Page 1 Operation & Maintenance WEAM005900 Manual WH609 WH613 WH714 WH713 WH714H WH716 TELESCOPIC HANDLERS MODEL SERIAL NUMBER WH609-1 395F60001 and up WH613-1 395F60003 and up WH713-1 395F70001 and up WH714-1 395F70002 and up WH714H-1 395F70003 and up WH716-1 395F70004 and up...
Page 3: Foreword 1.1 Foreword
1.1 FOREWORD • This manual has been developed by Komatsu Utility in order to supply their customers with all the necessary in- formation on the machine and the safety regulations related to it, as well as with the use and maintenance in- structions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
Page 4: Information On Safety
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and the persons in the vicinity will work in total safety, with no risk of damaging the machine. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu Utility or your lo- cal Dealer.
Page 5 INFORMATION ON SAFETY DANGER • Before starting any maintenance operation, position the machine on a firm and level surface, engage the safety locks of the equipment and the controls, stop the engine and apply the parking brake. • For the sake of clarity, some illustrations contained in this manual may represent the machine without guards.
Page 6: Introduction
• Use of the machine by persons under the effect of alcohol, medicines that may affect attention levels, drugs. • Use of the machine to lift persons or with forks, or pallets or equipment not approved from Komatsu Utility for this specific type of application.
Page 7: Main Characteristics
INTRODUCTION 1.3.3 MAIN CHARACTERISTICS • Simple and easy to use. • Cab (ROPS/FOPS level 2). • Servo steering through hydraulic system with priority to steering needs. Three steering modes selected with push buttons: - Two-wheel steering (compulsory for travelling on roads) - Four-wheel steering (round steering) - Crab steering •...
Page 8 INTRODUCTION SYNTHETIC BIODEGRADABLE OIL TYPE HEES On machines in which the synthetic biodegradable oil type HEES is used, the following operations are to be per- formed together with the standard maintenance operations: • After the first 250 hours of operation, change the hydraulic circuit drain filter. •...
Page 9: Product Identification
PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu Utility TELESCOPIC HANDLERS and their main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must be indicated to the Dealer when requiring assistance and ordering spare parts.
Page 10: Machine Identification Plate
PRODUCT IDENTIFICATION 1.4.2 MACHINE IDENTIFICATION PLATE TYPE SERIAL No. MANUFACTURING YEAR MASS RATED CAPACITY ENGINE POWER Product Identification Number MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A. 36025 NOVENTA VICENTINA (VI) - ITALY - 395-93-11570 RKA02031...
Page 11: Engine Serial Number And Exhaust Gas Emission Plate
PRODUCT IDENTIFICATION 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE The identification plate (1) is fixed to the timing case and indicates the engine model, total displacement and serial number. In addition to the Manufacturer’s trademark, the identification plate (2) also indicates the following: 1 - Engine type 2 - Engine Family 3 - Serial no.
Page 12: Rear Axle Serial Number
PRODUCT IDENTIFICATION 1.4.5 REAR AXLE SERIAL NUMBER The rear axle serial number is stamped on the plate positioned on the central body. RKAA0450 1.4.6 TRANSMISSION SERIAL NUMBER The transmission serial number is stamped on the plate posi- tioned on the transmission case, on the engine coupling side. RKAA0460 1.4.7 CAB SERIAL NUMBER The cab serial number is stamped on the plate positioned on the...
Page 13: Serial Numbers And Dealer's Address
PRODUCT IDENTIFICATION 1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS Machine No. Model Product identification number (PIN) Engine No. Front axle No. Rear axle No. Transmission No. Cab No. Optional equipment: Dealer: Address: Tel. Contact person: NOTES:...
Page 14: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD FOREWORD............................INFORMATION ON SAFETY ........................ INTRODUCTION ........................... 1.3.1 INTENDED USES........................1.3.2 IMPROPER OR UNAUTHORIZED USE .................. 1.3.3 MAIN CHARACTERISTICS...................... 1.3.4 RUNNING-IN ..........................PRODUCT IDENTIFICATION ....................... 1.4.1 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ..1.4.2 MACHINE IDENTIFICATION PLATE ..................
Page 15 TABLE OF CONTENTS 2.3.4 ROOM VENTILATION ......................2.3.5 PRECAUTIONS CONCERNING THE LIGHTS ................ 2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS- CHECKING THE WINDSHIELD WIPER BLADES ..............PRECAUTIONS TO BE TAKEN DURING WORK................2.4.1 WHEN STARTING THE ENGINE .................... 2.4.2 RULES FOR TRAVELLING ON ROADS .................
Page 16 TABLE OF CONTENTS 2.8.20 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS......2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES ..........2.8.22 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES».............. DESCRIPTION AND OPERATION OF THE MACHINE GENERAL VIEWS ..........................3.1.1 RIGHT SIDE VIEW ........................
Page 17 TABLE OF CONTENTS 3.6.4 HEATING THE HYDRAULIC OIL ..................... 3.6.5 HOW TO MOVE THE MACHINE ..................... 3.6.5.1 MOVING ON SLOPES .................... 3.6.5.2 MAXIMUM IMMERSION DEPTH ................PARKING THE MACHINE ........................3.7.1 PARKING ON LEVEL GROUND ....................3.7.2 PARKING ON SLOPES......................STOPPING THE ENGINE ........................
Page 18 TABLE OF CONTENTS 3.14.5.3 BRAKING SYSTEM ....................3.14.5.4 CONVERTER......................3.14.5.5 ENGINE........................MAINTENANCE GUIDE TO MAINTENANCE ........................MAINTENANCE NOTES ........................4.2.1 NOTES REGARDING THE ENGINE..................4.2.1.1 ENGINE OIL......................4.2.1.2 COOLANT ....................... 4.2.1.3 FUEL ........................4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM..............4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM..............
Page 19 TABLE OF CONTENTS 4.7.2.g CHECKING THE SERVICE BRAKES..............4.7.2.h CHECKING AND ADJUSTING THE PARKING BRAKE......... 4.7.3 MAINTENANCE EVERY 50 HOURS OF OPERATION OR EVERY 2 WEEKS....... 4.7.3.a LUBRICATING THE ARTICULATED JOINTS AND THE PADS......4.7.3.b LUBRICATING THE CHAIN GEAR SHAFTS (Only for 3-section boom version) ... 4.7.3.c DRAINING THE WATER SEPARATOR ..............
Page 20 TABLE OF CONTENTS 4.7.10.c CHANGING THE COOLANT .................. 4.7.10.d CHANGING THE BRAKING SYSTEM OIL ............. 4.7.10.e CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER..4.7.11 MAINTENANCE EVERY 3 YEARS ..................4.7.11.a CHANGING THE SAFETY BELT................4.7.12 MAINTENANCE EVERY 3000 HOURS OF OPERATION OR EVERY 3 YEARS ....4.7.12.a CHANGING THE ENGINE THERMOSTATIC VALVE ..........
Page 21: Safety Devices And Accident-Prevention Measures
SAFETY DEVICES AND ACCIDENT-PREVENTION MEASURES...
Page 22: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of a component provided with a safety plate, make sure that this plate is applied also to the new piece.
Page 23 SAFETY, NOISE AND VIBRATION PLATES 395-93-11391 RKAA0400...
Page 24 SAFETY, NOISE AND VIBRATION PLATES RKAA0740 RKAA0720...
Page 25 SAFETY, NOISE AND VIBRATION PLATES RKAA0710...
Page 26: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger signs applied onto the machine are accompanied by or illustrated through pictograms. The personnel in charge with handling and maintenance operations must know the symbols contained in the picto- grams perfectly;...
Page 27 SAFETY, NOISE AND VIBRATION PLATES SAFETY DISTANCE • Do not get near or stand within the machine operating area. 395-93-11400 RKA00160 395-93-11920 RKA01670 RISK OF ELECTROCUTION 395-93-11351 RKA00170...
Page 28 SAFETY, NOISE AND VIBRATION PLATES BEFORE LEAVING THE WORK POSITION 395-93-11341 RKA00180 DO NOT CLIMB ON THE ENGINE HOOD 395-93-11391 RKA00700 RISK OF CRUSHING 395-93-11380 RKA00690...
Page 29 SAFETY, NOISE AND VIBRATION PLATES EMERGENCY EXIT 20N-98-RB26101 RKA00520 DO NOT USE AS A PLATFORM 395-93-11511 RKA00790 DO NOT OPEN THE RADIATOR AND THE HYDRAULIC OIL TANK WHEN THE ENGINE IS HOT 395-93-11320 RKA00660...
Page 30 SAFETY, NOISE AND VIBRATION PLATES KEEP AT A SAFETY DISTANCE FROM THE EQUIPMENT – DO NOT CLIMB ON THE FORKS, NOR STAND UNDER THEM 395-93-11471 RKA00770 DO NOT WASH THE ENGINE CENTRAL UNIT WITH HIGH-PRESSURE JETS 395-93-11491 RKA00780 FILLING THE HYDRAULIC SYSTEM WITH •...
Page 31 SAFETY, NOISE AND VIBRATION PLATES HYDRAULIC OIL TOPPING UP 20M-98-RB26221 RWA00620 HYDRAULIC OIL LEVEL 20N-98-RB26041 RKA00560 HYDRAULIC OIL FILTER 20N-98-RB26051 RKA00550 REFUELLING 20M-98-RB26231 RWA00610 FUEL FILTER 20M-98-RB26271 RWA00590 ENGINE LUBRICATING OIL FILTER 20M-98-RB26261 RWA00600...
Page 32 SAFETY, NOISE AND VIBRATION PLATES ENGINE INTAKE FILTER 20M-98-RB26281 RWA00580 ENGINE COOLANT PRESSURE 20M-98-RB26331 RKA00570 TRANSMISSION OIL TOPPING UP 395-93-11430 RWA00730 TRANSMISSION OIL LEVEL 395-93-11440 RWA00740 TRANSMISSION OIL FILTER 395-93-11420 RWA00720 BRAKE OIL TOPPING UP 395-93-11450 RWA00750...
Page 33 SAFETY, NOISE AND VIBRATION PLATES BRAKE OIL LEVEL 395-93-11460 RWA00760 LUBRICATION POINTS 395-93-11410 RKA00710 POWER OUTLET 20N-98-RB26061 RKA00540 ANCHORING POINT FOR TRANSPORT AND LIFTING OPERATIONS RKA00530...
Page 34: Position Of The Noise Plates
Do not use fuel, petrol or solvents. • If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer. • In case of replacement of the cab door to which the noise plates...
Page 35: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES • Only trained and authorized personnel can use the machine and perform maintenance operations. • When using the machine or performing maintenance operations, follow all the applicable safety rules, the pre- cautions and the instructions indicated herein.
Page 36: Unauthorized Modifications
2.2.4 UNAUTHORIZED MODIFICATIONS • Any modifications made without the authorization of Komatsu Utility can involve hazards. • Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for injury or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATOR’S SEAT •...
Page 37: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MACHINE • Do not jump on or off the machine when it is at rest, nor when it is moving. • When getting on or off the machine, always use the handles and the safety ladders;...
Page 38: Preventing Fires Due To Fuel And Oil
GENERAL PRECAUTIONS 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL Fuel, oil and some types of antifreeze can be easily ignited if they get in contact with a flame. Fuel is flammable and therefore very dangerous. • Keep any naked flame away from flammable fluids. •...
Page 39: Preventing Damage Due To Asbestos Powder
GENERAL PRECAUTIONS 2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER • Asbestos powder can be hazardous to health if it is inhaled. • If you handle materials containing asbestos fibers, keep to the instructions given below: 1 - Do not use compressed air, but only exhaust fans to clean the machine, and make sure that the room in which you are working is properly ventilated.
Page 40: Fire Extinguishers And First Aid Kit
• If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator. Contact Komatsu Utility or a Komatsu Utility Dealer to have the cab structure and resistance checked in case of impact or damage.
Page 41: Precautions To Be Taken Before Starting Work
(earth, stones, etc.). • Check the safety belt and change it if it is broken or damaged. Replace any component only with homologated parts available at Komatsu Utility or its Dealers.
Page 42: Room Ventilation
PRECAUTIONS TO BE TAKEN BEFORE STARTING WORK 2.3.4 ROOM VENTILATION • Before starting the machine in confined or poorly ventilated places, provide for proper ventilation or connect the engine ex- haust pipe to a suction duct. The engine exhaust gases can be deadly. RKA00420 2.3.5 PRECAUTIONS CONCERNING THE LIGHTS •...
Page 43: Precautions To Be Taken During Work
PRECAUTIONS TO BE TAKEN DURING WORK 2.4 PRECAUTIONS TO BE TAKEN DURING WORK 2.4.1 WHEN STARTING THE ENGINE • Before getting on the cab, walk around the machine and check if there are leakages (fuel, engine coolant, oil), damage to the cab, lights and indicators, loose screws, damaged tyres, etc. •...
Page 44: Checks For Travelling In Reverse
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.3 CHECKS FOR TRAVELLING IN REVERSE. • When operating in areas that may be hazardous or have poor visibility, designate a person to direct the movements of the ma- chine and traffic on the work site. •...
Page 45: Moving On Slopes
If the engine stops abruptly, apply the parking brakes and im- mediately contact your Komatsu Utility Dealer. RKA01730 2 - Check the tyre inflation pressure; excessively low pressure...
Page 46: Working On Slopes
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.6 WORKING ON SLOPES The use of the machine on slopes must be regulated as follows: • Wheeled machine without frame levelling system and stabi- lizers: max. longitudinal and transversal inclination 2° (A - B). •...
Page 47: Working In Windy Weather Conditions
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.8 WORKING IN WINDY WEATHER CONDITIONS DANGER • Do not use the machine to lift large loads when the weather is windy. If the wind reaches degree 5 on the Beaufort scale (on dry land) and the boom must be extended as much as possible, the resulting sail effect may cause the overturning of the machine.
Page 48: Main Operating Modes
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.9 MAIN OPERATING MODES After performing the checks regarding the safety conditions of the machine (cab or canopy, tyre pressure, sound- ness of the forks or equipment and of the fastening parts), always adopt the following procedure, with no excep- tion: 2.4.9.1 LOADING THE MATERIAL ATTENTION...
Page 49 PRECAUTIONS TO BE TAKEN DURING WORK 3 - If the machine is equipped with stabilizers, lower them until raising the front tyres from the ground, keeping the frame lev- RKAA2240 4 - Adjust the equipment or the forks until they are perfectly lev- el;...
Page 50: Unloading The Material
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.9.2 UNLOADING THE MATERIAL ATTENTION • When placing loads in a high position, keep in mind that your visual perception is altered because of the distance. In this case, appoint an assistant who will signal what manoeuvres must be carried out, using the specif- ic signs agreed for handlers.
Page 51 PRECAUTIONS TO BE TAKEN DURING WORK DANGER • Do not move or handle the load over people working in the manoeuvre area or passing through it. • Pay the utmost attention to overhead lines, systems, lights, etc. 1 - Move slowly, in perpendicular direction, trying to get as near the unloading area as possible;...
Page 52: Preventing Electrocution
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.10 PREVENTING ELECTROCUTION • Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electrical lines always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 53: Preventing Damage Caused By The Work Equipment
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.13 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT • When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is limited, proceed with the greatest care to prevent the bucket or the forks from causing any damage. 2.4.14 WORKING ON LOOSE GROUND •...
Page 54: Parking The Machine
PRECAUTIONS TO BE TAKEN DURING WORK 2.4.15 PARKING THE MACHINE • Park the machine on firm and level ground. If this is not possible and it is necessary to park on a slope, po- sition the machine with the equipment directed downwards and carry out the following operations: 1 - Select the four-wheel steering mode and steer completely to the right or to the left, choosing the direction in which there...
Page 55: Transporting The Machine On Other Vehicles
TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE • Loading and unloading the machine on/from another vehicle al- ways involve potential hazards; pay the utmost attention during Ramps Rampe the entire operation.
Page 56: Battery
BATTERY 2.6 BATTERY 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES • Electrolytic batteries contain sulphuric acid, which can cause burns. It can also corrode clothing and make holes in it. In case of contact with battery acid, immediately wash the affected part with plenty of water.
Page 57: Precautions For Emergency Recovery
PRECAUTIONS FOR EMERGENCY RECOVERY 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY • The machine must be towed by using a pin inserted in the appo- site rear hole and secured with safety pins (1). • No special operations are required to tow the machine, provid- ed that the engine has been stopped.
Page 58: Precautions To Be Taken During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.1 WARNING PLATES • Before starting any maintenance operation, position the ma- chine on a firm and level surface, rest the equipment onto the ground, engage the safety locks of the equipment and the con- trols and stop the engine.
Page 59: Equipment
60 cm, in order not to damage the warning plates and the pictograms. If any plate should be dam- aged, request Komatsu Utility or your Komatsu Utility Dealer to send you a new one and change it.
Page 60: Use Of The Engine During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE • Before starting the engine, make sure that the parking brake has been applied. • Always stop the machine on a firm and flat surface and stop the engine before carrying out any maintenance op- eration or check.
Page 61: Checking The Coolant Level In The Radiator
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.10 CHECKING THE COOLANT LEVEL IN THE RADIATOR • Let the engine and the radiator cool down to a temperature be- low 42°C before checking the coolant level. • If it is necessary to remove the cap with hot engine, wear suita- ble clothes and protections and loosen the cap slowly, in order to release the pressure gradually.
Page 62: Precautions Concerning The Starter
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.13 PRECAUTIONS CONCERNING THE STARTER • Do not start the engine with a jumper connection between the starter terminals in the central unit or on the starter itself; if there is a short circuit, the whole electric system of the engine may be damaged and this may affect the reliability of the machine in critical conditions like low temperatures and the engine stop in case of emergency.
Page 63: Precautions Concerning High-Pressure Hoses And Fuel Pipes
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES AND FUEL PIPES • Do not bend high-pressure hoses or rub them with sharp or abrasive objects. Do not use bent or cracked pipes or hoses that were previously rejected because of leaks or fastening defects, since they may burst during use.
Page 64: Cooling Fan And Fan Belt
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.18 COOLING FAN AND FAN BELT • Be careful to the revolving parts and do not allow anyone to get too close to these parts, since clothes or parts of the body may get caught into them. •...
Page 65: Precautions To Be Taken When Inflating Tyres
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES • Always bear in mind that tyres can burst while being inflated, causing serious accidents. • Before inflating tyres, always check the wheel rims and the tyre walls and tread for dents, cuts, broken plies, or other defects.
Page 66 PAGE INTENTIONALLY LEFT BLANK...
Page 67: Description And Operation Of The Machine
DESCRIPTION AND OPERATION OF THE MACHINE...
Page 68: General Views
GENERAL VIEWS 3.1 GENERAL VIEWS 3.1.1 RIGHT SIDE VIEW LEFT LEFT LEFT FORW W ARD FORWARD RIGHT RIGHT RIGHT RKAA0402 3.1.2 LEFT SIDE VIEW RKAA0391 1 - Frame 8 - Final boom section 2 - Stabilizers 9 - Equipment-carrier 3 - Front axle 10 - Forks 4 - Rear axle 11 - Cab...
Page 69: Cab Inside General View
GENERAL VIEWS 3.1.3 CAB INSIDE GENERAL VIEW RKAA0690 RKAA0700 RKAA0680 1 - Gearshift-reverse lever 9 - Service brake pedal 2 - Operating mode selection unit 10 - Accelerator 3 - Steering mode selection unit 11 - Steering wheel 4 - Frame levelling push button (optional) 12 - Steering wheel position lock lever 5 - Stabilizers push buttons (optional) 13 - Dashboard...
Page 70: Instruments And Controls
INSTRUMENTS AND CONTROLS 3.2 INSTRUMENTS AND CONTROLS 3.2.1 INSTRUMENTS The following instruments are positioned on the upper part of the dashboard: RKAA0540 ENGINE COOLANT TEMPERATURE INDICATOR • Indicates the temperature of the engine coolant. • The relevant indications are given by the shifting of the bar in succession from bottom to top.
Page 71 INSTRUMENTS AND CONTROLS FUEL LEVEL INDICATOR • Indicates the fuel level in the tank and is divided into two-colour led bars: a - flashing red = low fuel (first bar). b - green = all the other bars. NOTE • Rated capacity of the tank: 130 l. IMPORTANT •...
Page 72: Warning Lights
INSTRUMENTS AND CONTROLS 3.2.2 WARNING LIGHTS The following warning lights are positioned on the lower part of the dashboard: RKAA0540 GENERATOR WARNING LIGHT (Red) This warning light comes on and activates the acoustic alarm when the starting circuit is energized and goes out when the en- gine reachs the idling speed;...
Page 73 INSTRUMENTS AND CONTROLS ENGINE OIL PRESSURE WARNING LIGHT (Red) This warning light comes on and activates the acoustic alarm with engine at rest when the starting circuit is energized and goes out as soon as the engine lubrication circuit is pressurized. If this warning light remains on or comes on with the engine run- ning, stop the machine immediately and try to locate the trouble.
Page 74 INSTRUMENTS AND CONTROLS FRONT WORK LIGHT (Yellow) (optional) This warning light comes on when the work light on the telescopic boom is operated. RKA00950 REAR WORK LIGHT (Yellow) (optional) This warning light comes on when the rear work light is operated. RKA00010 PARKING BRAKE WARNING LIGHT (Red) This warning light comes on when the parking brake is applied.
Page 75 INSTRUMENTS AND CONTROLS 11 - PARKING LIGHTS AND LOW BEAM WARNING LIGHT (Green) This warning light comes on when the parking lights and the low beam are operated with the corresponding switch «3.2.3 SWITCHES AND PUSH BUTTONS» pos. 1 - PARKING LIGHTS AND LOW BEAM SWITCH).
Page 76 INSTRUMENTS AND CONTROLS 15 - GENERAL ALARM WARNING LIGHT (Red) This warning light comes on: a - for about 3 seconds, during the general warning light check every time the machine is started; b - when the maximum temperature allowed for the engine cool- ant is exceeded.
Page 77: Switches And Push Buttons
INSTRUMENTS AND CONTROLS 3.2.3 SWITCHES AND PUSH BUTTONS RKAA0550 RKAA0560 RKAA0570 RKAA1140 RKAA0580...
Page 78 INSTRUMENTS AND CONTROLS PARKING LIGHTS AND LOW BEAM SWITCH This is a two-position switch; with one click it switches on the parking lights and instruments, with two clicks it switches on the low beam. The parking lights can be switched on even with the machine at rest.
Page 79 INSTRUMENTS AND CONTROLS 5 - 6 AVAILABLE OPTIONAL EQUIPMENT HYDRAULIC CIR- CUIT SWITCH This switch is complete with safety lock. When pressed to activate the circuit, it must be locked with a cur- sor to be held in this position; to deactivate the circuit, move the cursor to its original position (up), or press the switch again.
Page 80 INSTRUMENTS AND CONTROLS 10 - IGNITION SWITCH This is a rotary key switch with four positions marked by the fol- lowing symbols: « » - O (OFF) - I - « » (START). For further details on the use of this switch, see «3.6.2 START- ING THE ENGINE»).
Page 81 INSTRUMENTS AND CONTROLS 15 - MACHINE OPERATING MODE SELECTOR This is a three-position selector that must be operated exclusively with the machine at rest. With this selector it is possible to choose among three operating modes: TRAVEL, TRAVEL-WORK and WORK. For details on how to select and use the three operating modes, see «3.2.5 MACHINE CONTROLS».
Page 82 INSTRUMENTS AND CONTROLS 20 - TRANSMISSION DECLUTCH PUSH BUTTON This button makes it possible to disconnect the transmission in or- der to use all the power developed by the engine for the hydraulic system. It can be used when the TRAVEL-WORK or TRAVEL operating modes are selected.
Page 83 INSTRUMENTS AND CONTROLS RKAA0630 22 - Fan switch 23 - Air conditioner switch (optional) A - See «3.5.2 CAB» 22 - FAN SWITCH This is a three-speed switch that operates the fan motor. Turn the switch clockwise to increase ventilation. If operated after the tap installed on the heater has been opened, this switch ensures the circulation of warm air and serves as heat- ing switch (see «3.5.4 VENTILATION AND HEATING»).
Page 84: Electric Accessories
INSTRUMENTS AND CONTROLS 3.2.4 ELECTRIC ACCESSORIES ACOUSTIC ALARM The acoustic alarm starts when the circuits are energized with the ignition key (rotation to position «I») and stops automatically after the automatic check on the warning lights. The continuous sound during the use of the machine signals: •...
Page 85: Machine Controls
INSTRUMENTS AND CONTROLS 3.2.5 MACHINE CONTROLS RKAA0750 RKAA0760 RKAA0700 1 - Gearshift-reverse lever 2 - Steering mode selection unit 3 - Operating mode selection unit 4 - Frame levelling (optional) 5 - Stabilizers control (optional) 6 - Boom control lever RKAA0770 7 - SLI-Safe Load Indicator RKAA0780...
Page 86 INSTRUMENTS AND CONTROLS GEARSHIFT-REVERSE LEVER DANGER • Between the gearbox and the engine there is no mechani- cal connection; if the machine is parked on a slope, it can move freely even if the gears are engaged. For this reason, always apply the parking brake, in order to avoid serious damage.
Page 87 INSTRUMENTS AND CONTROLS a (F) a (F) a (F) b (R) b (R) b (R) RKAA0800 a - When shifted FORWARD (F) and rotated on its axis, the forward movement of the machine is enable. b - When shifted BACKWARD (R) and rotated on its axis, the reverse movement of the machine is enable. NOTE •...
Page 88 INSTRUMENTS AND CONTROLS All the functions are indicated by leds that come on or take on dif- ferent colours: RKAA0791 CONDITION Comes on when the machine is in NEUTRAL Used only with a diagnostic function, comes on only in case of failure Indicate what gear is engaged (N°) and the direction according to their colours.
Page 89 INSTRUMENTS AND CONTROLS 2 - The engagement of a gear can take place only after the se- lection of the travel direction and within maximum 5 seconds; if the gears are not engaged, the gearshift returns to the safe- ty postion (NEUTRAL). 3 - The gears are engaged by rotating the lever on its axis and releasing it after each engagement.
Page 90 INSTRUMENTS AND CONTROLS STEERING MODE SELECTION UNIT DANGER • When the engine is started the two-wheel steering is always enabled. The acoustic alarm when the machine starts moving means that the rear wheels aren’t aligned. Turn the steering wheel clockwise or anticlockwise until the rear wheels are aligned, which is confirmed by the coming on of the green warning light (9) and by the interruption of the acoustic alarm.
Page 91 INSTRUMENTS AND CONTROLS The operating functions of this unit are the following: 2-1 START When the machine is started, the two-wheel steering is al- ways selected and therefore the led (6) is on. If the rear wheels are misaligned: a - the intermittent acoustic alarm starts; b - the transmission is locked and therefore travel is inhibited;...
Page 92 INSTRUMENTS AND CONTROLS 2-3 TWO-WHEEL STEERING (2WS) If the four-wheel round or crab steering (4WS) is being used and the two-wheel steering (2WS) is selected with buttons (2) and (3) while the rear axle isn’t aligned: a - the intermittent acoustic alarm starts; b - the round or crab steering is maintained until the rear wheels are realigned;...
Page 93 INSTRUMENTS AND CONTROLS b - the two-wheel steering (2WS) is selected until the front wheels are aligned (led 6 and 8 on); RKAA0616 c - the 4WS round steering is selected (led 5 on). NOTE • If the 4WS ROUND steering is selected with the ma- chine in TRAVEL operating mode, the control is neither accepted, nor stored.
Page 94 INSTRUMENTS AND CONTROLS CASE (machine moving) a - the intermittent acoustic alarm starts and continues until the machine stops; b - the 2WS selection is maintained until the front wheels are aligned (led 8 on); RKAA0890 c - the 4WS crab steering is selected. RKAA0891 •...
Page 95 INSTRUMENTS AND CONTROLS c - the 4WS crab steering is selected (led 7 on). RKAA0894 CASE (machine moving) a - the intermittent acoustic alarm starts and continues until the machine stops; b - the 4WS round steering selection is maintained until the rear wheels are aligned (led 9 on);...
Page 96 INSTRUMENTS AND CONTROLS OPERATING MODE SELECTION UNIT The selector (1) is used to choose among three different operating modes: a - TRAVEL This operating mode allows the machine to travel only; therefore, it inhibits all movements regarding boom, work equipment, stabilizers and frame levelling. When this mode is selected, all the available gears can be used (5 forward + 3 reverse).
Page 97 INSTRUMENTS AND CONTROLS FRAME LEVELLING (optional) DANGER • The levelling of the frame must be carried out only with the machine at rest, in TRAVEL-WORK operating mode and before lowering the stabilizers. • Always level the machine frame before lifing the load to be handled. •...
Page 98 INSTRUMENTS AND CONTROLS STABILIZERS CONTROL (optional) DANGER • The stabilizers can be operated only in TRAVEL-WORK operating mode. • Before lowering or raising the stabilizers, make sure that no person or obstacle is within their operating range. • Before selecting a gear or the travel direction, make sure that the stabilizers have been completely raised.
Page 99 INSTRUMENTS AND CONTROLS 6-1 LEVER The boom control lever is positioned on the operator’s right and controls the boom lifting and lowering and the folding and dumping of the equipment according to the orthogonal movements listed below. N - Neutral A - Boom lowering B - Equipment dumping C - Boom lifting...
Page 100 INSTRUMENTS AND CONTROLS 6-3 HYDRAULIC EQUIPMENT CONTROL PUSH BUTTONS DANGER AUX 1 • After using the auxiliary line for the equipment, disconnect the circuit. Failure to disconnect the line after use may cause serious accidents and even death. In order to be able to use the auxiliary line for the hydraulic equip- AUX 2 ment, it is necessary to connect the circuit by pressing button on the dashboard (see «3.2.3 SWITCHES AND PUSH BUTTONS»).
Page 101 INSTRUMENTS AND CONTROLS SLI-SAFE LOAD INDICATOR DANGER • While lifting or handling a load, check the stability of the machine frequently; if the yellow warning lights come on, maximum attention must be paid while performing manouevres with the equipment control le- ver and travel speed must be reduced if the machine travels on uneven or wavy surfaces.
Page 102 INSTRUMENTS AND CONTROLS 7-1 INTERPRETING VISUAL MESSAGES AND ACOUSTIC ALARMS RKAA0850 The LED scale (2) goes from bottom to top, with the green LED coming on first and the others following up to the maximum level of risk corresponding to the red LED (8). NOTE •...
Page 103 INSTRUMENTS AND CONTROLS • Acoustic alarm: slow intermittence • Led 3, 4, 5 and 6: slow blinking • The instrument indicates that it is necessary to proceed at low speed, without using the accelerator and operating the controls slowly. RKAA1592 •...
Page 104 INSTRUMENTS AND CONTROLS PARKING BRAKE DANGER • The parking brake must be applied whenever the opeator leaves the cab, even if for a short time and even if the machine rests on firm and level ground. • In dangerous conditions the parking brake can be used also as emergency brake if the service brakes cannot stop the machine.
Page 105 INSTRUMENTS AND CONTROLS SERVICE BRAKE PEDAL DANGER • The service brakes are power-assisted; if the engine stops, the effort required to press the pedal and brake increases considerably. This will delay the braking response and make stopping distances longer, which increases the chances of causing accidents that may even be very serious. •...
Page 106 This increases the risk of overturning. • DO NOT resume work until your Komatsu Utility Dealer has repaired the malfunction. • When changing the operating mode from WORK to TRAV- EL-WORK or TRAVEL on laterally inclined ground with boom inclination below approximately 30°, pay attention to...
Page 107: Lifting Loads
LIFTING LOADS 3.3 LIFTING LOADS 3.3.1 READING THE LOAD CHARTS DANGER • Load charts are specific for each equipment installed and refer to the machine at rest on the wheels or the stabilizers, if provided, in any case always with levelled frame (if the frame levelling function is in- cluded) and in WORK operating mode.
Page 108 LIFTING LOADS The charts are reproduced on the two sides of rigid boards and indicate the data that are useful to choose the chart to be consulted according to the operating mode and the equipment installed on the machine. 14 m 14 m 3000 kg 3000 kg...
Page 109: Using The Charts
LIFTING LOADS 3.3.1.2 USING THE CHARTS 1 - Find the area in which the load is included on the table corresponding to the machine configuration. NOTE • If the load corresponds to the right delimiting line of the area, choose the successive area suitable for a heavier load.
Page 110 LIFTING LOADS 6 - Following the chart guide network, draw two lines corresponding to the boom lenght indicator and to the boom angle indicator. • If the two lines cross at point “A”, that is, within the area or on its right, the load is within the stability limits. •...
Page 111 LIFTING LOADS • EXAMPLES ATTENTION • The examples are not referred to specific machines and load values are expressed in units. Example Given a 180-unit load, to be lifted starting from a height corresponding to an angle of 35° and with boom lenght indicator matching C, point X must be found, i.e.
Page 112 LIFTING LOADS Example Given a 55-unit load to be lifted to the height of 7.3 m: 1 - Draw line a corresponding to the height of 7.3 m. 2 - Draw line b passing through the point corresponding to a 100 unit (more than 55) load; the data obtained is the inclination of the boom.
Page 113 LIFTING LOADS Example Given a 180-unit load to be lifted to the height of 10 m, find point Z (inside the 200-unit area) given by the inclina- tion of the boom equal to 54° and the extension included between F and G. The 10 m height can be reached more quickly and with more precision if operating with well defined boom exten- sions and inclinations;...
Page 114: Fuses And Relays
FUSES AND RELAYS 3.4 FUSES AND RELAYS IMPORTANT • Before changing a fuse, make sure that the ignition key is in position « ». • If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 115: Central Unit Fuses
FUSES AND RELAYS 3.4.1.1 CENTRAL UNIT FUSES F12 F13 RKA01870 POS. COLOUR CAPACITY CIRCUIT INVOLVED General alarm warning light Cigarette lighter Revolving light Brown 7.5A Radio - Roof light Brown 7.5A Acoustic alarm Light blue High beam Orange Stop lights Rear axle swing lock solenoid valve Steering control unit Brown...
Page 116 FUSES AND RELAYS F24 F25 F27 F28 RKA01880 POS. COLOUR CAPACITY CIRCUIT INVOLVED Brown Engine stop 7.5A Violet Parking lights (L.H. rear - R.H. front) - Number plate Violet Parking lights (R.H. rear - L.H. front) - Dashboard light Brown 7.5A Slow motion solenoid valve Light blue...
Page 117: Central Unit Relays
FUSES AND RELAYS 3.4.1.2 CENTRAL UNIT RELAYS RKA01890 POS. DESCRIPTION Horn High beam Low beam Reverse alarm Gear engaged Auxiliary functions disconnection upon starting Optional solenoid valve enablement Slow motion Front work lights (optional) Stop lights Stabilizer lock - frame levelling (optional) xle swing lock Optional equipment Optional equipment...
Page 118: Engine Line Fuses And Relays
FUSES AND RELAYS 3.4.2 ENGINE LINE FUSES AND RELAYS The fuses (1) and relays (2) are grouped on a single base (3) po- sitioned inside the engine compartment and can be reached by removing the cover (4). RKAA0721 RKAA1030 3.4.2.1 ENGINE LINE FUSES POS.
Page 119: Engine Line Relays
FUSES AND RELAYS 3.4.2.2 ENGINE LINE RELAYS RKA02070 POS. DESCRIPTION Air preheating Start Diesel oil preheating...
Page 120: Guards, Cab And Driver's Seat
GUARDS, CAB AND DRIVER’S SEAT 3.5 GUARDS, CAB AND DRIVER’S SEAT 3.5.1 ENGINE HOOD DANGER • Before opening the hood, lower and retract the boom com- pletely, then apply the parking brake. • Do not open the engine hood when the engine is running. •...
Page 121: Cab
GUARDS, CAB AND DRIVER’S SEAT 3.5.2 CAB DANGER • If, for any reason, the cab is subjected to an impact, or if the machine overturns, immediately contact your Komatsu Utility Dealer, which will verify the stiffness of the cab and make sure that the operator’s safety is guaranteed.
Page 122: Emergency Exit
GUARDS, CAB AND DRIVER’S SEAT Besides the fixed front, side and upper windows, the cab is fitted with a rear window (10) with compass opening in two fixed posi- tions; the opening and fixing in the open position can be obtained by engaging the pin (11) of the handle (12) in the slot provided in the block (13).
Page 123: Ventilation And Heating
GUARDS, CAB AND DRIVER’S SEAT 3.5.4 VENTILATION AND HEATING The ventilation and heating of the cab serve to reduce the opera- tor’s stress both in summer and in winter; these functions also serve to eliminate condensate from the front window, thus ensur- ing visibility during both work and travel.
Page 124 GUARDS, CAB AND DRIVER’S SEAT A further adjustable vent (5) is positioned in the lower part of the cab to heat the floor area. Two additional adjustable vents to defrost the upper window (po- sitioned on the cab ceiling) can be supplied for the machine ver- sions equipped with air conditioning system.
Page 125: Air Conditioner (Optional)
• Total or partial air recirculation is achieved by means of the knob (1). • Temperature can be adjusted by means of the knob (4). IMPORTANT • Do not tamper with the air conditioner; in case of doubts regarding the use or maintenance of this system, contact your Komatsu Utility Dealer.
Page 126: Seat
GUARDS, CAB AND DRIVER’S SEAT 3.5.6 SEAT 3.5.6.1 STANDARD SEAT The seat offers four adjustment options: a - longitudinal position; b - back inclination; c - degree of suspension, in order to dampen the inevitable vi- brations and jumps as much as possible; d - height and cushion inclination;...
Page 127: Optional Seat
GUARDS, CAB AND DRIVER’S SEAT 3.5.6.2 OPTIONAL SEAT The seat features five different adjustment options: a - longitudinal position; b - back inclination; c - degree of suspension, in order to dampen the inevitable vi- brations and jumps as much as possible; d - height and cushion inclination;...
Page 128: Steering Wheel
If this occurs, stop the machine using the parking brake and contact your Komatsu Utility Dealer immediately. This is a three-spoke steering wheel with ball grip (1) to enable RKAA1290 the operator to swiftly get the appropriate steering angle in case of movements with restricted radiuses.
Page 129: Window Shade
GUARDS, CAB AND DRIVER’S SEAT 3.5.9 WINDOW SHADE The window shade (1) allows to reduce light reflection into the cab when the machine is operating under the sun or in places where light is excessive. It is a roller blind and can be used to cover either the windshield or the upper window;...
Page 130: Fire Extinguisher
GUARDS, CAB AND DRIVER’S SEAT 3.5.11 FIRE EXTINGUISHER ATTENTION • The owner of the machine is responsible for installing and fixing the fire extinguisher where prescribed. • Periodically make sure that the fire extinguisher is full. If the operator deems it necessary to have the fire extinguisher on board, he must fix it to a bracket on the left pillar of the cab.
Page 131: Use Of The Machine
• Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, check around and under the machine to verify: 1 - if there are loose screws or nuts;...
Page 132: Operational Checks
USE OF THE MACHINE 3.6.1.3 OPERATIONAL CHECKS DANGER • All the checks must be carried out by the operator while seated, with fastened safety belt. The checks are intended to verify: 1 - that the parking brake is applied; 2 - that the forward-reverse selector is in neutral; 3 - the position of the boom, which must be completely retracted RWA01960 with the equipment resting on the ground.
Page 133: Starting The Engine
USE OF THE MACHINE 3.6.2 STARTING THE ENGINE DANGER • Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non-compliance with the safety regulations and the rule of the road.
Page 134: Starting With Cold Engine Or In Cold Climates
USE OF THE MACHINE 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES DANGER • If the battery electrolyte is frozen, neither charge the bat- tery, nor attempt to start the engine with a different power source, since the battery may explode. Before charging the battery or starting the engine with a different power source, wait for the electrolyte to melt and make sure that there are no leaks in the battery.
Page 135: Warming The Engine
USE OF THE MACHINE 3.6.3 WARMING THE ENGINE 1 - After starting the engine, let it warm up before starting work. 2 - The ideal warming up of the engine is achieved with a constant speed of approximately 1000 rpm and can be checked on the digital scale provided on the dashboard, which indicates the overheating with red bars.
Page 136 USE OF THE MACHINE 3.6.5 HOW TO MOVE THE MACHINE DANGER • Before moving the machine, make sure that you know the control functions and all the relevant safety regulations perfectly. • The operator must be sitting in the driving position with fastened safety belt and must have checked the position of the rear-view mirrors.
Page 137 USE OF THE MACHINE 3.6.5.1 MOVING ON SLOPES DANGER • Before starting work on slopes, always check the functionality of the brakes and of the parking brake. • Avoid engaging the high gears. • Do not move downhill with the gearshift in neutral, but keep always the low gears engaged. NON-COMPLIANCE WITH THESE RULES MAY CAUSE THE OPERATOR TO LOSE CONTROL OF THE MA- CHINE.
Page 138 USE OF THE MACHINE 3.6.5.2 MAXIMUM IMMERSION DEPTH DANGER • If it is necessary to work with the machine immersed in water or on river banks or sea shores, always check the water depth and the current flow. • Make sure that the surface on which you are working is sufficently firm. If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not exceed 40 cm;...
Page 139 PARKING THE MACHINE 3.7 PARKING THE MACHINE 3.7.1 PARKING ON LEVEL GROUND DANGER • Park the machine on firm and level ground, in a sufficiently wide space, so that the checks, daily lubrication and refuel- ling can be carried out without problems. •...
Page 140 PARKING THE MACHINE 3.7.2 PARKING ON SLOPES DANGER • Any movement of the machine when the operator is not on board may cause serious accidents and even death; to pre- vent this, carry out the operations described below. • Park on slopes only when it is absolutely necessary. •...
Page 141 STOPPING THE ENGINE 3.8 STOPPING THE ENGINE IMPORTANT • Do not stop the engine suddenly, except in case of emer- gency. The sudden stop of the engine while it is running shortens its life. • It is likewise recommended not to stop the engine sudden- ly if it has been running for a long period and is still hot;...
Page 142 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.1 LOADING AND UNLOADING THE MACHINE DANGER • The loading and unloading of the machine on-off the means of transport must be carried out on a flat surface and at a safety distance from the edges of ditches or from the road side.
Page 143 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.2 TRANSPORT 1 - Check the overall dimensions of the means of transport; the height, width and weight of the means of trans- port - machine included - must be compatible with the road and any tunnel, underpass, bridge, electric or tele- phone line that may be found on the way.
Page 144 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES 3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES During the cold season or in areas where temperatures are particularly low, especially during the night, it is neces- sary to take some countermeasures meant to limit any damage deriving from low temperatures.
Page 145 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES 3.10.4 OTHER PRECAUTIONS 1 - Before using the machine in normal operating conditions, carry out some slow movements both forward and in reverse. With the machine in WORK mode, operate the boom slowly, performing some complete movements, and if possible operate also the equipment-carrier.
Page 146 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 1 - At the end of the cold season, change the lubricants and the fuel. IMPORTANT • The coolant must be changed only if it is not permanent. For the relevant specifications, see «4.3 FUEL, COOLANT AND LUBRICANTS»...
Page 147 • Avoid installing non-approved equipment or equipment that is not provided with specific load charts is- sued or approved by Komatsu Utility. • Always make sure that the equipment is installed properly and that the retaining pins are completely en- gaged, and, for the manual type, that the pins are held in place by safety cotter pins.
Page 148 EQUIPMENT 3 - Hold the button until the lower coupling pins (3) are fully open. RKAA1330 4 - Partially extend the telescopic boom until the quick coupling (4) becomes visible. 5 - Operate the machine until aligning the quick coupling with the equipment to be attached.
Page 149 EQUIPMENT 3.12.2 INSTALLING EQUIPMENT WITH MANUAL COUPLING The procedure for installing equipment with manual coupling is similar to the procedure for installing equipment with hydraulic coupling. The only difference regards the lower coupling pins (1), which must be extracted and inserted by hand and secured with the safety cotter pins (2).
Page 150 EQUIPMENT 3.12.4 ORGANIZING THE WORK AREA If after a first inspection the area results to be uneven, encum- bered with big obstacles or made up of areas with considerable differences in height, it is advisable to level the ground as much as possible before starting work.
Page 151 EQUIPMENT 3.12.6 OPERATING THE MACHINE FITTED WITH FORKS 3.12.6.1 FORKING A LOAD ATTENTION • The machine must move in TRAVEL-WORK operating mode, with boom lowered and completely retracted. • The other forking operations must be carried out in WORK operating mode. Before starting work, it is important to know the mass of the load to be handled and to consult the load chart corresponding to the machine configuration (with or without stabilizers) (see «3.3 LIFT-...
Page 152 EQUIPMENT 5 - Shift the reverse lever (3) into neutral. ( N ) RKAA1271 6 - Select the WORK operating mode and make sure that the forks are as wide as possible and centered with respect to the equipment-carrier plate; if necessary, widen the forks, making sure that there are side retainers to prevent the load from slipping.
Page 153 EQUIPMENT 10 - Once the stability of the machine has been ascertained, fold the equipment further and, using the control lever, retract the boom to release the load and continue the manoeuvres until the boom is retracted and lowered at 30 cm from the ground. 11 - Disengage the parking brake, select the TRAVEL-WORK op- erating mode and if the machine is equipped with stabilizers raise them completely.
Page 154 EQUIPMENT 5 - Select the WORK operating mode. RKAA0922 6 - Lift and extend the boom until reaching the unloading area. ATTENTION • During these manoeuvres, pay attention to the SLI-Safe Load Indicator; the coming on of the warning lights (blink- ing fast or lighting up steadily, together with the sounding of the acoustic alarm, intermittent or continuous), indicates that the machine runs the risk of overturning.
Page 155 EQUIPMENT 8 - Lower the load until resting it where it must be unloaded and, after making sure that it is stable, release it by lifting and re- tracting the boom and therefore disengaging the forks. DANGER • Do not move the machine to disengage the forks. 9 - Retract and lower the boom completely before raising the stabilizers, if provided;...
Page 156 EQUIPMENT 3.12.8 USING THE MACHINE AS A LOADER ATTENTION • Fit the machine with an approved bucket, that is, one that is suitable for the job on hand and, above all, for the prod- uct to be handled or loaded. •...
Page 157 EQUIPMENT 2 - While the upper material falls down filling the bucket, raise the boom gradually and at the same time retract the bucket completely. RKA02160 3 - Reverse the motion of the machine and dump the bucket on- to the truck. IMPORTANT •...
Page 158 LONG PERIODS OF INACTIVITY 3.13 LONG PERIODS OF INACTIVITY 3.13.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY DANGER • When draining the fuel, do not smoke, nor use naked flames near the machine. Position a container under the machine to collect the fuel and avoid spilling it or pouring it on the tyres. If some fuel should be spilled, clean the dirty area immediately.
Page 159 LONG PERIODS OF INACTIVITY 3.13.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY NOTE • These operations must be carried out only if the engine is going to remain unused for more than 1 month. • The first two operations must be carried out only on engines that have already run for more than 200 hours.
Page 160 LONG PERIODS OF INACTIVITY 3.13.4 RESTARTING THE ENGINE NOTE • These operations must be carried out if the machine has been prepared for a period of inactivity of more than 1 month. 1 - Remove the seals from the exhaust pipe and the filler cap. 2 - Open the engine hood and the cab.
Page 161 • This is an extreme condition. If it occurs, it is necessary to resort to external means and report the acci- dent to the Komatsu Utility Dealer immediately. While waiting for the Dealer to arrive, remove the ignition key, mark off the area around the machine and keep it under close surveillance to ensure that nobody approaches.
Page 162 • If you are not sure about the manoeuvres to be carried out or if the problems to which the failure is due cannot be solved with routine maintenance, contact your Komatsu Utility Dealer. 1 - Only the operator can get on the problem machine, and only if the service brakes are functioning and steering is possible.
Page 163 OPERATIONS IN CASE OF FAILURE 3.14.4 IF THE ENGINE FAILS TO START BECAUSE THE BATTERY HAS RUN DOWN DANGER • When checking or carrying out any operation on the bat- tery, stop the engine and make sure that the ignition switch is in position «O».
Page 164 OPERATIONS IN CASE OF FAILURE 3.14.4.1 STARTING WITH BOOSTER CABLES DANGER • When using the machine in cold climates, before starting it with a different power source (and therefore with booster cables), make sure that the electrolyte isn’t frozen, as the battery may catch fire. Before starting the machine or recharging the battery, let the electrolyte melt down and make sure that there are no leakages in the battery.
Page 165 (•) Always contact your Komatsu Utility Dealer when you have to carry out this operation. • If the anomaly or its cause are not included in the table below, contact your Komatsu Utility Dealer for the nec- essary repair. 3.14.5.1 ELECTRIC CIRCUIT...
Page 166 OPERATIONS IN CASE OF FAILURE 3.14.5.3 BRAKING SYSTEM TROUBLE CAUSE REMEDY Braking not regular on one axle only: • Brake discs worn. (•) Change. • No oil in brake pump. (•) Top up and bleed circuit. • Air in braking circuit. (•) Bleed circuit.
Page 167 OPERATIONS IN CASE OF FAILURE 3.14.5.5 ENGINE TROUBLE CAUSE REMEDY Oil pressure warning light remains on • Oil level in oil pan too low. • Top up. even with engine at high speed: • Oil filter clogged. • Change filter. •...
Page 168 PAGE INTENTIONALLY LEFT BLANK...
Page 169 MAINTENANCE...
Page 170 • Carry out any operation on firm and level ground, after applying the parking brake. • Use Komatsu Utility genuine oils and greases; choose oils suitable for the ambient temperature. • Use clean oils and greases. Keep the oil and grease containers clean and prevent any foreign matter from get- ting into them.
Page 171 GUIDE TO MAINTENANCE DANGER • Oils, filters, seals, electric cables, coolant and batteries are considered special waste and must be col- lected and disposed of according to the anti-pollution regulations in force. • The combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale the fumes (see «2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE»).
Page 172 • Use only Komatsu Utility genuine spare parts. • Do not mix different types of oil. • Unless specified otherwise, the oils and the coolant used by Komatsu Utility to fill the tanks before the delivery of the machine are the following:...
Page 173 MAINTENANCE NOTES 4.2.1.3 FUEL • Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or re- duce its power. • Always refuel at the end of the workday. • When refuelling, make sure that there is no water on the fuel drum cover and take care not to draw condensate from the drum bottom.
Page 174 2 - Check of the battery electrolyte level. • Do not remove or eliminate any electric component installed on the machine and do not install any electric com- ponent with characteristics different from those specified and approved by Komatsu Utility. • Keep the electric system dry.
Page 175 The parts subject to wear such as filters must be replaced when performing routine maintenance. The timely change of these parts ensures an economic use of the machine. Use only Komatsu Utility genuine parts, which alone can guarantee excellent quality and interchangeability.. ITEM...
Page 176 FUEL, COOLANT AND LUBRICANTS 4.3 FUEL, COOLANT AND LUBRICANTS CORRECT SELECTION ACCORDING TO THE AMBIENT TEMPERATURE AMBIENT TEMPERATURE CAPACITY TANK/ FLUID RESERVOIR filling Change -30 -20 -10 40 50 °C SAE 5W-30 SAE 10W SAE 20W-20 Engine oil pan 12.8 12.8 SAE 30 API CI...
Page 177 • It is advisable to use only engine oil with CI classification in order to ensure the correct operation and constant reliability of the engine. • Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine, in the work equipment hydraulic circuit, in the transmission, in the axles and in the brakes.
Page 178 FUEL, COOLANT AND LUBRICANTS 4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES” Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended: SUPPLIER SYNTHETIC BIODEGRADABLE OIL “HEES”...
Page 179 DRIVING TORQUES FOR SCREWS AND NUTS 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 4.4.1 STANDARD DRIVING TORQUES Nm (Newton metre): 1 Nm = 0.102 kgm Thread 10.9 Pitch Wrench size diameter (mm) (mm) (mm) 0.96 ± 0.1 9.5 ± 1 1.3 ±...
Page 180 LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM (2-SECTION BOOM) IMPORTANT • For the lubrication procedures for single points, see «4.7 MAINTENANCE PLAN». 2000 h 1000 h 500 h 250 h 100 h 50 h 10 h RKA02200 395-93-11960 Engine oil Hydraulic oil Transmission oil Grease Brake oil...
Page 181 LUBRICATION 4.5.2 LUBRICATION DIAGRAM (3-SECTION BOOM) IMPORTANT • For the lubrication procedures for single points, see «4.7 MAINTENANCE PLAN». 2000 h 1000 h 500 h 250 h 100 h 50 h 10 h RKA02210 395-93-11950 Engine oil Hydraulic oil Transmission oil Grease Brake oil...
Page 182 NENTS NOTE • It is advisable to consult the Komatsu Utility Dealer to define the periodical replacement of the specified components, which should be performed on the fourth maintenance service to be carried out every 1000 hours of operation or before the first maintenance service to be carried out «EVERY 2 YEARS».
Page 183 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS 4.6.1 CRITICAL PARTS FOR SAFETY NOTE • For the serial numbers and the quantity of the components that periodically need changing, consult the spare parts catalogue section regarding the components connected with safety and the components that must be periodically changed.
Page 184 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS 4.6.1.2 DELIVERY HYDRAULIC SYSTEM RKA02220 Components related to safety that periodically Q.ty Change interval need changing Hydraulic pipe (Hydraulic pump - control valve) Hydraulic pipe Every 2 years or 1000 hours, which- (Hydraulic pump - auxiliary control valve) ever occurs first Hydraulic pipe (Hydraulic pump - solenoid valve)
Page 185 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS 4.6.1.3 CONTROL VALVE HYDRAULIC SYSTEM RKA02230 Components related to safety that periodically Q.ty Change interval need changing Hydraulic pipe (control valve - lifting boom iron pipe) Hydraulic pipe (tubi in ferro - lifting cylinder) Hydraulic pipe (control valve - compensating cylinder) Every 2 years or 1000 hours, which-...
Page 186 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS 4.6.1.4 BOOM HYDRAULIC SYSTEM RKA02400 Components related to safety that periodically Q.ty Change interval need changing Hydraulic pipe (iron pipe - extension boom iron pipe) Hydraulic pipe (iron pipe - extension cylinder) Hydraulic pipe (iron pipe - equipment carrier iron pipe) Every 2 years or 1000 hours, which- ever occurs first...
Page 187 MAINTENANCE PLAN 4.7 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED PART OPERATION PAGE Check electrolyte level Battery Inspect terminals and cables Engine air cleaners Check, clean or change Cab air filter Check and clean Fuses and relays Check and replace Windshield washer reservoir Check level Windshield washer blades Check...
Page 188 MAINTENANCE PLAN 4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION PART OPERATION PAGE Drive shafts Lubricate Front and rear axle oscillation joint Lubricate Wheel hub joints Lubricate 4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION • Carry out the following maintenance operations after the first 250 hours, together with those to be performed “EVERY 250 HOURS”.
Page 189 MAINTENANCE PLAN 4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION OR EVERY 6 MONTHS PART OPERATION PAGE Fuel filter Change Fuel tank Drain Hydraulic oil Check level Hydraulic oil drain filter Change Oil tank (Only for machines in which synthetic biode- Drain condensate gradable oil HEES is used) Engine oil...
Page 190 MAINTENANCE PLAN 4.7.11 MAINTENANCE EVERY 3 YEARS PART OPERATION PAGE Safety belt Change 4.7.12 MAINTENANCE EVERY 3000 HOURS OF OPERATION OR EVERY 3 YEARS PART OPERATION PAGE Engine thermostatic valve Change Engine antivibration and retaining screws Check Engine valve clearance and injection Check and adjust timing advance...
Page 191 MAINTENANCE PLAN 4.7.1 WHEN REQUIRED 4.7.1.a CHECKING THE BATTERY ELECTROLYTE LEVEL – INSPECTING TERMINALS AND CABLES DANGER • Carry out this check with the machine parked on level ground. • Check the level only after stopping the engine and if neces- sary add distilled water only before starting work.
Page 192 MAINTENANCE PLAN 4.7.1.b CHECKING, CLEANING OR CHANGING THE ENGINE AIR CLEANERS DANGER • Remove the air cleaner only after stopping the engine and do not start the engine if the air cleaner is open. • Wear safety goggles during the cleaning operations. IMPORTANT •...
Page 193 MAINTENANCE PLAN 8 - Put back the cover (2), rotating it clockwise. Make sure that the cover (2) is perfectly locked and make sure that the ejec- tor (5) is positioned on the lower part. 9 - Once the whole has been assembled, push the safety retain- er (1) toward the inside.
Page 194 MAINTENANCE PLAN 4.7.1.c CHECKING AND CLEANING THE CAB AIR FILTER DANGER • Wear safety goggles during the cleaning operations. The air suction for the ventilation of the cab is protected by a filter positioned on the rear outer side of the cab. This filter blocks all the impurities contained in the air and must be cleaned whenever a decrease in air circulation is observed.
Page 195 MAINTENANCE PLAN 4.7.1.d FUSES AND RELAYS – CHECK AND CHANGE IMPORTANT • Before changing a fuse, make sure that the ignition key is in position « ». • If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 196 MAINTENANCE PLAN 4.7.1.f CHECKING THE WINDSHIELD WIPER BLADES The windshield wiper blades should be checked once the windshield wipers have stopped working, by verifying the conditions of the windshield. If any lines are left on the windshield after washing and wiping it, this means that the scraping wire has deteriorat- ed and it is therefore necessary to change the blades.
Page 197 (See «4.3 FUEL, COOLANT AND LUBRICANTS»). IMPORTANT • Use only new oil. RKAA1460 • If constant and considerable leakages are observed, it is advisable to contact a Komatsu Utility Dealer to have the braking system checked and the necessary repairs carried out. RKAA1470...
Page 198 • Dirt, oil and fuel in the engine compartment near hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Utility Dealer. Before starting the engine, proceed as follows: Verify that the boom inclination indicator pendulum is free to rotate and reach the end of the scale and that it returns to its original position, performing the necessary adjustment swings, once it has been released.
Page 199 • If the level of fluid in the radiator is low and the expansion tank is filled with coolant, check for tightness and make sure that there are no air leakages from the pipe that con- nects the radiator to the expansion tank. If the problem persists, contact your Komatsu Utility Deal-...
Page 200 MAINTENANCE PLAN 4.7.2.e CHECKING THE ENGINE OIL LEVEL DANGER • Soon after the machine has been stopped, the engine is MAX. very hot and may cause burns; let the engine cool down before carrying out any check. MIN. The dipstick (1) can be reached after opening the engine hood. The oil level must be checked with cold engine and the machine parked on level ground.
Page 201 MAINTENANCE PLAN 4.7.2.g CHECKING THE SERVICE BRAKES IMPORTANT • Perform this check on firm, level ground, with no people or obstacles around. This checking procedure should be carried out with the machine in TRAVEL operating mode, i.e. the compulsory mode for circula- tion on roads.
Page 202 MAINTENANCE PLAN 4.7.3 MAINTENANCE EVERY 50 HOURS OF OPERATION OR EVERY 2 WEEKS • These maintenance operations should be carried out together with those to be performed every 10 HOURS. 4.7.3.a LUBRICATING THE ARTICULATED JOINTS AND THE PADS DANGER • The compensating cylinder must be lubricated on the head side from under the machine; always apply the parking brake and remove the ignition key.
Page 203 MAINTENANCE PLAN PARTS TO BE LUBRICATED 3-SECTION BOOM VERSION 2-SECTION BOOM VERSION RKA02430 Part Operation Head side (1 point) Lifting cylinder Base side (1 point) [note Compensating cylinder Head side (1 point) Tilting cylinder Head side (1 point) Equipment carrier fulcrum pins (2 points) Head side (1 point) Frame levelling cylinder (if provided)
Page 204 MAINTENANCE PLAN 4.7.3.b LUBRICATING THE CHAIN GEAR SHAFTS (Only for 3-section boom version) IMPORTANT • Clean the grease nipples thoroughly before applying the greasing pump. • After lubrication, remove all the grease that may have spread out. 1 - Using a syringe with hose (1) filled with the prescribed grease (see «4.3 FUEL, COOLANT AND LUBRICANTS»...
Page 205 MAINTENANCE PLAN 4.7.3.d LUBRICATING BOOM DANGER • The boom sections must be lubricated when they are com- pletely extended. As a safety precaution, position a stand capable of supporting the entire boom under the first tele- scopic boom before extending the boom sections and low- er the stabilizers to the ground, if they are provided.
Page 206 MAINTENANCE PLAN 4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION • These maintenance operations should be carried out together with those to be performed every 50 HOURS. 4.7.4.a LUBRICATING THE DRIVE SHAFTS The propeller shafts must be lubricated after thoroughly cleaning the grease nipples, by applying the greasing pump filled with the prescribed grease.
Page 207 MAINTENANCE PLAN 4.7.4.b LUBRICATING THE FRONT AND REAR AXLE SWING JOINT The four lubrication points (1) of the swing axle are located on its support flanges (2). The joint must be lubricated after thoroughly cleaning the grease nipples, by applying the greasing pump filled with the prescribed grease (see «4.3 FUEL, COOLANT AND LUBRICANTS»).
Page 208 MAINTENANCE PLAN 4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION • These maintenance operations should be carried out after the first 250 hours of operation, together with those to be performed every 250 HOURS. a - CHANGE THE HYDRAULIC OIL DRAIN FILTER b - CHANGE THE AXLE OILS (DIFFERENTIAL AND FINAL REDUCTION GEAR UNITS) c - CHANGE THE TRANSMISSION FILTER NOTE...
Page 209 MAINTENANCE PLAN PARTS TO BE LUBRICATED RKA02440 Part Operation Stabilizer cylinders – base side 2 points Tilting cylinder - base side 1 point Compensating cylinder - base side 1 point Boom inner hoses See «4.7.6.b» 4.7.6.b LUBRICATING THE BOOM INNER HOSES, ROLLERS AND GUARD ATTENTION •...
Page 210 MAINTENANCE PLAN 4.7.6.c CHECKING THE AXLE OIL LEVEL (FRONT AND REAR AXLE) DIFFERENTIAL This is a visual check and serves to verify if the lubricant reaches the hole (1); if necessary, top up using the prescribed oil. (See «4.3 FUEL, COOLANT AND LUBRICANTS»). The level hole (1) must be used also as filling hole.
Page 211 MAINTENANCE PLAN 4.7.6.d CHECKING THE TRANSMISSION OIL LEVEL DANGER • The transmission oil level must be checked with engine running and transmission still hot; be extremely careful and wear insulating, waterproof gloves in order to avoid severe burns. 1 - Before carrying out this check, park the machine on level ground;...
Page 212 This check is visual, must be carried out with cold engine and consists in inspecting the belt for cuts, fraying, cracks. If any of these defects can be observed, have the belt changed by a Komatsu Utility Dealer. RKAA1760 RKAA1770...
Page 213 MAINTENANCE PLAN 4.7.6.g CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (Optional) DANGER • The adjustment of the belt tension is a mechanical opera- 10 kg tion and must be carried out without working on the air conditioning system. 5-6mm •...
Page 214 MAINTENANCE PLAN 4.7.6.h CHECKING THE ADJUSTMENT OF THE PARKING BRAKE This is a visual check and consists in verifying that the screws (1) simultaneously stop against the retainers (2) when the parking brake is released. If the levers on which the screws are installed do not perform a full return stroke, do not use the machine and contact your Komatsu Utility Dealer immediately for the necessary service.
Page 215 MAINTENANCE PLAN 4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil HEES is used) This maintenance operation should be carried out after the first 500 hours of operation, together with those to be performed “EVERY 500 HOURS”.
Page 216 MAINTENANCE PLAN 4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION OR EVERY 6 MONTHS • Carry out the following operations together with those to be performed every 50, 100 and 250 HOURS. 4.7.8.a CHANGING THE FUEL FILTER DANGER • Change the filtering element after work, when the engine has cooled down to 40–45°C. •...
Page 217 • Do not add oil over the MAX. mark (upper edge of the sight gauge), as this would make the oil flow out. • If you notice a constant, unusual decrease in the oil level, contact your Komatsu Utility Dealer. RKAA1730...
Page 218 (7) of the cover (3) is not dam- aged and is correctly housed in its seat. ATTENTION • Thoroughly check the inside of the filter; if there is an unu- sual quantity of metal particles due to wear, contact your Komatsu Utility Dealer immediately. RKAA1830 RKAA1860...
Page 219 MAINTENANCE PLAN 4.7.8.e DRAINING CONDENSATE FROM THE OIL TANK (Only for machines in which synthetic biodegradable oil HEES is used) DANGER • After stopping the engine, with the machine in travel condi- tion, release any residual pressure from the tank by slowly loosening the filler cap.
Page 220 MAINTENANCE PLAN 4.7.8.f CHANGING THE ENGINE OIL DANGER • Change the oil with the machine parked on level ground and with the boom fully retracted. • Soon after the machine has been stopped, the engine is very hot and may cause burns; let the engine cool down to 40-45°C before draining the oil.
Page 221 MAINTENANCE PLAN 4.7.8.g CHANGING THE ENGINE OIL FILTER DANGER • Soon after the machine has been stopped, the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40–45°C before draining the oil.
Page 222 If this defect is noticed, contact your Komatsu Utility Dealer immediately for a thorough inspection and, if necessary, have the chain replaced.
Page 223 MAINTENANCE PLAN 4.7.8.i CHECKING AND TIGHTENING THE BOOM CHAINS (Only for the 3-section boom version) NOTE • A flapping noise between the chain and the boom probably indicates that the chains need tightening. DANGER • Before starting this check, remove the front equipment and place the machine on firm and level ground (see «3.7.1 PARKING ON LEVEL GROUND»).
Page 224 MAINTENANCE PLAN BOOM RETRACTION CHAIN 1 - Set the boom in horizontal position and check that the angle indicated on the goniometer (1) is 0°. RKAA1630 2 - Remove the screws (2) and the grease nipple (3); then re- move the rear casing (4) and the upper guards (5) of the chains (6).
Page 225 IMPORTANT • After two adjustments have been made, before attempting RKAA1670 to carry out the third one, have your Komatsu Utility Dealer check the stretching of the chain. NOTE • If the nut reaches the end of the thread, contact your Ko- matsu Utility Dealer to have the chain replaced.
Page 226 MAINTENANCE PLAN BOOM EXTENSION CHAINS After adjusting the retraction chain, adjust the extension chains using the rear adjustment unit “D” and proceed as follows: 1 - Extend the boom completely and place a stand under the in- termediate section in order to prevent the boom from falling down.
Page 227 RKAA1710 NOTE • After two adjustments have been made, before attempting to carry out the third one, have your Komatsu Utility Dealer check the stretching of the chains and evaluate if it is nec- essary to change them. • The maximum chain stretching allowed corresponds to 3%.
Page 228 This operation requires the removal of the chains and good knowledge of the operating methods. Contact your Komatsu Utility Dealer for this operation. As well as removing the chains, they will clean them, check their size and perform the final tension adjustment after reinstalling them.
Page 229 MAINTENANCE PLAN 4.7.8.k LUBRICATING THE EXTENSION CHAINS (Only for the 3-section boom version) DANGER • Before starting the lubrication procedure, remove the front equipment and place the machine on firm and level ground (see «3.7.1 PARKING ON LEVEL GROUND»). • The chain checking and tightening procedure must be car- ried out with boom sections fully extended.
Page 230 This check requires the removal of some parts and good knowledge of the operating methods is therefore essen- tial. Contact your Komatsu Utility Dealer to have this inspection carried out. During the maintenance service to be car- ried out EVERY 500 HOURS, they will also adjust any boom block clearance due to settling or wear.
Page 231 MAINTENANCE PLAN 4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION OR EVERY YEAR • Carry out the following maintenance operations together with those to be performed EVERY 50, 100, 250 and 500 HOURS. 4.7.9.a CHANGING THE FRONT AND REAR AXLE OIL DANGER •...
Page 232 MAINTENANCE PLAN 4.7.9.b CHANGING THE HYDRAULIC TRANSMISSION OIL ATTENTION • Before warming up the machine to change the oil, thoroughly clean the transmission and the final reduc- tion gear to remove any impurities from the areas involved in the operation. DANGER •...
Page 233 MAINTENANCE PLAN 4.7.9.c CHANGING THE HYDRAULIC TRANSMISSION FILTER DANGER • Soon after the machine has been stopped the transmission unit is very hot and may cause burns; let the machine cool down before changing the filter. • The oil that may be spilled during the replacement of the fil- ter will cause the floor to become slippery: use anti-slip shoes and immediately remove any trace of oil from the floor and the transmission unit.
Page 234 • Carry out these maintenance operations together with those to be performed every 50, 100, 250, 500 and 1000 HOURS. 4.7.10.a CHECKING THE ALTERNATOR AND THE STARTER • Have this inspection carried out by your Komatsu Utility Dealer. 4.7.10.b CHANGING THE ALTERNATOR BELT This procedure must be carried out by qualified personnel.
Page 235 MAINTENANCE PLAN 4.7.10.d CHANGING THE BRAKING SYSTEM OIL DANGER • Oil spilled on the floor may cause the floor to become slippery; immediately clean any dirty area. • Oil is considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.
Page 236 MAINTENANCE PLAN BLEEDING THE BRAKING CIRCUIT This operation is important, since it ensures the braking efficiency and power of the machine. Proceed as follows: 1 - Make sure that the oil in the braking system reservoir (4) reaches the maximum level. 2 - Start the engine and let it idle.
Page 237 MAINTENANCE PLAN 4.7.10.e CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER DANGER • After stopping the engine, with the machine positioned on level ground, boom fully retracted and lowered and parking brake applied, release any residual pressure from the tank by slowly loosening the filler cap.
Page 238 4.7.12.a CHANGING THE ENGINE THERMOSTATIC VALVE This procedure must be carried out by qualified personnel. Have this operation performed by your Komatsu Utility Dealer. 4.7.12.b CHECKING THE ENGINE ANTIVIBRATION AND RETAINING SCREWS This procedure must be carried out by qualified personnel.
Page 239 TECHNICAL DATA...
Page 240 TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 DIMENSIONS WITH FORKS NOTE • The following dimensional data refer to the machine equipped with the tyres listed below: WH609 - WH609 turbo:..405/70-24 PR14 WH613 - WH613 turbo:..405/70-24 PR14 WH713: ......15.5/80 24 PR12 WH714 - WH714H: ...14.00 24 PR16 WH716: ......14.00 24 PR16 RKA01640...
Page 241 TECHNICAL DATA Unit of measurement: mm WH609 WH613 WH713 WH714 WH714H WH716 2390 2390 2435 2450 2450 2450 2555 2555 2600 2615 2615 2615 2370 2370 2370 2405 2405 2405 2005 2005 2005 2005 2005 2005 3020 3020 3350 3350 3350 3350 4469...
Page 242 TECHNICAL DATA 5.1.2 TECHNICAL CHARACTERISTICS 5.1.2.1 TECHNICAL CHARACTERISTICS WH609 (Aspirated engine) TOTAL WEIGHT Total weight (machine ready to start equipped with forks, without stabilizers, without frame levelling device, without rear axle swing lock) ........... . . kg 8660 ENGINE Komatsu diesel engine model .
Page 243 TECHNICAL DATA 5.1.2.2 TECHNICAL CHARACTERISTICS WH609 (Turbo engine) TOTAL WEIGHT Total weight (machine ready to start equipped with forks, without stabilizers, without frame levelling device, without rear axle swing lock) ........... . . kg 8660 ENGINE Komatsu diesel engine model .
Page 244 TECHNICAL DATA 5.1.2.3 TECHNICAL CHARACTERISTICS WH613 (Aspirated engine) TOTAL WEIGHT Total weight (machine ready to start equipped with forks, with stabilizers, without frame levelling device, without rear axle swing lock) ........... . . kg 9800 ENGINE Komatsu diesel engine model .
Page 245 TECHNICAL DATA 5.1.2.4 TECHNICAL CHARACTERISTICS WH613 (Turbo engine) TOTAL WEIGHT Total weight (machine ready to start equipped with forks, with stabilizers, without frame levelling device, without rear axle swing lock) ........... . . kg 9800 ENGINE Komatsu diesel engine model .
Page 246 TECHNICAL DATA 5.1.2.5 TECHNICAL CHARACTERISTICS WH713 TOTAL WEIGHT Total weight (machine ready to start equipped with forks, with stabilizers, with frame levelling device, without rear axle swing lock) ........... . . kg 10550 ENGINE Komatsu diesel engine model .
Page 247 TECHNICAL DATA 5.1.2.6 TECHNICAL CHARACTERISTICS WH714 TOTAL WEIGHT Total weight (machine ready to start equipped with forks, with stabilizers, with frame levelling device, without rear axle swing lock) ........... . . kg 10620 ENGINE Komatsu diesel engine model .
Page 248 TECHNICAL DATA 5.1.2.7 TECHNICAL CHARACTERISTICS WH714H TOTAL WEIGHT Total weight (machine ready to start equipped with forks, with stabilizers, with frame levelling device, without rear axle swing lock) ........... . . kg 11180 ENGINE Komatsu diesel engine model .
Page 249 TECHNICAL DATA 5.1.2.8 TECHNICAL CHARACTERISTICS WH716 TOTAL WEIGHT Total weight (machine ready to start equipped with forks, stabilizers, frame levelling device and rear axle swing lock) ............kg 11590 ENGINE Komatsu diesel engine model .
Page 250 TECHNICAL DATA 5.1.3 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED • According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma- chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is subjected to vibrations lower than 0.5 m/sq.sec.
Page 251 TECHNICAL DATA 5.1.5 OPERATING PERFORMANCE 5.1.5.1 OPERATING PERFORMANCE WITH FORKS (ON WHEELS) NOTE • The indicated data have been taken with centre of gravity (G) of the load positioned at 500 mm. Max 500 mm Max 500 mm RWA38740 WH609 WH613 WH713 WH714...
Page 252 TECHNICAL DATA 5.1.5.2 OPERATING PERFORMANCE WITH FORKS (ON STABILIZERS) NOTE • The indicated data have been taken with centre of gravity (G) of the load positioned at 500 mm. Max 500 mm Max 500 mm RWA38740 WH613 WH713 WH714 WH714H WH716 WH613 turbo Max.

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Komatsu Utility WH609-1 Operation & Maintenance Manual

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