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Komatsu WA95-3, Operation & Maintenance Manual, Page: 1 / 198

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NOTICE

Komatsu has had the operating and maintenance in-
structions translated into all the languages of the
member states in the European Union. Should you
wish to have a version of the operating instructions
in another language, please don’t hesitate to ask at

your local dealer’s.

VEAM980500

Operation & Maintenance

Manual

WA95-

3

WHEEL LOADER

SERIAL NUMBERS 

HA980376

 and up

WARNING

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 near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.

Summary of Contents for WA95-3

Page 1: ... t hesitate to ask at your local dealer s VEAM980500 Operation Maintenance Manual WA95 3 WHEEL LOADER SERIAL NUMBERS HA980376 and up WARNING 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 near the machine for reference and periodically reviewed by all pers...

Page 2: ......

Page 3: ...asures 3 2 Safety Instructions 3 2 Safety Devices 3 2 Emergency Exit 3 2 Clothing and Personal Protection 3 2 Machine Modifications 3 3 Before You Leave the Driver s Seat 3 3 Mounting and Dismounting 3 3 Fire Prevention and Fire Fighting 3 4 Protection Against Asbestos Dust 3 5 Protection Against Injuries 3 5 Working at High Temperatures 3 5 Roll Over Protection System ROPS 3 6 Attachment for Prot...

Page 4: ...stem 4 23 Alarm Horn for Reverse Driving Option 4 23 Operation 5 1 Running in the Machine 5 3 Preparing the Machine Start 5 4 Visual Checks also refer to chapter Maintenance Prior to Machine Start 5 4 Adjustments Prior to Machine Start 5 6 Adjusting the Driver s Seat 5 6 Adjusting the Steering Column 5 7 Adjusting the Armrest 5 7 Adjusting the Rear View Mirrors 5 7 Adjusting the Heating and Ventil...

Page 5: ... to Start 7 23 Cooling System Checking the Coolant Level Topping Up Coolant 7 23 Engine Checking the Oil Level Topping Up Oil 7 24 Engine Draining Off Oil 7 24 Checking the Fuel Level Refuelling 7 25 Checking the Controls 7 25 Checking the Electrical Connections 7 26 Heater Air conditioning checking rate of air flow 7 26 Other Maintenance Measures Prior to Start 7 26 Maintenance upon Demand 7 27 C...

Page 6: ...n 7 52 Maintenance Every 1000 Operating Hours 7 53 Cooling System Exchanging Coolant and Cleaning the System 7 53 Front Axle Oil Change 7 55 Rear Axle Oil Change 7 55 Transfer Box Gearing Oil Change 7 55 Service Brake 7 55 Checking and Adjusting System Pressures 7 55 Checking and Adjusting the Valve Play 7 55 Checking and Adjusting the Injection Nozzles Nozzle Pressure and Fuel Jet Pattern 7 55 Ch...

Page 7: ...Information on these Operating Instructions ...

Page 8: ...1 2 Information on these Operating Instructions ...

Page 9: ...ctions the EU Declaration of Conformity CE and the licence are to be handed over to the new owner The owner of the machine has to ensure that all persons driving the machine have the legally required minimum age and are physically and mentally fit to perform the tasks they are charged with all persons in charge with operating or maintaining the machine are appropriately instructed before operation...

Page 10: ...intended Correct Use A loader is a machine which has its own drive and which is moving on either tracks or wheels By moving in forward direction a loader can load material or cut the ground with the work unit use of bucket provided for loading which is attached to its front The standard working cycle of a loader comprises filling and lifting the loading bucket transporting material and emptying th...

Page 11: ...g instructions and on the labels attached to the machine DANGER This word is used in the safety notes and on safety labels in situations or places where severe injuries cannot be ruled out if the danger is not avoided The safety notes or labels contain precautionary measures which must be heeded to avoid this danger WARNING This word is used in the safety notes and on safety labels if there is a p...

Page 12: ...example for Komatsu machines the manufacturer has to design the cab roof in such a way that a warning beacon can be attached to the roof However when driving the machine on roads this warning beacon must be covered Should you have any questions concerning standards and guidelines in the respective country the machine is to be used in please ask your Komatsu dealer before you start commissioning th...

Page 13: ...ctronical components which you install later comply with the valid version of the EMC directive 89 336 EEC and that they are labelled with the CE mark The following requirements must additionally be met for a later installation of mobile communication systems e g radio telephone Only install devices which have a licence referring to valid national regulations e g BZT licence in Germany The device ...

Page 14: ...o Volume m Hydr pressure bar Weight kg Bucket WA95 3 42W 70 12021 1 1 387 42W 70 12030 1 1 411 42W 70 12090 0 9 185 670 42W 70 12100 0 9 185 620 42W 70 12210 1 0 185 700 42W 70 12240 1 0 185 640 42W 70 12051 1 25 410 42W 70 12061 1 6 420 42W 70 12120 1 0 185 540 42W 70 12080 1 5 185 770 42W 70 12110 1 0 185 615 CE_1WA95 TBL ...

Page 15: ...W Machine with counterweight CE conforming equipment WA 95 3 1 2 3 4 Type Part No Work load of fork carrier STD kg pair Work load of fork carrier with CTW kg pair Weight kg Fork carrier WA95 3 42U 70 12080 2500 1870 2600 1950 121 CE conforming equipment WA 95 3 1 2 3 4 Type Part No Carrying capacity mm kg Carrying capacity mm kg Weight kg crane boom WA95 3 42U 70 12530 500 1500 1000 1300 100 CE_2W...

Page 16: ...1 1 0 Information on these Operating Instructions CE Conforming Equipment of the Manufacturer According to Document 42W 93 11130 U DTP BA75 CEAUS75 WMF ...

Page 17: ...oint front axle vertical B1 Distance driver s eye front axle horizontal B2 Distance driver s eye front axle vertical D1 Distance front axle lower edge of headlights horizontal D2 Distance front axle lower edge of headlights vertical G Weight of the equipment and carrying load without additional counterweight H1 Distance bucket pivoting point upper edge of bucket vertical carrying position H2 Dista...

Page 18: ...1 1 2 Information on these Operating Instructions ...

Page 19: ...2 1 Loading and Transporting the Machine Loading and Transporting the Machine ...

Page 20: ...2 2 Loading and Transporting the Machine ...

Page 21: ... Articulated steering unlocked 2 Articulated steering locked 4 Insert the bolt and secure it with the spring bolt Lifting the Machine DANGER Danger of pinching An unlocked articulated steering may suddenly move Secure the articulated steering before you lift up the machine Danger of accidents Carrying ropes with insufficient carrying capacities may tear so that the machine may fall down Only lift ...

Page 22: ...mensions Weights and Operating Values Driving Machine Onto Loading Area of Transport Vehicle WARNING If the transport vehicle or the loading ramp starts skidding while you are driving up the loading ramp the machine may fall off the ramp and cause severe accidents Secure the transport vehicle against accidental movement Secure the wheels of the low bed loader with wheel chocks or wedges The transp...

Page 23: ...el chocks or wedges to avoid falling down and skidding CAUTION Stay ropes that are incorrectly attached may damage the machine Only fasten the eye hooks of the stay ropes at the marked attachment points When the machine is on the loading area of the transport vehicle secure the articulated steering as described in the chapter Securing the Articulated Steering Then block the wheels of the machine w...

Page 24: ...m 5580 T1 Width with bucket mm 2150 The 1 1 m standard bucket given in the table is also available with blade attachment T2 Width without bucket above wheels mm 2060 G Height including ROPS mm 2750 D Track front section Track rear section mm mm 1590 1590 Special buckets 125 m light weight material bucket 1 6 m light weight material bucket 0 9 m multi purpose bucket B Width over tyres mm 2150 H Dis...

Page 25: ...ial no stamp marking 1 Machine name plate with serial no Engine name plate 1 with serial no EPA label 2 Serial no and address of manufacturer Must be filled in before machine is put into service Serial No Machine Serial No Engine Dealer Name Dealer Address Telephone Fax Maintenance Personnel SE NO_75 TBL ...

Page 26: ...2 8 Loading and Transporting the Machine ...

Page 27: ...to adhere to these safety instructions can lead to accidents with serious injuries Read and adhere to all safety instructions This chapter also contains safety instructions for special equipment and attachments Safety ...

Page 28: ...protective grid above the fan see opposite figure Safety devices must be kept in perfect condition Emergency Exit In an emergency situation you can use the door on the right hand side of the driver s cab seen from the driving direction as an emergency exit Clothing and Personal Protection Do not wear loose fitting clothing jewellery or open long hair There is danger that you get caught by control ...

Page 29: ...ore you leave the driver s seat Store the ignition key in a safe place 5 Close the cabin door Mounting and Dismounting Do not jump on or off the machine Do not mount on or dismount from a moving machine Always use the handle bars and tread steps for mounting or dismounting the machine Do not hold onto the control levers while mounting and dismounting To ensure safe hold hold the handle bar with on...

Page 30: ...move wooden chippings leaves paper and other highly inflammable materials that may have collected in the engine compartment since they could cause a fire Do not operate the machine in the vicinity of naked light Fire Extinguisher and First Aid Kit A fire extinguisher can be stored in the compartment under the driver s seat Two appropriate fastening points are already attached to the back of the co...

Page 31: ...rating the machine the engine coolant the engine oil and the hydraulic oil are extremely hot and under pressure Do not try to unscrew caps drain water or oil or replace filters directly after operating the machine since this may lead to severe burns due to hot fluids or hot machine parts Wait until the temperature has fallen Strictly adhere to the described procedures when performing the required ...

Page 32: ...tachment for Protection Against Falling Objects FOPS IMPORTANT FOPS is a fixed component of the cab When you work on a site where there is danger of falling rocks or other objects the machines must be equipped with a FOPS If the FOPS is modified without permission or damaged its stability is impaired In this case the FOPS must be replaced since its correct function can no longer be guaranteed Atta...

Page 33: ...your hands after work Batteries produce detonating gas Detonating gas is extremely ex plosive and may be ignited even by the smallest spark Do not disconnect the battery while the engine is still running Prior to start of work on batteries set the start switch to 0 Set the main switch of the battery if installed to Off Avoid any short circuits via the poles or the pole terminals of the battery due...

Page 34: ...company to determine the lines positions Ensure that these facilities will not be damaged When working with water or crossing sand banks first check the subsoil and depth and flow rate of the water Ensure that the permitted water depth will not be exceeded In the Driver s Cab Do not leave any tools or spare parts lying around in the cab These may actuate damage or block control levers pedals or sw...

Page 35: ...e in engine speed or an exceeding of the engine s maximum rpm This may lead to a fire an explosion and major damage to property It may also happen that the engine cannot be switched off anymore Also refer to chapter Operation in Closed Areas Mirrors Windows and Lighting Clean the windows and the headlights to ensure maximum sight Adjust the rear view mirror in such a way that you have an excellent...

Page 36: ...of bolts and spring bolts Always wear the safety belt when operating the machine Reversing These rules must be observed for all machines i e also for those machines equipped with a reversing warning system Check that there is nobody near the machine or in the way Before you start reversing sound the horn to warn persons within or near the operating area When working in potentially dangerous areas ...

Page 37: ... Driving sideways on these surfaces may result in the machine sliding Drive very slowly and carefully When driving down a slope use the braking power of the engine and drive slowly If the engine stops while you are driving on a slope immediately apply the service brake to stop the machine Then apply the parking brake Lower the work unit When driving on a hill with a load drive uphill in forward di...

Page 38: ... transmission line proceed as follows 1 Do not leave the driver s cab The driver s cab is a Faraday cage protecting you from electric shock 2 Warn other persons and tell them to stay far away from both the power line and your machine 3 Try to move the machine out of the range of influence of the overhead power transmission line by moving it away from the line moving away the work unit etc 4 Have t...

Page 39: ... the ground The load may vary considerably depending on the structure of the snow For this reason reduce the load and pay attention that the machine does not start to skid Height Limitation When working in areas with height limitations e g in tunnels beneath bridges or power transmission lines or in garages pay attention that the work unit does not touch or damage these facilities Brakes Use the b...

Page 40: ...sporting are in perfect condition The overall height of the palette pile must not exceed 2 m Make sure that the fork tines are adapted to the length of the load Move the fork tines so far under the load that the load comes to a rest at the fork back If you are transporting a load which is impairing your sight on the route you must drive the machine into a direction in which you have free sight If ...

Page 41: ...el chocks 2 to ensure that the machine cannot roll away When parking the machine on public roads ensure that it does not obstruct traffic Put up signal lamps and required warning signs to ensure that passing traffic can clearly see the machine Adhere to all regulations on parking vehicles and securing building sites Before you leave the machine completely lower the work unit onto the ground Secure...

Page 42: ...low and drive slowly Do not carry out steering movements on the ramps If required drive off the ramps again correct alignment of the machine and drive up again After loading i e when the machine is on the transport vehicle apply the parking brake Block the wheels of the machine with wheel chocks Set the steering wheel of the machine to straight driving Secure the articulated steering with the lock...

Page 43: ...at work is being carried out on the machine If required put up additional warning signs around the machine You may purchase these warning signs from your Komatsu dealer Tools Only use tools which are suitable for the task you want to carry out If you use damaged or makeshift tools or tools which are of inferior quality injuries may occur Safety Related Parts The quality of these parts is subject t...

Page 44: ...e the articulated steering against accidental movement using the locking bar position 2 Supporting the boom When work needs to be conducted under a raised boom then the boom must be supported against the danger of suddenly falling For this purpose you should use either a jack stand which should be positioned below the boom or a support device 1 which is mounted over the piston rod The support devi...

Page 45: ...chine using wheel chocks Do not work under a machine that is not appropriately supported Keeping the Machine Clean Always keep the machine clean and tidy Oil grease and tools lying around involve danger since they may cause slipping or tripping over Do not clean sensors plugs and the interior of the driver s cab with water or steam If water seeps into the electric system there is danger of uncontr...

Page 46: ... according to the relevant environmental regulations If the machine is provided with a fuel sieve in the tank opening do not remove this fuel sieve before you start refuelling Coolant The machine is provided with an aluminium cooling system Apply only coolants in the prescribed mixing ration Caution antifreeze is highly inflammable To check the coolant level first switch off the engine and wait fo...

Page 47: ...oves and use a piece of cardboard or wood when checking for oil leaks If you have been hit by an oil jet immediately go and see a doctor and explain what has happened Handling of the Pressure Accumulator WARNING Danger of injury Pressure accumulator is filled with highly pressurised nitrogen Do not open or damage the pressure accumulator Immediately inform your Komatsu dealer if you detect malfunc...

Page 48: ...an or the belt are cut off or hurled away Do not wear loose clothing neckerchiefs or the like or open long hair that might get caught Waste Material Do not pour used oil into the sewage system rivers etc Collect used oil of the machine in appropriate containers Do not let oil flow out onto the ground Adhere to all applicable laws and regulations when disposing of harmful substances such as oil fue...

Page 49: ...o not let off pressure when the pressure in a warm tyre has increased Do not light a fire and do not carry out welding near the tyre Keep the working area free of pointed or sharp objects that may damage the tyre Avoid any overload The values for the tyre pressure and for the permitted speed correspond to the manufacturer specifications and refer to standard operations If you want to perform speci...

Page 50: ...Labeling 3 2 4 Labeling All safety labels must be kept clean all times Missing or damaged safety labels must be replaced Positions of Safety Labels ...

Page 51: ...Labeling 3 2 5 Information Labels High Speed version only ...

Page 52: ...Labeling 3 2 6 ...

Page 53: ...Controls and Indicators ...

Page 54: ...4 2 Controls and Indicators ...

Page 55: ...4 3 Controls and Indicators 1 Tumbler 6 Lifting cylinder 2 Bucket cylinder 7 Headlight 3 Bucket Direction indicator 4 Boom 8 Rear wheel 5 Front wheel Overall View of the Machine ...

Page 56: ...ir filter warning light 22 Parking brake warning light 23 Charging current warning light 24 Driving direction switch indicators 25 Engine oil pressure warning light 26 Direction indicator control lamp 27 Air preheater control lamp 28 Heated rear windscreen indicator 29 Working lights switch and control lamp 30 Driving range switch and control lamp up to 20 km h 31 Coolant temperature indicator 32 ...

Page 57: ... group comprises the control lamps for high beam low beam heated rear windscreen air preheater direction indicator driving direction switch ALS electronics option and control lamps for the high speed gear option Measuring indicators This group comprises the fuel gauge the operating hour meter and the temperature indicator of the coolant Warning lights This group comprises the warning lights for ch...

Page 58: ...4 6 Controls and Indicators Warning Lights 1 Brake fluid warning light 2 Air filter warning light 3 Parking brake warning light 4 Charging current warning light 5 Engine oil pressure warning light ...

Page 59: ...you set the start switch to the I operating position With the engine running As soon as the engine runs the generator starts to generate current and to charge the battery At the same time the charging current warning light will go out A fault is present if the charging current warning light does not go out while the engine is running In the latter case proceed as described in chapter Troubleshooti...

Page 60: ...ontrol lamp high speed gear switched on active only with high speed version 8 Control lamp in the high speed gear switch high speed gear switched off option 9 ALS Electronics control lamp active only with built in ALS Electronics 10 Control lamp in the ALS Electronics switch option 11 Control lamp in the air conditioning switch option 12 Warning beacon control lamp option 8 9 75_004d 10 12 11 swit...

Page 61: ... fault has occurred in the direction indicator system In this case proceed as described in chapter Troubleshooting 3 Air preheater control lamp The control lamp lights up if you set the start switch to the I operating position and if the air preheater is running It will go out if the heating cycle is over The running period of the air preheater depends on the ambient temperature You can start the ...

Page 62: ...when the machine drives faster than 5 k m h 10 Control lamp in the ALS Electronics switch option The ALS Electronics switch with control lamp is only installed in machines which are provided with the ALS Electronics The control lamp in the switch lights up in green when the ALS Electronics is switched on 11 Control lamp in the air conditioning switch option The air conditioning switch with control...

Page 63: ...4 1 1 Controls and Indicators Measuring Indicators 1 Fuel level indicator 2 Operating hour meter 3 Coolant temperature indicator ...

Page 64: ...f the operating hour meter is ON the icon on top of the operating hour meter is flashing 3 Coolant temperature indicator The coolant temperature indicator shows the temperature of the coolant If you set the power switch to the I position with the coolant being war mer than 70 C the temperature indicator will show the current coolant temperature If the temperature is normal during operation the gre...

Page 65: ...riving direction switch 8 Start switch 9 Fan rotary switch for ventilation and heating 10 Heating temperature switch 11 Heated rear windscreen switch 12 Switch and control lamp for driving range up to 20 km h 13 Working lights switch and control lamp 14 Switch for inside lighting without fig 15 Battery main switch option without fig 16 High speed gear switch with control lamp option 17 ALS Electro...

Page 66: ...me you keep the switch pressed 3 Switch of rear windscreen wiper and washer This switch is used to switch on off the rear windscreen wiper and was her The switch has two switching stages Switching stage 1 locks in permanently and is used to switch on off the windscreen wiper If you hold the switch pressed in switching stage 2 the windscreen was her is only operated for the time you keep the switch...

Page 67: ...mp lights up How to flash one s lights high beam In order to flash your lights you need to draw the lever briefly in the direction of the steering wheel The high beam is only switched on as long as you draw the lever The high beam control lamp will also light up for that time Switching on the high beam In order to switch on the high beam you must press the lever completely down In this position th...

Page 68: ...ns in this position with the engine running II Start position In start position II the engine starts IMPORTANT You may only start the engine if the driving direction switch is set to the neutral position N 9 Fan rotary switch for ventilation and heating This rotary switch permits to regulate the fan step by step Switch setting 1 Fan off Switch setting 2 Low air flow Switch setting 3 Medium air flo...

Page 69: ...inside lighting has three different switch settings Switch setting 1 Steady light Switch setting 0 Off Switch setting 2 Steady light NOTE You can also switch on the inside lighting if the start switch is in stop position 0 For this reason switch off the inside lighting before you leave the driver s cab 15 Battery main switch option NOTE Do not operate the battery main switch with the engine runnin...

Page 70: ...chine drives faster than 5 k m h the ALS Electronics is automatically activated and the ALS Electronics control lamp lights up on the instrument panel If the machine drives slower than 5 k m h the ALS Electronics is switched off and the control lamp on the instrument panel goes out However the control lamp in the ALS Electronics switch remains lit in green 18 Air conditioning switch with control l...

Page 71: ...Levers Pedals 1 Brake pedal 2 Parking brake 3 Safety lever for the work hydraulic system 4 Steering column adjustment 5 Accelerator pedal 6 Multifunctional lever 7 Control lever for special equipment 8 Switching lever for bucket without fig ...

Page 72: ...g brake warning light lights up in the instrument panel The machine will drive again if you re loosen the parking brake IMPORTANT You cannot start the machine with the parking brake being applied If you set the driving direction switch to the F position forward driving or R reversing with the parking brake still being applied the alarm buzzer will sound 3 Safety lever for the work hydraulic system...

Page 73: ... The multifunctional lever is locked in this position The floating position is provided for planing operations removing subsoil In this switch position the work unit is lowered by its own weight and can be freely operated by external parties S Lower The boom is lowered in this position If the engine is switched off you can lower the boom in this position 0 Hold The boom is held in position H Raise...

Page 74: ...ition 1 Close multi purpose bucket Position 0 Neutral position Position 2 Open multi purpose bucket If you use attachments requiring a steady oil flow e g brush snow remover the control lever has the following functions Position 1 Work unit turns backwards Position 0 Neutral position Position 2 Work unit turns forward Position 3 Work unit turns forward in permanent operation locks in For permanent...

Page 75: ...nsport Always secure the bolt of the traction device which is fixed to a chain with the spring bolt Socket CAUTION Danger of accidents Electrical devices may interfere with the on board electronics For this reason connect only the working lamp to the socket You may connect a working lamp to the socket 1 Door Unlocking System Both doors have a locking mechanism which locks in if you open the door c...

Page 76: ...4 2 4 Controls and Indicators ...

Page 77: ...Operation ...

Page 78: ...5 2 Operation ...

Page 79: ...d prematurely and its service life may be shortened A new machine must be run in and maintained very carefully and thoroughly The following points are particularly important After the engine has been started it must run in idle for 5 minutes Operation with heavy loads or at high speeds is to be avoided Sudden starts sudden acceleration jerky steering and stopping is to be avoided this does not app...

Page 80: ...ng rods and hoses for cracks premature wear and tear and play Repair damaged parts 2 Remove dirt and dust Check the area around the engine and the radiator for accumulated dirt or dust Additionally check whether combustible material has accumulated near the battery or near hot parts of the machine e g the exhaust Remove completely any accumulated dirt or dust 3 Check engine and cooling system Chec...

Page 81: ...achine the seat belt must be renewed Check the belt the brackets and the buckle of the seat belt If the bellt the brackes or the buckle of the seat belt are damaged the seat belt must be renewed Check the tightening screws of the brackets for tightness Tight loose screws Tightening torque 25 30 Nm 12 Check ROPS Check whether screws are loose or damaged Have loose screws tightened and damaged screw...

Page 82: ... and hold it in this position To lift up the front part of the seat it is necessary to relieve your weight from the front section of the seat cushion by standing up Then sit down on the front part in order to press down the front section of the seat Release the lever if you have reached the right position The seat is now locked in its position Then pull lever 4 and hold it in this position To lift...

Page 83: ...able seating position while at the same time having an optimum view of the work unit Hold the steering wheel in this position 3 Pull up the locking lever again to lock the steering column in this position Adjusting the Armrest Proceed as follows to adjust the height of the armrest 1 1 Loosen the screw 2 2 Either pull out or push back the armrest to reach the multifunctional lever Your forearm shou...

Page 84: ... The heating capacity depends on the coolant temperature of the engine Full heating capacity is only realised if the engine is completely warmed up You can realise maximum heating inside the cabin if you open all air ventilation nozzles set the temperature rotary switch to maximum heating power while switching on the fan with its highest level You may realise a comfortable temperature if you open ...

Page 85: ...trol lever 2 to cold 3 Press the switch for the air conditioning The air conditioning system is now switched on and the control lamp in the switch shines blue The greatest cooling effect is achieved with this setting particularly if the engine is running at high revs As soon as the required temperature has been reached turn the blowers down by one stage and carry out any further adjustment of the ...

Page 86: ...lt before you start work and do not take it off during work Put on the safety belt in such a way that it is not twisted and fits tightly The machine is provided with a lap belt which is automatically rolling up When pulled slowly automatic belts ensure full freedom of action but block immediately if you suddenly brake or accelerate or if you drive downhill or take corners Putting on the safety bel...

Page 87: ...l lamp lights up if the air preheater is in operation IMPORTANT The running period of the air preheater depends on the ambient temperature If the ambient temperature is low the preheating process may take more time 4 Press down slightly the accelerator pedal 5 If the control lamp of the air preheater has gone out you can turn the ignition key to the start position II in order to start up the engin...

Page 88: ...eed the maximum time 10 seconds permitted for the multi function lever in the tip in position 3 While the engine is warming up observe all measuring instruments and warning lights and eliminate immediately any fault 4 Let the engine run with lightweight load further until the engine coolant temperature indicator 1 lights up in the green range 5 Ensure that the exhaust gas colour is normal and that...

Page 89: ... during rides on public roads and cannot be moved 4 Press down the brake pedal and hold it in this position 5 Release the parking brake Press the celebration adjustment knob to this at the parking brake lever Press down the locking button of the parking brake lever The release the locking button The parking brake warning light goes out 6 Set the drive direction switch to the desired direction sett...

Page 90: ... damages Ensure that the machine stands still and that the engine is run ning before you switch the high speed gear on or off Switching on the high speed gear Push the switch lock 2 to the right hold it in this position and press the switch If the high speed gear is switched on control lamp 3 goes out and control lamp 1 lights up If the high speed gear should not engage control lamp 1 remains unli...

Page 91: ...u change the driving direction The drive direction switch is used to switch between forward and reverse gear or vice versa The machine may still roll if you change the driving direction Position F Driving forward Position N Neutral Position R Reversing Reverse Driving The machine can drive forward or backwards reversing at the same speed Before driving backwards pay particularly that nobody is in ...

Page 92: ...r hill flanks The limiting values are defined in chapter Limiting Values for Slopes Do not turn on a slope or drive across a slope Turn or cross the section only level ground When driving on slopes avoid driving on grass fallen leaves or steel plates Driving sideways on these surfaces types may result in the machine sliding Drive very slowly and carefully To keep the centre of gravity as low as po...

Page 93: ...operating situation 2 independent of the accelerator pedal position If it is required to press down the accelerator pedal completely in order to be able to use the full load output of the engine of the work hydraulic system you can nevertheless use the brake pedal to reduce the speed of the machine or to stop it completely If the service brake breaks down If the machine is not stopped after pressi...

Page 94: ...s Before you leave the cab turn the locking lever for the work hydraulic system into position 1 As a result the work hydraulic system is blocked 5 Protect the work hydraulic system against unintentional activation by turning the locking lever of the work hydraulic system into position 1 Parking the machine on a slope Whenever possible stop the machine on level ground If you have to park the machin...

Page 95: ... the road o be used Contact the responsible Komatsu trader or the tyre dealer to obtain the required information The required tyre pressure can be found in the tyres and tyre pressure table in chapter Maintenance Basics Check the tyre pressure with the tyres being cold before driving Lower the work unit to its transport position and move it completely to its rear limit stop position Always drive w...

Page 96: ...quick change unit 7 Tip in the quick change unit until the work unit is connected to the limit stops on the the quick change unit by setting the multi function lever into position E fig 75_016 8 Lock the quick change unit by setting the control lever for special equipment into position 2 fig 75_042 The interlocking pins 2 will then be visible fig 75_280 WARNING If the work unit is not properly att...

Page 97: ... E fig 75_016 8 Lock the quick change unit by setting the control lever for special equipment into position 2 fig 75_042 9 Switch off the engine 10 Set the change over lever for the supplementary control circuit in position 1 to its limit stop figure 75_160 11 Set the control lever for special equipment to position 1 figure 75 _042 12 Connect the hydraulic hoses of the multi purpose bucket to the ...

Page 98: ... avoid unnecessary wear and tear of the tyres Try to work on level ground and remove any rocks and large stones which are sticking out of the surface Always drive in straight direction into the heap or slope This ensures that you have always the largest intrusive force while reducing tyre wear and tear at the same time For removing operations lift the bucket as soon as you drive into the heap or s...

Page 99: ...ing surface of proximity switch 3 Then tighten the bolts to hold the bracket in position 3 Loosen two nuts 5 and adjust to make a clearance of 3 to 5 mm 0 12 to 0 20 in between bar 2 and the sensing surface of proximity switch 3 Then re tighten the nuts Tightening torque 15 20 Nm 4 After the adjustment start the engine and raise the lift arm Operate the bucket control lever to the DUMP position th...

Page 100: ...until it reaches a height of approx 30 cm over the ground and hold the bucket in this position NOTE If the bucket touches the ground the front wheels may be lifted from the ground resulting in premature wear and tear of the rear wheels 3 Then proceed with slowly lowering the bucket onto the ground 4 Brake right in front of the material to be removed using the service brake while pressing down the ...

Page 101: ...bucket only on one side since the equilibrium of the machine may be impaired 1 Drive up to the soil heap in a straight line 2 Slow down the machine using the service brake while keeping the accelerator pedal pressed down at the same time 3 Bend the bucket edge slightly down 4 While driving forward move slightly the multi function lever of the boom in order to remove only a thin layer of the surfac...

Page 102: ...gh speed Drive slowly into a heap of soil or rocks NOTE Avoid any excessive shaking of the bucket Always operate with respect to the condition of the tyres see section Tyre appropriate operation Loading in diagonal direction Align the machine in rectangular position to the heap Drive the machine backwards in straight line after you have filled the bucket Then let the dump truck drive between heap ...

Page 103: ...t of the bucket which will be distributed when the machine is driving forward Taking off soil If the surface is filled up you may level the ground WARNING Danger of accidents Careless reverse driving may lead to severe accidents Before you drive backwards make sure that nobody is behind the machine Warn persons who are in your way by sounding the horn Dump the bucket slightly down Drive backwards ...

Page 104: ...rklift truck attachment as horizontal as possible while piling up Picking up the load 1 Drive slowly up to the load to be picked up CAUTION Danger of accidents If the load does not lie in centre of gravity the stability of the machine is impaired Drive under the load until it is touching the fork back of the forklift truck attachment 2 Drive so far under the load until it touches the fork back of ...

Page 105: ... lines Adhere to the instructions indicated in the chapter Safety Working in the vicinity of electrical overhead lines Operation on slopes Adhere to the instructions indicated in the chapter Safety Driving on slopes Working on loose soil Adhere to the instructions indicated in the chapter Safety Working On Loose Soil After the work is finished 1 Walk around the machine and visually inspect the wor...

Page 106: ...n pressure be measured at an authorised garage If the speed is continuously increased the starter may remain switched on until the engine finally starts up Let the engine warm up with increased idle speed for some minutes before starting to work During the warm up phase operate the hydraulics devices several times without load Add a standard antifreeze to the water in the windshield washer assy If...

Page 107: ...a dry room which is frost free in winter Check whether the coolant is set to a temperature of 37 C Refill antifreeze if necessary During the standstill Perform the following actions in order to keep the machine in operating condition during the standstill WARNING Danger of poisoning if the engine is run in doors Open the windows and doors before you start the engine in doors Let the engine run onc...

Page 108: ...5 3 2 Operation ...

Page 109: ...Troubleshooting ...

Page 110: ...6 2 Troubleshooting ...

Page 111: ...cators The following list contains the troubleshooting tables with explanations of warning lights and indicators Charging current warning light see Electrical System Engine oil pressure warning light see Engine Brake oil warning light see Brakes Air filter warning light see Engine Parking brake warning light see Brakes Coolant temperature indicator see Engine Fuel level indicator see Engine ...

Page 112: ...ion Check function of generator replace defective generator Tension generator drive belt to low Tension drive belt Generator produces unusual noise Generator defective Replace generator Starter does not start the engine Electrical connection without function Check terminals connections and cables Battery charge insufficient Re charge battery Check function of battery replace defective battery Star...

Page 113: ...nes and hoses Line or hose connections of engine lubricating system leaky Check line and hose connections visual check oil leaks Repair leaky line and hose connections Oil pressure switch without function Check function of oil pressure switch replace defective oil pressure switch Vapour is let off at the pressure valve of the radiator cap Coolant level in radiator too low Top up coolant ensure cor...

Page 114: ...defective or loose Replace defective radiator cap re tighten loose radiator cap Temperature display coolant with the engine at operating temperature the temperature display coolant does not indicate a temperature Temperature display without function Check function of temperature display replace defective temperature display Engine does not start Fuel tank empty Refill fuel and bleed fuel system Ai...

Page 115: ...rature display coolant Unusual mechanical noise Defective silencer Replace silencer Tappet clearance too wide Adjust tappet clearance Engine does not start or stops during operation top LED of fuel level indicator flashes Fuel tank empty Refill fuel and bleed fuel system Warning light air filter warning light air filter is on when engine is running Air filter of filter insert dirty Clean or replac...

Page 116: ... Wrong control pressure Check control pressure reset if required Wrong high pressure Check high pressure reset if required Inch valve defective or set incorrectly Check setting of inch valve Replace defective inch valve Hydraulic filter dirty Replace filter element of hydraulic filter Switching relay without function Check function of switching relay repair or replace defective switching relay Hyd...

Page 117: ...oil quality Fill in prescribed hydraulic oil Oil level in hydraulic oil tank too low Top up hydraulic oil Cylinders move jerky Oil level in hydraulic oil tank too low Top up hydraulic oil 75FAUL08 TBL Hydrostatic Drive Unit Continued Fault Causes Remedy Unusual noise Oil level in hydraulic oil tank too low Top up hydraulic oil Inclusions of air in lines and units of the hydraulic system faulty ble...

Page 118: ...ulic system Steering wobbles Clearance of steering cylinder bolt too large Check fastenings of steering cylinder replace defective cylinder bolts Faulty operation of hydraulic system Check function of hydraulic system 75FAUL11 TBL Brake Fault Causes Remedy Brake has no effect Multi disks of brake worn Replace multi disks of brake Air in brake system Bleed brake system Warning light brake oil reser...

Page 119: ...medy Blower insufficient air flow Blower filter clogged Clean or replace filter 75FAUL12 TBL These measures must be performed by the responsible dealer Axles Axles Fault Causes Remedy Noise Oil level in axle too low Top up oil 75FAUL07 TBL Driver s cab ...

Page 120: ...e the machine Emergency Lowering System The machine is provided with a pressure accumulator for the work hydraulic system If the engine is not running you can lower the work unit with the multi function lever NOTE If you have secured the work hydraulic system with the locking lever of the work hydraulic system you cannot lower the work unit 1 Make sure that nobody is standing below the work unit 2...

Page 121: ...tive poles are connected a clamp slips off and touches the machine Firmly connect the clamps When connecting and disconnecting the cables pay attention that the cable ends neither touch each other nor the machine the two machines do not touch each other 1 Turn the start switch of the defective machine to 0 OFF 2 Connect one clamp of the battery jumper cable to the positive terminal of the discharg...

Page 122: ... the machine a short circuit is produced which may damage parts of the electrical system When disconnecting the cables pay attention not to let the cable ends touch each other or the machine After starting of the engine disconnect the battery jumper cables by reversing the steps you performed to connect the cables 1 Disconnect one clamp of the battery jumper cable from the engine block 2 Disconnec...

Page 123: ...en the towing attachment at the marked eyes At the rear part of the machine fasten the towing attachment at the hitch Before you tow a machine with a hydrostatic drive system establish a short circuit connection between the high pressure side and the low pressure side of the variable pump For this purpose turn the high pressure valves in the valve block about 2 revolutions Proceed as follows 1 Set...

Page 124: ...being towed Always use two machines to tow off a machine with defective brakes Connect all three machines with appropriate towing attachments If you want to tow machine a with defective brakes or if you have to tow a machine driving downhill use two machines for towing Attach the machine that you want to give a tow to a larger machine with sufficient tractive and braking force Attach a second mach...

Page 125: ...et the driving direction switch 1 to its neutral position N 5 Switch off the engine 6 Apply the parking brake 2 and slowly release the pedal of the service brake The machine must stand still NOTE All repairs on the brake system must be performed by a garage which is authorised by Komatsu Checking the Service Brake WARNING Danger of accidents Always put on the safety belt Drive the machine on a fla...

Page 126: ...6 1 8 Troubleshooting ...

Page 127: ...Maintenance ...

Page 128: ...7 2 Maintenance Basics ...

Page 129: ...ce Before you start maintenance or repair work position the machine as follows unless stated otherwise 1 Park the machine on solid and level ground 2 Set the machine to the specified position for maintenance and repair 3 Lower the work unit to the ground and position it as shown in the drawing 4 Set all control levers to either the neutral or the hold position 0 5 Turn the safety lever of the work...

Page 130: ...r the boom and you cannot support the bucket park and secure the machine as follows 1 Park the machine on level ground 2 Apply the parking brake 3 Place wheel chocks in front of the wheels to prevent the machine from rolling away 4 With the bucket in its dumping position lower the bucket onto the ground with either its cutting edge or teeth Precautionary Measures When Cleaning the Machine Do not p...

Page 131: ...d in water Dusty Working Areas Adhere to the following measures when working in dusty working areas Pay attention to the warning lamp of the air filter to detect a blocked air filter insert in time In addition clean the air filter insert more frequently than specified in the maintenance schedule Frequently clean the external surfaces of the radiator to ensure unobstructed flow of air Replace the f...

Page 132: ...al cycles and the equipment where they may cause malfunctions Regularly replace all filters For details refer to the following description of maintenance work in these operating and maintenance instructions Replace the filters more often if you work under difficult conditions depending on the oil and fuel that you use e g high sulphur content Do not try to clean filter cartridges for re use Always...

Page 133: ...he responsible Komatsu dealer Always replace the oil filter when you perform an oil change We recommend that you have the engine oil and the hydraulic oil checked at regular intervals by the responsible Komatsu dealer to get an impression of the machine s condition Lubricating Grease Lubricating grease reduces wear and operating noise The grease nipples not specified in the maintenance schedule ar...

Page 134: ... time If the fuel tank has been run empty or filters have been replaced ventilate the fuel system Refer to chapter Maintenance Every 500 Operating Hours If you use fuels with a sulphur content between 0 5 and 1 0 cut in half the interval for an oil change If you use fuels with a sulphur content of over 1 0 quarter the interval for an oil change Storage of Oil and Fuel Store oil and fuel in doors i...

Page 135: ...e This antifreeze does among other things protect against corrosion in the cooling system it lubricates moving parts and it increases the coolant s boiling point For this reason it must also be used when working in hot working areas Antifreeze is highly inflammable For this reason take care that antifreeze does not come into contact with naked light If the coolant level is too low the air in the c...

Page 136: ...lant 50 Water Min Freeze Proofing 34 C 17 0 Fuel Tank Diesel Fuel CFPP Class B CFPP Class D CFPP Class E CFPP Class F DIN EN 590 up to 0 C up to 10 C up to 15 C up to 20 C 130 0 Grease Nipple Lithiumsoap Based Multi Purpose Grease MPG A KP2N 20 NLGI 2 Air conditioning Coolant Refrigerating machine oil NRS NRS R134a CFC free PAG polyalkyleneglycol 1200 g 180 cm The specified filling volumes represe...

Page 137: ...f the outer layer deformations that do not correspond to the normal shape of the installed hose when the hose is pressurised and depressurised leaks damage to hose fittings or connections between fittings and hoses damage due to storage the storage time for hoses should not exceed two years When replacing hoses do not forget to replace also all accessory O rings gaskets and similar parts Welding I...

Page 138: ...bling the parts Use the part numbers specified in the spare parts catalogue for ordering of spare parts Position Part No Part Designation Quant Replacement Interval Engine Oil Filter YM119005 35100 Cartridge 1 First maintenance after 50 operating hours Maintenance every 250 operating hours Fuel Filter YM119000 55600 Cartridge 1 Maintenance every 500 operating hours Hydraulic Oil Filter 42U 62 1315...

Page 139: ...e battery relay Maintenance of the electrical system comprises 1 Checking the tension of the generator belt 2 Checking the generator belt for damage and wear and 3 Checking the acid level in the battery Fuses CAUTION Parts of the electrical system may be damaged if you replace fuses with the ignition switched on Turn the start switch to switching position 0 OFF before starting to replace fuses Fus...

Page 140: ...machine 1 Starter stop magnet socket 10A Solenoid valves gear unit 10A 2 Inside lighting radio 10A Direction indicator horn 10A 3 Hazard flasher 10A Instrument lighting 10A 4 Windscreen wiper and windscreen washer front and rear 20A Working light 20A 5 Brake light reversing warning system warning beacon 10A Side lamp left lamp registration number 10A 6 Fan ventilation heating 20A Side lamp right 1...

Page 141: ...ng the tyre pressure pay attention to fissures peeling and unusual wear and tear Remove nails pieces of metal and other undesired material from the tyre WARNING If the tyre bursts or if the parts of a rim consisting of several parts come apart while the tyre is being inflated parts of the tyre or rim may cause injury or damage to property Use a tyre inflating hose with clamping device to inflate t...

Page 142: ...cold If the tyres are too soft increase the tyre pressure accordingly The following degree of resilience tyre loaded unloaded of the front tyres can be used as the guideline for the visual check Transport of normal loads horizontal position of boom approx 15 25 Digging rear wheels lifted off the ground approx 25 30 TYRES RECOMMENDED TYRE PRESSURE for driving on roads for operation Manufacturer Siz...

Page 143: ...le Ended Ring Spanners 42T 09 H0450 42T 09 H0460 42T 09 H0470 42T 09 H0440 Spanner Openings 8 10 mm 13 15 mm 17 19 mm 24 27 mm 2 Screwdriver 421 98 H1120 3 Screwdriver 421 98 H1110 4 Hammer 421 98 H1140 5 Bag 421 98 H1130 6 Lever Type Hand Gun Grease 424 98 H1010 TOOLS75 TBL ...

Page 144: ...parts and original parts must be identical NOTE Do not apply excessive torque to plastic parts Tighten plastic parts only manually Metric Bolts Coarse Pitch Thread Strength Class 10 9 Thread diameter of the bolt mm Wrench Size mm Steel Aluminium Cast a b Nm kpm Nm kpm M6 10 14 1 4 7 7 0 77 M8 13 35 3 5 19 0 1 9 M10 17 15 70 7 0 37 0 3 7 M12 19 115 11 5 64 0 6 4 M14 22 185 18 5 101 5 10 15 M16 24 2...

Page 145: ...1 5 19 120 12 0 67 0 6 7 M14 x 1 5 22 200 20 0 110 0 11 0 M16 x 1 5 24 300 30 0 167 5 16 75 M18 x 1 5 27 440 44 0 243 0 24 3 M18 x 2 27 420 42 0 230 0 23 0 M20 x 1 5 30 620 62 0 338 5 33 85 M20 x 2 30 322 5 32 25 M22 x 1 5 32 820 82 0 454 5 45 45 M22 x 2 32 436 0 43 6 M24 x 1 5 36 1090 109 0 596 0 59 6 M24 x 2 36 1040 104 0 573 0 57 3 M27 x 2 41 1500 150 0 832 0 83 2 M30 x 2 46 2120 212 0 1158 0 1...

Page 146: ...7 2 0 Maintenance Basics ...

Page 147: ...om the Fuel Tank 7 36 Checking the Service Brake and Oil Level Refilling Oil 7 36 Checking the Battery and Acid Level 7 37 Re Charging the Battery 7 38 Lubrication 7 39 Maintenance Every 100 Operating Hours 7 40 Draining the Water Separator Removing Water and Dirt Deposits 7 40 Maintenance Every 250 Operating Hours 7 41 Changing the Engine Oil and Oil Filter Cartridge 7 41 Checking the V Belt Cond...

Page 148: ...Pressure of third Control Circuit 7 55 Maintenance Every 2000 Operating Hours 7 56 Hydraulic System Oil Change 7 56 Ventilating the Hydraulic Oil Tank 7 57 Cooling System Checking the Antifreeze Content of the Coolant 7 57 Checking the Cooling System 7 57 Checking the Fuel Pump 7 57 Checking the Fuel and Coolant Tubes Replacing the Tubes if required 7 57 Checking the Water Pump 7 57 Checking and A...

Page 149: ...expansion tank is between the FULL and LOW markings If the coolant level does not reach up to the LOW marking top up coolant 3 Therefore remove the cover cap of the expansion tank 4 Top up coolant until the level reaches up to the FULL marking 5 After topping up firmly close the cover cap 6 Usually the radiator needs not to be opened However for safety reasons it is required to check the refrigera...

Page 150: ...ing drain off some oil see Engine Draining Off Oil 5 Close the oil filler 2 Engine Draining Off Oil If you have topped up too much oil you must drain off the excess oil Have an oil trough with a sufficient capacity ready 1 Before you start maintenance work park and secure the machine as described in the chapter Preparing the Machine for Maintenance 2 Loosen the screw 1 at the bottom cover plate 2 ...

Page 151: ...Fluids 4 After refuelling firmly close the filler Checking the Controls 1 Turn the start switch to the operating position I An alarm buzzer sounds until the machine is started 2 Check that the following alarm and control indicators are on until the engine is started Charging current 1 Engine oil level 2 Parking brake 3 Intake air preheater 4 3 Check that the fuel level indicator 5 indicates the fu...

Page 152: ...lumn is strong enough Attention The circulating air jets arrow must be open 4 If insufficient air is coming out of the jets either the filter fleece in the heating air conditioning unit is dirty and will have to be cleaned or replaced or the condenser in the air conditioning system is dirty and will have to be cleaned see Maintenance every 500 operating hours Other Maintenance Measures Prior to St...

Page 153: ...e of the condenser The steps on the right have to be unscrewed and the condenser swung out for access Cooler condition Normal Abnormal Temperature of high and low pressures pipes High pressure pipie is hot Low pressure pipe is cold Clear difference in temperature High pressure pipe is warm Low pressure pipe is cold Little difference in temperature Amost no difference in temperature between high an...

Page 154: ...art to perform maintenance work 1 Before you start maintenance work park and secure the machine as described in the chapter Preparing the Machine for Maintenance 2 Clean the grease nipples marked by arrows 3 Use a grease gun to fill the grease nipples with a sufficient volume of lubricating grease Articulated steering 3 points 4 Remove the used lubricating grease that is pressed out of the bearing...

Page 155: ...not been parked and secured correctly Park the machine on a solid even surface and secure it before you start to perform maintenance work 1 Before you start maintenance work park and secure the machine as described in the chapter Preparing the Machine for Maintenance 2 Loosen the screw 1 at the bottom cover plate 2 and swivel the cover plate to the side 3 Put the oil trough under the drain screw 4...

Page 156: ...ghtly touches the filter holder Then tighten the filter cartridge according to the filter manufacturer s specification 13 After replacing the filter cartridge fill in clean engine oil until the oil level reaches up to the H marking on the oil dipstick For details on recommended engine oils see section Lubricants and Service Fluids 14 Close the oil filler 2 15 Let the engine run in idle for about f...

Page 157: ...e work park and secure the machine as described in the chapter Preparing the Machine for Maintenance WARNING Danger of injuries When the engine is in operation there is danger of severe injuries by moving parts within the engine compartment Do not work within the engine compartment while the engine is in operation 2 Press down the V belt in the middle of the longest straight part You should be abl...

Page 158: ... Pull the filter element off the handle and dispose of the filter element 8 Clean the inner surface of the filter housing Before you start cleaning check that there is no undesired material in the filter housing 9 Put the handle onto the new filter element 10 Insert the new filter element into the housing 11 Screw on the filter cap and tighten it with 20 Nm 12 Ventilate the system at the tank acco...

Page 159: ...king brake 2 Place drip pan or container underneath the drain plug 1 3 Unscrew drain plug 1 and drain oil into container 4 Drive machine until the planetary gearing drain plug hole 1 is in a horizontal 3 o clock position 5 Fill planetary gearing with oil until the oil reaches the lower lip of the drain plug hole 1 6 Clean drain plug and attach clean undamaged or new washer 7 Screw drain plug in ti...

Page 160: ... the gear unit at operating temperature 1 Before you start maintenance work park and secure the machine as described in the chapter Preparing the Machine for Maintenance 2 Unscrew the screw plugs 1 and 2 3 Drain the oil 4 Clean the screw plugs and replace the gaskets 5 Tightly screw in the screw plug 2 6 Fill in oil via the check drill hole 1 until the oil reaches up to the bottom edge of the chec...

Page 161: ...d secure machine as described in chapter Preparing the Machine for Maintenance 2 Stop the engine and let it cool down 3 Open the engine cover 4 Turn the radiator cap arrow slowly to the first stop and let the pressure escape Then press the cap down and turn further to remove 5 Check that the radiator is filled up to the overflow with coolant If not then top up to the overflow with coolant 6 After ...

Page 162: ...TION Danger of accidents If you use usually available brake fluid for filling up the operational efficiency of the brake system may be impaired Use only the prescribed oil for filling up Do not use brake fluid Pay attention to utmost cleanness 1 For maintenance operations park and secure machine as described in chapter Preparing the Machine for Maintenance 2 Check the brake fluid level at the expa...

Page 163: ...ng the Machine for Maintenance 2 Check the battery and pole terminals for proper fit 3 Clean the environment of the plugs 4 Remove all plugs and check whether the battery acid is at the acid level markings Refill distilled water if the acid level is too low NOTE In cold weather refill distilled water only immediately before the starting the machine The water can then mix with the battery acid and ...

Page 164: ...ons do not come near the battery with fire and do not produce any sparks Interrupt the charging process if the temperature of the battery acid exceeds 45 C Switch off the battery charger as soon as the battery is re charged If the battery is overloaded the following situations may occur 1 The battery may be overheated 2 Decrease in the battery acid volume 3 Damage of the electrode plates Do not mi...

Page 165: ...perations as described in chapter Preparing the Machine for Maintenance 2 Clean the grease nipples which are indicated by the arrows 3 Use a grease gun to press sufficient grease into the grease nipples Lifting cylinder 1 right and left side 2 locations each Rocker arm 2 1 location Boom 3 2 locations Tipping cylinder 4 2 locations Quick change unit 5 3 locations Clamshell bucket 6 3 locations 4 Re...

Page 166: ...ed after 10 and 50 hours of operation fall also into this maintenance category Draining the Water Separator Removing Water and Dirt Deposits Keep a container ready for collecting the liquid from the water separator 1 1 Loosen the drain plug 2 2 Let the water run off 3 Screw in and tighten the drain plug 4 Check for leaks ...

Page 167: ... of operation fall also into this maintenance category Changing the Engine Oil and Oil Filter Cartridge See chapter Maintenance After the First 50 Operating Hours Checking the V Belt Condition See chapter Maintenance After the First 50 Operating Hours Checking and Adjusting the V belt Tension See chapter Maintenance After the First 50 Operating Hours ...

Page 168: ... Switch off engine Lower work unit and apply parking brake 2 Unscrew the locking screw 1 of the drill hole 3 Check the oil level The oil level must reach up to the bottom edge of the check drill hole 4 If the oil level is too low top up oil via the check drill hole of the screw plug For details on recommended oils see section Lubricants and Operating Agents 5 Tightly screw in the screw plug 6 Chec...

Page 169: ...changed Removing the filter cartridge WARNING Danger of injury When the engine is running you may hurt yourself on the movable components inside the engine room Do not perform any operation in the engine room with the engine running 1 For maintenance operations park and secure machine as described in chapter Preparing the Machine for Maintenance 2 Open the twistlocks on the cover of the air filter...

Page 170: ...the cartridge back and forth in the solution Then rinse the filter cartridge with clean water starting with the inside and then proceeding to the outside max 3 bars and let it dry at a temperature of max 50 C Checking the filter cartridge Usually it is required to check each air filter cartridge before it is re installed For this purpose insert a into the cartridge and visually check the filter pa...

Page 171: ...on firm level ground and secure it before starting the maintenance operations 1 For maintenance operations park the machine as described in chapter Preparing the Machine for Maintenance 2 Clean the grease nipples which are indicated by the arrows 3 Use a grease gun to press sufficient grease into the grease nipples 4 Remove the old grease which is extruding at the bearings Front steering cylinder ...

Page 172: ...ce operations park and secure machine as described in chapter Preparing the Machine for Maintenance 2 Clean the area around the fuel filter 1 3 Unscrew the filter element counterclockwise with the filter screwdriver 4 Clean the filter head 5 Fill up the new filter element with clean fuel 6 Lubricate the sealing faces of the filter element lightly with engine oil 7 During reassembly re tighten the ...

Page 173: ...e tighten the vent screw 6 Loosen the vent screw 4 at the fuel filter 3 7 Operate the fuel pump until bubble free fuel leaks out at the vent screw 8 Re tighten vent screw 9 Re lock the cover of the fuel pump WARNING Danger of injury When the engine is running you may hurt yourself on the movable components inside the engine room Do not perform any operation in the engine room with the engine runni...

Page 174: ...the filter element 7 the gasket 8 and the spiral spring 9 7 Remove water and dirt from the housing 8 Clean the filter element and blow dry it with compressed air 9 Check the filter element and replace it if it is damaged 10 Re insert the spiral spring the gasket 8 and the filter element 11 Position the gasket 6 and the housing 12 Insert a new o ring 10 13 Re tighten the drain plug at the bottom si...

Page 175: ... running the oil level in the transfer box can significantly rise Therefore only check the gear oil level with the engine running idle at operating temperature The gearshift assembly must be in neutral position DANGER Danger of injury When the engine is running you may hurt yourself on the movable components inside the engine room Do not perform any operation in the engine room with the engine run...

Page 176: ...ty Filter NOTE If the filter element is replaced for the third time in sequence it is required to replace also the safety filter 1 Open the air filter and remove the air filter insert 1 Proceed as described in chapter Air Filter Removing and Re Installing the Filter Insert Checking and Cleaning the Filter Insert 2 Pull out the safety filter 2 3 In order to prevent that dust enters the interior of ...

Page 177: ...utlet nozzles 4 and 5 to the right and left of the steering column Caution The circulating air jets arrow must be open 7 If the air flow is still too weak the filter fleece must be replaced 8 Screw front cover 1 back on Cleaning the Condenser of Air Conditioning DANGER Do not wash the condenser with a steam cleaner Otherwise the condenser will get hot and may break down If there is mud or dust sti...

Page 178: ...ing Hours Checking the ALS Accumulator Gas Pressure Option Each time you perform the operations described in the sections Every 500 Service Hours you should ask your Komatsu dealer to check the accumulator gas pressure Pressure 24 bar ...

Page 179: ...cape DANGER Danger of fire Antifreeze may ignite at the hot engine Wait until the engine has cooled down before refilling antifreeze NOTE The coolant must be exchanged after max two years NOTE While preparing the coolant make sure to adhere to the prescribed mixing proportions to ensure a freezing protection up to 37 C This is also valid for countries with moderate climate The coolant has to consi...

Page 180: ... C 8 After the cleaning switch off the engine and open the drain valve to let the entire cooling system run empty Re lock the drain valve and slowly fill the cooling system with clean water 9 Let the engine run for five minutes with a coolant temperature of approx 80 C 10 Then let the cooling system run empty again If the extruding water is not clean the cooling system must be re flushed until the...

Page 181: ... brake disks Checking and Adjusting System Pressures NOTE All repairs on the brake system must be performed by a garage which is authorised by Komatsu Checking and Adjusting the Valve Play NOTE Have the valve play checked and adjusted at an authorised Komatsu garage Checking and Adjusting the Injection Nozzles Nozzle Pressure and Fuel Jet Pattern NOTE Have the nozzle pressure of the injection nozz...

Page 182: ...nd 2 Lower the work unit onto the ground 3 Switch off the engine 4 Secure the articulated steering with the articulated steering lock 1 5 Unlock the feeding and ventilation screw 2 by turning it slowly to let the pressure escape 6 Loosen the screw plug 4 of the hydraulic oil tank and let the oil run off 7 Re tighten the screw plug with its seal being in perfect condition 8 Unscrew the feeding and ...

Page 183: ...tion to the prescribed mixing proportion NOTE The coolant must contain antifreeze in all climate regions The antifreeze does not only decrease the freezing point but also increases the boiling point It lubricates movable components and lip seals and prevents corrosion and foam formation Checking the Cooling System NOTE Let the cooling system check be performed at a garage which is authorised by Ko...

Page 184: ...Maintenance Every 2000 Operating Hours 7 5 8 Checking and Adjusting the Fuel Injection and Injection time NOTE Let the injection time be checked at a garage which is authorised by Komatsu ...

Page 185: ...Technical Data ...

Page 186: ...ds 1st Driving Range 5 7 km h 2nd Driving Range 20 0 km h Driving Speed forward and backwards High speed version overdrive switched off 1st Driving Range 5 4 km h 2nd Driving Range 14 0 km h Driving Speed forward and backwards High speed version overdrive switched on 1st Driving Range 11 6 km h 2nd Driving Range 30 0 km h Tractive force max 48 9 kN Turning radius Outside Counterweight 4100 mm Oute...

Page 187: ...ons for the relative machinery class in compliance with ISO 7096 The actual acceleration value of the upper limbs is less than 2 5 m s2 The actual acceleration value for the body is less than 0 76 m s2 These values were determined using a representative machine and with the help of the measurement procedures that are defined in the directives ISO 2631 1 and ISO 5349 Limit Values for Slopes Maximum...

Page 188: ...Technical Data 8 4 ...

Page 189: ...Special Equipment and attachments 9 1 Special Equipment and Attachments ...

Page 190: ...Special Equipment and attachments 9 2 ...

Page 191: ...d end of the lifting cylinder is connected to the pressure accumulator Precautionary Measures for Switching on the ALS Electronics WARNING If the ALS system is switched on during a journey or when the working attachment is in raised position it may move up or down depending upon the bucket load For this reason extreme caution is advised when operating the switch When inspecting and servicing the m...

Page 192: ...e ALS Electronics switch The control lamp in the switch goes out Handling of the Pressure Accumulator WARNING Danger of injury Pressure accumulator is filled with highly pressurised nitrogen Do not open or damage the pressure accumulator Immediately inform your Komatsu dealer if you detect malfunctions or defects of pressure accumulators Filling the pressure accumulator with gas or topping up gas ...

Page 193: ...Index ...

Page 194: ...10 2 Index ...

Page 195: ...lics Hydrostat drive unit 6 8 A Air conditioning 4 10 4 18 5 9 Checking 7 27 checking rate of air flow 7 26 cleaning Condenser 7 51 cleaning replacing Filter Fleece 7 51 Switching 5 9 Air ventilation nozzles 5 8 5 9 Alarm horn 4 23 ALS Electronics 9 3 Application fields 1 4 Articulated steering Lock 2 3 Securing 2 3 Attachments See Equipment B Batteries Connection disconnection 3 7 Re charge 7 38 ...

Page 196: ... Air conditioning checking rate of air flow 7 26 Checking the Air Conditioning System 7 27 Cleaning the Condenser 7 51 Air filter Cleaning and replacing 7 43 Replacing the filter insert 7 50 Replacing the safety filter 7 50 Axles Oil change 7 33 7 55 Battery Checking the acid level 7 37 Re charging 7 38 Checking the instrument panel 7 25 Checking the wheel nuts 7 32 Cleaning the machine 7 4 Coolin...

Page 197: ... Ajsting the work unit Bucket reset guiding 5 27 Changing the driving direction 5 15 Digging 5 25 Driving 5 13 On slopes 5 14 Driving with high speed gear 5 14 Filling up with soil 5 27 In water 5 29 Loading 3 12 5 24 Loading in diagonal direction 5 26 Mining operations 5 27 Near overhead lines 5 29 On loose soil 5 29 On slopes 5 29 On snow 5 29 On steep slopes 5 29 Piling up material 5 27 Planing...

Page 198: ...screen wiper and washer 4 14 Hazard flasher switch 4 14 Heated rear windscreen 4 16 High speed gear 4 18 Horn button 4 14 Light switch 4 15 Rear windscreen wiper and washer 4 14 Start switch 4 16 Switch for driving range up to 20 km h 4 17 Switch for inside lighting 4 17 Temperature rotary switch 4 16 Warning beacon 4 18 Working lights switch 4 17 T Taking off soil 5 27 Technical data 8 2 Tilt ang...

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