Komatsu WA95-3 Operation & Maintenance Manual
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Komatsu WA95-3 Operation & Maintenance Manual

Komatsu WA95-3 Operation & Maintenance Manual

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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 near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
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.
WA95-
WHEEL LOADER
SERIAL NUMBERS
WARNING
HA980376
and up
VEAM980500
3

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  • Page 1 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...

  • Page 3: Table Of Contents

    Contents Contents Information on these Operating Instructions .............. 1-1 Why You Should Read these Operating Instructions ..............1-3 Notes on Safety Regulations ......................1-4 Correct Use ................................. 1-4 Safety Notes in the Operating Instructions ......................... 1-4 Standards and Guidelines ............................1-6 CE-Conforming Equipment ......................
  • Page 4 Contents Working On Loose Soil ............................. 3-13 Working with the Forklift Truck Attachment ....................... 3-14 Parking the Machine ..............................3-15 Transport ............................3-16 Loading and Unloading the Machine ........................3-16 Transport ................................... 3-16 Safety Measures During Maintenance ..................3-17 Personnel .................................. 3-17 Prior to Start of Maintenance Measures ........................
  • Page 5 Contents Dumping/Unloading ..............................5-26 Planing ..................................5-27 Working With the Forklift Truck Attachment ......................5-28 Precautions For Special Operations ......................... 5-29 After the work is finished ............................5-29 Instructions for Winter Operation ..........................5-30 Longer Standstill Periods of the Machine ......................... 5-31 Troubleshooting ......................
  • Page 6 Contents 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 ......................

  • Page 7: Information On These Operating Instructions

    Information on these Operating Instructions...
  • Page 8 Information on these Operating Instructions 1 - 2...

  • Page 9: Why You Should Read These Operating Instructions

    If the operating instructions have been lost or if they have become unreadable, because they are dirty, you may receive a new copy from Komatsu or your local Komatsu dealer. If the machine is resold, the operating instructions, the EU Declaration of Conformity (CE), and the licence are to be handed over to the new owner.

  • Page 10: Notes On Safety Regulations

    Komatsu or your responsible Komatsu dealer. These operating instructions may refer to attachments and special equipment not available from your local Komatsu dealer. Should you require attachments or special equipment, ask your responsible Komatsu dealer.
  • Page 11 Should you have any doubt concerning safety of a procedure, either directly contact Komatsu or your responsible Komatsu dealer. The following signal words are used to indicate safet notes in these...

  • Page 12: Standards And Guidelines

    For 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.
  • Page 13 Information on these Operating Instructions Notes on Later Installation of Electrical and Electronical Devices and Components Electrical or electronical devices and/or components installed later emit electromagnetic radiation which may influence the proper function of electronic components and parts of the machine. This may impair safety of the machine and endanger persons.

  • Page 14: Ce-Conforming Equipment

    Information on these Operating Instructions CE-Conforming Equipment CE-conforming equipment – Hydr. WA 95-3 Volume Weight Type Part No. pressure m³ 42W-70-12021 42W-70-12030 42W-70-12090 42W-70-12100 42W-70-12210 Bucket WA95-3 42W-70-12240 42W-70-12051 1,25 42W-70-12061 42W-70-12120 42W-70-12080 42W-70-12110 CE_1WA95.TBL 1 - 8...
  • Page 15 / pair kg / pair *) 2500 *) 2600 Fork carrier WA95-3 42U-70-12080 **) 1870 **) 1950 Standing security 80% of the tipping load on firm and level ground Standing security 60% of the tipping load on uneven ground...

  • Page 16: Ce-Conforming Equipment Of The Manufacturer According To Document 42W-93-11130

    Information on these Operating Instructions CE-Conforming Equipment of the Manufacturer According to Document 42W-93-11130 U:\DTP\BA75\CEAUS75.WMF 1 - 1 0...
  • Page 17 Information on these Operating Instructions CE-Conforming Equipment WA 95 42W-93-11130 Manufacturer According to Document 42W-93- 11130 1,670 The responsibility for observing the regulations which are valid for wheel 1,180 loaders with "exchangeable equipment/attachments" (e. g. bucket or forklift truck attachment), which is supplied by other manufacturers lies with the supplier of the relevant parts which were subsequently 1,980 fitted to the machine.
  • Page 18 Information on these Operating Instructions 1 - 1 2...

  • Page 19: Loading And Transporting The Machine

    Loading and Transporting the Machine Loading and Transporting the Machine 2- 1...
  • Page 20 Loading and Transporting the Machine 2- 2...

  • Page 21: Securing The Articulated Steering

    Loading and Transporting the Machine Loading and Transporting the Machine If you have to transport the machine over far distances, either use a low bed loader or a railway wagon. You may lift the machine onto the transport vehicle. Optionally, you may drive it onto the low bed loader or railway wagon via loading ramp (also refer to "Safety Measures During Operati- on, Transport").

  • Page 22: Driving Machine Onto Loading Area Of Transport Vehicle

    Loading and Transporting the Machine “ „ 7 5 _ 16 2 a Information signs attached to the machine indicate the attachment points.To avoid damage to the machine, attach the eye hooks only to the attachment points. X = Machine accessories: 2 brackets, order no.

  • Page 23: Securing The Machine During Transport

    Loading and Transporting the Machine The loading ramps (3) must be aligned to the wheel tracks (5) of the machine. The loading ramps must be secured in such a way that they cannot slip while the machine is being loaded. Support the loading ramps by placing support blocks (2) under both ramps.

  • Page 24: Dimensions, Weights, And Operating Values

    Loading and Transporting the Machine Dimensions, Weights, and Operating Values Dimensions, Operating Values Bucket capacity according to m³ ISO 7546 Loose weight t/m³ Stat. tipping load, straight 4860 Stat. tipping load, bent by 40° 4200 Working load without CTW 2500 Working load with CTW 2600 Tear-out force, hydraulic...

  • Page 25: Technical Data

    Loading and Transporting the Machine Technical Data Machine name-plate position (see enlargement) Serial 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: ..................
  • Page 26 Loading and Transporting the Machine 2- 8...

  • Page 27: Safety

    Safety DANGER Failure 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.

  • Page 28: General Safety Measures

    General Safety Measures General Safety Measures Safety Instructions • Do not operate or service the machine unless you have been trained and are authorised to do so. • Always adhere to all instructions, measures, and safety instructions when operating or servicing the machine. •...

  • Page 29: Machine Modifications

    Komatsu will not be liable for modifications performed without prior expressed consent by the manufacturer. • Komatsu will not be liable for any injuries or damage resulting from unapproved modifications. Before You Leave the Driver's Seat 1. Lower the work unit onto the ground.

  • Page 30: Fire Prevention And Fire Fighting

    General Safety Measures Fire Prevention and Fire Fighting • Fuel, oil, and antifreezing compound are highly inflammable and could cause a fire. • Do not approach inflammable material with naked light. • Prior to refuelling, switch off the engine and stop smoking. •...

  • Page 31: Protection Against Asbestos Dust

    General Safety Measures Protection Against Asbestos Dust Asbestos dust is a health hazard if breathed in. This machine is free of any parts containing asbestos. When handling material that may contain asbestos fibres, strictly adhere to all legal instructions and regulations. Furthermore, adhere to the following protective measures for your own protection: •...

  • Page 32: Roll-Over Protection System (Rops)

    • Do not use attachments that have not been approved of by Komatsu Hanomag or the responsible Komatsu dealer. If you use attachments which have not been approved of, safety, correct operation, and service life of the machine may be impaired.

  • Page 33: Battery

    General Safety Measures Battery The batteries are filled with sulphuric acid (battery acid). • Always wear safety goggles when handling batteries. • Contact of battery acid with eyes can cause blindness. If acid should get into your eyes, immediately rinse your eyes with ample water and call for medical help.

  • Page 34: Before You Start The Engine

    Safety Measures During Operation Before You Start the Engine Workplace Safety • Before you start operation, check the working area for dangerous working conditions. • Inspect the surface of the soil in the working area and determine the optimum and safest procedure. •...

  • Page 35: In-Door Operation

    Safety Measures During Operation In-Door Operation Do not operate machines in-door unless these areas are sufficiently ventilated (e.g. workshops). Caution - Danger of intoxication! Gas, Dust, and Inflammable Vapours Do not operate combustion engines in an environment that may contain inflammable gases or vapours.

  • Page 36: Machine Operation

    Safety Measures During Operation Machine Operation Before You Start the Engine • Walk around the machine to check whether persons or objects are in the way before you get on the machine. • Do not start the engine, if a warning sign has been attached to the control lever or another point.

  • Page 37: Driving On Slopes

    Safety Measures During Operation Driving On Slopes • Keep sufficient distance to ridges and steep slopes. There is danger of the machine tipping over or sliding down on steep slopes, embankments, or hill flanks. The limiting values are defined in chapter "Limiting Values for Slopes".

  • Page 38: Working Close To Overhead Power Transmission Lines

    Safety Measures During Operation Working Close to Overhead Power Transmission Lines • A voltage overspill may occur, if you or the machine get too close to overhead power transmission lines. For this reason, always heed the required safety distance between the machine and the overhead power transmission lines.

  • Page 39: Good Vision

    Safety Measures During Operation Good Vision • When working in dark areas, switch on the working lights of the machine and provide additional lighting for the working area. • If vision is impaired, e.g. due to mist, snow, or rain, interrupt work and wait until vision has improved to such an extent that safe work is ensured again.

  • Page 40: Working With The Forklift Truck Attachment

    Safety Measures During Operation Working with the Forklift Truck Attachment • Check daily, before starting operation, the fork tines of the machine for visual damages (e.g. fissures, cracks, abrasion). Also the protective device for unintentional removing or shifting of the fork tines may have no faults.

  • Page 41: Parking The Machine

    Safety Measures During Operation Parking the Machine • If possible, park the machine on an even surface. If you have to park the machine on a slope, you must park the machine with the work unit pointing down the slope. Lower the work unit (1) until it firmly touches the ground, or let the cutting edge of the bucket sink deeply into the soil.

  • Page 42: Transport

    Safety Measures During Operation Transport Loading and Unloading the Machine Loading and unloading is potentially dangerous. For this reason, proceed with extreme care. • Load and unload the machine only on solid and level ground. Keep a safety distance to the edge of the road. •...

  • Page 43: Safety Measures During Maintenance

    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.
  • Page 44 Safety Measures During Maintenance Prior to Start of Inspection and Maintenance Prior to start of inspection and maintenance operations, park the machine on solid, even ground. Lower the work unit. If your machine is provided with ALS Electronics, you must switch off the ALS Electronics. Switch off the engine (start switch to position '0') and safeguard the machine.

  • Page 45: During Maintenance

    Safety Measures During Maintenance During Maintenance Attachments Attachments removed from the machine must be put down in a safe location in such a way that they cannot tip over. Caution - risk of injury! Working Under the Machine • Always lower all movable work units onto the ground or set them to their lowest positions before you start to perform maintenance or repair measures under the machine.
  • Page 46 Safety Measures During Maintenance Refuelling and Topping Up of Oil • Spilled fuel or oil involves danger of slipping and fire. For this reason, immediately remove any spilled liquid. • Always refuel and top up oil in a place that is sufficiently ventilated. •...
  • Page 47 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 in the pressure accumulator is strictly limited to persons authorised to handle highly pressurised gas.
  • Page 48 Safety Measures During Maintenance Fan and Belts • Always keep sufficient distance from rotating parts and pay attention that nothing gets within the operating range of rotating parts. • There is danger that parts getting caught by the fan or the belt are cut off or hurled away.

  • Page 49: Tyres

    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 special operations, contact the responsible Komatsu dealer or the tyre manufacturer. Storing Tyres •...

  • Page 50: Labeling

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

  • Page 51: Information Labels

    Labeling Information Labels High Speed version only 3-2 5...
  • Page 52 Labeling 3- 2 6...

  • Page 53: Controls And Indicators

    Controls and Indicators...
  • Page 54 Controls and Indicators 4 - 2...

  • Page 55: Overall View Of The Machine

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

  • Page 56: Controls And Indicators

    Controls and Indicators Controls and Indicators Overall View Instrument panel Horn button Light switch Direction indicator lever Inch-Brake pedal Unlocking system of left door Parking brake Steering column adjustment 10 Driving direction switch 11 Multifunctional lever 12 Control lever for special equipment 13 Accelerator pedal 14 Socket 15 Unlocking system of right door...

  • Page 57: Instrument Panel

    Controls and Indicators Instrument Panel The instrument panel can be divided in (A) Control lamps (B) Measuring indicators (C) Warning lights In the following sections of this chapter, all elements required for an efficient machine operation are explained in detail. Control lamps This group comprises the control lamps for high beam, low beam, heated rear windscreen, air preheater, direction indicator, driving direction switch,...

  • Page 58: Warning Lights

    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 4 - 6...
  • Page 59 Controls and Indicators Brake fluid warning light If the brake fluid supply is too low, the brake fluid warning light lights up in red. In this case you must immediately stop the machine and switch off the engine. Proceed as described in chapter "Troubleshooting“. 7 5 _0 0 6 Air filter warning light If the air filter is polluted, the air filter warning light lights up in red.

  • Page 60: Control Lamps

    Controls and Indicators Control Lamps switch in the cabin on the top right at roof 7 5_ 00 4d lining (1) Driving direction switch indicator (2) Direction indicator control lamp (3) Air preheater control lamp (4) Heated rear windscreen indicator (5) High beam control lamp (6) Low beam control lamp (7) High-speed gear control lamp, high-speed gear switched on (active only with high speed version)
  • Page 61 Controls and Indicators Driving direction switch indicators The indicators of the driving direction switch indicate which driving direction you have selected: left arrow lights up: Machine drives backwards (driving direction switch in ‘R’ position) right arrow lights up: Machine drives forward (driving direction switch in ‘F’...
  • Page 62 Controls and Indicators High-speed gear control lamp (option) The high-speed gear control lamp is a feature of machines from the “high-speed version” series. It lights up if the high-speed gear is switched 7 5 _ 0 52 Control lamp in the high-speed gear switch (option) The high-speed gear switch with control lamp is a feature of machines from the “high-speed version”...

  • Page 63: Measuring Indicators

    Controls and Indicators Measuring Indicators (1) Fuel level indicator (2) Operating hour meter (3) Coolant temperature indicator 4 - 1 1...
  • Page 64 Controls and Indicators Fuel level indicator If you set the start switch to the ‘I’ operating position, the fuel gauge indicates the available fuel supply. The tank is full The tank is in the critical range During operation, it is recommended to keep the fuel supply between ‘R’ 7 5 _0 3 2 and ‘1’.

  • Page 65: Switches

    Controls and Indicators Switches switch in the cabin on the top right at roof lining 75 _ 04 3e (1) Switch and control lamp of hazard flashers (2) Switch of front windscreen wiper and washer (3) Switch of rear windscreen wiper and washer (4) Direction indicator lever (5) Horn button (6) Light switch...
  • Page 66 Controls and Indicators Hazard flasher switch This switch is used to switch on/off the hazard flasher. NOTE You may switch on the hazard flasher only in an emergency situation. If you switch on the hazard flasher, all direction indicators of the machine 7 5 _0 2 8 will start to flash.
  • Page 67 Controls and Indicators Light switch The light switch is used to switch on/off the main headlights, the side lamps and the taillights. Switching off the lights Switch in ‘0’ position Switching on the parking light 4 7 0_ 1 0 2 Turn the light switch to the front until it reaches position ‘1’.
  • Page 68 Controls and Indicators (8) Start switch You can start and switch off the engine with the start switch. '0'': Stop position In this position, the engine is switched off, permitting you to remove the ignition key. All functional circuits are interrupted in the stop position. 'I': Operating position 7 5 _ 2 0 9 The control lamps light up in the operating position ‘I’...
  • Page 69 Controls and Indicators (12) Switch for driving range up to 20 km/h This switch is used to change between the machine’s two speed ranges. If you operate the switch, the machine will drive in speed range 2 (up to 20 km/h). If the switch is set to OFF, the machine drives in speed range 1 (up to 7.5 km/h).
  • Page 70 Controls and Indicators (16) High-speed gear switch with control lamp (option) The high-speed gear switch is a feature of machines from the “high- speed version” series. This switch is used to change between the machine’s standard speed ranges and the high-speed gear. If you switch on the high-speed gear, the control lamp in the switch goes out and the machine can be driven up to a speed of 30 k.p.h.

  • Page 71: Control Levers, Pedals

    Controls and Indicators Control 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.) 4 - 1 9...
  • Page 72 Controls and Indicators Brake pedal ATTENTION • If you are driving downhill, let the engine run and use the braking effect of the engine. If required, brake additionally using the brake pedal. • Danger of accidents due to unintentional braking! Do not use the brake pedal as a foot rest.
  • Page 73 Controls and Indicators Accelerator pedal The accelerator pedal regulates the speed (r.p.m.) and performance of the engine. Multifunctional lever for the work hydraulic system The work unit is operated with the multifunctional lever. The multifunctional lever has 6 positions which control the work unit as follows: Float The multifunctional lever is locked in this position.
  • Page 74 Controls and Indicators Control lever for special equipment The control lever for special equipment has three switch settings whose functions depend on the type of the used special equipment. If the standard bucket, the light-weight material bucket or the forklift truck attachment is attached to the quick-change unit, the control lever for special equipment provides the following functions: Position '1': Locking pins for work unit are drawn in...

  • Page 75: Articulated Steering Catch

    Controls and Indicators Articulated Steering Catch The articulated steering catch is used to join rigidly the front and rear part of the machine, thus preventing the articulated steering from bending. You must block the articulated steering before the machine is hoisted or before repairs or maintenance operations are being performed.
  • Page 76 Controls and Indicators 4 - 2 4...

  • Page 77: Operation

    Operation...
  • Page 78 Operation 5 - 2...

  • Page 79: Running In The Machine

    Operation Running in the Machine Before the shipment, each machine was carefully checked and adjusted. A machine that is to be newly commissioned has to be treated with utmost care during its first 100 operating hours. If the machine is used for work involving loads exceeding the specified maximum load for the running-in period, its performance may be impaired prematurely and its service life may be shortened.

  • Page 80: Preparing The Machine Start

    Operation Preparing the Machine Start Visual Checks (also refer to chapter "Maintenance Prior to Machine Start") WARNING Danger of fire! Oil or fuel leaking out or accumulated combustible materials may catch fire at hot parts of the machine, e.g. the exhaust! Prior to starting the machine, check the oil and fuel lines for leaks and immediately repair any leaks.
  • Page 81 12. Check ROPS Check whether screws are loose or damaged. Have loose screws tightened and damaged screws replaced by a Komatsu-dealer. Loose screws must only be tightened with the specified tightening torque. Damaged screws must only be replaced by original parts.

  • Page 82: Adjustments Prior To Machine Start

    Operation Adjustments Prior to Machine Start Adjusting the Driver’s Seat After each change of the driver, newly adjust the driver’s seat. Before you start operation, check that the seat is adjusted in such a way that you can fully floor the brake pedal when you lean against the backrest. Proceed as follows to adjust the seat according to your requirements: Weight adjustment Turn the handwheel (1) to set the vibration absorbing system to the...

  • Page 83: Adjusting The Steering Column

    Operation Adjusting the Steering Column WARNING Do not change the angle of inclination of the steering column while you are driving, since this may lead to severe accidents! Stop the machine, before you change the angle of inclination of 7 5 _ 2 8 1 the steering column.

  • Page 84: Adjusting The Heating And Ventilation System

    Operation Adjusting the Heating and Ventilation System Adjusting the ventilation system When the ventilation system is operated, air is blown into the driver's cab. If the cabin is closed, a light overpressure is built up, preventing dust from outside to settle down in the cab. To increase the volume of filtered fresh air, you can open the ventilation grid a little.

  • Page 85: Operating The Air Conditioning

    Operation Operating the Air Conditioning NOTE • Only operate the air-conditioning with the engine running. • Run the air-conditioning for at least 10 minutes every month irrespective of season. This prevents the compressor shaft seal from drying out. The windows and doors of the operator’s cab must be closed when operating the air conditioning.

  • Page 86: Putting On The Safety Belt

    Operation Putting on the Safety Belt WARNING • Danger of injury! A damaged safety belt, a safety belt that has been stretched in an accident, or a safety belt the belt fixings or fastening screws of which have not been mounted correctly will not protect you sufficiently in case of accident! Replace the safety belt, if it is damaged, or if the machine has been involved in an accident.

  • Page 87: Starting And Switching Off The Engine

    Operation Starting and Switching Off the Engine Starting the Engine Pull the parking brake lever. Set the drive direction switch to its neutral position ‘N’. NOTE You may only start the engine, if the driving direction switch is set to the neutral position 'N'. 7 5 _ 02 3 CAUTION Unintentional start-up of the engine may lead to severe...

  • Page 88: Switching Off The Engine

    Operation Warming up the engine NOTE • You must not accelerate the engine abruptly before the warm- up phase is finished. • Do not let the engine run idle for longer than 20 minutes at its lower or top speed. If it is necessary to let the engine run idle for a longer time, you must load the engine briefly from time to time or let it run at medium speed.

  • Page 89: Driving

    Operation Driving Start-Up CAUTION Careless driving may lead to accidents! Before starting to drive, ensure that no persons are near the machine and sound the horn before you drive up. Start up the engine as described in chapter "Starting up the engine“. Raise the work unit into its transport position.

  • Page 90: Driving With The High-Speed Gear

    Operation Starting the machine on slopes CAUTION Careless driving may lead to accidents! Before starting up, ensure that no persons are near the machine and sound the horn before driving. Start up the engine as described in chapter "Starting and switching off the engine“.

  • Page 91: Changing The Driving Direction

    Operation Changing the Driving Direction WARNING Careless changes of the driving direction may cause severe accidents! Before you change the driving direction from forward to reverse driving or vice versa, you must make sure that no persons or obstacles are in your way. CAUTION The engine may be damaged if you are driving at a high speed and then change abruptly from forward to reverse driving or...

  • Page 92: Turning

    Operation Turning NOTE • The machine may fall over if you turn abruptly at a high speed. • If the machine is halted during the ride, the servo-assisted steering will be deactivated. You may then only proceed with steering the machine with considerably higher effort. Turning on slopes, dams or hills Keep sufficient distance to ridges and steep slopes.

  • Page 93: Braking

    Operation Braking While driving, you may reduce your speed with the service brake (1). After the machine has stopped, you must secure it with the parking brake (2). Pulling the parking brake Press the locking button. Pull up the parking brake lever. Release the locking button.

  • Page 94: Stopping

    Operation Stopping Avoid abrupt stopping. Proceed as follows, if you want to stop the machine: Release the accelerator pedal and press down the brake pedal. Set the drive direction switch into its neutral position ‘N’. Apply the parking brake. Lower the work unit onto the ground. 7 5 _ 02 3 WARNING Unintentional activation of the multifunctional-lever or...

  • Page 95: Longer-Distance Driving

    The required tyre pressure, the driving speed or the tyre type may vary depending on the condition or structure of the road o be used. Contact the responsible Komatsu trader or the tyre dealer to obtain the required information. •...

  • Page 96: Operating The Machine

    Operation Operating the Machine Selecting a work unit Refer to chapter "CE-Conforming Equipment“ for information on the work units registered. Picking up the work unit (except multi-purpose bucket) Connect the multi-purpose bucket as described in section "Picking up the multi-purpose bucket“, page 5-20. Make sure that the change-over lever for the additional control unit is in position '2' (fig.
  • Page 97 Operation Picking up the multi-purpose bucket Set the change-over lever for the additional control unit into position '2' (fig. 75_160). Start the engine. Unlock the quick-change unit by setting the control lever for special equipment into position ‘1’ (fig. 75_042). Lift the boom slightly, by setting the multi-function lever into position ‘H’...

  • Page 98: Tyre-Appropriate Operation

    Operation Removing the multi-purpose bucket Lower the multi-purpose bucket onto level ground. Switch off the engine. Set the control lever for special equipment first to position ‘1’ and then to position ‘2’ (figure 75_042). Turn the change-over lever for the supplementary control circuit to position ‘2’...

  • Page 99: Adjusting The Bucket Positioner

    Operation Adjusting the Bucket Positioner Lower the bucket to the ground and set the bucket to the desired digging angle. Set the bucket control lever to HOLD, stop the engine and adjust as follows. Loosen two bolts (1) and adjust mounting bracket (4) of the proximity switch so that the rear tip of angle (2) is in line with the center of the sensing surface of proximity switch (3).

  • Page 100: Loading

    Operation Loading CAUTION Danger of accidents! The machine may fall over if you transport a load with the bucket lifted too high! Lower the bucket during transporting loads in order to lower the centre of gravity of the machine. The loading operation of wheel loaders is based on the following cycle: Removing or digging ¡...
  • Page 101 Operation To prevent that the bucket dig in too deep into the material to be removed, you must lift the boom while driving into the material. Lifting the boom ensures a sufficient thrust force. 4 70 _ 1 99 Tip in the bucket. 4 70 _ 2 16 If there is too much material inside the bucket, you must briefly tip it in, dump it and lower it in order to reduce the load and to prevent...

  • Page 102: Transporting

    Operation Transporting Make sure that the transport route is in perfect condition and that nobody is in your way. Remove any rocks or large stones which have fallen down out of the operating range (see chapter „Tyre-appropriate operation“). Hold the bucket in tip-in position. Lower the boom to its transport position. If the boom is in transport position, the two red arrows of the transport position marking on the lifting cylinder will be next to each other.

  • Page 103: Planing

    Operation Piling up material Do not position the bucket in its maximum tip-in or dumping position while piling up material. Instead, use the required mining angle. The rear counterweight must not touch the ground. 47 0 _ 22 5 Planing Planing operations are required for levelling the ground.

  • Page 104: Working With The Forklift Truck Attachment

    Operation Working With the Forklift Truck Attachment Operations with an forklift truck attachment on a wheel loader differ from operations with the bucket or a forklift truck. Take into account the following notes and the instructions indicated in the chapter "Safety“: •...

  • Page 105: Precautions For Special Operations

    Operation Precautions For Special Operations Working in water While operating in water or on swampy ground, the water must not reach the underside of the axle housing. Wash the machine after the work has been finished and check the lubricating points. Working on snow Adhere to the instructions in the chapter "Safety“, "Working On Snow“.

  • Page 106: Instructions For Winter Operation

    Operation Instructions for Winter Operation Before the cold season Before the cold season begins, you should perform the following preparatory measures to ensure troublefree operation also in the winter months. • The machine is provided with a aluminium radiator. Therefore, the cooling system must be set to -37°C for the whole year.

  • Page 107: Longer Standstill Periods Of The Machine

    Recharge the battery. After the standstill NOTE If the machine was not moved once a month, contact the responsible Komatsu trader to arrange a maintenance appointment. After a longer standstill period, perform the following works before starting up the machine: •...
  • Page 108 Operation 5 - 3 2...

  • Page 109: Troubleshooting

    Troubleshooting...
  • Page 110 Troubleshooting 6 - 2...

  • Page 111: Warning Lights And Indicators

    Troubleshooting Troubleshooting Have all malfunctions and causes of malfunctions that are not given in the tables below remedied by your responsible Komatsu dealer. Warning Lights and Indicators The following list contains the troubleshooting tables with explanations of warning lights and indicators: Charging current warning light see "Electrical System"...

  • Page 112: Electrical System

    Troubleshooting Electrical System Electrical System Fault Causes Remedy Warning light charging current: Electrical connection without *) Check terminals, connections, and warning light charging current is function cables off, when the engine is switched off and the start switch is set to its operating position 'I' Warning light charging current: Electrical connection without...

  • Page 113: Engine

    Troubleshooting Engine Engine Fault Causes Remedy Warning light engine oil pressure: Oil level in engine too low Top up engine oil with the engine running the Engine oil filter (filter cartridge) Replace engine oil filter (filter warning light is on and an dirty cartridge) acoustic alarm signal is given...
  • Page 114 Troubleshooting Engine (Continued) Fault Causes Remedy Temperature display coolant: Engine is overheated Let the engine run idle without load, temperature display coolant in red until the engine has sufficiently zone, top LED is flashing, cooled down and the temperature acoustic alarm is given indicator of the coolant has returned to the green range Tension of fan's drive belt too low Tension drive belt...
  • Page 115 Troubleshooting Engine (Continued) Fault Causes Remedy Temporarily, combustion sounds Injection nozzles defective *) Replace injection nozzles like breathing Unusual combustion noise Wrong fuel Use prescribed fuel Engine temperature too high Allow engine to cool down (engine overheated) See "Engine - temperature display coolant"...

  • Page 116: Hydraulic System

    Troubleshooting Hydraulic System Hydrostatic Drive Unit Fault Causes Remedy Machine does not drive Parking brake applied Release parking brake Driving direction switch in position Set driving direction switch to either position 'F' or 'R' Driving direction switch without *) Check function of driving direction function switch Oil level in hydraulic oil tank too...
  • Page 117 Troubleshooting Hydrostatic Drive Unit (Continued) Fault Causes Remedy Unusual noise Oil level in hydraulic oil tank too Top up hydraulic oil Inclusions of air in lines and units Bleed hydraulic system of the hydraulic system (faulty bleeding) 75FAUL06.TBL Work Hydraulic System Fault Causes Remedy...

  • Page 118: Brakes

    Troubleshooting Brakes 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 reserve: Brake oil level in brake oil tank too Top up brake oil warning light brake oil reserve is Check brake system for damage and...

  • Page 119: Axles

    Troubleshooting Axles Axles Fault Causes Remedy Noise Oil level in axle too low Top up oil 75FAUL07.TBL Driver's cab Driver's Cab Fault Causes Remedy Blower: insufficient air flow Blower filter clogged Clean or replace filter 75FAUL12.TBL *) These measures must be performed by the responsible dealer. 6 - 1 1...

  • Page 120: Emergency Steering Characteristics

    Troubleshooting Emergency Steering Characteristics If the engine breaks down during driving, you may proceed with steering the machine. However, you will need considerable more effort. If the engine breaks down, immediately drive to the roadside, switch on the hazard flasher and secure the machine. Emergency Lowering System The machine is provided with a pressure accumulator for the work hydraulic system.

  • Page 121: Starting The Engine With A Battery Jumper Cable

    Troubleshooting Starting the Engine with a Battery Jumper Cable NOTE • The current-supplying battery and the discharged battery must have identical nominal voltages. • The capacity of the current-supplying battery must not be significantly lower than the capacity of the discharged battery. •...
  • Page 122 Troubleshooting Starting the Engine The engine of the machine with the charged battery must run at high idle-running speed. Start the engine of the machine with the discharged battery. If the engine does not start up immediately, wait at least two minutes, before you make a second attempt.

  • Page 123: Towing The Machine

    Troubleshooting Towing the Machine WARNING Towing with a tractor of insufficient weight may cause accidents! Perform towing using a machine weighing at least as much as the machine that you want to tow off. CAUTION Towing to start the engine will damage the hydrostatic drive system! Do not give the machine a tow to start the engine.
  • Page 124 Please aks your responsible Komatsu dealer for details, if you want to give a particular machine a tow. 6 - 1 6...

  • Page 125: Inadequate Braking Effect

    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.
  • Page 126 Troubleshooting 6 - 1 8...

  • Page 127: Maintenance

    Maintenance...
  • Page 128 Maintenance Basics 7- 2...

  • Page 129: Maintenance Basics

    Maintenance Basics Maintenance Basics CAUTION Maintenance work must only be performed by trained and qualified personnel. Also refer to chapter " Safety Measures During Maintenance". To ensure troublefree operation of the machine, it must be serviced at regular intervals. Control daily the operating hour meter to determine which of the maintenance measures is required.

  • Page 130: Cleaning The Machine

    Maintenance Basics Cleaning the Machine Always keep the machine clean. Ensure that grease nipples, air vent holes, and oil level indicators are always clean. Avoid contamination of operating agents with impurities. This will reduce malfunctions to a minimum. WARNING If somebody accidentally lowers the bucket while cleaning is being performed under the boom, this may lead to severe accidents! Before you start performing of cleaning work under the boom,...

  • Page 131: Working-Area-Dependent Maintenance

    Maintenance Basics Working-Area-Dependent Maintenance Muddy or Wet Working Areas • Immediately clean the machine after work to protect the components against corrosion. • Perform maintenance and lubrication measures more frequently when working in areas with unfavourable working conditions. • Daily lubricate the bolts of the work unit, if it is often used in water. Dusty Working Areas Adhere to the following measures when working in dusty working areas: •...

  • Page 132: Lubricants And Operating Agents

    Do not open the packages containing the spare filters unless you will mount them immediately. • Always use Komatsu original spare filters. Refuelling and Topping Up of Oil Always refuel and top up oil in a sufficiently ventilated place. If the machine is equipped with a fuel strainer in the tank filler neck, do not remove the fuel strainer when refuelling.
  • Page 133 Biodegradable Hydraulic Oil and Lubricating Grease Biodegradable hydraulic oil and lubricating grease - based on synthetic esters - can be used for Komatsu machines. Please contact our factory representatives for information about the products which suit best your type of application which are approved by Komatsu.
  • Page 134 Maintenance Basics Fuel The fuel injection pump is a precision device. If the fuel in the fuel injection pump contains water or dirt, this will damage the fuel injection pump. • Proceed with utmost care when storing or refuelling, to avoid intrusion of impurities into the fuel.
  • Page 135 Always adhere to the information given in the operating and maintenance instructions when using antifreeze. • Our machines are delivered with original Komatsu antifreeze. 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.
  • Page 136 Maintenance Basics Table of Lubricants and Operating Agents Lubricants and Operating Agents BI-Codes*), Specifications, and Filling Volumes WA95-3 Filling Lubricants and Temperature Viscosity Volume in Operating BI-Codes Quality Classes Ranges Classes Litres Agents approx. CCMC D4 EO 1540 A -15° to 45° C SAE 15W-40 ¹)

  • Page 137: Replacing Safety-Related Parts

    Worn safety-related parts may cause accidents! Have parts which are important for machine safety and fire protection replaced in a Komatsu garage at regular intervals. Have the following parts replaced in the Komatsu garage at regular intervals, even if they are not visibly worn: •...

  • Page 138: Spare Parts And Consumable Components

    Perform this work at regular intervals and as prescribed to ensure an efficient use of the machine. • Only use original Komatsu spare parts. • After removing the gaskets, clean the sealing surfaces. Replace gaskets and O-rings by new ones. Pay attention not to forget any gaskets and O-rings when re-assembling the parts.

  • Page 139: Electrical System

    • Do not remove or modify electrical components installed in the machine. • Only install Komatsu Hanomag-approved electrical components. • When cleaning the machine or during heavy rainfall, pay attention that water does not get into the electrical system. •...
  • Page 140 Maintenance Basics Fuse Assignment Starter stop magnet, 10A Solenoid valves gear unit socket Inside lighting, Direction indicator, radio horn Hazard flasher 10A Instrument lighting Windscreen wiper and windscreen washer 20A Working light front and rear Brake light, Side lamp left, reversing warning lamp registration number system, warning beacon...

  • Page 141: Tyres

    Maintenance Basics Tyres Tyre Components 1 Steel Cord Belt 4 Liner 2 Radial Carcass 5 Diagonal Carcass 3 Bead Core 6 Bead Cores Checking the Tyres Particularly after work on rocky surfaces, check the tyres for damage, wear and tear, and fissures. Tighten loose screws and nuts. For reasons of safety, replace the tyres, if you detect one or several of the following faults: •...
  • Page 142 Maintenance Basics NOTE • Check that the machine is unloaded before you check the tyre pressure. • Prior to start of work, measure the tyre pressure of the cold tyres. If the tyre pressure is too low, the tyre will be overloaded. If the tyre pressure is too high, this will lead to formation of notches in the tyre resulting in bursting of the tyre when it is subjected to shock load.

  • Page 143: Tools

    Maintenance Basics Tools Designation Part No. Remark Spanner Openings: 42T-09-H0450 8/10 mm Set of Double-Ended Ring 42T-09-H0460 13/15 mm Spanners 42T-09-H0470 17/19 mm 42T-09-H0440 24/27 mm Screwdriver 421-98-H1120 Screwdriver 421-98-H1110 Hammer 421-98-H1140 421-98-H1130 Lever Type Hand Gun 424-98-H1010 (Grease) TOOLS75.TBL 7- 1 7...

  • Page 144: Torque For Standard Nuts And Bolts

    Maintenance Basics Torque for Standard Nuts and Bolts Provided that no other values are given, tighten the metric screws with a strength value of 10.9 and the nuts with a strength value of 10 applying the torques given in the tables. The torque that must be applied depends on the diameter of the thread (a) and the size of the spanner (b) of both the nut and the screw.
  • Page 145 Maintenance Basics Metric Fine Screw Thread - Strength Class 10.9 Thread diameter of the Wrench Size bolt Steel Aluminium Cast (mm) (mm) M8 x 1 20.0 M10 x 1 17 (15) 42.0 M10 x 1.25 17 (15) 39.0 M12 x 1.25 12.5 70.0 M12 x 1.5...
  • Page 146 Maintenance Basics 7- 2 0...

  • Page 147: Maintenance Schedule

    Maintenance Schedule Maintenance Schedule Maintenance Prior 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 ............................
  • Page 148 Maintenance Shedule 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 Checking the Accumulator Gas Pressure of third Control Circuit ..............7-55 Maintenance Every 2000 Operating Hours ..................

  • Page 149: Maintenance Prior To Start

    Maintenance Prior to Start Maintenance Prior to Start Cooling System, Checking the Coolant Level, Topping Up Coolant CAUTION • A wrong water/coolant mixing ratio will damage the radiator! Always mix water and coolant in the ratio 50:50. This also applies to countries with a hot climate. •...

  • Page 150: Engine, Checking The Oil Level, Topping Up Oil

    Drain the oil. Check the removed oil for metal parts or undesired material. If the oil contains such particles, inform the responsible Komatsu dealer. Remove the cover cap (3) from the drain valve. Remove the drain hose (5) from the drain valve (4). This will cause the drain valve to close.

  • Page 151: Checking The Fuel Level, Refuelling

    Check that the fuel level indicator (5) indicates the fuel level in the fuel tank. NOTE Contact your responsible Komatsu dealer, if one or several of the indicators do not light up. Do not only use the indicators to perform the checks prior to start. Always perform the work described as regular maintenance, too.

  • Page 152: Checking The Electrical Connections

    Remove inflammable material from the electrical system. NOTE If a fuse blows, or if there are any signs of a short-circuit within the electrical system, inform your responsible Komatsu dealer. Regularly check that the terminals are fastened tightly, retighten loose terminals.

  • Page 153: Maintenance Upon Demand

    At the same time, inspect the flow of coolant (R134a) through the sight glass to check the gas level. Contact your Komatsu dealer for this inspection. The sight glass is installed next to the receiver at the side of the condenser.

  • Page 154: Maintenance Every 10 Operating Hours

    Maintenance Every 10 Operating Hours Maintenance Every 10 Operating Hours Lubrication DANGER There is danger of severe accidents, if you perform maintenance work at a machine that has not been parked and secured correctly! Park the machine on a solid, even surface and secure it, before you start to perform maintenance work.

  • Page 155: Maintenance After The First 50 Operating Hours

    Drain the oil. Check the removed oil for metal parts or undesired material. If the oil contains such particles, inform the responsible Komatsu dealer. Remove the cover cap (3) from the drain valve. Remove the drain hose (5) from the drain valve (4). This will cause the drain valve to close.

  • Page 156: Replacing The Oil Filter Cartridge

    Maintenance After the First 50 Operating Hours Replacing the Oil Filter Cartridge 10. Turn the filter screwdriver anti-clockwise to unscrew the filter cartridge (1). 11. Clean the filter holder. Completely fill up the new filter cartridge with engine oil. Slightly oil both the gasket and the thread of the cartridge with engine oil.

  • Page 157: V-Belt, Checking The Condition

    Maintenance After the First 50 Operating Hours V-Belt, Checking the Condition Check the drive belt for fissures. Transversal fissures in direction of the belt width are permitted. Longitudinal fissures in direction of the belt length crossing transversal fissures, missing parts, or damaged tissue layers are not permitted.

  • Page 158: Hydraulic System, Replacing The Filter Insert

    Maintenance After the First 50 Operating Hours Hydraulic System, Replacing the Filter Insert WARNING Frequent contact between used hydraulic oil and skin may cause skin lesions and other physical damage! Wear rubber gloves when changing the filter. Thoroughly wash off any hydraulic oil adhering to your skin. Lower the work unit onto the floor.

  • Page 159: Front And Rear Axle, Oil Change

    Maintenance After the First 50 Operating Hours Front and Rear Axle, Oil Change WARNING Frequent contact between used hydraulic oil and skin may cause skin lesions and other physical damage! Wear rubber gloves when changing the oil. Thoroughly wash off any hydraulic oil adhering to your skin. DANGER There is danger of severe accidents, if you perform mainte- nance work at a machine that has not been parked and...

  • Page 160: Transfer Box Gearing - Changing Oil

    Maintenance After the First 50 Operating Hours Transfer Box Gearing - Changing Oil WARNING Frequent contact between used hydraulic oil and skin may cause skin lesions and other physical damage! Wear rubber gloves when changing the oil. Thoroughly wash off any hydraulic oil adhering to your skin. DANGER There is danger of severe accidents, if you perform maintenance work at a machine that has not been parked and...

  • Page 161: Maintenance Every 50 Operating Hours

    11. Run the engine until warm. 12. Check points 2. to 5. again. NOTE If coolant has been toppe up regualry in the radiator or expansion tank, then the system should be checkesd by your local Komatsu dealer an repaired if required. 7-35...

  • Page 162: Draining Off Water And Dirt Deposits From The Fuel Tank

    If the oil level is too low, fill prescribed oil into the expansion tank. For detailed specifications, see section "Lubricants and operating agents“. 7 5 _ 2 3 8 If you detect a significant oil loss, inform the responsible Komatsu dealer. 7-36...

  • Page 163: Checking The Battery And Acid Level

    Maintenance Every 50 Hours of Operation Checking the Battery and Acid Level WARNING • Danger of injury! The battery contains strongly aggressive battery acid which may squirt out and burn your eyes! Carry goggles and rubber gloves if you work on the battery. Immediately rinse your eyes or skin using plenty of water and go to see a doctor.

  • Page 164: Re-Charging The Battery

    Maintenance Every 50 Hours of Operation Re-Charging the Battery Re-charging a built-in battery • Disconnect the cable of the negative pole before re-charging or pull the battery main switch, in order to interrupt the power supply. Otherwise, the alternator is damaged due to high voltage peaks. •...

  • Page 165: Lubrication

    Maintenance Every 50 Hours of Operation Lubrication Lubricating points of the work unit DANGER If you perform maintenance operations at a machine which is not properly parked and secured, severe accidents may occur! ark the machine on firm, level ground and secure it before starting the maintenance operations.

  • Page 166: Maintenance Every 100 Operating Hours

    Maintenance Every 100 Operating Hours Maintenance Every 100 Operating Hours All maintenance operations to be performed 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).

  • Page 167: Maintenance Every 250 Operating Hours

    Maintenance Every 250 Operating Hours Maintenance Every 250 Operating Hours All maintenance operations to be performed after 10, 50 and 100 hours 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".

  • Page 168: Front And Rear Axle, Checking The Oil Level

    Maintenance Every 250 Operating Hours Front and Rear Axle, Checking the Oil Level DANGER There is danger of severe accidents, if you perform maintenance work at a machine that has not been parked and secured correctly! Park the machine on a solid, even surface and secure it, before you start to perform maintenance work.

  • Page 169: Air Filter, Removing And Re-Installing The Filter Insert, Checking And Cleaning The Filter Insert

    Maintenance Every 250 Operating Hours Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert Structure of the air filter The air filter consists of the air filter housing, the dust exhaust valve, the filter cartridge and the safety filter. Maintenance demand If the air filter warning indicator (1) lights up, the air filter cartridge is dirty.
  • Page 170 Maintenance Every 250 Operating Hours Cleaning with compressed air CAUTION • Whirled up dust particles may hurt the eyes! Carry goggles if you clean the filter cartridges with compressed air. • Dangerous dust particles may irritate the lung! Carry a dust-protection mask if you clean the filter cartridges with compressed air.

  • Page 171: Cleaning The Radiator Segments

    Maintenance Every 250 Operating Hours Cleaning the Radiator Segments The radiator segments must be checked daily and cleaned with compressed air, if required. NOTE Do not hold the compressed air nozzle or water nozzle too close to the radiator segments. Use no scrubber for cleaning since the plates may be damaged.

  • Page 172: Maintenance Every 500 Operating Hours

    Maintenance Every 500 Operating Hours Maintenance Every 500 Operating Hours All maintenance operations to be performed after 10, 50 and 250 hours of operation also fall into this maintenance category. Changing the Fuel Filter and Filter Element DANGER Danger of fire! Fuel may ignite on hot surfaces! Only change the filter elements if the engine has sufficiently cooled down.

  • Page 173: Changing The Filter Cartridge Of The Hydraulic System

    Maintenance Every 500 Operating Hours Purging the Fuel System DANGER Fuel in the injection system is under pressure. Carry goggles and rubber gloves if you work on the injection pump. If you are hit by a high-pressure fuel beam, immediately go into medical treatment.

  • Page 174: Cleaning The Water Separator

    Maintenance Every 500 Operating Hours Cleaning the Water Separator Keep a container ready for collecting the liquid from the water separator (1). Loosen the drain plug (2). Let the water and fuel run off. Loosen the screw (4) at the bottom side. Remove the housing (5) from the cover.

  • Page 175: Lubrication

    Maintenance Every 500 Operating Hours Lubrication DANGER If you perform maintenance operations at a machine which is not properly parked and secured, severe accidents may occur! Park the machine on firm, level ground and secure it before starting the maintenance operations. For maintenance operations, park and secure machine as described in chapter "Preparing the Machine for Maintenance“.

  • Page 176: Air Filter, Replacing The Filter Insert, Replacing The Safety Filter

    Maintenance Every 500 Operating Hours Air Filter, Replacing the Filter Insert, Replacing the Safety Filter Replacing the Filter Insert NOTE If the filter element is replaced for the third time in sequence, it is required to replace also the safety filter. Open the air filter and remove the air-filter insert (1).

  • Page 177: Heater/Air Conditioning: Cleaning/Replacing Filter Fleece Or Cleaning Condenser

    Maintenance Every 500 Operating Hours Heater/Air Conditioning: cleaning/replacing Filter Fleece or cleaning Condenser Clean Filter Fleece of Heater Unit NOTE If the filter fleece is too dirty it must be replaced. Remove screws on the front cover (1) on the driver's cab (4 screws). Withdraw filter (2) from the heater unit (3).

  • Page 178: Checking The Als-Accumulator Gas Pressure (Option)

    Maintenance Every 500 Operating 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) 7-52...

  • Page 179: Maintenance Every 1000 Operating Hours

    Maintenance Every 1000 Operating Hours Maintenance Every 1000 Operating Hours All maintenance operations to be performed after 10, 50, 250 and 500 hours of operation fall also into this maintenance category. Cooling System, Exchanging Coolant and Cleaning the System WARNING Danger of being burnt! The coolant is under pressure if the engine is hot.
  • Page 180 Maintenance Every 1000 Operating Hours Draining off the coolant Switch off the engine and let it cool down. Swivel the radiator cap (arrow) slowly to the side, up to the first fixed stop, and let the pressure escape. Then press down the cover, while proceeding with swivelling.

  • Page 181: Front Axle, Oil Change

    Checking the Accumulator Gas Pressure of third Control Circuit Each time you perform the operations described in the sections Every 1000 Service Hours, you should ask your Komatsu dealer to check the accumulator gas pressure.(Pressure: 20 bar). 7- 5 5...

  • Page 182: Maintenance Every 2000 Operating Hours

    Maintenance Every 2000 Operating Hours Maintenance Every 2000 Operating Hours All maintenance operations to be performed after 10, 50, 250, 500 and 1000 hours of operation also fall into this maintenance category. Hydraulic System, Oil Change WARNING • Frequent skin contact with used hydraulic oil may cause skin damages and other injuries! Carry rubber gloves for exchanging the filter.

  • Page 183: Ventilating The Hydraulic Oil Tank

    Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required) NOTE Have the fuel and coolant tubes checked and replaced, if required, at an authorised Komatsu garage. Checking the Water Pump NOTE Let the water pump be checked at a garage which is authorised by Komatsu.

  • Page 184: Checking And Adjusting The Fuel Injection And Injection Time

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

  • Page 185: Technical Data

    Technical Data...
  • Page 186 Technical Data Technical Data Specifications Model Komatsu 4D 106E - 2 HC Engine Output, (ISO 9249) 55 kW (75 PS) / 2500 min-1 Torque, max.(DIN Engine 70020) 263 Nm / 1500 min-1 Starter 12 V - 3.0 kW Three-Phase Generator 12 V - 60 A...

  • Page 187: Noise Emission Levels

    Technical Data Noise Emission Levels Two rating plates with details of the machine's noise level must be mounted on the machine: In compliance with EC directive 95/27/EC 1 plate for sound pressure level = 73 dB/A 1 plate for sound power level = 98 dB/A No alterations may be made to the machine which could have an influence on the noise emission levels...
  • Page 188 Technical Data 8 - 4...

  • Page 189: Special Equipment And Attachments

    Special Equipment and attachments Special Equipment and Attachments 9- 1...
  • Page 190 Special Equipment and attachments 9- 2...

  • Page 191: Als-Electronics

    Special Equipment and attachments ALS-Electronics Always read this section before installing and operating the ALS- Electronics as safe as possible. Structure and Functioning Principle of the ALS-Electronics The ALS-Electronics uses the hydraulic shock-absorbing effect of the pressure accumulator (integrated into the circuit at the piston head end of the lifting cylinder) to absorb vibrations during driving.

  • Page 192: Handling Of The Pressure Accumulator

    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 in the pressure accumulator is strictly limited to persons authorised to hand- le highly pressurised gas.

  • Page 193: Index

    Index...
  • Page 194 Index 10 - 2...
  • Page 195 Index Warning beacon 4-10 Control levers 4-19 Air conditioning 4-10, 4-18, 5-9 Control lever for bucket 4-22 Checking 7-27 Multifunctional lever for the work hydraulic syste checking rate of air flow 7-26 4-21 cleaning Condenser 7-51 Safety lever for the work hydraulic system 4-20 cleaning/replacing Filter Fleece 7-51 Steering column adjustment 4-20 Switching 5-9...
  • Page 196 Index Work hydraulics system 6-9 Taking out of service 5-31 Steering 6-8 Transporting 2-3, 3-16 Warning indicators 6-3 Washing 7-4 Filling up 5-27 Machine modifications 1-6 Filter. See Spare parts Maintenance Fire extinguisher 3-4 After operation 5-29 Fire prevention 3-4 After standstill 5-31 First-aid kit 3-4 Air conditioning...
  • Page 197 Index In water 5-29 Pressure Accumulator 7-52, 7-55 Loading 3-12, 5-24 Prior to start 5-4, 7-23 Loading in diagonal direction 5-26 Rear axle Mining operations 5-27 Oil change 7-33, 7-55 Near overhead lines 5-29 Service brake 7-55 On loose soil 5-29 Checking the oil level 7-36 On slopes 5-29 Refilling oil 7-36...
  • Page 198 Index Fire extinguisher 3-4 Roll-over protection 3-6 Taking off soil 5-27 Safety equipment Technical data 8-2 First-aid kit 3-4 Tilt angle Safety instructions Maximum angle 8-3 Appearance 1-4 Towing the machine 6-15 Asbestos dust 3-5 Traction device 4-23 Attachments 3-1 Tractive force 8-2 Battery 3-7 Transporting...

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