PUSH BUTTONS optional These a...

Page 81: ...e to steer with the front wheels only compulsory for circulation on roads or with four wheels for either round or crab steering For more details on the steering mode selection procedure see 3 2 5 MACHINE CONTROLS 17 BOOM EXTENSION AND RETRACTION POTENTIOMETER This is a proportional potentiometer rotating in two directions that returns to the center whenever released Turn it forward to extend the b...

Page 82: ...ine for the hydraulic system It can be used when the TRAVEL WORK or TRAVEL operating modes are selected 21 DIRECTION INDICATORS DIMMER SWITCH HORN FRONT WINDSHIELD WIPER WASHER A Left direction indicator B Right direction indicator C Horn D Low beam high beam switch E High beam signaller F Windshield wiper G Windshield washer RKAA0831 20 RKAA1580 21 G F B E D C A E D A B C F G ...

Page 83: ...arm air and serves as heat ing switch see 3 5 4 VENTILATION AND HEATING On machines provided with air conditioning system the fan en sures the circulation of cool air see 3 5 5 AIR CONDITIONER optional 23 AIR CONDITIONER SWITCH optional This is a two position switch and if rotated clockwise led on it op erates the air conditioner For further details on how to use this switch see 3 5 5 AIR CON DITI...

Page 84: ...during the use of the machine signals misalignment of the rear wheels interval between selection and actual operation of the selected steering mode 2 ROOF LIGHT This lamp is used to check the instruments and the inside of the cab and to consult the load charts when visibility is poor The roof light can be switched on by pressing one of its short sides 3 POWER OUTLET A power outlet is positioned on...

Page 85: ...50 RKAA0780 6 8 9 1 10 3 2 7 4 5 1 Gearshift reverse lever 2 Steering mode selection unit 3 Operating mode selection unit 4 Frame levelling optional 5 Stabilizers control optional 6 Boom control lever 7 SLI Safe Load Indicator 8 Parking brakes 9 Service brake pedal 10 Accelerator pedal ...

Page 86: ...tion the gear and consequently also the travel speed The gearshift reverse lever unit is available in two versions STANDARD manual shift of all gears SEMI AUTOMATIC manual engagement of the first three gears and automatic management of 4th and 5th gear The visual signals emitted by the led are the same and the only difference lies in the push button 2 provided only for the semi automatic version w...

Page 87: ...L N IMPORTANT Damage to the transmission may occur if the machine is allowed to coast with the engine off Damage to the transmission may also occur if the machine travel direction is reversed at an excessive speed Do not allow the machine to coast Reverse the machine travel direction only with the machine in 1st gear and moving at less than 4 km h The lever in position N rotated on its horizontal ...

Page 88: ...to the safety position LED N RED to start moving shift the lever to the NEUTRAL position N select the travel direction and engage a gear the 2nd gear is automatically engaged LED CONDITION N Comes on when the machine is in NEUTRAL T Used only with a diagnostic function comes on only in case of failure 1 5 Indicate what gear is engaged N and the direction according to their colours RED with machine...

Page 89: ...s case the shifting control is stored but the shifting isn t carried out immediately several gear shifts are carried out in 1 5 seconds until the selected gear is en gaged Example If the machine travels in 2nd forward gear at high speed and the 1st gear is engaged the leds are in the following condi tion led 1 is green and led 2 is green but flashing the flashing of the led signals to the operator...

Page 90: ...at rest while the round or two wheel steering can be selected also when the machine is moving with 1st or 2nd gear engaged or with TRAVEL WORK operating mode selected The steering mode is selected according to the type of ground and to the type of operation to be carried out Three steering modes are available a Two wheel steering 2WS warning light 6 on this is the compulsory steering mode for circ...

Page 91: ...g is selected the misalignment of the rear wheels can take place with speed un der or over 13 km h in both cases the acoustic alarm starts sounding intermittently if the speed is under 13 km h continuously if the speed exceeds 13 km h The realignment procedure with speed under 13 km h is the following a turn the steering wheel until the front wheels are aligned led 8 on b select the round steering...

Page 92: ...NG MODE If the 4WS round steering is selected with push buttons 1 and 2 when the machine is in WORK or TRAVEL WORK operating mode with two wheel steering 2WS engaged and front wheels misaligned a the 2WS selection is maintained until the front wheels are aligned led 8 on b the 4WS round steering is selected led 5 on If the 4WS round steering is selected with push buttons 1 and 2 when the machine i...

Page 93: ...rol is neither accepted nor stored 2 5 4WS CRAB STEERING MODE If the 4WS CRAB steering is selected with push buttons 3 and 4 when the machine is in WORK or TRAV EL WORK operating mode with two wheel steering 2WS engaged and front wheels misaligned 1st CASE machine at rest a the 2WS selection is maintained until the front wheels are aligned led 8 on b the 4WS crab steering is selected RKAA0616 1 2 ...

Page 94: ...WS CRAB steering is selected with push buttons 3 and 4 when the machine is in WORK or TRAV EL WORK operating mode with 4WS round steering engaged and front and or rear wheels misaligned 1st CASE machine at rest a the 4WS round steering selection is maintained until the rear wheels are aligned led 9 on b the two wheel steering 2WS is selected until the front wheels are aligned led 8 on RKAA0890 4 3...

Page 95: ...teering selection is maintained until the rear wheels are aligned led 9 on c the two wheel steering 2WS is selected until the front wheels are aligned led 8 on d the 4WS crab steering is selected led 7 on NOTE If the 4WS CRAB steering is selected with the machine in TRAVEL operating mode the control is neither ac cepted nor stored RKAA0894 7 8 9 RKAA0892 4 3 5 9 RKAA0893 6 8 9 RKAA0894 7 8 9 ...

Page 96: ...hat must be used to prepare the ma chine for lifting operations to carry out if necessary the load balance tests before lifting the load and before moving to reach the unloading point In this mode only the 1st and 2nd gear both forward and re verse are available This operating mode can be selected with the machine at rest and also in TRAVEL condition in the latter case the gears will be shifted do...

Page 97: ... the machine travels on slopes that are transversal to the travel di rection and even if the machine isn t loaded The transversal levelling of the frame is achieved by pressing the rocker button 1 that when released stops the movement of the frame the maximum inclination possible is 10 The frame must be checked using the water level 2 see 3 2 1 INSTRUMENTS the level must be centered laterally If d...

Page 98: ...The use of the stabilizers is inhibited when boom inclination re ferred to the frame exceeds approximately 30 6 BOOM CONTROL LEVER DANGER Before carrying out any manoeuvre with this lever the operator must be seated in driving position with fastened safety belt Before using the machine the operator must get acquainted with the functions and use of all the con trols grouped on the boom control leve...

Page 99: ...ting Equipment folding IMPORTANT In the TRAVEL WORK operating mode independently of the boom extension and in order to increase the transversal stability of the machine if the boom inclination exceeds approximately 30 which can be checked on the goniometer applied to the left side of the first section of the boom the movement of the frame with respect to the axles is automatically locked if the re...

Page 100: ... movements produced by each individual push of the buttons Before starting work the operator must check the corre spondence between the AUX buttons and the directions of movement of the equipment since the person who con nected the pipes may have inverted the connections 6 4 TRANSMISSION DECLUTCH PUSH BUTTON DANGER Avoid using this button when the machine works or travels on slopes This button is ...

Page 101: ...e indicator may be affected by these conditions Refer to the load charts If the instrument is faulty or in case of doubts on its functionality immediately contact your Komatsu Utility Dealer The SLI Safe Load Indicator is positioned on the right post of the cab and is clearly visible to the operator This instrument comprises warning lights and push buttons having the following functions a POWER wa...

Page 102: ...g of the SLI Safe Load Indicator refers only to the longitudinal stability of the machine Acoustic alarm OFF Led 3 or Led 3 and 4 ON The instrument indicates that the machine is stable Proceed with care Acoustic alarm OFF Led 3 4 and 5 ON The instrument indicates that the machine is near the place where it will be necessary to operate with slow boom lifting and extension movements and with reduced...

Page 103: ...ing condition thus sig nalling that it is prohibited to lower and extend the boom it is only allowed to retract the boom to restore safety conditions by operating the controls carefully and reducing the engine rpm Acoustic alarm ON continuous alarm Led 3 4 5 6 7 and 8 ON The instrument indicates that the conditions of the machine are such that it runs the risk of overturning DANGER The machine may...

Page 104: ...y pulling the lower lever 2 and accompanying the lever 1 that automatically returns to its neutral position The engagement of the parking brake is indicat ed by the coming on of the warning light on the dashboard For further details see 3 2 2 WARNING LIGHTS The application of the parking brake has different functions ac cording to the operating mode selected TRAVEL With brake applied gearshift rev...

Page 105: ...of this pedal is proportional to the force applied and is distributed on both axles ATTENTION If the machine doesn t decelerate gradually or the pedal reaches its end of stroke stop the machine immediately using also the parking brake if necessary apply the park ing brake and have the braking system inspected by an Au thorized Repair Shop 10 ACCELERATOR PEDAL This pedal is positioned on the right ...

Page 106: ...e the lock manually by rotating the operating mode se lector see 3 2 5 MACHINE CONTROLS to the WORK position 11 2 WORK MODE 1 In this condition the axle is locked with any inclination of the boom when the axle is locked the warning light see 3 2 2 WARNING LIGHTS comes on 2 Before starting any load lifting operations the operator must check the condition of the warning light see 3 2 2 WARN ING LIGH...

Page 107: ...es expressed in meters for the boom length covered by each sector all the sectors are divided in 10 angle lines DANGER Machine instability can result in injury or death To ensure stability during operation the following conditions must be observed a Tires must be correctly inflated see 5 1 2 TECHNICAL CHARACTERISTICS b The machine frame must be level if the machine is equipped with frame levelling...

Page 108: ... 3 4 5 6 7 8 9 10 11 1 10 m 9 8 7 6 5 4 3 2 1 0 1 2 G F E D C B A 0 5m 300 kg 300 kg 300 kg 500 kg 500 kg 500 kg 750 kg 750 kg 750 kg 1000 kg 1000 kg 1000 kg 1500 kg 1500 kg 1500 kg 2000 kg 2000 kg 2000 kg 3500 kg 3500 kg 3500 kg 3000 kg 2500 kg 5 1 3 2 6 2 4 1230 kg 1230 kg 1230 kg 1500 kg 1500 kg 1500 kg 2500 kg 2500 kg 2500 kg 3500 kg 3500 kg 3500 kg 1 Model of the machine for which the chart i...

Page 109: ...responds to the fully extended position of the boom 5 The boom angle reference scale 3 gives an indication of the angle of the boom For the instructions below in order to as sess the intended load a Position the machine near the load as possible For detail see 3 12 6 OPERATING THE MACHINE FITTED WITH FORKS b Raise and extend the boom in order to move the work tool into position for the operation A...

Page 110: ...utions must be taken If the lines cross in one area but the load exceeds the weight value relevant to that area do not lift the load DANGER Before releasing the load make sure that the machine is within the maximum distance allowed by the chart Always retract the boom first and then lower the load Do not invert this operation sequence RKA02281 RADIUS m HEIGHT m BOOM ANGLE INDICATOR 12 13 14 0 1 2 ...

Page 111: ...responding to 200 units more than 180 and therefore is within the lifting capacity of the machine up to the maximum angle allowed by the machine since the center of gravity of the load is always on the right of line A The load can be lowered to the ground and released as long as the boom is retracted enough to keep the center of gravity of the load within the area delimited by line A RKA02290 RADI...

Page 112: ... the boom 3 From the crossing point draw line c that indicates the extension of the boom It is possible to deposit the load on the ground provided that the boom is retracted and therefore the load doesn t pass beyond the left line B RKA02300 RADIUS m 0 5 m 12 13 14 0 1 2 3 4 5 6 7 8 9 10 11 1 15 m 11 m 9 8 7 6 5 4 3 2 1 0 1 2 10 150 G F E D C B A 45 45 45 100 100 100 150 150 150 HEIGHT m Y Y Y B 3...

Page 113: ...ding to letters E and D provided that the inclination respectively 63 and 73 3 corresponding to points Z1 and Z2 be varied NOTE The choice of the possible extension to be used depends exclusively on the position of the front part of the machine with respect to fixed obstacles walls gutters etc and on the load deposit distance with respect to the point that can be reached by the machine RKA02310 RA...

Page 114: ...ace them only with new fuses having the same capacity If the engine does not run when the ignition switch is turned to position START check the main fuse and if necessary change it 3 4 1 CENTRAL UNIT FUSES AND RELAYS The fuses 1 and relays 2 are grouped on a single base 3 po sitioned in the right body side of the cab The central unit can be reached by removing the panel 4 RKAA1010 1 3 2 RKAA1020 4...

Page 115: ...ghts F8 Red 10A Rear axle swing lock solenoid valve F9 Red 10A Steering control unit A4 F10 Brown 7 5A EGS F11 Orange 5A Free F12 Light blue 15A Front work lights optional A5 F13 Brown 7 5A Front windshield wiper washer F14 Red 10A Dimmer switch direction indicators F15 Red 10A Rear windshield wiper Upper windshield wiper optional 10 10 10 7 5 7 5 15 5 10 10 7 5 5 15 7 5 10 RKA01870 A F1 F2 F3 F4 ...

Page 116: ...3 Red 10A Boom equipment solenoid valve F24 Red 10A Direction indicators unit B4 F25 Orange 5A Pre heating unit F26 Violet 3A Dashboard F27 Violet 3A SLI Safe Load Indicator display B5 F28 Brown 7 5A Parking lights F29 Orange 5A Rear work lights optional F30 Yellow 20A Air conditioner condenser fans optional 20 3 10 5 3 7 5 RKA01880 B 7 5 3 5 3 20 10 F16 F16 F17 F17 F17 F18 F18 F18 F19 F19 F19 F20...

Page 117: ...nctions disconnection upon starting K7 Optional solenoid valve enablement K8 Slow motion K9 Front work lights optional K10 Stop lights K11 Stabilizer lock frame levelling optional K12 Axle swing lock K13 Optional equipment K14 Optional equipment K15 Proportional solenoid valve enablement RKA01890 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K15 K14 ...

Page 118: ... LINE FUSES POS COLOUR CAPACITY CIRCUIT INVOLVED FG1 Red 50A Aux functions relay general power supply FG2 Yellow 30A Cab ventilation motor relay FG3 Red 50A Starter unit power supply FG4 Red 50A Fuse central unit and diesel oil preheating relay power supply FG5 Brown 175A Air preheating relay power supply RKAA0721 1 RKAA1030 1 3 2 1 1 RKAA1040 FG1 FG2 FG3 FG4 RKAA1050 FG5 RKAA1040 FG1 FG2 FG3 FG4 ...

Page 119: ...FUSES AND RELAYS 117 3 4 2 2 ENGINE LINE RELAYS POS DESCRIPTION K18 Air preheating K19 Start K22 Diesel oil preheating RKA02070 K18 K19 K22 ...

Page 120: ... engine when the hood is open unless this is ex pressly prescribed for certain maintenance operations Non compliance with these rules may lead to serious acci dents After releasing the lock 1 press the push button 2 raise the hood 3 and open it completely reaching the position defined by the gas spring 4 and by the relevant safety retainer 5 To close the hood press the safety retainer 5 of the gas...

Page 121: ...y more lock the door The cab is provided with a single door 1 that is used by the oper ator to get on and off the machine The door comprises two parts that can be opened independently of each other and that can be opened completely and secured in this position The upper part 2 of the door is used to ensure the circulation of fresh air To open and fix it pull the handle 3 and open the upper part 2 ...

Page 122: ...ant retainers both when closed and when open 3 5 3 EMERGENCY EXIT The cab s emergency exit is through the rear window and is sig nalled by an emergency exit label 1 on the window itself There are two different ways to abandon the cab through the rear window Machines without air conditioning open the window com pletely by rotating the handle and pushing the glass outwards Machines with air conditio...

Page 123: ...ir change are achieved by means of a 3 speed fan installed in the cab protected by a panel 1 and operated by means of the selector 7 The outside air intake inlet is protected by a filter 2 positioned on the back of the cab 3 and extractable from the outside while air distribution is obtained through a series of adjustable vents with variable flow rate 4 both for the side flows and for the flows th...

Page 124: ...quipped with air conditioning system A radiator having the function to heat the air conveyed into the cab is installed beside the fan this is used in the cold season and receives the hot water necessary for the heat exchange directly from the engine cooling circuit The water supply flow is partialized or excluded by means of a cock operated by the knob 6 The intensity of the hot water flow can be ...

Page 125: ...e intermediate positions make it possi ble to mix external and internal air This function ensures quicker heating of the cab and is very use ful when working in particularly polluted environments tunnels dusty or evil smelling places etc ATTENTION Do not use the air recirculation function too long in rainy or cold days since this would increase the fogging of the in side of the windows Avoid smoki...

Page 126: ...ent of the back is obtained by operating the levers 3 and at the same time exerting pressure with the back the back will automatically adapt to the physical structure of the operator The adjustment of the suspension is carried out with the lever 4 and can be controlled by observing the position of the indicator 5 The operator must carry out this adjustment while seated the right suspension degree ...

Page 127: ...tainer pin is correctly engaged in its seat The position of the back can be adjusted by operating the levers 2 and at the same time exerting pressure with the back the back will automatically adapt to the physical structure of the oper ator The degree of suspension can be adjusted by rotating the knob 3 and checking the graduated scale on the knob itself The ideal position is reached when the weig...

Page 128: ...se of movements with restricted radiuses As well as adjusting the seat the Operator can adapt the inclina tion of the steering wheel 2 to his physique Angular movements can be obtained after lifting the lever 3 once the desired position has been reached release the lever 3 5 8 SAFETY BELT DANGER Fasten the safety belt before starting the engine The safety belt must be changed when it is frayed dam...

Page 129: ...n it is unrolled 3 5 10 TECHNICAL DOCUMENTATION ATTENTION The use and maintenance manual and the spare parts cata logue are integral parts of the machine and must always ac company it even in case of resale The manual 1 and the load charts 2 must be handled with care and always kept on the machine so that they can be quickly con sulted when necessary keep the manual in the rear compartment 3 of th...

Page 130: ... and fixing the fire extinguisher where prescribed Periodically make sure that the fire extinguisher is full If the operator deems it necessary to have the fire extinguisher on board he must fix it to a bracket on the left pillar of the cab The bracket can be screwed using the holes 1 provided on the pillar 2 RKAA1190 1 2 ...

Page 131: ...the condition of the safety belt 10 the efficiency of the instruments and of the dashboard 11 the condition of the cab windows and the efficiency of lights work lights and direction indicators 3 6 1 2 DAILY CHECKS DANGER Do not smoke while refuelling and adding oil and avoid using naked flames or non homologated lighting means to check the fuel and oil level in order not to cause fires If some fue...

Page 132: ...etracted with the equipment resting on the ground The successive check is carried out by turning the ignition key to position I to supply voltage to the control panel and check the functionality of the acoustic alarm the warning lights positioned on the dashboard and of the SLI Safe Load Indicator and if the push button of the auxiliary circuit for the hydraulic equipment is in position off warnin...

Page 133: ... that there is no one within the operating radius of the machine and sound the horn Before starting the engine make sure that the gearshift reverse lever is in neutral position A safety device does not allow the machine to be started with engaged gears or selected travel direction 3 6 2 1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES 1 Turn the ignition key to position START 2 As soon as the ...

Page 134: ...oduct that facilitate the cold start ing of the engine since these are ether based and may cause explosions Turn the ignition key to the preheating position and make sure that the warning light comes on when the warning light goes out proceed as follows 1 Slightly press the accelerator pedal and turn the ignition key to position START for maximum 15 seconds 2 As soon as the engine starts release t...

Page 135: ...ons any abnormal situation must be examined thoroughly and its cause must be immediately eliminated 3 6 4 HEATING THE HYDRAULIC OIL When warming up the engine especially in the cold season it is advisable to heat also the hydraulic system oil For this purpose when the coolant temperature has reached approximately 60 C proceed as follows 1 Lift the boom slowly and completely for several times 2 Ext...

Page 136: ...il and then make sure that the stabiliz ers are completely raised At this point release the parking brake Proceed as follows 1 Select the operating mode TRAVEL or TRAVEL WORK 2 Select the steering mode see 3 2 5 MACHINE CON TROLS 3 Select the travel direction by shifting the control lever for ward F or backward R 4 Engage the gears within 5 seconds from the selection of the travel direction 5 Acce...

Page 137: ...k the work area for snow landslips gravel loose ground and anything that may suddenly modify the work con ditions and the stability of the machine 2 When travelling downhill or uphill without load engage the forward gear and travel with boom lifted in transport position Figures A B 3 When travelling downhill or uphill carrying a load always keep the boom directed upwards travelling forward uphill ...

Page 138: ...is sufficently firm If it is necessary to work with the machine immersed in water make sure that the maximum depth does not exceed 40 cm working in deeper water may cause serious damage ATTENTION After moving or working with the machine immersed in water on the seashore or on river banks always remove any mud or sand from the fulcrum pins of the stabilizers and the equipment that have been im mers...

Page 139: ... When leaving the machine remove the ignition key use the ladders and handles lock the cab The operator is directly responsible for any damage caused by improper parking operations 1 Park the machine on firm and level ground in a sufficiently wide space 2 Move the gearshift reverse lever 1 to position N and apply the parking brake 2 3 Stop the engine following the procedure indicated in para graph...

Page 140: ...wards and resting against an obstacle 2 Select the round steering mode with the push buttons 1 and 2 and steer the wheels completely directing them uphill 3 Shift the reverse lever 3 into neutral 4 Apply the parking brake 4 5 Stop the engine following the procedure indicated in para graph 3 8 STOPPING THE ENGINE 6 Leave the driving position using the ladders and handles pro vided for this purpose ...

Page 141: ...ng for a long period and is still hot in this case let the engine idle at minimum 1200 1300 rpm for about 5 minutes in order to allow it to cool down gradually before stopping it Before stopping the engine proceed as follows 1 Retract the boom completely and rest the equipment onto the ground 2 Shift the gearshift reverse lever to neutral and apply the park ing brake 3 Stop the engine The engine c...

Page 142: ... ramps must be suitable for the machine gauge Position the ramps with a maximum inclination of 15 Remove any trace of oil grease or ice from the ramps and the loading board Do not change direction when the machine is already on the ramps if necessary go down and find the correct direc tion 1 Remove the equipment from the boom 2 The machine must get on the ramps with the boom directed forward with ...

Page 143: ...machine is indicated on the CE identification plate Always keep at a safety distance while the machine is being lifted The manoeuvres must be carried out only by the person responsible for these operations who must fol low the correct procedure and take all the necessary measures To lift the machine use the points indicated which are symmetrical and indicated by apposite picto grams 1 Remove the e...

Page 144: ...anged every 2 years 3 10 3 BATTERY DANGER To avoid explosions due to the presence of gas do not provoke sparks and do not use naked flames near the battery The battery electrolyte is dangerous If it comes in contact with the eyes or the skin immediately rinse with plenty of water and consult a doctor without delay To prevent the fluid from freezing add distilled water in the morning before startin...

Page 145: ... and water completely from the machine body Park the machine on firm ground if the machine must be parked near banks or ditches park it on wooden boards in order to distribute the weight of the machine on a larger surface 2 Be careful to water drops forming on the hydraulic cylinder rods these drops must be completely removed since if they freeze the cylinder gaskets may be damaged After removing ...

Page 146: ...NT The coolant must be changed only if it is not permanent For the relevant specifications see 4 3 FUEL COOLANT AND LUBRICANTS 2 Make sure that the cooling fan belt is in good conditions 3 Make sure that the fins of the radiator and of the heat exchanger are clean 4 Check the radiator cap gasket and spring in case of doubt regarding tightness and setting change the cap ...

Page 147: ...nnecting the lifting forks and the bucket However the same procedure applies to all pieces of equipment that can be used with equip ment carriers with hydraulic or manual coupling Any equipment with non standard coupling requires specific equipment carriers and must be approved by Komatsu Utility Approved standard equipment includes lifting forks loader for general purpose or for light materials a...

Page 148: ...installed lift slowly and centre the connections and the equipment 8 Using the control lever draw back the quick coupling until it rests on the lower part of the equipment 9 Press and hold the AUX2 7 button until the lower coupling pins 3 are fully engaged 10 Disconnect the auxiliary circuits enablement switch 1 IMPORTANT Before using the equipment make sure that the lower cou pling pins are compl...

Page 149: ...e engine 1 Disconnect the delivery and drain pipes 1 and 2 from the quick couplings of the pin control cylinders 2 Remove the protection elements of the equipment quick cou plings and install them on the couplings of the lock pin cylin ders 3 Connect the equipment to the pipes 1 and 2 4 Start the engine and lift the equipment so that it is completely visible 5 Press and lock the optional equipment...

Page 150: ...rry out the job 3 12 5 OPERATING THE EQUIPMENT DANGER Always fasten the safety belt Always warn the authorised persons present on the work site by sounding the horn IMPORTANT The illustrations shown are the basic ones that are necessary for a correct use and exploitation of the machine the operator must get familiar with the controls and the operation method described and learn to organize work in...

Page 151: ...ration with or without stabilizers see 3 3 LIFT ING LOADS If the mass of the load isn t known proceed as indicated below 1 Get as near the load as possible perpendicularly and select the TRAVEL WORK operating mode with the selector 1 2 Use the water level to check if the frame needs levelling if necessary and if the frame levelling device is provided level the frame 3 If the machine is equipped wi...

Page 152: ...end and lower the boom until the forks held the load firm ly 9 Lift the load slowly a few centimeters by folding the equip ment to check the stability of the machine on the SLI Safe Load Indicator see 3 2 5 MACHINE CONTROLS 7 SLI SAFE LOAD INDICATOR NOTE If the machine has reached or exceeds the stability limit lower and release the load and if possible move the ma chine nearer in order to reduce ...

Page 153: ...ore starting to move towards the un loading area 3 If necessary select the steering mode two wheel round or crab steering see 3 2 5 MACHINE CON TROLS and start travelling slowly in order to get as near the unloading area as possible always in perpen dicular position 3 12 6 3 STACKING THE LOAD 1 With the machine in TRAVEL WORK operating mode move perpendicularly and get as near the unloading ar ea ...

Page 154: ...hting up steadily together with the sounding of the acoustic alarm intermittent or continuous indicates that the machine runs the risk of overturning Retract the boom completely and give up stacking the load since the capacity of the machine isn t sufficient for this operation See 3 2 5 MACHINE CONTROLS 7 SLI SAFE LOAD IN DICATOR 7 Incline the equipment carrier forward until the forks are in lev e...

Page 155: ...achine equipped with forks has two safety locks 1 these are constructed and positioned in such a way as to be always in tegral with the equipment holder 2 even when the forks 3 are operating Fastening is achieved with two pins 4 that engage in the safety retainers 1 and in the equipment holder 2 the two pins are held in position by safety pins 5 For travelling on roads proceed as follows 1 Remove ...

Page 156: ...encum bered with big obstacles or characterized by considerable height differences before starting work it is advisable to level the ground as much as possible both for the machine and for the vehicles to be loaded This preliminary operations will make work quicker ensure better results and at the same time reduce the operator s stress and the straining of the machine components furthermore this w...

Page 157: ...bucket completely 3 Reverse the motion of the machine and dump the bucket on to the truck IMPORTANT Start loading the truck from the cab side and if the material is sufficiently homogeneous dump the material from the maximum height in order to increase its compaction and its distribution on the loading platform RKA02160 RKA02170 ...

Page 158: ...machine completely and very carefully retouching any scratch on the paintwork in order to avoid oxidation 2 Drain and change all the fluids of the hydraulic circuits and the lubricants axles reduction gears converter following the indications given in the maintenance instructions 3 Change all the filtering elements air filter engine oil filter hydraulic circuit filters fuel filter 4 To prevent the...

Page 159: ...g peri od of inactivity 7 Loosen the alternator fan and coolant pump belt 8 Reconnect the pump intake pipe to the tank 9 Seal the exhaust pipe and all the intake and breather openings with adhesive tape and vynil bags 10 Position a sign with the clear writing NO ENGINE OIL on the steering wheel and on the engine IMPORTANT These operations must be repeated every 6 months 3 13 3 MAINTENANCE DURING A...

Page 160: ...ding as indicated in paragraph 3 6 2 STARTING THE ENGINE and make sure that the engine oil pressure warning light goes out when the starter has run for approx 5 seconds 10 After starting the engine let it run at low idle for 15 minutes 11 Warm the hydraulic cylinders by lifting and extending the boom and the equipment carrier slowly more than once 3 13 5 AFTER A LONG PERIOD OF INACTIVITY Consideri...

Page 161: ...ndition If it occurs it is necessary to resort to external means and report the acci dent to the Komatsu Utility Dealer immediately While waiting for the Dealer to arrive remove the ignition key mark off the area around the machine and keep it under close surveillance to ensure that nobody approaches This area is very dangerous in par ticular if the weather is windy ...

Page 162: ...r or towing cables If you are not sure about the manoeuvres to be carried out or if the problems to which the failure is due cannot be solved with routine maintenance contact your Komatsu Utility Dealer 1 Only the operator can get on the problem machine and only if the service brakes are functioning and steering is possible ATTENTION If the failure involves the engine there is no hydraulic pressur...

Page 163: ...t with this fluid immediately rinse the involved part with plenty of water If the acid gets into the eyes immediately rinse with plenty of water and consult a doctor without delay When working on the battery always wear goggles and gloves When removing the battery disconnect first the earth cable when installing the battery connect first the positive cable If a tool makes contact with the positive...

Page 164: ...e cables with great care prevent the cables disconnected from the battery from touching oth er parts of the machine in order to avoid the explosion of the hydrogen IMPORTANT Cables and pliers must be suitable for the current load that must be transferred The battery to be used for the starting must have greater capacity or at least the same capacity as the battery of the machine to be started Make...

Page 165: ... Check and repair Charge battery Change Starter pinion engages and then disen gages Battery charge insufficient Charge battery Starter makes engine run slowly Battery charge insufficient Faulty starter Charge battery Change Starter disengages before engine has started Faulty cables Battery charge insufficient Check and repair Charge battery Engine oil pressure warning light does not come on when e...

Page 166: ...very pump Clutch shaft or piston rings dam aged Leakages due to clutch piston pump locked open Top up Clean element and seat Change Change rings Clean valve carefully Pump delivery insufficient Oil level too low Intake filter clogged Faulty pump Top up Clean filter Change Overheating Damaged rings Faulty pump Oil level too low Dirty heat exchanger Damaged heat exchanger Remove disassemble and reas...

Page 167: ... connections fuel and injection pumps Bleed the circuit Contact Dealer Engine stops Fuel filters clogged Air in fuel supply circuit Other causes Change Check pipes connections fuel and injection pumps Bleed the circuit Contact Dealer Engine overheats Radiator clogged Insufficient tension of water pump and fan belt Low coolant Air filters clogged Clean fins Check and adjust belt tension Top up Clea...

Page 168: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 169: ...MAINTENANCE 167 ...

Page 170: ...hift reverse unit connector positioned under the steering wheel 5 Do not apply more than 200V continuously 6 Connect the earth cable within 1 m from the point where the welding operation must be carried out 7 Avoid placing gaskets and bearings between the welding area and the earth cable Do not use flammable fluids to clean any parts of the machine Keep naked flames away from these fluids and avoi...

Page 171: ...st be col lected and disposed of according to the anti pollution regulations in force The combustible material of some components may become extremely dangerous if it burns For this reason avoid any contact of burnt material with your skin or eyes and do not inhale the fumes see 2 8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ...

Page 172: ...e coolant serves to keep the engine at the correct temperature and therefore to ensure optimal operating con ditions check the coolant level in the expansion tank daily and top up when necessary FLUID SPECIFICATIONS Engine oil SAE 15W 40 Spec API CI Hydraulic system oil SAE 10W 30 Spec API CI Hydraulic system biodegradable oil Only for machines in which synthetic biodegradable oil type HEES not of...

Page 173: ...ork The maintenance operations required for the hydraulic system are the following 1 daily check of the oil level in the tank 2 periodical change of the oil filter 3 periodical change of the oil and cleaning of the intake filter Always bleed the circuit after changing the oil filter or the oil When a component is removed from the circuit check the gaskets and O rings and change them if they are da...

Page 174: ...ation of any op tional equipment contact your Komatsu Utility Dealer If any electric welding operation has to be carried out disconnect the battery the alternator and the gearshift re verse unit connector 4 2 4 NOTES REGARDING LUBRICATION Lubrication makes the operations carried out with the machine and work equipment smoother while preventing wear and the noise that may be produced if the articul...

Page 175: ...ne Use only Komatsu Utility genuine parts which alone can guarantee excellent quality and interchangeability ITEM CODE DESCRIPTION Q ty CHANGE INTERVAL Hydraulic oil drain filter 848101178 Cartridge 1 Every 500 hours Engine oil filter EA2992242 Cartridge 1 Fuel filter EA504073234 Cartridge 1 Converter oil filter DG4209211 Cartridge 1 Every 1000 hours Air cleaner 848101189 848101190 Main cartridge ...

Page 176: ...nal reduction gear ea 0 7 0 7 Rear axle Differential 7 1 7 1 Final reduction gear ea 0 7 0 7 Hydraulic transmission OLIO ATF GM DEXRON II D DEXRON is a reg istered trademark of General Motors Cor poration 13 5 11 7 Transmission reduction gear 0 25 0 25 Braking system 0 65 0 65 Fuel tank DIESEL OIL 130 130 Engine cooling system PERMANENT COOLANT 20 LUBRICATION POINTS CONSISTENCY TYPE Articulated jo...

Page 177: ...ion and constant reliability of the engine Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine in the work equipment hydraulic circuit in the transmission in the axles and in the brakes First filling quantity total quantity of oil including the oil for the components and pipes Oil change quantity quantity of oil necessary ...

Page 178: ...oil in the hydraulic system empty the system completely disconnect ing the cylinders and all the parts that may contain conventional oil and replace the drain filter with a new one Start the engine and let it idle without using the work equipment wait until the oil reaches a temperature of at least 40 C then start moving the equipment so that all the parts of the system are filled with oil Stop th...

Page 179: ... 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16 18 20 22 24 2 2 5 2 5 2 5 3 24 27 30 32 36 19 5 2 27 3 38 4 52 6 66 7 191 21 262 28 372 40 511 57 644 70 27 3 37 4 53 6 73 8 92 10 268 29 366 36 524 57 719 80 905 98 27 30 3 3 5 41 46 96 10 131 14 945 100 1287 140 135 15 184 20 1329 140 1810 190 ITEM DESCRIPTION kgm Nm Cab Front support screws 20 196 Re...

Page 180: ...UBRICATION DIAGRAM 2 SECTION BOOM IMPORTANT For the lubrication procedures for single points see 4 7 MAINTENANCE PLAN RKA02200 2000 h 1000 h 500 h 100 h 50 h 10 h 250 h 395 93 11960 Hydraulic oil Grease Engine oil Transmission oil Brake oil ...

Page 181: ...ON DIAGRAM 3 SECTION BOOM IMPORTANT For the lubrication procedures for single points see 4 7 MAINTENANCE PLAN RKA02210 2000 h 1000 h 500 h 100 h 50 h 10 h 250 h 395 93 11950 Hydraulic oil Grease Engine oil Transmission oil Brake oil ...

Page 182: ...ine maintenance after a certain period it is advisable to change them inde pendently of their state in order to keep the machine efficient over time Repair or replace these components immediately in case of failures or anomalies even if the time interval pre scribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for changing ...

Page 183: ... regarding the components connected with safety and the components that must be periodically changed When changing pipes always change O rings gaskets and analogous components 4 6 1 1 FUEL SUPPLY SYSTEM No Components related to safety that periodically need changing Q ty Change interval 1 Fuel pipe Fuel tank fuel pump 1 Every 2 years or 1000 hours which ever occurs first 2 Fuel pipe Injection pump...

Page 184: ...nents related to safety that periodically need changing Q ty Change interval 1 Hydraulic pipe Hydraulic pump control valve 1 Every 2 years or 1000 hours which ever occurs first 2 Hydraulic pipe Hydraulic pump auxiliary control valve 1 3 Hydraulic pipe Hydraulic pump solenoid valve 1 RKA02220 1 3 2 ...

Page 185: ...l valve lifting boom iron pipe 2 Every 2 years or 1000 hours which ever occurs first 2 Hydraulic pipe tubi in ferro lifting cylinder 2 3 Hydraulic pipe control valve compensating cylinder 2 4 Hydraulic pipe control valve extension boom iron pipe 2 5 Hydraulic pipe control valve equipment carrier iron pipe 2 6 Hydraulic pipe auxiliary control valve auxiliary system iron pipe 2 RKA02230 5 1 6 4 1 3 ...

Page 186: ...lic pipe iron pipe extension boom iron pipe 2 Every 2 years or 1000 hours which ever occurs first 2 Hydraulic pipe iron pipe extension cylinder 2 3 Hydraulic pipe iron pipe equipment carrier iron pipe 2 4 Hydraulic pipe iron pipe equipment carrier cylinder 1 5 Hydraulic pipe iron pipe auxiliary system iron pipe 2 6 Hydraulic pipe pipe optional equipment 1 RKA02400 5 1 4 5 1 2 6 ...

Page 187: ...ades Check 194 g Cab door and engine hood hinges Lubricate 194 h Fork support rod Lubricate 194 i Fuel tank Check fuel level 194 j Brake oil reservoir Top up brake oil 195 No PART OPERATION PAGE a Various checks 196 b Acoustic alarms warning lights and instruments Check operation 196 c Engine coolant Check level 197 d Radiator fluid Check level 197 e Engine oil Check level 198 f Tyres Check pressu...

Page 188: ...biodegradable oil HEES is used Carry out the following operations after the first 500 hours of operation together with those to be performed EVERY 500 HOURS a CHANGE THE HYDRAULIC OIL AND CLEAN THE INTAKE FILTER No PART OPERATION PAGE a Drive shafts Lubricate 204 b Front and rear axle oscillation joint Lubricate 205 c Wheel hub joints Lubricate 205 No PART OPERATION PAGE a Articulated joints Lubri...

Page 189: ...rsion Check for oxidation 220 i Boom chains Only for 3 section boom version Check and tighten 221 j Extension boom chains Only for 3 section boom version Check length 226 k Chains Only for 3 section boom version Lubricate 227 l Chain drive gear bushings Only for 3 section boom version Check clearance 228 m Sliding pads Check clearance 228 n Wheels Check nut driving torque 228 No PART OPERATION PAG...

Page 190: ... 3000 HOURS OF OPERATION OR EVERY 3 YEARS No PART OPERATION PAGE a Safety belt Change 236 No PART OPERATION PAGE a Engine thermostatic valve Change 236 b Engine antivibration and retaining screws Check 236 c Engine valve clearance and injection timing advance Check and adjust 236 ...

Page 191: ...ngine hood The electrolyte level in each cell must be about 6 mm above the plate edge if necessary remove the cell plugs and top up using exclusively distilled water If on the contrary the level is low because some fluid has been spilled add electrolyte with concentration suitable for the ambient temperature See 3 10 3 BATTERY NOTE When adding distilled water or electrolyte do not exceed the level...

Page 192: ...HOOD To clean the primary element proceed as follows 1 Release the safety retainer 1 moving it toward the outside 2 Rotate the cover 2 anticlockwise by approximately 12 5 and then remove it 3 Extract the filtering element 3 4 Slightly strike the filtering element 3 on the palm of your hand in such a way as to remove the dust it contains and blow compressed air on its inner surface keeping the air ...

Page 193: ...ng element and the safety car tridge Change the primary filtering element after 6 cleaning oper ations or after one year Every time the primary filtering ele ment is replaced the safety cartridge must be replaced too To change the safety cartridge 6 after removing the primary ele ment 3 proceed as follows 1 Remove the safety cartridge 6 and replace it with a new one 2 Once the safety cartridge 6 h...

Page 194: ...rs If the machine is provided with air conditioning system besides the external filter 3 there is also an additional internal filter 6 for air recirculation This is a filter that holds the impurities contained in the air and it must be cleaned whenever a decrease in air circulation is per ceived The filter can be reached from the inside of the cab and to clean the filtering element it is necessary...

Page 195: ...and relays are grouped on a single base positioned in side the engine compartment and can be reached by removing the cover 1 For information on the capacity of the fuses and relays to be re placed see 3 4 2 ENGINE LINE FUSES AND RELAYS 4 7 1 e CHECKING THE WINDSHIELD WASHER FLUID LEVEL If there is air in the windshield washer fluid check the washer fluid level in the reservoir 1 If necessary add d...

Page 196: ...ATTENTION Inject grease until all the residual old grease has come out After lubrication remove all the grease that has come out and clean the area 4 7 1 h LUBRICATING THE FORK SUPPORT ROD The fork support rod should be lubricated when the widthwise movement of the forks is difficult Use a brush to lubricate the support rod For further information on the appropriate grease to use see 4 3 FUEL COOL...

Page 197: ... brake oil reservoir 1 can be reached after removing the front guard 2 This is a visual check and if necessary the reservoir must be topped up with the prescribed oil until reaching the MAX mark See 4 3 FUEL COOLANT AND LUBRICANTS IMPORTANT Use only new oil If constant and considerable leakages are observed it is advisable to contact a Komatsu Utility Dealer to have the braking system checked and ...

Page 198: ...clean as well as the inside of the cab 4 7 2 b CHECKING THE ACOUSTIC ALARMS WARNING LIGHTS AND INSTRUMENTS This checking procedure concerns three units 1 Acoustic alarm and warning lights on the dashboard this check is performed by turning the ignition key to position I In this condition the red warning lights on the dashboard should come on and the acoustic alarm should start sounding If a red wa...

Page 199: ...IMPORTANT The upper MIN and MAX marks indicate the level reached by the coolant after expansion at operating temperature 4 7 2 d CHECKING THE RADIATOR FLUID LEVEL DANGER Carry out this check with the machine parked on level ground Do not remove the radiator cap when the fluid is hot since the fluid may be sprayed out of the radiator and cause burns Loosen the cap slowly to release any residual pre...

Page 200: ...lubricant table for the ambient temper ature See 4 3 FUEL COOLANT AND LUBRICANTS IMPORTANT If it is necessary to check the oil level during or soon after work stop the engine and wait 15 minutes before carrying out the check 4 7 2 f CHECKING THE TYRE PRESSURE DANGER When inflating a tyre the operator must stand in front of the tread Do not exceed the pressure values indicated in the TECH NICAL DAT...

Page 201: ...CKING AND ADJUSTING THE PARKING BRAKE IMPORTANT During running in check the efficiency of the parking brake after the first 100 hours of operation CHECK Check conditions Tyre pressure in accordance with the prescribed values Road surface dry compact with a gradient of approx 20 Machine in operating conditions without load 1 Start the engine see 3 6 2 STARTING THE ENGINE 2 Align the machine in trav...

Page 202: ...oroughly before applying the greasing pump After lubrication remove all the contaminated grease that may have spread out and clean the area If the machine is used in difficult conditions carry out these operations more frequently than usual 1 Park the machine on firm and level ground as described in 3 7 1 PARKING ON LEVEL GROUND 2 Make sure that the gearshift reverse lever 1 is in neutral po sitio...

Page 203: ... Base side 1 point 7 Stabilizers fulcrum pin if provided 2 points 8 Stabilizers suppport fulcrum pin if provided 2 points 9 Stabilizer cylinders if provided Head side 2 points 10 Boom fulcrum pin 1 point 11 Telescopic boom sliding pads with completely retracted and lowered boom sections 2 section boom 2 points 3 section boom 4 points 12 Telescopic boom sliding pads with completely extended and low...

Page 204: ...and clean the area 4 7 3 c DRAINING THE WATER SEPARATOR DANGER Fuel is flammable do not use naked flames and do not smoke while draining the water separator If some fuel is spilled wipe it up immediately This operation serves to drain the condensate water and must be carried out with full tank in order to prevent air from entering the fuel supply circuit The condensate must be drained at the end o...

Page 205: ...d the boom sections until they are completely out and in horizontal position stop the engine and apply the parking brake 3 Remove any used oil from the boom sections and clean the block sliding areas and the grease nipples 1 and 2 thor oughly 4 Using the grease nipples 1 and 2 positioned on the lower end of the main 3 and intermediate 4 boom sections in ject grease to lubricate the front sliding p...

Page 206: ...eller shafts must be lubricated after thoroughly cleaning the grease nipples by applying the greasing pump filled with the prescribed grease See 4 3 FUEL COOLANT AND LUBRICANTS Once the lubrication procedure has been carried out make sure that all the points have been lubricated and re move the used grease that may have spread out of the joints RKA02320 a b c d e a 2 points b 1 point c 1 point d 2...

Page 207: ... have spread out of the joints 4 7 4 c LUBRICATING THE WHEEL HUB JOINTS The lubrication points of the hub joints are shown in the figure and it is important to remember that they are located in symmetrical positions on the machine The joints must be lubricated after removing the guards and after thoroughly cleaning the grease nipples 1 and 2 by applying the greasing pump filled with the prescribed...

Page 208: ...ER The compensating cylinder must be lubricated on the base side from an intermediate position between the frame and the wheel always apply the parking brakes and remove the ignition key IMPORTANT Clean the grease nipples thoroughly before applying the greasing pump After lubrication remove all the contaminated grease that may have spread out and clean the area If the machine is used in difficult ...

Page 209: ...cation procedure with completely retracted boom after removing the rear cover of the main boom section Use only the prescribed grease see 4 3 FUEL COOLANT AND LUBRICANTS and apply it to the guard with a brush No Part Operation 1 Stabilizer cylinders base side 2 points 2 Tilting cylinder base side 1 point 3 Compensating cylinder base side 1 point 4 Boom inner hoses See 4 7 6 b RKA02440 2 4 3 1 RKA0...

Page 210: ...s filling hole Use a 12 mm wrench FINAL REDUCTION GEAR This check must be carried out on each reduction gear positioned with its plug on the horizontal axis If necessary move the machine slightly until reaching the speci fied position which is indispensable for an accurate check This a visual check and serves to verify if the lubricant reaches the hole 2 if necessary top up using the prescribed oi...

Page 211: ...it reaches 85 88 C and keep the engine idling 2 Open the engine hood and extract the dipstick 1 3 Make sure that the level reaches the maximum mark If necessary with the engine still idling add the appropriate quantity of the prescribed oil See 4 3 FUEL COOLANT AND LUBRICANTS 4 Reintroduce the dipstick and stop the engine 5 Make sure that the reduction gear oil level is halfway up the sight gauge ...

Page 212: ...ily components even if in small quantities since they facilitate the sticking of dust which negatively affects the heat exchange process Clean the outside of the radiator or of the heat exchanger whenever they are dirty with oil or greasy or oily substances If the machine is used in dusty places clean the radiator and the heat exchanger more frequently in or der to prevent the fins from clogging 4...

Page 213: ...ressure exerted is approximately 10 kg the resulting de flection must be approx 5 6 mm When the belt is new the resulting deflection must be approx 4 mm If the resulting deflection exceeds the values indicated proceed as follows 1 Remove the belt guard 4 2 Loosen the screw 5 that fastens the cam 6 3 Loosen the screw 7 that fastens the compressor 2 4 Loosen the nut 8 and tighten the screw 9 to achi...

Page 214: ...p against the retainers 2 when the parking brake is released If the levers on which the screws are installed do not perform a full return stroke do not use the machine and contact your Komatsu Utility Dealer immediately for the necessary service 4 7 6 i CHECKING THE ELECTROLYTE LEVEL For details on this checking procedure see 4 7 1 WHEN REQUIRED RKAA1800 1 2 ...

Page 215: ... oil HEES is used This maintenance operation should be carried out after the first 500 hours of operation together with those to be performed EVERY 500 HOURS CHANGE THE HYDRAULIC OIL AND CLEAN THE INTAKE FILTER For further details on the various maintenance operations see 4 7 5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ...

Page 216: ...card the filter 3 Clean the inside of the head 3 4 Lubricate the gasket of the new filter and tighten until it rests against the gasket 5 Give another half turn by hand 6 Bleed the fuel supply circuit BLEEDING THE CIRCUIT After filling the tank proceed as follows 1 Turn the ignition key to position I 2 Loosen the bleeder screw 4 on the filter casing head 3 3 Operate the fuel pump 5 and keep it run...

Page 217: ... drained at the end of work or in any case with the machine at a temperature of 40 45 C in order to prevent the condensate from freezing when the tempera ture drops thereby making the draining operation impossi ble The condensate and the impurities that may have accumu lated inside the tank must be eliminated before refuelling 4 7 8 c CHECKING THE HYDRAULIC OIL LEVEL DANGER The oil level must be c...

Page 218: ...us components due to their wear To replace the filter proceed as follows 1 Slowly loosen the filler cap 1 to release any residual pres sure from the tank and then remove the cap 2 Remove the screws 2 and the filter cover 3 3 Remove the cartridge 4 and the spring 5 4 Clean the magnetic rings 6 that are positioned on the cover 3 to block the metal particles 5 Change the cartridge 4 6 Reassemble the ...

Page 219: ...gulations in force The purpose of this operation is to let any condensate deposited on the bottom of the tank flow out To do that perform the following steps in the sequence indicated 1 Loosen the filler cap 1 to release any residual pressure from the tank 2 To let the condensate flow out loosen the drain plug 2 until no more water is present in the fuel that flows out 3 Tighten the plug 2 IMPORTA...

Page 220: ...ange also the oil filter see 4 7 8 g CHANGING THE ENGINE OIL FILTER Proceed as follows 1 Open the engine hood see 3 5 1 ENGINE HOOD 2 Remove the drain plug 1 of the oil pan gathering the used oil that flows out into a container with suitable capacity While the oil flows out remove the filler cap 2 so that the oil can flow out freely 3 Change the filter see 4 7 8 g CHANGING THE ENGINE OIL FILTER 4 ...

Page 221: ...on regulations in force This operation must be carried out whenever the oil is changed Proceed as follows 1 Unscrew and remove the old filter 1 using the special wrench provided 2 Clean the contact surface between the gasket and the filter support 2 3 Fill the new filter with engine oil lubricate the gasket and screw thoroughly until the filter rests against the gasket 4 Give another half turn by ...

Page 222: ...afety block in central position under the front part of the frame This is a visual check and consists in spotting signs of oxidation on the extension and retraction chains For the inspection proceed as follows 1 Remove the screws and the rear cover 1 of the main boom section 2 2 While the operator slowly extends the boom sections inspect the side links of the retraction chain 3 and the sides of th...

Page 223: ...vided Do not rest the boom so as to it can run freely At the end of the tension adjustment procedures before using the machine or in any case before re tracting the boom sections reassemble and fasten all the chain protection guards Failure to comply with these instructions can lead to severe hazard If the machine isn t equipped with stabilizers place a safety block in central position under the f...

Page 224: ...rews 2 and the grease nipple 3 then re move the rear casing 4 and the upper guards 5 of the chains 6 3 Verify that the distance B is more than 0mm that is that the end boom section 7 doesn t rest against the intermediate section 8 when the latter makes contact with the main boom section 9 A 0mm RKAA1611 2 4 3 RKAA1630 1 RKAA1640 5 6 RKAA1650 A B A B 8 9 7 ...

Page 225: ...t is obtained 4 Measure the distance B when the intermediate boom sec tion is in contact with the main boom section 5 Extend the boom sections approximately 500 mm 6 Tighten the chain adjusting nut 11 turning it clockwise until the distance between the end boom section being retracted and the intermediate section corresponds to B IMPORTANT After two adjustments have been made before attempting to ...

Page 226: ...can run freely 2 Slowly retract the boom sections approximately 50 mm to slacken the chains 12 slightly 3 Measure the distance H between the chains 12 and the surface of the boom 7 halfway between the front sprocket and the rear coupling that is in the rear casing connection ar ea ATTENTION H is a fixed value for this machine and corresponds to The distances H of the two chains 12 must be equal to...

Page 227: ...ade before attempting to carry out the third one have your Komatsu Utility Dealer check the stretching of the chains and evaluate if it is nec essary to change them The maximum chain stretching allowed corresponds to 3 For this check count 33 pitches of the mounted chain at this point measure this last distance and if it is equal to or exceeds 647 7 3 5 mm 34 pitches of a new chain it is necessary...

Page 228: ...if the distances H are shorter than prescribed adjust the extension chains again see BOOM EXTENSION CHAINS 4 Reassemble all the casing and guards 4 and 5 previously removed taking care to secure them properly 5 Put back the grease nipple 3 and carry out the greasing op eration 4 7 8 j CHECKING THE LENGTH OF THE CHAINS Only for the 3 section boom version This operation requires the removal of the c...

Page 229: ...ut the lubricating procedure in a well ventilated ar ea or even better outdoors since inhaling oil vapours can be harmful If using a low pressure oil spray always wear a suitable facemask for organic and inorganic aerosol filtration gog gles with side shields and waterproof gloves and spray the oil from a position sheltered from the wind This operation must be carried out only after a negative oxi...

Page 230: ...This check requires the removal of some parts and good knowledge of the operating methods is therefore essen tial Contact your Komatsu Utility Dealer to have this inspection carried out During the maintenance service to be car ried out EVERY 500 HOURS they will also adjust any boom block clearance due to settling or wear 4 7 8 n CHECKING THE WHEEL NUT DRIVING TORQUE This check serves to restore th...

Page 231: ...le the oil flows out remove the plug 1 Use a 12mm hexagon wrench 2 Once the oil has been drained put back the plug 2 and add oil of the prescribed type through the plug hole 1 until reaching the level corresponding to the lower edge of the hole itself 3 Put back the plug 1 FINAL REDUCTION GEAR 1 Move the machine until the plug 3 is in low position on the vertical axis 2 Remove the plug 3 and let t...

Page 232: ... engine hood and extract the dipstick 1 2 Remove the drain plug 2 and let the oil flow into a container with suitable capacity 3 Remove the filter 3 and change it See 4 7 9 c CHANG ING THE HYDRAULIC TRANSMISSION FILTER DRIVING GEAR 4 Remove the drain plug 4 and let the oil flow into a container with suitable capacity 5 While the oil flows out remove the filler cap 5 6 When the oil has been drained...

Page 233: ... the transmission oil is changed Proceed as follows 1 While the transmission oil is being drained use the special wrench provided to unscrew and remove the old filter 1 3 Clean the contact surface between the gasket and the filter support 2 4 Lubricate the gasket fit it in its seat and screw the filter thor oughly until it touches the gasket 5 Give another half turn by hand 6 Start the engine let ...

Page 234: ...nt Slowly loosen the radiator cap in order to release any re sidual pressure Coolant is considered special waste and must be collected and disposed of according to the anti pollution regulations in force IMPORTANT The change of permanent coolant does not require any washing cycle to remove deposits from the circuit 1 Open the engine hood see 3 5 1 ENGINE HOOD 2 Loosen and remove the upper cap 1 of...

Page 235: ...out with the machine positioned on level ground with boom fully retracted and lowered and parking brake applied Drain the oil and wash the system proceeding as follows 1 Apply a small pipe for the collection of the oil to the drain screws 1 and loosen them 2 Remove the front guard 2 and the cap 3 from the reservoir 4 3 Operate the brake pedal until the oil contained in the reser voir 4 runs out 4 ...

Page 236: ... and repeat the operations described above until no air bubbles can be no ticed in the oil that flows out of the drain screw 1 5 Carry out the same procedure on the remaining brake as semblies 6 After bleeding start the machine and check the braking per formance see 4 7 2 g CHECKING THE SERVICE BRAKES if necessary repeat the bleeding procedure 7 Put back the front guard 2 IMPORTANT When bleeding t...

Page 237: ...ompressed air max 3 bars IMPORTANT Carefully check the condition of the filtering element grid and if there is any doubt about its soundness change it 6 Position the gasket 6 and put back the flange 5 complete with filter 7 7 Connect the intake coupling 3 and secure it with the clamps 8 Change the drain filter see 4 7 8 d CHANGING THE HY DRAULIC OIL DRAIN FILTER 9 Put back the drain plug 2 and fil...

Page 238: ...7 12 a CHANGING THE ENGINE THERMOSTATIC VALVE This procedure must be carried out by qualified personnel Have this operation performed by your Komatsu Utility Dealer 4 7 12 b CHECKING THE ENGINE ANTIVIBRATION AND RETAINING SCREWS This procedure must be carried out by qualified personnel Have this operation performed by your Komatsu Utility Dealer 4 7 12 c CHECKING AND ADJUSTING THE ENGINE VALVE CLE...

Page 239: ...TECHNICAL DATA 237 ...

Page 240: ...ollowing dimensional data refer to the machine equipped with the tyres listed below WH609 WH609 turbo 405 70 24 PR14 WH613 WH613 turbo 405 70 24 PR14 WH713 15 5 80 24 PR12 WH714 WH714H 14 00 24 PR16 WH716 14 00 24 PR16 Q B D G F E N K L P H U V A2 C A1 R1 R2 L T S W Z RKA01640 ...

Page 241: ...350 3350 3350 F 4469 4469 5099 5124 5124 5124 G 5525 5700 6170 6170 6170 6865 H 400 400 430 465 465 465 K 1660 1835 1720 1720 1720 2415 L 1220 1220 1220 1220 1220 1220 N 845 845 1100 1100 1100 1100 P 50 50 50 50 50 50 Q 3630 3630 3630 3630 3630 R1 5072 5273 5336 5336 5336 5959 R2 3615 3615 3724 3724 3724 3724 S 1214 1214 1214 1214 1214 1214 T 100 100 100 130 130 130 U 47 47 38 39 39 39 V 19 19 20 ...

Page 242: ...res and engine at 2300 rpm TYRES NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRT...

Page 243: ... 2300 rpm TYRES NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is...

Page 244: ... 2300 rpm TYRES NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is...

Page 245: ...300 rpm TYRES NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is a...

Page 246: ... ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is absolutely forbidden mount tyres not indicated below For more informations contact your Komatsu Utility Dealer GEARS 1st 2nd 3rd 4t...

Page 247: ...ure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is absolutely forbidden mount tyres not indicated ...

Page 248: ...m TYRES NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is absolut...

Page 249: ...NOTE The maximum inflation pressure indicated on the tyre may differ from the pressure stated in the table be low To ensure the maximum stability of the machine KEEP TO THE INFLATION PRESSURE VALUES INDI CATED IN THE TABLE which have been agreed with the tyre manufacturers in accordance with the standards set by the European Tyre and Rim Technical Organisation ETRTO ATTENTION It is absolutely forb...

Page 250: ... subjected to vibrations lower than 0 5 m sq sec 5 1 4 LOAD DISTRIBUTION ON THE AXLES NOTE The values indicated in the table below refer to the machine ready to start with operator on board equipped with forks filled with coolant lubricants and fuel without optional equipment WH609 WH609 turbo WH613 WH613 turbo WH713 WH714 WH714H WH716 Load on front axle kg 4050 5290 5230 5300 5230 5760 Load on re...

Page 251: ...13 WH613 turbo WH713 WH714 WH714H WH716 Max lifting capacity kg 3500 3500 3700 4000 4500 4000 Lifting capacity at max height kg 2700 1000 2000 350 2000 3000 1500 3000 2000 3500 2000 Lifting capacity with max outreach kg 1100 300 600 450 520 280 Max lifting height m 9 0 12 4 12 9 13 9 13 9 15 9 Reach at max lifting height m 0 4 1 4 0 7 1 0 1 0 1 8 Max forward outreach m 5 2 8 8 8 7 9 6 9 6 11 7 Out...

Page 252: ...WH714 WH714H WH716 Max lifting capacity kg 3500 3700 4000 4500 4000 Lifting capacity at max height kg 3500 3700 4000 4000 2500 Lifting capacity with max outreach kg 1230 1460 1300 1350 1000 Max lifting height m 12 7 13 1 14 1 14 1 16 1 Reach at max lifting height m 0 8 0 1 0 4 0 4 1 0 Max forward outreach m 8 8 8 7 9 6 9 6 11 7 Outreach with 1 ton load m 8 8 8 7 9 6 9 6 11 7 RWA38740 Max 500 mm Ma...

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