Page 1 VEAM940200 Operation & Maintenance Manual :$ :+((//2$'(5 SERIAL NUMBER +$ and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine.
Page 3 +$ and up This material is proprietary to Komatsu Hanomag Aktiengesellschaft and is not to be reproduced, used, or dis- closed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
Page 5 PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUC- TION. EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.
Page 6 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM Komatsu America International Company AND RETURN TO ——> 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME PURCHASE ORDER NO.
Page 7: Table Of Contents
TABLE OF CONTENTS INTRODUCTION FORWORD ..............SAFETY INFORMATION .
Page 8 10.1.5 • • MIRRORS, WINDOWS, AND LIGHTING ......... . 10.2 •...
Page 9 CONTROLS AND INDICATORS GENERAL VIEW OF THE MACHINE ..........CONTROLS AND INDICATORS .
Page 10 19.5.5 • • BRAKING ON SLOPES ............19.6 •...
Page 11 21.5 • BRAKES ..............21.6 •...
Page 12 MAINTENANCE SCHEDULE ........... . . MAINTENANCE PRIOR TO START .
Page 13 29.6.3 • • REMOVING THE FILTER CARTRIDGE ......... . 29.6.4 •...
Page 15: Introduction
INTRODUCTION...
Page 16: Forword
Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.
Page 17: Safety Information
• This word is used for important additional information. Safety precautions are described in chapter "Safety". Komatsu America International Company cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.
Page 18: Introduction
If the machine is used for a purpose that is not listed in this manual, Komatsu America International Company cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 19: Location Of Plates, Table To Enter Serial No. And Distributor
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR MACHINE SERIAL NO. PLATE POSITION 1 - POSITION OF PLATE On the center right of the front frame. 2 - POSITION OF STAMP ENGINE SERIAL NO.
Page 20: Why You Should Read These Operating Instructions
Komatsu or your local Komatsu dealer. If the machine is resold, the operating instructions, and the licence are to be handed over to the new owner.
Page 21: Notes On Safety Regulations
Should you have any doubt concerning safety of a procedure, either directly contact Komatsu America In- ternational Company or your local Komatsu dealer.
Page 22: Equipment
Part No. pressure cuft (m³) lb (kg) 42T-70-12000 24.733 (0,7) 571 (259) 42T-70-12010 24.733 (0,7) 626 (284) Bucket WA65-3 42T-70-12120 19.433 (0,55) 1168 (530) 42U-70-12140 35.335 (1,0) 571 (259) 1 - Typ 3 - Volumen Type Volume 2 - Teile Nr.
Page 23 (kg) lb (kg) lb (kg) *) 4189 *) 4409 (1900) (2000) Fork carrier WA65-3 42U-70-12080 267 (121) **) 3197 **) 3030 (1450) (1500) *) Standing security 80% of the tipping load on firm and level ground **)Standing security 60% of the tipping load on uneven ground 1 - Typ 4 - Tragfähigkeit mit CTW...
Page 24 EQUIPMENT...
Page 25 LOADING AND TRANSPORTING THE MACHINE...
Page 26: Loading And Transporting The Machine
LOADING AND TRANSPORTING THE MACHINE 8. LOADING AND TRANSPORTING THE MACHINE If you have to transport the machine over far distances, use an appropriate transport vehicle. You may either lift or drive the machine onto an appropriate transport vehicle via loading ramp (also refer to "10. Safety Measures dur- ing Operation").
Page 27 LOADING AND TRANSPORTING THE MACHINE “ „ 7 5 _1 6 2a Information signs attached to the machine indicate the attachment points. To avoid damage to the machine, at- tach the eye hooks only to the attachment points. Machine equipment „X“: •...
Page 28: Driving Machine Onto Loading Area Of Transport Vehicle
LOADING AND TRANSPORTING THE MACHINE DRIVING MACHINE ONTO LOADING AREA OF TRANSPORT VEHICLE • If the transport vehicle or the loading ramp starts skidding while you are driving up the loading ramp, the machine may fall off the ramp and cause severe accidents! Secure the transport vehicle against accidental move- ment.
Page 29: Securing The Machine During Transport
LOADING AND TRANSPORTING THE MACHINE SECURING THE MACHINE DURING TRANSPORT • If the machine is insufficiently secured, it may start to skid or fall off the transport vehicle and cause severe accidents! Always secure the machine with ropes and wheel chocks or wedges to avoid falling down and skidding. •...
Page 30 LOADING AND TRANSPORTING THE MACHINE...
Page 31: Safety
SAFETY...
Page 32 Safety • Failure to adhere to these safety instructions can lead to serious injury or death! Read and adhere to all safety instructions. This chapter also contains safety instructions for special equipment and attachments.
Page 33: General Safety Measures
GENERAL SAFETY MEASURES 9. GENERAL SAFETY MEASURES SAFETY INSTRUCTIONS • Do not operate or service the machine unless you have been trained and are authorized to do so. • Always adhere to all instructions, measures, and safety instructions when operating or servicing the machine. •...
Page 34: Clothing And Personal Protection
• Ensure that no unauthorised person is within the danger zone. 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 35: Fire Prevention And Fire Fighting
GENERAL SAFETY MEASURES FIRE PREVENTION AND FIRE FIGHT- • 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 36: Fire Extinguisher And First-Aid Kit
GENERAL SAFETY MEASURES 9.8.1 FIRE EXTINGUISHER AND FIRST-AID KIT • If, in the course of certain operations, there is danger of fire, fire extinguishers must be at hand. Familiarise with the use of the fire extinguishers. The fire extinguisher is located in the compartment under the driver's seat.
Page 37: Protection Against Injuries
GENERAL SAFETY MEASURES 9.10 PROTECTION AGAINST INJURIES Do not insert any part of your body in the operating range of moving parts, such as work unit and cylinder, or machine and work unit. Never stand in a hazardous area. Distances vary when the work unit or steering are operated, this may lead to se- rious injuries.
Page 38: Roll-Over Protection System (Rops)
• Do not use attachments that have not been approved of by Komatsu or the local Komatsu dealer. If you use at- tachments which have not been approved of, safety, correct operation, and service life of the machine may be impaired.
Page 39: Battery
GENERAL SAFETY MEASURES 9.15 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 40: Safety Measures During Operation
SAFETY MEASURES DURING OPERATION 10. SAFETY MEASURES DURING OPERATION 10.1 BEFORE YOU START THE ENGINE 10.1.1 WORKPLACE SAFETY • Before you start operation, check the working area for danger- ous working conditions. • Inspect the surface of the soil in the working area and deter- mine the optimum and safest procedure.
Page 41: In-Door Operation
SAFETY MEASURES DURING OPERATION 10.1.3 IN-DOOR OPERATION Do not operate machines in-door unless these areas are suffi- ciently ventilated (e.g. workshops). Caution - Danger of intoxication! 10.1.4 GAS, DUST, AND INFLAMMABLE VAPOURS Do not operate combustion engines in an environment that may contain inflammable gases or vapours. These gases, dusts, or vapours may ignite or be sucked in by the suction system, thus causing a rise in engine speed or an exceeding of the engine's maximum rpm.
Page 42: Machine Operation
SAFETY MEASURES DURING OPERATION 10.2 MACHINE OPERATION 10.2.1 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 43: Driving
SAFETY MEASURES DURING OPERATION 10.2.3 DRIVING • When driving, set the bucket to the transport position. The bucket is in its transport position when the transport position markings on frame and boom are aligned in parallel. • When driving on uneven ground, drive slowly and avoid sud- den steering movements.
Page 44: Emergency Lowering System
SAFETY MEASURES DURING OPERATION 10.2.5 EMERGENCY LOWERING SYSTEM When the engine is in operation or not in operation, you may lower the work unit with the emergency lowering system. • Ensure that nobody is standing under the work unit. Likewise you may release the rest pressure in the hydraulic circuit.
Page 45: Loading
SAFETY MEASURES DURING OPERATION • Should the work unit come into contact with a power transmission line, proceed as follows: 1 - Do not leave the driver's cab. The driver's cab is a "Faraday cage" protecting you from electric shock. 2 - Warn other persons and tell them to stay far away from both the power line and your machine.
Page 46: Brakes
SAFETY MEASURES DURING OPERATION 10.2.11 BRAKES • Use the brake pedal only for braking, do not use the brake pedal as a foot rest. • When you are driving downhill, you can use the braking force of the engine by reducing the speed (rpm) of the engine.
Page 47: Working With The Forklift Truck Attachment
SAFETY MEASURES DURING OPERATION 10.2.13 WORKING WITH THE FORKLIFT TRUCK 1 9 .6 8 5 in ATTACHMENT (5 0 0 m m ) • Check daily, before starting operation, the fork tines of the ma- chine for visual damages (e.g. fissures, cracks, wear and tear). Also the protective device preventing unintentional removing 1 9 .6 8 5 in or shifting of the fork tines may have no defects.
Page 48: Parking The Machine
SAFETY MEASURES DURING OPERATION 10.2.14 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 49: Transport
SAFETY MEASURES DURING OPERATION 10.3 TRANSPORT 10.3.1 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 50: Safety Measures During Maintenance
If required, put up additional warning signs around the machine. You may purchase these warning signs from your Komatsu deal- 75_060G B 11.2.2 TOOLS Only use tools which are suitable for the task you want to carry out.
Page 51: Prior To Start Of Inspection And Maintenance
SAFETY MEASURES DURING MAINTENANCE 11.2.4 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. Switch off the engine (start switch to position '0') and safeguard the ma- chine.
Page 52: During Maintenance
SAFETY MEASURES DURING MAINTENANCE 11.3 DURING MAINTENANCE 11.3.1 ATTACHMENTS Attachments removed from the machine must be stored in a safe location and in such a way that they cannot tip over. Caution - risk of injury! 11.3.2 WORKING UNDER THE MACHINE •...
Page 53: Refueling And Topping Off Oil
SAFETY MEASURES DURING MAINTENANCE 11.3.5 REFUELING AND TOPPING OFF OIL • Spilled fuel or oil involves danger of slipping and fire. For this reason, immediately remove any spilled liquid. • Always refuel and top off oil in a place that is sufficiently venti- lated.
Page 54: Use Of Lighting
SAFETY MEASURES DURING MAINTENANCE 11.3.7 USE OF LIGHTING Always use explosion-proof lighting when checking fuel, oil, cool- ant, or battery acid. 11.3.8 HIGH-PRESSURE HOSES Neither bend high-pressure hoses nor hit them with hard ob- jects. Do not use piping or hoses with fissures, cracks, or bends, since they may burst during operation.
Page 55: Fan And Belts
SAFETY MEASURES DURING MAINTENANCE 11.3.10 FAN AND BELTS • Always keep sufficient distance from rotating parts and pay at- tention 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 56: Tires
If you want to perform special operations, contact the local Komatsu dealer or the tire manufacturer. 11.4.1 STORING TIRES • Basically, tires must be stored in a protected room that cannot be accessed by unauthorised persons.
Page 57: Labeling
LABELING 12. LABELING • All safety labels must be kept clean all times. Missing or damaged safety labels must be replaced. 12.1 POSITION OF SAFETY LABELS b ,c,d ,e 1 0 ,7,A 2 4 ,17 (4 2U -93 -11 A 9 0 ) (4 2U -93 -11 D 7 0 ) (4 2U -93 -11 A 8 0 ) (4 2U -93 -11 A 2 0 )
Page 58 LABELING b ,c,d,e 1 0 ,7 ,A 2 4 ,1 7 (42 U -93 -11B 70 ) (42 U -93 -11C 10 ) 42U-93-11B90 (42 U -93 -11B 90 ) (42 U -93 -11B 80 ) (42 U -93 -11C 60 ) (42 U -93 -11C 50 ) (42 U -93 -11C 20 ) (42 U -93 -11C 30 )
Page 59: Position Of Standard Labels
LABELING 12.2 POSITION OF STANDARD LABELS (4 2 T -9 3 -11 0 1 0 ) 42U-93-11170 (4 2 U -9 3 -111 7 0 ) 09690-B0560 (0 9 69 0 -B 0 5 6 0 ) 42U-93-11160 (4 2 U -9 3 -111 6 0 ) 42U-93-11000 (4 2 U -9 3 -110 0 0 ) (4 2 U -9 3 -111 8 0 )
Page 60 LABELING...
Page 61: Controls And Indicators
CONTROLS AND INDICATORS...
Page 62: General View Of The Machine
GENERAL VIEW OF THE MACHINE 13. GENERAL VIEW OF THE MACHINE 1 - Rocker arm 6 - Lift cylinder 2 - Bucket cylinder 7 - Head lamp 3 - Bucket Direction indicator 4 - Boom 8 - Rear wheel 5 - Front wheel...
Page 63: Controls And Indicators
CONTROLS AND INDICATORS 14. CONTROLS AND INDICATORS 14.1 GENERAL VIEW 1 - Instrument panel 2 - Horn button 3 - Light switch 4 - Direction indicator lever 5 - Inch-brake pedal 6 - Unlocking system of left door 7 - Parking brake 8 - Safety lever for work hydraulic system 9 - Steering column adjustment 10 - Driving direction switch...
Page 64: Switches And Controls
CONTROLS AND INDICATORS 14.1.1 SWITCHES AND CONTROLS 75_001 20 - Brake fluid warning light 21 - Air filter warning light 22 - Parking brake warning light 23 - Charging current warning light 24 - Driving direction switch indicators 25 - Engine oil-pressure warning light 26 - Direction indicator control lamp 27 - Air preheater control lamp 28 - Heated rear windscreen indicator...
Page 65: Instrument Panel
CONTROLS AND INDICATORS 14.2 INSTRUMENT PANEL 75_003 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.
Page 66: Warning Lights
CONTROLS AND INDICATORS 14.3 WARNING LIGHTS 75_007 1 - Brake fluid warning light 2 - Air filter warning light 3 - Parking brake warning light 4 - Charging current warning light 5 - Engine oil-pressure warning light...
Page 67 CONTROLS AND INDICATORS 1 - 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 "21. Trouble- shooting".
Page 68 CONTROLS AND INDICATORS 5 - ENGINE OIL-PRESSURE WARNING LIGHT Before you start up the engine: The engine oil-pressure warning light must light up if you set the start switch to the operating position ‘I’. At the same time, the acoustic warner will sound. With the engine running: After starting the engine, the lubricating pressure builds up and the lamp goes out.
Page 69: Control Lamps
CONTROLS AND INDICATORS 14.4 CONTROL LAMPS 7 5_00 4 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...
Page 70 CONTROLS AND INDICATORS 1 - DRIVING DIRECTION SWITCH INDICATORS The indicators of the driving direction switch indicate which driv- ing 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 71 CONTROLS AND INDICATORS 5 - HIGH BEAM CONTROL LAMP The high beam control lamp lights up if you change from low beam to high beam. It also lights up if you flash your lights. 75_026 6 - LOW BEAM CONTROL LAMP The low beam control lamp lights up when you switch on the low beam.
Page 72: Measuring Indicators
CONTROLS AND INDICATORS 14.5 MEASURING INDICATORS 7 5_0 08 1 - Fuel level indicator 2 - Operating hour meter 3 - Coolant temperature indicator...
Page 73 CONTROLS AND INDICATORS 1 - FUEL LEVEL INDICATOR If you set the start switch to the operating position ‘I’, the fuel gauge indicates the available fuel supply. 1: The tank is full R: The tank is in the critical range During operation, it is recommended to keep the fuel supply be- tween ‘R’...
Page 74: Switches
CONTROLS AND INDICATORS 14.6 SWITCHES 7 5 _ 0 4 3 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 7 - Driving direction switch...
Page 75 CONTROLS AND INDICATORS 1 - HAZARD FLASHER SWITCH This switch is used to switch on/off the hazard flasher. • You may switch on the hazard flasher only in an emergen- cy situation. If you switch on the hazard flasher, all direction indicators of the machine will start to flash.
Page 76 CONTROLS AND INDICATORS 4 - DIRECTION INDICATOR LEVER The direction indicator lever is used to switch on/off the direction indicators. Switching on the right direction indicators:Press direction indica- tor lever to the front ‘1’ Switching on the left direction indicators:Draw direction indica- tor lever to the back ‘2’...
Page 77 CONTROLS AND INDICATORS 7 - DRIVING DIRECTION SWITCH You can change the driving direction of the machine with the driving direction switch. Position ‘F’:Forward driving Position ‘N’:Neutral position Position ‘R’: Reverse driving 75_023 • You can only start the engine if the driving direction switch is switched to the neutral position ‘N’.
Page 78 CONTROLS AND INDICATORS 9 - FAN ROTARY SWITCH FOR VENTILATION AND HEATING This rotary switch permits to regulate the fan step by step. Switch setting 1: Fan off Switch setting 2: Low air flow Switch setting 3: Medium air flow Switch setting 4: High air flow 75_039...
Page 79 CONTROLS AND INDICATORS 13 - WORKING LIGHTS SWITCH • The front working lights may blind oncoming traffic! Before driving on public roads, turn off the working lights. This switch is used to switch on/off the working lights. 75_030 14 - SWITCH FOR INSIDE LIGHTING The inside lighting has three different switch settings: Switch setting 1: Steady light...
Page 80: Control Levers, Pedals
CONTROLS AND INDICATORS 14.7 CONTROL LEVERS, PEDALS 1 - Brake pedal 2 - Parking brake 3 - Safety lever to close or open the work hydraulic system 4 - Steering column adjustment 5 - Accelerator pedal 6 - Multifunctional lever 7 - Control lever for special equipment 8 - Switching lever for bucket (without fig.)
Page 81 CONTROLS AND INDICATORS 1 - BRAKE PEDAL • 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 82 CONTROLS AND INDICATORS 4 - STEERING COLUMN ADJUSTMENT The lever for adjusting the steering column position permits to in- cline the steering column smoothly in two directions (front or back). The adjustment range is 4.92 in (125 mm). Proceed as described in chapter "17. Adjustments Prior to Ma- chine Start".
Page 83 CONTROLS AND INDICATORS 6 - MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAU- LIC SYSTEM The work unit is operated with the multifunctional lever. The mul- tifunctional lever has 6 positions which control the work unit as follows: SW Floating position The multifunctional lever is locked in this position.
Page 84 CONTROLS AND INDICATORS 7 - 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 equip- ment. 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 func- tions:...
Page 85: Articulated Steering Catch
CONTROLS AND INDICATORS 14.8 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 86: Door Unlocking System
CONTROLS AND INDICATORS 14.11 DOOR UNLOCKING SYSTEM Both doors have a locking mechanism which locks in if you open the door completely to prevent the door from closing while driv- ing. In order to be able to close the door, you must draw the re- spective door unlocking system (1) to the back.
Page 87: Operation
OPERATION...
Page 88: Running In The Machine
RUNNING IN THE MACHINE 15. RUNNING IN THE MACHINE Before shipment, each machine was carefully checked and adjusted. A machine which is to be run in for the first time has to be treated with utmost care during its first 100 operating hours. If the machine is used for work involv- ing loads exceeding the specified maximum load valid for the running-in period, its performance may be prema- turely impaired and its service life may be shortened.
Page 89: Preparing The Machine Start
PREPARING THE MACHINE START 16. PREPARING THE MACHINE START 16.1 VISUAL CHECKS (also refer to chapter "24. Maintenance Prior to Start") • Danger of fire! Oil or fuel leaking out or accumulated combustible materials may catch fire at hot parts of the machine, e.g.
Page 90 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 91: Adjustments Prior To Machine Start
ADJUSTMENTS PRIOR TO MACHINE START 17. ADJUSTMENTS PRIOR TO MACHINE START 17.1 ADJUSTING THE DRIVER’S SEAT After each change of the driver, re-adjust the driver’s seat. Before you start operation, check that the seat is ad- justed in such a way that you can fully floor the brake pedal when you lean against the backrest. Proceed as fol- lows to adjust the seat according to your requirements: 1 - WEIGHT ADJUSTMENT Turn the handwheel (3) to set the vibration absorbing sys-...
Page 92: Adjusting The Steering Column
ADJUSTMENTS PRIOR TO MACHINE START 17.2 ADJUSTING THE STEERING COLUMN • Do not change the angle of inclination of the steering col- umn while you are driving, since this may lead to severe accidents! • Stop the machine, before you change the angle of inclina- tion of the steering column.
Page 93: Adjusting The Heating And Ventilation System
ADJUSTMENTS PRIOR TO MACHINE START 17.5 ADJUSTING THE HEATING AND VENTILATION SYSTEM 17.5.1 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.
Page 94: Putting On The Safety Belt
ADJUSTMENTS PRIOR TO MACHINE START 17.6 PUTTING ON THE SAFETY BELT • 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 in- volved in an accident.
Page 95: Starting And Switching Off The Engine
STARTING AND SWITCHING OFF THE ENGINE 18. STARTING AND SWITCHING OFF THE ENGINE 18.1 STARTING THE ENGINE 1 - Ensure parking brake is engaged. 2 - Set the drive direction switch to its neutral position ‘N’. • You may only start the engine, if the driving direction switch is set to the neutral position 'N'.
Page 96: Warming Up The Engine
STARTING AND SWITCHING OFF THE ENGINE 18.1.1 WARMING UP THE ENGINE • 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 idle at medium speed.
Page 97: Switching Off The Engine
STARTING AND SWITCHING OFF THE ENGINE 18.2 SWITCHING OFF THE ENGINE • If you switch off the engine abruptly after heavy opera- tions without prior cool-down period, the service life of the engine may be severely impaired. It is recommended to switch off the engine abruptly only in the event of an emergency.
Page 98: Driving
DRIVING 19. DRIVING 19.1 START-UP • Careless driving may lead to accidents! • Before starting to drive, ensure that no persons are near the machine and sound the horn before you start to drive. 1 - Start up the engine as described in chapter "18.1 Starting the Engine".
Page 99: Starting The Machine On Slopes
DRIVING 19.1.1 STARTING THE MACHINE ON SLOPES • Careless driving may lead to accidents! Before starting up, ensure that no persons are near the machine and sound the horn before driving. 1 - Start up the engine as described in chapter "18. Starting and Switching Off the Engine".
Page 100: Reverse Driving
DRIVING 19.3 REVERSE DRIVING The machine can drive forward or backwards (reversing) at the same speed. Before driving backwards, pay par- ticularly care, that nobody is in your way. If necessary, rely on another person for aid. Sound the horn before start- ing to drive to make sure, that anybody who might be in your way is appropriately warned.
Page 101: Braking
DRIVING 19.5 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). 19.5.1 PULLING THE PARKING BRAKE 1 - Press the locking button. 2 - Pull up the parking brake lever.
Page 102: Braking On Slopes
DRIVING 19.5.5 BRAKING ON SLOPES • The service brake may overheat and be damaged while driving downhill! Let the engine run while driving downhill. If required, brake in addition using the brake pedal. • Danger of accidents due to unintentional braking! Do not use the brake pedal as a foot rest.
Page 103: Longer-Distance Driving
• The required tire pressure, the driving speed or the tire type may vary depending on the condition or structure of the road o be used. Contact the responsible Komatsu trader or the tire dealer to obtain the required informa- tion.
Page 104: Operating The Machine
OPERATING THE MACHINE 20. OPERATING THE MACHINE 20.1 PREPARING THE WORK EQUIPMENT 20.1.1 SELECTING A WORK UNIT Refer to chapter "7. Equipment" for information on the work units registered. 20.1.2 PICKING UP THE WORK UNIT (EXCEPT MULTI-PURPOSE BUCKET) Connect the multi-purpose bucket as described in section „Pick- ing up the multi-purpose bucket“...
Page 105: Removing The Work Unit
OPERATING THE MACHINE 20.1.3 REMOVING THE WORK UNIT 1 - Lower the work unit onto level ground. 2 - Unlock the quick-change unit by setting the control lever for special equipment into position ‘1’ (fig. 75_042). 3 - Set the quick-change unit into the dumping position ‘A’ (fig. 75_016) using the multi-function lever, until the quick- change unit is unhooked of the pickup hooks of the work unit.
Page 106 OPERATING THE MACHINE 9 - Connect the hydraulic hoses of the multi-purpose bucket to the quick attach couplers (2) (fig. 75_161) and (3) (fig. 75_275). 10 - Lock the quick-change unit by setting the control lever for special equipment into position ‘2’ (fig. 75_042). 75_161 11 - Set the change-over lever for the additional control circuit into position '1' (fig.
Page 107: Removing The Multi-Purpose Bucket
OPERATING THE MACHINE 20.1.5 REMOVING THE MULTI-PURPOSE BUCKET 1 - Lower the multi-purpose bucket onto level ground. 2 - Turn the change-over lever for the additional control circuit to position ‘2’ (fig. 75_160). 3 - Unlock the quick-change unit by setting the control lever for special equipment into position ‘1’...
Page 108: Tire Service Life
OPERATING THE MACHINE 20.2 TIRE SERVICE LIFE Removing piles of loose soil or rock debris may cause premature wear and tear of the tires due to cracks and small fissures. As a result, the service life of the tires is reduced. Proceed as follows to avoid unnecessary wear and tear of the tires: •...
Page 109: Loading
OPERATING THE MACHINE 20.3 LOADING • 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 principle: →...
Page 110 OPERATING THE MACHINE 5 - Press down the accelerator pedal and drive the bucket into the material to be removed. In order to remove the material, it is required that you align horizontally the cutting edge of the bucket while driving into the material. When you are loading rock debris, it is necessary to lower the bucket slightly.
Page 111: Excavation Works
OPERATING THE MACHINE 20.3.2 EXCAVATION WORKS During excavation works, ensure that you do not load the bucket only on one side, since the equilibrium of the machine may be impaired. 1 - Drive up to the soil heap in a straight line. 2 - Slow down the machine using the service brake while keep- ing the accelerator pedal pressed down at the same time.
Page 112: Transporting
OPERATING THE MACHINE 20.4 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 "20.2 Tire Service Life").
Page 113: V-Shaped Loading
OPERATING THE MACHINE 20.5.2 V-SHAPED LOADING Position the dump truck in such a way that the angle between the dump and the dump truck is approx. 60°. Fill the bucket and shake it. This leads to a better distribution of the cargo in the bucket and prevents that material falls down to the back.
Page 114: Planing
OPERATING THE MACHINE 20.6 PLANING Planing operations are required for levelling the ground. For this purpose, a straight bucket without claws is suit- able. Planing includes two operation steps - filling up and taking off ground. 20.6.1 FILLING UP It may be necessary to fill up the uneven ground in front of the machine with soil. Proceed as follows: •...
Page 115: Working With The Forklift Truck Attachment
OPERATING THE MACHINE 20.7 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 specified in the chapter "Safety": •...
Page 116: Precautions For Special Operations
OPERATING THE MACHINE 20.8 PRECAUTIONS FOR SPECIAL OPERATIONS 20.8.1 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.
Page 117: Instructions For Winter Operation
OPERATING THE MACHINE 20.10 INSTRUCTIONS FOR WINTER OPERATION 20.10.1 BEFORE THE COLD SEASON Before the cold season begins, you should perform the following preparatory measures to ensure troublefree op- eration also in the winter months. • The machine is provided with a aluminium radiator. Therefore, the cooling system must be set to -34.6°F (-37°C) for the whole year.
Page 118: During The Standstill
• Recharge the battery. 20.11.3 AFTER THE STANDSTILL • If the machine was not moved once a month, contact the local Komatsu dealer to arrange a mainte- nance appointment. After a longer standstill period, perform the following works before starting up the machine: •...
Page 119 TROUBLESHOOTING...
Page 120: Troubleshooting
21. TROUBLESHOOTING Have all malfunctions and causes of malfunctions that are not given in the tables below remedied by your local Komatsu dealer. 21.1 WARNING LIGHTS AND INDICATORS The following list contains the troubleshooting tables with explanations of warning lights and indicators: Charging current warning light see "21.2 Electrical System"...
Page 121: Electrical System
Starter turns engine only slowly Battery charge insufficient Re-charge battery Starter defective *) Replace starter Starter disengages before engine is Battery charge insufficient Re-charge battery started Starter defective *) Replace starter *) These measures must be performed by your local Komatsu dealer.
Page 122: Engine
Top up coolant (ensure correct mixing of the radiator cap ratio) Coolant level too low Leaks in the cooling system Check lines and hoses (visual check: coolant leaks) *) Replace defective lines and hoses *) These measures must be performed by your local Komatsu dealer.
Page 123 Exhaust fume colour temporarily black Air filter insert dirty Clean or replace air filter insert Injection nozzle defective *) Replace injection nozzles Engine compression too low *) Check tappet clearance *) These measures must be performed by your local Komatsu dealer.
Page 124 Warning light air filter: warning light air Air filter of filter insert dirty Clean or replace filter insert of air filter filter is on when engine is running *) These measures must be performed by your local Komatsu dealer.
Page 125: Hydraulic System
Check tension of drive belt Hydraulic filter dirty Replace filter element of hydraulic filter Oil level in hydraulic oil tank either too Correct oil level in hydraulic oil tank high or too low *) These measures must be performed by your local Komatsu dealer.
Page 126 Fill in prescribed hydraulic oil Oil level in hydraulic oil tank too low Top off hydraulic oil Cylinders move jerky Oil level in hydraulic oil tank too low Top off hydraulic oil *) These measures must be performed by your local Komatsu dealer.
Page 127: Brakes
Clearance of steering cylinder bolt too *) Check fastenings of steering cylin- large der; replace defective cylinder bolts Faulty operation of hydraulic system *) Check function of hydraulic system *) These measures must be performed by your local Komatsu dealer.
Page 128: Axles
TROUBLESHOOTING 21.6 AXLES AXLES FAULT CAUSES REMEDY Noise Oil level in axle too low Top off oil *) These measures must be performed by your local Komatsu dealer.
Page 129: Emergency Steering Characteristics
TROUBLESHOOTING 21.7 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 ma- chine.
Page 130: Starting The Engine With A Battery Jumper Cable
TROUBLESHOOTING 21.9 STARTING THE ENGINE WITH A BATTERY JUMPER CABLE • 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 131: Starting The Engine
TROUBLESHOOTING 21.10 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 132: Towing The Machine
TROUBLESHOOTING 21.11 TOWING THE MACHINE • Towing with a tractor of insufficient weight may cause ac- cidents! Perform towing using a machine weighing at least as much as the machine that you want to tow off. • Towing to start the engine will damage the hydrostatic drive system! Do not give the machine a tow to start the engine.
Page 133: Towing A Machine With Defective Brakes
When towing on an even and horizontal surface, the tractive force that you need is much less than the tractive force that you need when towing on a slope or uneven surface. Please ask your local Komatsu dealer for details, if you want to give a particular machine a tow.
Page 134 TROUBLESHOOTING...
Page 135 MAINTENANCE...
Page 136: Maintenance Basics
MAINTENANCE BASICS 22. MAINTENANCE BASICS • Maintenance work must only be performed by trained and qualified personnel. Also refer to chapter "Safety Mea- sures During Maintenance". To ensure troublefree operation of the machine, it must be ser- viced at regular intervals. Control daily the operating hour meter to determine which of the maintenance measures is required.
Page 137: Cleaning The Machine
MAINTENANCE BASICS 22.2 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. • If somebody accidentally lowers the bucket while cleaning is being performed under the boom, this may lead to severe accidents! Before you start performing cleaning work under the boom, either support the bucket or lower it onto the ground.
Page 138: Lubricants And Operating Agents
After an oil change or oil filter change, check the oil and oil filter for an unusual high number of metal parts or oth- er undesired material. In case you detect an unusual high contamination, inform your responsible Komatsu deal- 22.4.3 CHANGING FILTERS...
Page 139: Lubricating Grease
22.4.7 BIODEGRADABLE HYDRAULIC OIL AND LUBRICATING GREASE Biodegradable hydraulic oil and lubricating grease - based on synthetic esters - can be used for Komatsu ma- chines. Please contact our factory representatives for information about the products which suit best your type of application which are approved by Komatsu.
Page 140: Coolants
• 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 141 MAINTENANCE BASICS Blank for Technical Reason...
Page 142: Table Of Lubricants And Operating Agents
MAINTENANCE BASICS 22.4.12 TABLE OF LUBRICANTS AND OPERATING AGENTS LUBRICANTS AND OPERATING AGENTS BI-CODES*), SPECIFICATIONS, AND FILLING VOLUMES WA65-3 Lubricants Filling Volume Quality Temperature Viscosity and Service BI-Codes in Litres Classes Ranges Classes Fluids approx. CCMC D4 or, if -15° to 45° C SAE 15W-40 ¹)
Page 143: Lubrication Chart
MAINTENANCE BASICS 22.4.13 LUBRICATION CHART...
Page 144: Replacing Safety-Related Parts
Have parts which are important for machine safety and fire protection replaced at your local Komatsu dealer at regular intervals. Have the following parts replaced at your local Komatsu dealer at regular intervals, even if they are not visibly worn: •...
Page 145: 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 with new ones. Pay atten- tion not to forget any gaskets and O-rings when re-assembling the parts.
Page 146: Electrical System
• Do not remove or modify electrical components installed in the machine. • Only install Komatsu Utility Corporation approved electrical components. • When cleaning the machine or during heavy rainfall, pay attention that water does not get into the electrical sys- tem.
Page 147: Slow-Blowing Fuses
MAINTENANCE BASICS 22.7.3 SLOW-BLOWING FUSES If the power supply fails, the reason for this may be that one of the slow-blowing fuses (1) has blown. Check the electrical sys- tem and replace defective fuses. 75 _ 2 6 5 F3 80A: Main Power Supply / Starter F4 50A: Intake Air Heater...
Page 148: Tires
MAINTENANCE BASICS 22.8 TIRES 22.8.1 TIRE COMPONENTS 1 - Steel Cord Belt 2 - Radial Carcass 3 - Bead Core 4 - Liner 5 - Diagonal Carcass 6 - Bead Cores 22.8.2 CHECKING THE TIRES Particularly after work on rocky surfaces, check the tires for dam- age, wear and tear, and fissures.
Page 149 MAINTENANCE BASICS • Check that the machine is unloaded before you check the tire pressure. • Prior to start of work, measure the tire pressure of the cold tires. If the tire pressure is too low, the tire will be overloaded. If the tire pressure is too high, this will lead to formation of notches in the tire resulting in bursting of the tire when it is subjected to shock load.
Page 150: Tools
MAINTENANCE BASICS 22.9 TOOLS Designation Part No. Remark Spanner Openings: 42T-09-H0450 8/10 mm Set of Double-Ended Ring Spanners 42T-09-H0460 13/15 mm 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 (Grease) 424-98-H1010...
Page 151: Torque For Standard Nuts And Bolts
MAINTENANCE BASICS 22.10 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 152 MAINTENANCE BASICS METRIC FINE SCREW THREAD - TENSILE STRENGTH CLASS 10.9 Thread diameter of bolt Width across flat Steel Aluminium Cast 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 153: Maintenance Schedule
MAINTENANCE SCHEDULE 23. MAINTENANCE SCHEDULE MAINTENANCE PRIOR TO START ..........24.1 •...
Page 154 MAINTENANCE SCHEDULE 29.6.2 • • MAINTENANCE DEMAND ........... . . 29.6.3 •...
Page 155: Maintenance Prior To Start
MAINTENANCE PRIOR TO START 24. MAINTENANCE PRIOR TO START 24.1 VISUAL CHECKS (refer to chapter "16. Preparing the Machine Start") 24.2 COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING OFF COOLANT • A wrong water/coolant mixing ratio will damage the radia- tor! Always mix water and coolant in the ratio 50:50.
Page 156: Engine, Checking The Oil Level, Topping Off Oil
MAINTENANCE PRIOR TO START 24.3 ENGINE, CHECKING THE OIL LEVEL, TOPPING OFF OIL • After you have switched off the engine, wait at least 5 min- utes before you check the engine oil level. The machine must stand on an even surface. 1 - Pull out the oil dipstick (1) and wipe off the oil with a clean 75_204 cloth.
Page 157: Engine, Draining Off Oil
MAINTENANCE PRIOR TO START 24.4 ENGINE, DRAINING OFF OIL If you have topped off too much oil, you must drain off the excess oil. Have an oil trough with a sufficient capacity ready. 1 - Loosen the screw (1) at the bottom cover plate (2) and swiv- el the cover plate to the side.
Page 158: Checking The Fuel Level, Refueling
MAINTENANCE PRIOR TO START 24.5 CHECKING THE FUEL LEVEL, REFU- ELING • Danger of fire! Fuel that has spilled over may ignite! Immediately remove fuel that has spilled over. 1 - Turn the start switch to the operating position 'I' and check the fuel level indicated on the fuel level indicator.
Page 159: Checking The Controls
3 - Check that the fuel level indicator (5) indicates the fuel level in the fuel tank. • Contact your local 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.
Page 160: Checking The Parking Brake
MAINTENANCE PRIOR TO START 24.7 CHECKING THE PARKING BRAKE 24.7.1 TEST CONDITIONS • Tire pressure: according to specification • Road surface: dry, solid surface with a gradient of 18% • Machine: ready for operation 24.7.2 TEST PROCEDURE 1 - Start the engine, set the machine to straight driving, and 7 5 _ 2 1 3 drive the machine with an empty bucket up a gradient of 18%.
Page 161: Checking The Electrical Connections
Remove inflammable material from the electrical system. • If a fuse blows, or if there are any signs of a short-circuit within the electrical system, inform your local Komatsu dealer. Regularly check that the terminals are fastened tightly, retighten loose terminals.
Page 162: Maintenance Every 10 Operating Hours
MAINTENANCE EVERY 10 OPERATING HOURS 25. MAINTENANCE EVERY 10 OPERATING HOURS 25.1 LUBRICATION • There is danger of severe accidents, if you perform main- tenance 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 163: Maintenance After The First 50 Operating Hours
6 - Let the oil drain off into the oil trough. 7 - Check the removed oil for metal parts or undesired material. If the oil contains such particles, inform the local Komatsu dealer. 8 - Remove the drain hose (5), this will cause the drain valve (4) to close.
Page 164: Replacing The Oil Filter Cartridge
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.1.1 REPLACING THE OIL FILTER CARTRIDGE 11 - Turn the filter screwdriver counterclockwise to unscrew the filter cartridge (1). 12 - Clean the filter holder. Completely fill up the new filter car- tridge with engine oil. Slightly oil both the gasket and the thread of the cartridge with engine oil.
Page 165: V-Belt, Checking The Condition
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.2 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 166: Hydraulic System, Replacing The Filter Insert
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.4 HYDRAULIC SYSTEM, REPLACING THE FILTER INSERT • 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. 1 - Lower the work equipment onto the floor.
Page 167: Checking And Tightening The Wheel Nuts
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.5 CHECKING AND TIGHTENING THE WHEEL NUTS • Loose wheel nuts may cause severe accidents! Regularly check and tighten the wheel nuts. Retight loose nuts. Tightening torque: 45.89 kgm to 50.989 kgm (450 - 500 Nm) 75_159 •...
Page 168: Front And Rear Axle, Changing Oil
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.6 FRONT AND REAR AXLE, CHANGING OIL • 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. •...
Page 169: Transfer Gear - Changing Oil
MAINTENANCE AFTER THE FIRST 50 OPERATING HOURS 26.7 TRANSFER GEAR - CHANGING OIL • 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. •...
Page 170: Maintenance Every 50 Operating Hours
- Run the engine until warm. Check points 1 to 5 again. • If coolant has to be topped off regularly in the radiator or expansion tank, then the system should be checked by your local Komatsu dealer and repaired if required.
Page 171: Draining Off Water And Dirt Deposits From The Fuel Tank
3 - If the oil level is too low, fill prescribed oil into the expansion tank. For detailed specifications, see section "22.4 Lubricants and Operating Agents". 7 5 _ 2 3 8 4 - If you detect a significant oil loss, inform your local Komatsu dealer.
Page 172: Checking The Battery And Acid Level
MAINTENANCE EVERY 50 OPERATING HOURS 27.4 CHECKING THE BATTERY AND ACID LEVEL • Danger of injury! The battery contains highly toxic battery acid which may squirt out and burn your eyes! Use goggles and rubber gloves if you work on the battery. Immediately rinse your eyes or skin using plenty of water and immediately seek medical attention.
Page 173: Re-Charging A Built-In Battery
MAINTENANCE EVERY 50 OPERATING HOURS 27.4.1 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 will be damaged due to high voltage peaks. •...
Page 174: Lubrication
MAINTENANCE EVERY 50 OPERATING HOURS 27.5 LUBRICATION 27.5.1 LUBRICATING POINTS OF THE WORK EQUIPMENT • If you perform maintenance operations at a machine which is not properly parked and secured, severe acci- dents may occur! Park the machine on firm, level ground and secure it be- fore starting the maintenance operations.
Page 175: Maintenance Every 100 Operating Hours
MAINTENANCE EVERY 100 OPERATING HOURS 28. MAINTENANCE EVERY 100 OPERATING HOURS All maintenance operations to be performed after 10 and 50 hours of operation fall also into this maintenance category. 28.1 DRAINING THE WATER SEPARA- TOR, REMOVING WATER AND DIRT DEPOSITS Keep a container ready for collecting the liquid from the water separator (1).
Page 176: Maintenance Every 250 Operating Hours
MAINTENANCE EVERY 250 OPERATING HOURS 29. MAINTENANCE EVERY 250 OPERATING HOURS All maintenance operations to be performed after 10, 50 and 100 hours of operation also fall into this maintenance category. 29.1 CHANGING THE ENGINE OIL AND OIL FILTER CARTRIDGE See chapter "26.
Page 177: Front And Rear Axle, Checking The Oil Level
MAINTENANCE EVERY 250 OPERATING HOURS 29.5 FRONT AND REAR AXLE, CHECKING THE OIL LEVEL • There is danger of severe accidents, if you perform main- tenance 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 178: Air Filter, Removing And Re-Installing The Filter Insert, Checking And Cleaning The Filter Insert
MAINTENANCE EVERY 250 OPERATING HOURS 29.6 AIR FILTER, REMOVING AND RE-INSTALLING THE FILTER INSERT, CHECKING AND CLEANING THE FILTER INSERT 29.6.1 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. 29.6.2 MAINTENANCE DEMAND If the air filter warning indicator (1) lights up, the air filter car- tridge is dirty.
Page 179: Cleaning Or Exchanging The Filter Cartridge
MAINTENANCE EVERY 250 OPERATING HOURS 29.6.4 CLEANING OR EXCHANGING THE FILTER CARTRIDGE Depending on the degree of contamination, the air-filter insert can be cleaned using compressed air or water to which a mild detergent can be added. • The air-filter insert must be replaced, if the air-filter con- trol light lights up only short time after cleaning.
Page 180: Checking The Filter Cartridge
MAINTENANCE EVERY 250 OPERATING HOURS 29.6.5 CHECKING THE FILTER CARTRIDGE Usually, it is required to check each air filter cartridge before it is re-installed. For this purpose, insert a lamp into the cartridge and visually check the filter paper against the transmitted light. If you detect small holes or spots on which the paper is thin, the in- sert is defective and must be replaced.
Page 181: Maintenance Every 500 Operating Hours
MAINTENANCE EVERY 500 OPERATING HOURS 30. MAINTENANCE EVERY 500 OPERATING HOURS All maintenance operations to be performed after 10, 50, 100 and 250 hours of operation also fall in- to this maintenance category. 30.1 CHANGING THE FUEL FILTER AND FILTER ELEMENT •...
Page 182: Bleeding The Fuel System
MAINTENANCE EVERY 500 OPERATING HOURS 30.1.1 BLEEDING THE FUEL SYSTEM • Fuel in the injection system is under pressure. Use goggles and rubber gloves if you work on the injec- tion pump. If you are hit by a high-pressure fuel stream, immediately seek medical attention.
Page 183: Changing The Filter Cartridge Of The Hydraulic System
MAINTENANCE EVERY 500 OPERATING HOURS 30.2 CHANGING THE FILTER CARTRIDGE OF THE HYDRAULIC SYSTEM See chapter „Maintenance After the First 50 Operating Hours“. 30.3 CLEANING THE WATER SEPARA- Keep a container ready for collecting the liquid from the water separator (1). 1 - Loosen the drain plug (2).
Page 184: Lubrication
MAINTENANCE EVERY 500 OPERATING HOURS 30.4 LUBRICATION • 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. 1 - For maintenance operations, park and secure machine as described in chapter "22.1 Preparing the Machine for Maintenance".
Page 185: Air Filter, Replacing The Filter Insert, Replacing The Safety Filter
MAINTENANCE EVERY 500 OPERATING HOURS 30.6 AIR FILTER, REPLACING THE FILTER INSERT, REPLACING THE SAFETY FILTER 30.6.1 REPLACING THE FILTER INSERT • If the filter element is replaced for the third time in se- quence, it is required to replace also the safety filter. 1 - Open the air filter and remove the air-filter insert (1).
Page 186: Maintenance Every 1000 Operating Hours
MAINTENANCE EVERY 1000 OPERATING HOURS 31. MAINTENANCE EVERY 1000 OPERATING HOURS All maintenance operations to be performed after 10, 50, 100, 250 and 500 hours of operation fall al- so into this maintenance category. 31.1 COOLING SYSTEM, EXCHANGING COOLANT AND CLEANING THE SYSTEM •...
Page 187: Cleaning The Cooling System
MAINTENANCE EVERY 1000 OPERATING HOURS 31.1.2 CLEANING THE COOLING SYSTEM • The cooling system may only be filled slowly since other- wise the included air cannot escape completely. After fill- ing up, wait approx. 3 minutes and refill liquid, if required. 6 - Fill up the cooling system slowly with cleaning fluid (Adhere to the specifications of the cleaning agent manufac- turer).
Page 188: Front Axle, Oil Change
31.4 TRANSFER GEAR, OIL CHANGE See chapter "26. Maintenance After the First 50 Operating Hours". 31.5 SERVICE BRAKE • All repairs on the brake system must be performed by your local Komatsu dealer. 31.5.1 CHANGING OIL 31.5.2 CHECKING TUBES AND LINES 31.5.3 CHECKING THE BRAKE DISKS FOR WEAR AND TEAR...
Page 189: Maintenance Every 2000 Operating Hours
MAINTENANCE EVERY 2000 OPERATING HOURS 32. MAINTENANCE EVERY 2000 OPERATING HOURS All maintenance operations to be performed after 10, 50, 100, 250, 500 and 1000 hours of operation also fall into this maintenance category. 32.1 HYDRAULIC SYSTEM, OIL CHANGE • Frequent skin contact with used hydraulic oil may cause skin damages and other injuries! Use rubber gloves for exchanging the filter.
Page 190: Bleeding The Hydraulic Oil Tank
• Let the fuel pump be checked at your local Komatsu dealer. 32.6 CHECKING THE FUEL AND COOLANT TUBES, REPLACING THE TUBES (IF REQUIRED) • Have the fuel and coolant tubes checked and replaced, if required, at your local Komatsu dealer.
Page 191: Checking The Water Pump
MAINTENANCE EVERY 2000 OPERATING HOURS 32.7 CHECKING THE WATER PUMP • Let the water pump be checked at your local Komatsu dealer. 32.8 CHECKING AND ADJUSTING THE FUEL INJECTION AND INJECTION TIME • Let the injection time be checked at your local Komatsu dealer.
Page 192 MAINTENANCE EVERY 2000 OPERATING HOURS...
Page 193 TECHNICAL DATA...
Page 194: Technical Data
TECHNICAL DATA 33. TECHNICAL DATA SPECIFICATIONS Model Komatsu 4D 94E - 1 HC Engine Output (ISO 9249) 37 kW (49.4 Hp) / 2500 rpm Torque, max. (ISO 9249) 160 - 174 Nm / 1600 rpm Engine Starter Motor 12 V - 2.3 kW...
Page 195: Noise Emission Levels
TECHNICAL DATA 33.1 NOISE EMISSION LEVELS Sound pressure level = 73 dB/A Sound power level = 96 dB/A No alterations may be made to the machine which could have an influence on the noise emission levels 33.2 VIBRATION LEVEL When used for its intended purpose, levels of vibration for the earthworking machine transmitted from the opera- tor's seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096.
Page 196: Limit Values For Slopes
TECHNICAL DATA 33.3 LIMIT VALUES FOR SLOPES 33.3.1 MAXIMUM SLOPE ANGLE FOR OPERATING THE MACHINE If operating the machine on a slope, its angle must not exceed 30° uphill, downhill or sideways. If you angle the machine at more than 30° during operation, the motor, transmission, hydraulic system or axles, will not be sup- plied with sufficient oil and can be damaged.

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Komatsu WA65-3 Operation & Maintenance Manual

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