Komatsu Wa95
Komatsu Wa95
Komatsu Wa95
Manual
VEAM980500
WA95-3
WHEEL LOADER
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
NOTICE
Komatsu has had the operating and maintenance instructions translated into all the languages of the
member states in the European Union. Should you
wish to have a version of the operating instructions
in another language, please dont hesitate to ask at
your local dealers.
Contents
Contents
Information on these Operating Instructions .............................................................. 1-1
Why You Should Read these Operating Instructions .................................................................... 1-3
Notes on Safety Regulations ......................................................................................................... 1-4
Correct Use ................................................................................................................................................................. 1-4
Safety Notes in the Operating Instructions ................................................................................................................. 1-4
Standards and Guidelines ........................................................................................................................................... 1-6
0-1
Contents
Working On Loose Soil ............................................................................................................................................. 3-13
Working with the Forklift Truck Attachment ............................................................................................................... 3-14
Parking the Machine ................................................................................................................................................. 3-15
0-2
Contents
Dumping/Unloading ................................................................................................................................................... 5-26
Planing ...................................................................................................................................................................... 5-27
Working With the Forklift Truck Attachment .............................................................................................................. 5-28
Precautions For Special Operations ......................................................................................................................... 5-29
After the work is finished ........................................................................................................................................... 5-29
Instructions for Winter Operation .............................................................................................................................. 5-30
Longer Standstill Periods of the Machine ................................................................................................................. 5-31
Maintenance.................................................................................................................... 7-1
Maintenance Basics ....................................................................................................................... 7-3
Cleaning the Machine ................................................................................................................................................. 7-4
Working-Area-Dependent Maintenance ..................................................................................................................... 7-5
Lubricants and Operating Agents ............................................................................................................................... 7-6
Replacing Safety-Related Parts ................................................................................................................................ 7-11
Spare Parts and Consumable Components ............................................................................................................. 7-12
Electrical System ....................................................................................................................................................... 7-13
Tyres ......................................................................................................................................................................... 7-15
Tools ........................................................................................................................................................................... 7-17
Torque for Standard Nuts and Bolts .......................................................................................................................... 7-18
0-3
Contents
Checking the Battery and Acid Level ........................................................................................................................ 7-37
Re-Charging the Battery ........................................................................................................................................... 7-38
Lubrication ................................................................................................................................................................. 7-39
0-4
1 -2
Please note:
If the owner modifies safety-related parts of the machine, the certificate
of conformity of the manufacturer will lapse and the person who has
performed the modification has to issue a new certificate. Should you
have any questions concerning this point, please do not hesitate to ask
Komatsu.
1 -3
Correct Use
A loader is a machine which has its own drive and which is moving on
either tracks or wheels. By moving in forward direction, a loader can load
material or cut the ground with the work unit (use of bucket) provided for
loading which is attached to its front.
The standard working cycle of a loader comprises filling and lifting the
loading bucket, transporting material, and emptying the loading bucket.
If you use the machine for any other purpose than specified above, we
will not accept any responsibility for safety. All considerations concerning
safety will then be up to the owner or the operating and maintenance
personnel. In any case, neither you nor any other person are/is authorised
to perform work and functions explicitly prohibited in these operating
instructions.
1 -4
DANGER
NOTE
IMPORTANT
1 -5
1 -6
Only use portable or mobile devices in the cab, if they are connected
to a stationary external aerial.
When installing the aerial, make sure that it is installed correctly with
a good chassis earth connection between the aerial and the chassis
of the vehicle.
In addition, adhere to all information about installation and connection of
cables and maximum power input indicated in the manufacturer's
installation instructions of the machine.
1 -7
CE-Conforming Equipment
CE-conforming equipment
WA 95-3
Bucket
Type
Part No.
Volume
m
Hydr.
pressure
bar
Weight
kg
42W-70-12021
1,1
---
387
42W-70-12030
1,1
---
411
42W-70-12090
0,9
185
670
42W-70-12100
0,9
185
620
42W-70-12210
1,0
185
700
42W-70-12240
1,0
185
640
42W-70-12051
1,25
---
410
42W-70-12061
1,6
---
420
42W-70-12120
1,0
185
540
42W-70-12080
1,5
185
770
42W-70-12110
1,0
185
615
WA95-3
CE_1WA95.TBL
1 -8
CE-conforming equipment
WA 95-3
Fork carrier
*)
**)
STD
CTW
Type
Part No.
WA95-3
42U-70-12080
*) 2500
**) 1870
*) 2600
**) 1950
Weight
kg
121
Standing security 80% of the tipping load on firm and level ground
Standing security 60% of the tipping load on uneven ground
Machine in standard version
Machine with counterweight
CE-conforming equipment
WA 95-3
crane boom
Type
Part No.
WA95-3
42U-70-12530
500 / 1500
1000 / 1300
Weight
kg
100
CE_2WA95.TBL
1 -9
U:\DTP\BA75\CEAUS75.WMF
1-10
WA 95
42W-93-11130
A1
1,670
A2
1,180
Sh
545
B1
1,980
B2
1,860
C1
1,490
C2
1,490
D1
285
D2
1,075
2,480
H1
1,030
H2
1,400
270
X1
X2
*) valid in Germany
A1
A2
B1
B2
D1
D2
G
H1
H2
J
Sh
X1
X2
Y1
Y2
a
b1
c
d1
d2
e
h
Y1
Y2
a
52
b1
860
312
d1
40
d2
40
15
200
Tyre
Bucket
42W-70-12030
1.1 m
CEDok95.TBL
1-11
1-12
Loading and
Transporting the
Machine
2- 1
2- 2
4.
CAUTION
Incorrectly attached ropes may damage the machine!
Only fasten the eye hooks of the carrying ropes at the marked
attachment points.
There are two attachment points each at the front part and the rear part
of the machine. These attachment points are shown in the following figure.
2- 3
7 5 _ 16 2 a
1
75 _ 26 9
DANGER
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.
CAUTION
Stay ropes that are incorrectly attached may damage the
machine!
Only fasten the eye hooks of the stay ropes at the marked
attachment points.
When the machine is on the loading area of the transport vehicle, secure
the articulated steering as described in the chapter "Securing the
Articulated Steering". Then, block the wheels of the machine with wheel
chocks or wedges and secure the machine with ropes in such a way that
it will neither start to skid nor tip over during transport. To avoid damage
to the machine, only fasten the eye hooks of the stay ropes at the marked
attachment points. The attachment points to be used are the two eye
hooks at the front frame and the tie bolt at the rear frame of the machine.
The positions of the attachment points are shown in the figure on the
previous page.
After Transport
After transport, remove all securing devices, such as wheel chocks or
wedges and ropes. Remove the catch of the articulated steering before
you drive the machine off the transport vehicle. For this purpose, reverse
the steps 1 through 4 described in the chapter "Securing the Articulated
Steering".
2- 5
1.1
Loose weight
t/m
2.0
kg
4860
kg
4200
kg
kg
2500
2600
kN
72.5
kN
57.0
Operating weight
kg
5830
mm
4455
mm
5550
mm
5580
T1
mm
2150
T2
mm
2060
mm
2750
mm
mm
1590
1590
mm
2150
mm
1035
mm
mm
395
505
Centre of gravity,
height above axle centre
mm
420
mm
1440
ABM_95E.TBL
2- 6
Technical Data
Machine name-plate position
(see enlargement)
..................................................................................
..................................................................................
Dealer Name
..................................................................................
Dealer Address
..................................................................................
..................................................................................
Telephone
..................................................................................
Fax
..................................................................................
Maintenance Personnel
..................................................................................
SE-NO_75.TBL
2- 7
2- 8
Safety
DANGER
Failure to adhere to these safety instructions can lead to
accidents with serious injuries!
Read and adhere to all safety instructions.
This chapter also contains safety instructions for special equipment
and attachments.
Do not operate or service the machine unless you have been trained
and are authorised to do so.
Always adhere to all instructions, measures, and safety instructions
when operating or servicing the machine.
When working together with other persons, agree beforehand on all
hand signals that you want to use to avoid accidents due to
misunderstandings.
Safety Devices
Check that all safety devices and covers of the machine are correctly
installed.
Ensure that damaged safety devices and covers are repaired before
you start the machine.
Use all safety devices as prescribed, e.g. the safety lever for the work
hydraulic system (see opposite figure) and the safety belt.
Do not remove any of the safety devices e.g. the protective grid above
the fan (see opposite figure). Safety devices must be kept in perfect
condition.
Emergency Exit
In an emergency situation, you can use the door on the right-hand side
of the driver's cab (seen from the driving direction) as an emergency
exit.
3- 2
Machine Modifications
3- 3
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.
Refuelling and refilling of oil are to be performed in sufficiently ventilated
places.
Store oil and fuel in special places appropriate for this purpose. Ensure
that unauthorised persons do not have access to these places.
Tightly close all cover caps.
Check the fuel system, the lubrication system, and the hydraulic system
for leaks. Have leaks repaired. Remove any excess oil, fuel, or other
inflammable substances.
Carefully and completely remove wooden chippings, leaves, paper,
and other highly inflammable materials that may have collected in the
engine compartment, since they could cause a fire.
Do not operate the machine in the vicinity of naked light.
3- 4
Directly after operating the machine, the engine coolant, the engine
oil, and the hydraulic oil are extremely hot and under pressure. Do not
try to unscrew caps, drain water or oil, or replace filters directly after
operating the machine, since this may lead to severe burns due to hot
fluids or hot machine parts. Wait until the temperature has fallen.
Strictly adhere to the described procedures when performing the
required measures.
Lower the work equipment.
Switch off the engine and wait for the radiator to cool down before you
unscrew the radiator cap. Slowly turn the radiator cap until it reaches
the first catch to let the pressure escape. Then, proceed turning the
cap further and remove it. If you do not let the pressure escape, boiling
water may spurt out when you remove the radiator cap.
Switch off the engine. Allow the hydraulic oil to cool down before you
unscrew the cap of the hydraulic tank to drain the hydraulic oil. Slowly
turn the cap of the hydraulic tank to let the pressure escape from the
tank. If you do not let the pressure escape, oil may spurt out when
you remove the cap of the hydraulic tank.
3- 5
Attachments
3- 6
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. Rinse your eyes with water until a doctor arrives
or you are able to visit an ophthalmologist or go to a hospital.
Sulphuric acid that gets into contact with skin or clothing may cause
acid burns. Immediately rinse the area that has come into contact
with the acid with ample water.
When working in the area of the battery, your hands may unintentionally
get in touch with acid. For this reason, do not touch your eyes while
working in the area of the battery. Always wash your hands after work.
Batteries produce detonating gas. Detonating gas is extremely explosive and may be ignited even by the smallest spark.
Do not disconnect the battery while the engine is still running.
Prior to start of work on batteries, set the start switch to '0'. Set the
main switch of the battery (if installed) to 'Off'.
Avoid any short-circuits via the poles or the pole terminals of the battery
due to unintentional touching with metal objects, such as tools.
When removing or inserting the battery, note which of the poles is the
positive (+) and which is the negative (-) one. Always disconnect the
mass cable first and reconnect it last.
Tightly fasten the pole terminals. Loose pole terminals may produce
sparks and thus cause explosions. Ensure that the cover of the positive pole (+) is always mounted.
Tighten the cover caps.
When repairing the electrical system or performing electric welding,
disconnect the negative (-) pole terminal from the battery to interrupt
the electric circuit.
3- 7
Before you start operation, check the working area for dangerous
working conditions.
Inspect the surface of the soil in the working area and determine the
optimum and safest procedure.
Determine the required safety measures against dangers on public
roads in co-operation with the owners, users, and responsible
authorities.
On sites where there are underground water pipes, gas pipes, or
conduits for high voltage cables, contact the responsible supply
company to determine the lines' positions. Ensure that these facilities
will not be damaged.
When working with water or crossing sand banks, first check the
subsoil and depth and flow rate of the water. Ensure that the permitted
water depth will not be exceeded.
3-8
Do not leave any tools or spare parts lying around in the cab. These
may actuate, damage, or block control levers, pedals, or switches.
Store these parts in the tool box.
Keep the cab floor, the control elements, the tread steps, and the
handrails free of oil, grease, and excessive dirt.
Immediately repair any damage. Tighten loose screw connections.
Check the safety belt, the belt buckle, and the fastening elements
for damage and wear. Replace worn or damaged parts.
In-Door Operation
Do not operate machines in-door unless these areas are sufficiently
ventilated (e.g. workshops).
Caution - Danger of intoxication!
3- 9
Machine Operation
Before You Start the Engine
Reversing
These rules must be observed for all machines, i.e. also for those
machines equipped with a reversing warning system:
Before you start reversing, sound the horn to warn persons within or
near the operating area.
Driving
3-10
Driving On Slopes
7 5 _ 01 6
3- 1 1
A voltage overspill may occur, if you or the machine get too close to
overhead power transmission lines. For this reason, always heed
the required safety distance between the machine and the overhead
power transmission lines.
Nominal Voltage
up to 1000 V
over 1 kV
up to 110 kV
over 110 kV
up to 220 kV
over 220 kV
up to 380 kV
with unknown
nominal voltage
Safety Distance
1m
3m
4m
5m
5m
The safety distances given here reflect the German safety standards.
You can find the safety distances applying to your country in the
relevant national regulations.
Before you start work, obtain information about line voltages from
your supply company.
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.
3. Try to move the machine out of the range of influence of the overhead
power transmission line by moving it away from the line, moving
away the work unit, etc.
4. Have the power in the line switched off.
Loading
3-12
Good Vision
Working On Snow
Height Limitation
When working in areas with height limitations, e.g. in tunnels, beneath
bridges or power transmission lines, or in garages, pay attention that the
work unit does not touch or damage these facilities.
Brakes
Use the 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. If required, you
can additionally press down the braking pedal for braking.
3- 1 3
Check daily, before starting operation, the fork tines of the machine
for visual damages (e.g. fissures, cracks, abrasion). Also the
protective device for unintentional removing or shifting of the fork
tines may have no faults. Never operate with a damaged forklift truck
attachment.
Make sure that the distance between the individual fork tines is
sufficient.
Make sure that the fork tines are adapted to the length of the load.
Move the fork tines so far under the load that the load comes to a
rest at the fork back.
Always drive slowly when you are transporting loads (speed range
1).
If you are driving on slopes or hills, transport the load always in such
a way that it is pointing to uphil.
3-14
500 m m
500 m m
7 5_ 1 56
3- 1 5
Transport
Loading and Unloading the Machine
Loading and unloading is potentially dangerous. For this reason,
proceed with extreme care.
Load and unload the machine only on solid and level ground. Keep
a safety distance to the edge of the road.
Block the wheels of the transport vehicle (1) and place support blocks
(2) under both ramps before driving the machine onto the transport
vehicle.
Only use ramps (3) with appropriate carrying capacities and widths.
The ramps must be long enough to ensure that the maximum loading
gradient (4) of 15% is not exceeded.
Ensure that the ramps are positioned and fastened safely and that
both sides have the same height. Set the distance between the ramps
to the distance between the wheel tracks (5).
Ensure that the surfaces of the ramps are clean and free of grease,
oil, ice, and loose material. Remove any dirt adhering to the wheels.
When loading and unloading the machine, keep the engine speed
low and drive slowly.
Do not carry out steering movements on the ramps. If required, drive
off the ramps again, correct alignment of the machine, and drive up
again.
After loading, i.e. when the machine is on the transport vehicle, apply
the parking brake.
Block the wheels of the machine with wheel chocks.
Set the steering wheel of the machine to straight driving.
Secure the articulated steering with the locking bar.
Position '1'
Articulated steering unlocked.
Position '2'
Articulated steering locked.
Always secure the locking bar with the bolt and the spring bolt in
both positions.
Secure the machine on the transport vehicle by means of appropriate
fastening equipment. Only use the attachment points on the machine
for lifting and securing. For safety reasons, do not use any other
points for fastening (e.g. axle, cardan shaft, articulated steering,
bucket teeth, or strapping around the cab).
Transport
3-16
Safety-Related Parts
The quality of these parts is subject to normal wear and tear. For this
reason, replace safety-related parts by new ones at regular intervals,
regardless of whether they are defective or not.
Safety-related parts are:
Fuel system:
fuel hose, overflow hose, and tank cap
Hydraulic system: all hydraulic hoses
Immediately replace defective parts, even if the interval for replacement
has not elapsed.
Replace hydraulic hoses every 6 years.
3- 1 7
3- 1 8
7 5 _ 02 3
During Maintenance
Attachments
Attachments removed from the machine must be put down in a safe
location in such a way that they cannot tip over.
Caution - risk of injury!
Always lower all movable work units onto the ground or set them to
their lowest positions before you start to perform maintenance or repair
measures under the machine.
Block the wheels of the machine using wheel chocks.
Do not work under a machine that is not appropriately supported.
Specific Measures
Always wear appropriate safety clothes and safety goggles when you
perform grinding, welding, use a sledge hammer or carry out similar work.
3- 1 9
Spilled fuel or oil involves danger of slipping and fire. For this reason,
immediately remove any spilled liquid.
Always refuel and top up oil in a place that is sufficiently ventilated.
After refuelling and topping up, close the filling openings with cover
caps.
Do not use fuel for rinsing or cleaning of components.
Ensure that neither oil nor fuel can seep into the soil or water. Dispose of used substances according to the relevant environmental
regulations.
If the machine is provided with a fuel sieve in the tank opening, do not
remove this fuel sieve before you start refuelling.
Coolant
Use of Lighting
Always use explosion-proof lighting when checking fuel, oil, coolant, or
battery acid.
3- 2 0
Always take into account that the hydraulic lines are subjected to high
pressure.
Do not top up oil, drain oil, or perform maintenance or inspection
measures unless the work unit is completely lowered and the system
is depressurised.
If oil comes out under high pressure, this involves danger of an oil jet
penetrating the skin or getting into the eyes. For this reason, always
wear safety goggles and thick safety gloves, and use a piece of
cardboard or wood when checking for oil leaks.
If you have been hit by an oil jet, immediately go and see a doctor and
explain what has happened.
3- 2 1
Always keep sufficient distance from rotating parts and pay attention
that nothing gets within the operating range of rotating parts.
There is danger that parts getting caught by the fan or the belt are cut
off or hurled away.
Do not wear loose clothing, neckerchiefs or the like, or open, long
hair that might get caught.
Waste Material
Do not pour used oil into the sewage system, rivers, etc.
Collect used oil of the machine in appropriate containers. Do not let
oil flow out onto the ground.
Adhere to all applicable laws and regulations when disposing of harmful
substances, such as oil, fuel, coolant, solvents, filters, batteries, etc.
3- 2 2
Tyres
Handling of Tyres (also refer to chapter "Tyres")
Tyres may burst and the resulting blast wave or parts whirling around
may cause severe injury or damage. Make sure that the applicable
procedures for servicing and replacing of wheels or tyres are fully
understood and that only correct procedures are used.
To ensure safety and reduce wear and tear, always adhere to the following
instructions:
Inflate tyres up to the defined pressure. If the tyre pressure is too low,
the tyres may heat up and burst. If the tyre pressure is too high, there
is also danger that the tyre may burst.
If a tyre heats up considerably, inflammable gases are produced. A
burning tyre may burst very easily, thus spreading fire over a large
area.
Check the tyre pressure when the tyres are still cold. Do not let off
pressure, when the pressure in a warm tyre has increased.
Do not light a fire and do not carry out welding near the tyre.
Keep the working area free of pointed or sharp objects that may
damage the tyre.
Avoid any overload.
The values for the tyre pressure and for the permitted speed correspond
to the manufacturer specifications and refer to standard operations. If
you want to perform special operations, contact the responsible Komatsu
dealer or the tyre manufacturer.
Storing Tyres
3- 2 3
Labeling
Labeling
All safety labels must be kept clean all times. Missing or damaged
safety labels must be replaced.
3- 2 4
Labeling
Information Labels
3-2 5
Labeling
3- 2 6
4 -2
1
2
3
4
5
Tumbler
Bucket cylinder
Bucket
Boom
Front wheel
6 Lifting cylinder
7 Headlight
Direction indicator
8 Rear wheel
4-3
Instrument panel
Horn button
Light switch
Direction indicator lever
Inch-Brake pedal
Unlocking system of left door
Parking brake
9
10
11
12
13
14
15
16
17
4 -4
Instrument Panel
4-5
Warning Lights
(1)
(2)
(3)
(4)
(5)
4 -6
7 5 _0 0 6
7 5 _ 01 3
7 5 _0 0 5
7 5 _0 11
7 5 _0 1 2
4-7
Control Lamps
1 0 11 1 2
7 5_ 00 4d
4 -8
7 5 _0 1 0
75 _ 0 0 9
7 5 _0 1 4
75 _ 0 22
7 5 _ 0 26
7 5 _0 2 7
4-9
7 5 _ 0 52
7 5 _ 0 53
6 5-7
4 -10
Measuring Indicators
4 -11
7 5 _0 3 2
7 5 _0 3 3
4 -12
7 5 _ 0 34
Switches
1
2
13
12
16
17 18 19
4
5
6
switch in the cabin on
the top right at roof
lining
10
11
75 _ 04 3e
4 -13
7 5 _0 2 8
7 5_ 10 0
After you have passed the bend, the direction indicator lever automatically
returns to its home position and the direction indicator will be switched
off.
(5) Horn button
The horn sounds when you press the horn button.
7 5 _ 0 18
4 -14
4 7 0_ 1 0 2
7 5 _ 29 1
Forward driving
Neutral position
Reverse driving
7 5 _ 02 3
NOTE:
You can only start the engine if the driving direction switch is
switched to the neutral position N.
4 -15
0
I
P
II
75_209
Fan off
Low air flow
Medium air flow
High air flow
3
2
1
7 5_ 0 3 9
7 5 _ 0 40
7 5 _0 2 2
4 -16
7 5 _ 0 31
CAUTION
The front working lights may blind oncoming traffic!
Before driving on public roads, turn off the working lights.
75 _ 0 30
Steady light
Off
Steady light
0
NOTE
You can also switch on the inside lighting, if the start switch is in
stop position 0. For this reason, switch off the inside lighting before
you leave the drivers cab.
7 5 _ 0 35
4 -17
7 5 _0 5 3
A LS _ 1
R u n du m _ 1
4 -18
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Brake pedal
Parking brake
Safety lever for the work hydraulic system
Steering column adjustment
Accelerator pedal
Multifunctional lever
Control lever for special equipment
Switching lever for bucket (without fig.)
4 -19
Brake pedal
1
ATTENTION
If you are driving downhill, let the engine run and use the
braking effect of the engine. If required, brake additionally
using the brake pedal.
Danger of accidents due to unintentional braking!
Do not use the brake pedal as a foot rest.
The brake is operated via a combined brake/inch pedal. The brake has
an effect on the two multi-disk brakes in the rear axle. The inching exerts
an additional braking effect on the hydrostatic drive system.
(2) Parking brake
The parking brake is a mechanical device for operating the two multidisk brakes in the rear axle.
As soon as you pull the parking brake lever from its normal position, the
braking action comes into effect. If the start switch is set to the I operating
position, the parking brake warning light lights up in the instrument panel.
The machine will drive again, if you re-loosen the parking brake.
75 _ 26 4
IMPORTANT
You cannot start the machine with the parking brake being applied.
If you set the driving direction switch to the F position (forward
driving) or R (reversing) with the parking brake still being applied,
the alarm buzzer will sound.
(3) Safety lever for the work hydraulic system
The safety lever for the work hydraulic system protects the work hydraulic
system against unintentional activation. Before driving on streets or
beginning maintenance operations, it is required to block the work
hydraulic system with this safety lever.
Position '1': boom secured
Position '2': Operating position
7 5 _ 2 81
4 -20
Float
Lower
Hold
Raise
Tilt
Dump
7 5 _ 01 6
4 -21
The control lever for special equipment has three switch settings whose
functions depend on the type of the used special equipment.
If the standard bucket, the light-weight material bucket or the forklift truck
attachment is attached to the quick-change unit, the control lever for
special equipment provides the following functions:
Position '1': Locking pins for work unit are drawn in
Position '0': Neutral position (locking pins are drawn in; you can pick up
the work unit in this position)
Position '2': Locking pins for work unit are extended
If the multi-purpose bucket is attached to the quick-change unit, the control
lever has the functional assignment described above. If the switching
lever for the bucket is in position 1, the multi-purpose bucket is active.
You can then operate the multi-purpose bucket via the control lever for
special equipment. It then has the following functions:
Position '1': Close multi-purpose bucket
Position '0': Neutral position
Position '2': Open multi-purpose bucket
7 5 _1 6 0
If you use attachments requiring a steady oil flow (e.g. brush, snow
remover), the control lever has the following functions:
Position '1': Work unit turns backwards
Position '0': Neutral position
Position '2': Work unit turns forward
Position '3': Work unit turns forward in permanent operation (locks in)
For permanent operation, you must set the control lever to position 3.
The control lever locks in this position.
NOTE
Without connected special equipment, you must not set the control
lever for special equipment to switch settings 1, 2 or 3. If you do
not heed this note, the work hydraulic system will operate in order
to counteract overpressure thus unnecessarily heating up the oil.
7 5 _1 6 0
4 -22
Traction Device
You can use the traction device (hitch) to tow off, e.g., another machine
or trailer. You must also fix the machine at the tie bolt during transport.
Always secure the bolt of the traction device, which is fixed to a chain,
with the spring bolt.
75_267
Socket
CAUTION
Danger of accidents!
Electrical devices may interfere with the on-board electronics.
For this reason, connect only the working lamp to the socket.
7 5 _0 4 8
1
7 5 _1 5 7
75_303
4 -23
4 -24
Operation
Operation
5 -2
Operation
After the engine has been started, it must run in idle for 5 minutes.
5-3
Operation
WARNING
Danger of fire! Oil or fuel leaking out or accumulated combustible
materials may catch fire at hot parts of the machine, e.g. the
exhaust!
Prior to starting the machine, check the oil and fuel lines for
leaks and immediately repair any leaks. Store combustible
material in a safe place.
2.
3.
4.
Check the gear unit, axles, hydraulic tank and hoses and the
connecting points
Check whether oil is leaking out of the gear unit, axles, hydraulic
tank and hoses, and connecting points Repair damaged parts.
5.
6.
Check wheels
Check the tyres for cracks, damages and wear and tear. Check the
wheel rims and lock rings for cracks, damage, and wear and tear.
Tighten loose wheel nuts. Repair damaged parts. Replace missing
valve caps.
.
5 -4
Operation
7.
Check handrails
Check handrails for damage and loose screws. Repair damaged
parts and tighten loose screws.
8.
9.
5-5
Operation
Weight adjustment
Turn the handwheel (1) to set the vibration absorbing system to the
weight of the driver.
(2)
5 -6
1
2
5
4
3
7 5 _ 0 20
Operation
Adjusting the Steering Column
1
2
WARNING
Do not change the angle of inclination of the steering column
while you are driving, since this may lead to severe accidents!
Stop the machine, before you change the angle of inclination of
the steering column.
75_281
You may use this lever for continuous adjustment of the steering columns
(1) angle of inclination. (Adjustment range 125 mm)
Proceed as follows:
1. Push down the locking lever.
2. Adjust it in such a way that you can reach the steering wheel from a
comfortable seating position while at the same time having an
optimum view of the work unit. Hold the steering wheel in this position.
3. Pull up the locking lever again to lock the steering column in this
position.
3.
75_017
5-7
Operation
Adjusting the Heating and Ventilation System
Adjusting the ventilation system
When the ventilation system is operated, air is blown into the driver's
cab. If the cabin is closed, a light overpressure is built up, preventing
dust from outside to settle down in the cab. To increase the volume of
filtered fresh air, you can open the ventilation grid a little.
7 5 _1 5 3
The air is distributed via the air ventilation nozzles (1 and 2) on the lefthand and right-hand side of the steering column. You may open or close
the nozzles individually. The exhaust direction can be varied using the
diffusing disks. You can direct the air ventilation nozzles (1) onto the
front windshield and the air ventilation nozzles (2) onto the side windows.
1
2
75 _ 2 9 3
7 5_ 1 5 8
You may realise a comfortable temperature, if you open all air ventilation
nozzles, set the temperature rotary switch to a comfortable temperature
and set the fan to an appropriately low air throughput.
To cool down the temperature inside the cabin, open all air ventilation
nozzles, set the temperature rotary switch to position 'Cold' and set the
fan to its highest level.
To prevent premature tiredness due to lack of oxygen, it is recommended
to open the door a little from time to time and to lock it in this position.
Optionally, you may leave open the ventilation grid above the side window.
5 -8
7 5 _ 0 40
Operation
Operating the Air Conditioning
NOTE
Only operate the air-conditioning with the engine running.
The windows and doors of the operators cab must be closed when
operating the air conditioning.
The circulating air jets (arrow) must be open.
We recommend ventilating the operators cab thoroughly first when
starting the machine and switching on the air conditioning if the machine
has been standing in bright sunshine for any length of time.
2.
6 5 -9
3.
Press the switch for the air conditioning. The air conditioning system
is now switched on and the control lamp in the switch shines blue.
The greatest cooling effect is achieved with this setting, particularly
if the engine is running at high revs. As soon as the required
temperature has been reached, turn the blowers down by one stage
and carry out any further adjustment of the temperature using the
temperature control. The lowest blower setting can be used if only a
low cooling effect is required.
K lim a_ 2
4.
The air is distributed via the air ventilation nozzles (1 and 2) on the
left-hand and right-hand side of the steering column. You may
open or close the nozzles individually. The exhaust direction can
be varied using the diffusing disks. You can direct the air ventilation
nozzles (1) onto the front windshield and the air ventilation nozzles
(2) onto the side windows.
5-9
Operation
Putting on the Safety Belt
WARNING
The machine is provided with a lap belt which is automatically rolling up.
When pulled slowly, automatic belts ensure full freedom of action, but
block immediately, if you suddenly brake or accelerate, or if you drive
downhill or take corners.
Putting on the safety belt
1.
2.
3.
4.
5 -10
Operation
CAUTION
Unintentional start-up of the engine may lead to severe
accidents!
Before starting up the engine, make sure that there are no
persons or obstacles near the engine. In addition, sound the
horn before you start the engine.
3.
Turn the ignition key into the operating position I. The fuel supply
(1) is indicated. The charging current (3) and engine oil-pressure (4)
warning lights light up. The parking brake (2) warning light lights up,
if the parking brake is pulled. The air preheater (5) control lamp
lights up, if the air preheater is in operation.
IMPORTANT
The running period of the air preheater depends on the ambient
temperature. If the ambient temperature is low, the preheating
process may take more time.
7 5 _0 3 8
0
4.
5.
6.
7.
I
P
II
75_209
For starting up the engine in cold weather, see section: "Winter Operation.
5 -11
Operation
Warming up the engine
NOTE
You must not accelerate the engine abruptly before the warmup phase is finished.
Do not let the engine run idle for longer than 20 minutes at its
lower or top speed. If it is necessary to let the engine run idle
for a longer time, you must load the engine briefly from time to
time or let it run at medium speed.
Do not immediately begin with work after starting the engine. Prior to
operation, perform the following preparations and checks:
1. Press down slightly the accelerator pedal and let the engine run
without load at medium speed for approx. 5 minutes.
2. Proceed as follows in order to heat up the hydraulic oil at low ambient
temperatures:
Allow the engine to run consistently during the warm-up phase. For
warming the hydraulic oil, reset the multi-function lever for the work
hydraulic system in short intervals from position 0 (holding) into
position E (tip-in position). Then reset it to its 0 position. Make
sure not to exceed the maximum time (10 seconds) permitted for
the multi-function lever in the tip-in position.
3. While the engine is warming up, observe all measuring instruments
and warning lights and eliminate immediately any fault.
4. Let the engine run with lightweight load further until the engine coolant
temperature indicator (1) lights up in the green range.
5. Ensure that the exhaust gas colour is normal and that the exhaust
pipe produces neither abnormal noises nor vibrations. Eliminate
possible defects.
7 5 _ 01 6
7 5 _0 2 4
3.
4.
5.
Check the temperature of the engine with the help of the coolant
temperature indicator (1).
If the engine is overheated, you must let it run at medium speed or 5
minutes before you switch it off, so that the engine can cool down
sufficiently.
Lower the work unit.
Turn the ignition key into its stop position 0 in order to switch off the
engine.
Pull the key from the start switch.
5 -12
7 5 _0 2 4
Operation
Driving
Start-Up
CAUTION
Careless driving may lead to accidents!
Before starting to drive, ensure that no persons are near the
machine and sound the horn before you drive up.
1.
2.
3.
4.
5.
7 5_ 2 6 4
6.
7.
7 5 _ 02 3
Release the brake pedal and press down the accelerator pedal at
the same time in order to start the machine.
5 -13
Operation
Starting the machine on slopes
CAUTION
Careless driving may lead to accidents!
Before starting up, ensure that no persons are near the machine
and sound the horn before driving.
1.
2.
3.
4.
5.
6.
7 5 _ 02 3
CAUTION
Switching the high-speed gear on or off during driving may lead
to gearbox damages!
Ensure that the machine stands still and that the engine is running, before you switch the high-speed gear on or off.
5 -14
Operation
Changing the Driving Direction
WARNING
Careless changes of the driving direction may cause severe
accidents!
Before you change the driving direction from forward to reverse
driving or vice versa, you must make sure that no persons or
obstacles are in your way.
CAUTION
The engine may be damaged if you are driving at a high speed
and then change abruptly from forward to reverse driving or
vice versa!
Brake until the machine has nearly come to a standstill before
you change the driving direction.
The drive direction switch is used to switch between forward and reverse
gear or vice versa. The machine may still roll, if you change the driving
direction.
Position 'F' Driving forward
Position 'N' Neutral
Position 'R' Reversing
7 5 _ 02 3
Reverse Driving
The machine can drive forward or backwards (reversing) at the same
speed.
Before driving backwards, pay particularly that nobody is in your way. If
necessary, rely on another person for aid. Sound the horn before starting
to drive to make sure, that anybody who might be in your way is
appropriately warned.
While driving backwards, turn your head into the driving direction. It is
not sufficient to rely on the rear view mirrors.
5 -15
Operation
Turning
NOTE
The machine may fall over if you turn abruptly at a high speed.
5 -16
Operation
Braking
While driving, you may reduce your speed with the service brake (1).
After the machine has stopped, you must secure it with the parking brake
(2).
Pulling the parking brake
1.
2.
3.
1
Releasing the parking brake
1.
2.
3.
4.
7 5_ 2 6 4
CAUTION
If you use the service brake too often while driving downhill, it may overheat
and be damaged. You can avoid this by driving downhill in the lower
speed range and by using the braking effect of the engine. (In the lower
speed range the driving range switch will be switched off and the control
lamp will go out.)
5 -17
Operation
Stopping
Avoid abrupt stopping. Proceed as follows, if you want to stop the
machine:
1. Release the accelerator pedal and press down the brake pedal.
2. Set the drive direction switch into its neutral position N.
3. Apply the parking brake.
4. Lower the work unit onto the ground.
7 5 _ 02 3
WARNING
Unintentional activation of the multifunctional-lever or
moving of the equipment may lead to accidents!
Before you leave the cab, turn the locking lever for the work
hydraulic system into position 1. As a result, the work
hydraulic system is blocked.
5.
1
75 _ 26 9
5 -18
Operation
Longer-Distance Driving
If the machine is driven over long routes at a high speed and without
having adapted the tyre pressure, the tyres will become very hot. This
leads to premature wear and tear of the tyres which should be avoided if
possible. Adhere to the following instructions if you must drive the machine
over a long distance:
The required tyre pressure, the driving speed or the tyre type may
vary depending on the condition or structure of the road o be used.
Contact the responsible Komatsu trader or the tyre dealer to obtain
the required information.
The required tyre pressure can be found in the tyres and tyre pressure
table in chapter "Maintenance Basics.
Check the tyre pressure with the tyres being cold before driving.
Lower the work unit to its transport position and move it completely
to its rear limit stop position.
Adhere to the valid motor vehicle traffic regulations and drive very
careful. Make sure that the working lights and the warning beacon
are turned off while driving on public roads.
Make a break of 30 minutes after driving for one hour. Check the
tyres and all particularly strained parts during driving on public roads
whether they are still fully functioning or damaged.
5 -19
Operation
7 5 _ 01 6
4.
5 -20
2
75_280
Operation
Picking up the multi-purpose bucket
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Set the change-over lever for the additional control unit into position
'2' (fig. 75_160).
Start the engine.
Unlock the quick-change unit by setting the control lever for special
equipment into position 1 (fig. 75_042).
Lift the boom slightly, by setting the multi-function lever into position
H (fig. 75_016).
Tilt the quick-change unit slightly to the front by setting the multifunction lever into position A (fig. 75_016)
Drive the machine to the work unit until the quick-change unit (1) is
below the pickup hooks of the work unit. Then, lift the boom until the
work unit catches the quick-change unit.
Tip in the quick-change unit until the work unit is connected to the
limit stops on the the quick-change unit by setting the multi-function
lever into position E (fig. 75_016).
Lock the quick-change unit by setting the control lever for special
equipment into position 2 (fig. 75_042).
Switch off the engine.
Set the change-over lever for the supplementary control circuit in
position ,1' to its limit stop (figure 75_160).
Set the control lever for special equipment to position ,1' (figure 75_042).
Connect the hydraulic hoses of the multi-purpose bucket to the quick
couplings (2) (figure 75_161) and (3) (figure 75_275).
Start the engine.
You can now operate the multi-purpose bucket with the control lever
for special equipment (figure 75_042).
Position '1':
Position '0'.
Position '2':
7 5 _ 01 6
1
WARNING
If the work unit is not properly attached, it can suddenly fall
down and cause severe accidents.
Carefully lift the work unit and check whether it is completely
locked in by slowly tipping it in and dumping it.
14. Check whether the work unit is completely locked by tipping it in and
then dumping it.
7 5 _ 1 61
75 _2 75
5 -21
Operation
Removing the multi-purpose bucket
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tyre-Appropriate Operation
Removing heaps of loose soil or rock debris may cause premature wear
and tear of the tyres due to cracks and small fissures. As a result, the
service life of the tyres is reduced. Proceed as follows to avoid
unnecessary wear and tear of the tyres:
Try to work on level ground and remove any rocks and large stones
which are sticking out of the surface.
Always drive in straight direction into the heap or slope. This ensures
that you have always the largest intrusive force while reducing tyre
wear and tear at the same time.
For removing operations, lift the bucket as soon as you drive into
the heap or slope. This procedure permits to increase the load of
the front wheels, prevents slipway of the front wheels and reduces
wear and tear of the tyres.
Lower the bucket slowly onto the ground. If the bucket touches the
ground too fast, the front wheels may be lifted from the ground, thus
leading to premature wear and tear of the rear tyres.
7 5 _ 01 6
Operation
Adjusting the Bucket Positioner
1.
Lower the bucket to the ground and set the bucket to the desired
digging angle. Set the bucket control lever to HOLD, stop the engine
and adjust as follows.
2.
Loosen two bolts (1) and adjust mounting bracket (4) of the proximity
switch so that the rear tip of angle (2) is in line with the center of the
sensing surface of proximity switch (3). Then tighten the bolts to
hold the bracket in position.
3.
4.
After the adjustment, start the engine and raise the lift arm. Operate
the bucket control lever to the DUMP position, then operate it to the
TILT position and check that the bucket control lever is automatically
returned to HOLD when the bucket reaches the desired angle.
5 -23
Operation
Loading
CAUTION
Danger of accidents! The machine may fall over if you transport
a load with the bucket lifted too high!
Lower the bucket during transporting loads in order to lower
the centre of gravity of the machine.
The loading operation of wheel loaders is based on the following cycle:
Removing or digging Transport Dumping
In the following sections, the individual operation steps of this cycle are
explained.
Removing piled up soil
CAUTION
If you perform removal operations with bent machine, you may
damage the articulated steering and the cardan shaft!
Always drive into the material which you want to remove in
straight direction.
For removal operations, adhere to the instructions in section "Tyreappropriate operation. For removal operations, proceed as follows:
1. Drive in straight line to the piled up soil.
2. While driving forward, lower the bucket rapidly until it reaches a height
of approx. 30 cm over the ground and hold the bucket in this position.
NOTE
If the bucket touches the ground, the front wheels may be lifted from
the ground, resulting in premature wear and tear of the rear wheels.
3.
4.
5.
Then, proceed with slowly lowering the bucket onto the ground.
Brake right in front of the material to be removed using the service
brake, while pressing down the accelerator pedal at the same time.
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 dump the bucket slightly down.
While removing rock debris, ensure that no rock gets under the
bucket. This may lead to the front wheels being lifted from the ground,
thus resulting in premature wear and tear of the rear wheels.
Always hold the load in the centre of the bucket. If the load is shifted
to one side, the equilibrium of the machine will be impaired.
5 -24
4 7 0 _1 9 6
Operation
6.
To prevent that the bucket dig in too deep into the material to be
removed, you must lift the boom while driving into the material. Lifting
the boom ensures a sufficient thrust force.
4 70 _ 1 99
7.
4 70 _ 2 16
6.
If there is too much material inside the bucket, you must briefly tip it
in, dump it and lower it in order to reduce the load and to prevent
that you lose the load during the transport.
47 0 _ 21 7
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 keeping the
accelerator pedal pressed down at the same time.
3. Bend the bucket edge slightly down.
4.
4 7 0_ 2 1 8
4 7 0_ 2 1 9
5.
4 7 0_ 2 2 0
5 -25
Operation
Transporting
Make sure that the transport route is in perfect condition and that nobody
is in your way. Remove any rocks or large stones which have fallen down
out of the operating range (see chapter Tyre-appropriate operation).
Hold the bucket in tip-in position. Lower the boom to its transport position.
If the boom is in transport position, the two red arrows of the transport
position marking on the lifting cylinder will be next to each other.
Dumping/Unloading
Always select the dumping/unloading type with the smallest turning circle
and driving effort in order to work as efficiently as possible.
WARNING
Danger of accidents! If you turn or brake abruptly with the lifted
load, the load may fall out of the bucket and cause accidents!
Turn slowly with the load lifted and brake cautiously.
CAUTION
The bucket and the machine are damaged if you drive into a
heap of soil or rocks with high speed!
Drive slowly into a heap of soil or rocks.
NOTE
Avoid any excessive shaking of the bucket. Always operate with respect
to the condition of the tyres (see section "Tyre-appropriate operation.
Loading in diagonal direction
Align the machine in rectangular position to the heap. Drive the machine
backwards in straight line after you have filled the bucket. Then, let the
dump truck drive between heap and machine. Drive up to the dump truck
and unload the material.
This operation requires not much time and reduces considerably the
cycle times.
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. Drive the machine backwards from the
heap and align the machine with the dump truck. Raise the bucket to its
maximum height. Drive up forward to the dump truck and unload the
material.
If you keep the turning angle of the machine as small as possible, the
work will be more efficiently.
5 -26
4 7 0 _2 2 3
47 0 _ 2 24
Operation
Piling up material
Do not position the bucket in its maximum tip-in or dumping position
while piling up material. Instead, use the required mining angle. The rear
counterweight must not touch the ground.
47 0 _ 22 5
Planing
Planing operations are required for levelling the ground. For this purpose,
a straight bucket without claws is suitable. Planing includes two operation
steps - filling up and taking off ground.
Filling up
It may be necessary to fill up the uneven ground in front of the machine
with soil. Proceed as follows:
NOTE
For fill-up operations, lower the bucket max. by 15 to the front.
Fill the bucket with soil. Drive slowly forward with the machine and
distribute the soil little by little from the bucket. If you must fill up particularly
large uneven surfaces, you should place additional soil in front of the
bucket, which will be distributed when the machine is driving forward.
Taking off soil
If the surface is filled up, you may level the ground.
WARNING
Danger of accidents! Careless reverse driving may lead to severe
accidents!
Before you drive backwards, make sure that nobody is behind
the machine. Warn persons who are in your way by sounding
the horn.
Dump the bucket slightly down. Drive backwards and draw the bucket
over the ground.
In order to receive a particularly even surface, you must lower the boom
to its floating position. Drive slowly backwards and draw the bucket with
its plane underside over the ground.
4 70 _ 2 2 1
Prospecting
Prospecting is a special type of planing. It is used to wear off the top
layer of soil.
CAUTION
The bucket teeth and bucket are damaged if you mine with the
bucket in dumping position!
For prospecting operations, align the underside of the bucket
until it is in parallel to the ground surface.
Always drive in the lower speed range while performing prospecting
operations.
5 -27
Operation
Working With the Forklift Truck Attachment
Operations with an forklift truck attachment on a wheel loader differ from
operations with the bucket or a forklift truck. Take into account the following
notes and the instructions indicated in the chapter "Safety:
Do not take up loads which are so high that you cannot see onto the
route.
During the ride, hold the load as low as possible in order to have free
sight onto the route.
Always drive slowly (speed range 1) with the load.
500 m m
500 m m
2.
3.
4.
5.
6.
7.
8.
Drive so far under the load until it touches the fork back of the forklift
truck attachment.
Tip in slightly the forklift truck attachment so that the load cannot fall
down.
Lower the boom to its transport position. The two red arrows of the
transport position marking on the lifting cylinder will then be next to
each other.
Then lift the load to the appropriate height only shortly before you
reach the stacking surface. Raise the load a little higher than
necessary.
Set the load surface slowly and from above onto the stacking.
Slowly lower the boom so far that you can pull out the fork tines
below the load.
Make sure that nobody is behind the machine and drive off backwards
from the stacking surface.
5 -28
7 5_ 1 56
Operation
Precautions For Special Operations
Working in water
While operating in water or on swampy ground, the water must not reach
the underside of the axle housing. Wash the machine after the work has
been finished and check the lubricating points.
Working on snow
Adhere to the instructions in the chapter "Safety, "Working On Snow.
Dumping on steep slopes
Adhere to the instructions indicated in the chapter "Safety, "During Loading.
Working in the vicinity of electrical overhead lines
Adhere to the instructions indicated in the chapter "Safety, "Working in
the vicinity of electrical overhead lines.
Operation on slopes
Adhere to the instructions indicated in the chapter "Safety, "Driving on
slopes.
Working on loose soil
Adhere to the instructions indicated in the chapter "Safety, "Working On
Loose Soil.
2.
3.
4.
Walk around the machine and visually inspect the work unit, the car
body and the chassis. In addition, pay attention to emerging oil and
water. Eliminate immediately any fault or defect.
Fill up the fuel tank.
Remove highly flammable material from the engine room since it
represents a fire risk.
Clean the chassis landing gear roughly.
5 -29
Operation
Instructions for Winter Operation
Before the cold season
Before the cold season begins, you should perform the following
preparatory measures to ensure troublefree operation also in the winter
months.
VUse oils with the prescribed viscosities which are suitable for the
cold weather to be expected in your region (see "Lubricants and
Operating Agents).
If the injection system, the starter, the battery and the generator are
in perfect condition, it is ensured that the engine can be easily started
and that the machine can be operated troublefree even in extremely
cold weather. Let these important components be checked at an
authorised garage before the winter starts.
Let the engine warm up with increased idle speed for some minutes
before starting to work. During the warm-up phase, operate the
hydraulics devices several times without load.
After Operation
Realise the following actions to make sure that the machine can be started
the next time without problems:
Remove mud and water from the car body. This prevents that
sealings are damaged due to freezing.
Park the machine on hard and dry ground. If this is not possible, you
must park the machine on wooden planks. The planks prevent that
the wheels are freezing to the ground.
5 -30
Operation
Longer Standstill Periods of the Machine
Before the standstill
Perform the following actions, if the machine is to be shut down over a
longer period of time:
Clean the entire machine, including the engine room, and let it dry.
Fill up the fuel tank. Lubricate the machine and change the oils.
Apply a thin grease film to the piston rods of the hydraulic cylinders.
Wipe away the grease from the piston rods of the hydraulic cylinders.
Drive the machine over a short route so that the movable parts are
coated with a new oil film.
Remove the grease from the piston rods of the hydraulic cylinders.
Check the oil levels and, if necessary, refill oil. Lubricate the machine.
5 -31
Operation
5 -32
Troubleshooting
Troubleshooting
6 -2
Troubleshooting
Troubleshooting
Have all malfunctions and causes of malfunctions that are not given in the tables below remedied by your
responsible Komatsu dealer.
6 -3
Troubleshooting
Electrical System
Electrical System
Fault
Causes
Remedy
Generator defective
Replace generator
Re-charge battery
*) Check function of battery; replace
defective battery
Re-charge battery
Starter defective
*) Replace starter
Re-charge battery
Starter defective
*) Replace starter
Re-charge battery
*) Replace starter
75FAUL03.TBL
6 -4
Troubleshooting
Engine
Engine
Fault
Causes
Warning light engine oil pressure: Oil level in engine too low
with the engine running the
Engine oil filter (filter cartridge)
warning light is on and an
dirty
acoustic alarm signal is given
Lines or hoses of engine
lubricating system damaged
Remedy
Top up engine oil
Replace engine oil filter (filter
cartridge)
Check lines and hoses (visual check:
oil leaks)
*) Replace defective lines and hoses
6 -5
Troubleshooting
Engine (Continued)
Fault
Causes
Remedy
Let the engine run idle without load,
until the engine has sufficiently
cooled down and the temperature
indicator of the coolant has returned
to the green range
Wrong fuel
6 -6
Troubleshooting
Engine (Continued)
Fault
Causes
Remedy
Wrong fuel
Defective silencer
*) Replace silencer
6 -7
Troubleshooting
Hydraulic System
Causes
Parking brake applied
Remedy
Release parking brake
Oil level in hydraulic oil tank either Correct oil level in hydraulic oil tank
too high or too low
75FAUL05.TBL
6 -8
Troubleshooting
Hydrostatic Drive Unit (Continued)
Fault
Unusual noise
Causes
Oil level in hydraulic oil tank too
low
Remedy
Top up hydraulic oil
Causes
Remedy
75FAUL08.TBL
6 -9
Troubleshooting
Brakes
Brake
Fault
Brake has no effect
Causes
Remedy
Brake oil level in brake oil tank too Top up brake oil
low
Check brake system for damage and
leaks (visual check: brake oil leaks)
75FAUL09.TBL
Parking Brake
Fault
Brake is ineffective
Causes
Remedy
*) Replace multi-disks
75FAUL10.TBL
Steering
Fault
Causes
Remedy
Steering wobbles
6-10
Troubleshooting
Axles
Axles
Fault
Noise
Causes
Oil level in axle too low
Remedy
Top up oil
75FAUL07.TBL
Driver's cab
Driver's Cab
Fault
Blower: insufficient air flow
Causes
Blower filter clogged
Remedy
Clean or replace filter
75FAUL12.TBL
6-11
Troubleshooting
Emergency Steering Characteristics
If the engine breaks down during driving, you may proceed with steering
the machine. However, you will need considerable more effort.
If the engine breaks down, immediately drive to the roadside, switch on
the hazard flasher and secure the machine.
7 5 _ 01 6
6-12
Troubleshooting
Starting the Engine with a Battery Jumper Cable
NOTE
CAUTION
A short-circuit may damage parts of the electrical system. A
short-circuit may occur, if:
the positive (+) and negative (-) clamps touch each other
when you connect them to the battery, or if they are
conductively connected (e.g. by a tool),
the cable ends neither touch each other nor the machine,
1.
2.
3.
4.
Connect the other clamp of the battery jumper cable to the engine
block of the machine with the discharged battery.
6-13
Troubleshooting
Starting the Engine
The engine of the machine with the charged battery must run at high
idle-running speed. Start the engine of the machine with the discharged
battery. If the engine does not start up immediately, wait at least two
minutes, before you make a second attempt.
CAUTION
Danger of short-circuit! When disconnecting the cables, pay
attention not to let the cable ends touch each other or the
machine. When the cable ends touch each other or the machine,
a short-circuit is produced which may damage parts of the
electrical system!
When disconnecting the cables, pay attention not to let the cable
ends touch each other or the machine.
After starting of the engine, disconnect the battery jumper cables by
reversing the steps you performed to connect the cables.
1. Disconnect one clamp of the battery jumper cable from the engine
block.
2. Disconnect the other clamp of the battery jumper cable from the
negative terminal (-) of the charged battery.
3. Disconnect the clamp of the battery jumper cable from the positive
terminal (+) of the charged battery.
4. Disconnect the other clamp of the battery jumper cable from the
positive terminal (+) of the discharged battery.
6-14
Troubleshooting
Towing the Machine
WARNING
Towing with a tractor of insufficient weight may cause accidents!
Perform towing using a machine weighing at least as much as
the machine that you want to tow off.
CAUTION
Towing to start the engine will damage the hydrostatic drive
system!
Do not give the machine a tow to start the engine. This will not
start the engine, but may damage the hydrostatic drive system.
To avoid damage to the hydrostatic drive system, do not tow the machine
for more than 1 km. The towing speed must not exceed 2 km/h.
Perform towing using a machine weighing at least as much as the machine
that you want to tow off. Connect both machines with appropriate towing
attachments.
CAUTION
Towing attachments fastened to inappropriate points may
damage the machine!
Only fasten the towing attachment to the points provided for
this purpose.
At the front part of the machine, fasten the towing attachment at the
marked eyes. At the rear part of the machine, fasten the towing attachment
at the hitch.
7 5 _ 02 3
6-15
Troubleshooting
NOTE
When the engine is switched off, the power-assisted steering is not
operational, i.e. you have to apply much more force to steer the
machine.
If you lift up the rear axle of the machine with a lorry-mounted crane, you
can tow off the machine over longer distances and at speeds exceeding
2 km/h. Before you do this you must, however, remove the cardan shaft
of the front axle. In addition, secure the articulated steering with the locking
bar, in the same way as it is required for transport of the machine on a
low bed loader or by train.
WARNING
If the brakes of the machine that you want to give a tow are
defective, uncontrolled movement of the machine may cause a
crash while it is being towed!
Always use two machines to tow off a machine with defective
brakes. Connect all three machines with appropriate towing
attachments.
If you want to tow machine a with defective brakes, or if you have to tow
a machine driving downhill, use two machines for towing. Attach the
machine that you want to give a tow to a larger machine with sufficient
tractive and braking force. Attach a second machine to the rear part of
the machine that you want to give a tow. In this way, you avoid uncontrolled
movement of the machine.
Towing can be performed under various conditions. Thus, it is impossible
to determine all the requirements that may apply to a particular condition.
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 aks your responsible Komatsu dealer for details, if you want to
give a particular machine a tow.
6-16
Troubleshooting
Inadequate Braking Effect
Checking the Parking Brake
Test Conditions
Test Procedure
1. Start the engine, set the machine to straight driving, and drive
the machine with an empty bucket up a gradient of 25%.
2. Stop the machine with the service brake and do not release your
foot again to keep the service brake applied.
3. Lower the bucket.
4. Set the driving direction switch (1) to its neutral position 'N'.
5. Switch off the engine.
6. Apply the parking brake (2) and slowly release the pedal of the service
brake.
The machine must stand still.
NOTE
All repairs on the brake system must be performed by a garage
which is authorised by Komatsu.
WARNING
Danger of accidents!
Always put on the safety belt.
Drive the machine on a flat, dry and solid road at a speed of 20 km/h and
apply brakes. For this purpose, release the accelerator pedal and quickly
step on the brake pedal. The braking distance must not exceed 5m.
NOTE
All repairs on the brake system must be performed by a garage
which is authorised by Komatsu.
6-17
Troubleshooting
6-18
Maintenance
Maintenance Basics
7- 2
Maintenance Basics
Maintenance Basics
CAUTION
Maintenance work must only be performed by trained and
qualified personnel. Also refer to chapter " Safety Measures During
Maintenance".
To ensure troublefree operation of the machine, it must be serviced at
regular intervals. Control daily the operating hour meter to determine
which of the maintenance measures is required.
When performing maintenance work, do not keep loose items in your
pockets. Loose items could fall into the machine during maintenance
work.
Preparing the Machine for Maintenance
Before you start maintenance or repair work, position the machine as
follows, unless stated otherwise:
1. Park the machine on solid and level ground.
2. Set the machine to the specified position for maintenance and repair.
3. Lower the work unit to the ground and position it as shown in the
drawing.
4. Set all control levers to either the neutral or the hold position '0'.
5. Turn the safety lever of the work hydraulic system to position '1'.
6. Take out the start key and store it in a safe place.
7. Apply the parking brake.
8. Apply the warning sign you received together with the tools at the
start switch.
9. Put wheel chocks in front and behind the wheels.
10.Secure the articulated steering with the articulated steering catch.
11.If required, remove dirt.
7- 3
Maintenance Basics
Cleaning the Machine
Always keep the machine clean. Ensure that grease nipples, air vent
holes, and oil level indicators are always clean. Avoid contamination of
operating agents with impurities. This will reduce malfunctions to a
minimum.
WARNING
If somebody accidentally lowers the bucket while cleaning is
being performed under the boom, this may lead to severe
accidents!
Before you start performing of cleaning work under the boom,
either support the bucket or lower it onto the ground.
If you have to perform cleaning work under the boom and you cannot
support the bucket, park and secure the machine as follows:
1. Park the machine on level ground.
2. Apply the parking brake.
3. Place wheel chocks in front of the wheels to prevent the machine
from rolling away.
4. With the bucket in its dumping position, lower the bucket onto the
ground with either its cutting edge or teeth.
Precautionary Measures When Cleaning the Machine
Fire Prevention
Do not use any highly inflammable cleaning agents for cleaning of parts.
If by way of exception you have to use inflammable cleaning agents,
keep the cleaning agent away from fire and do not smoke while you are
working.
7- 4
Maintenance Basics
Working-Area-Dependent Maintenance
Muddy or Wet Working Areas
7- 5
Maintenance Basics
Lubricants and Operating Agents
Draining Off Hot Operating Agents
There is danger of scalding, when you drain off hot oils or hot coolant
and remove the corresponding filters immediately after you have switched
off the engine. For this reason, wait until the engine has cooled down to
approx. 60 C, before you start to perform maintenance work.
But: Do not remove oils when the engine is cold.
Checking the Oil Level and Changing Oil
Check the oil level and change the oil or oil filter in a dust-free place to
avoid contamination of service fluids by undesired material.
After an oil change or oil filter change, check the oil or oil filter for an
unusual high number of metal parts or other undesired material. In case
you detect an unusual high contamination, inform your responsible
Komatsu dealer.
Changing the Filter
Filters avoid introduction of undesired material into the individual cycles
and the equipment where they may cause malfunctions.
Regularly replace all filters. For details refer to the following description
of maintenance work in these operating and maintenance instructions.
Replace the filters more often, if you work under difficult conditions,
depending on the oil and fuel that you use (e.g. high sulphur content).
Do not try to clean filter cartridges for re-use. Always replace used
filter cartridges by new ones.
Do not open the packages containing the spare filters unless you will
mount them immediately.
Always use Komatsu original spare filters.
7- 6
Maintenance Basics
Oil
The oil in the engine and the hydraulic system is subjected to extreme
conditions (high temperatures, high pressure). Thus, its quality
deteriorates the longer it is used.
Always use the types of oil specified for the particular use and
temperature in the operating and maintenance instructions. Always
adhere to the specified intervals for oil changes.
Pay particular attention not to contaminate oil and grease when topping
them up. A lot of malfunctions are caused by contaminated oil.
Do not mix oils of different types or makes.
Always top up with the required volume of oil. If the volume of oil used
for topping up is too high or too low, this may lead to malfunctions.
If the oil in the work hydraulic system is not clear but milky, it is very
likely that there is either water or air present within the system. In this
case, inform the responsible Komatsu dealer.
Always replace the oil filter when you perform an oil change.
We recommend that you have the engine oil and the hydraulic oil
checked at regular intervals by the responsible Komatsu dealer to get
an impression of the machine's condition.
Lubricating Grease
Lubricating grease reduces wear and operating noise.
The grease nipples not specified in the maintenance schedule are
only to be used for overhauling purposes; for this reason, they do not
have to be lubricated.
Lubricate parts heavily moving - due to a long service life - with grease.
Remove old grease which is pressed out during lubrication. Ensure
that the lubricating grease is not contaminated with sand or dirt, since
this would result in premature wear and tear.
7- 7
Maintenance Basics
Fuel
The fuel injection pump is a precision device. If the fuel in the fuel injection
pump contains water or dirt, this will damage the fuel injection pump.
Proceed with utmost care when storing or refuelling, to avoid intrusion
of impurities into the fuel.
Always use the fuel specified in the operating and maintenance
manuals.
If the temperature of diesel fuel falls below -15C, paraffin may
precipitate, blocking filters and hoses. For this reason, always use a
diesel fuel appropriate for these temperatures.
To prevent humidity from condensing in the fuel tank, always refill the
fuel tank after daily work has been finished.
After refuelling, wait at least ten minutes before draining off dirt
precipitations and water. Swirled up impurities will precipitate again
during this period of time.
If the fuel tank has been "run empty" or filters have been replaced,
ventilate the fuel system. Refer to chapter "Maintenance Every 500
Operating Hours".
If you use fuels with a sulphur content between 0.5 and 1.0%, cut in
half the interval for an oil change. If you use fuels with a sulphur content
of over 1.0%, quarter the interval for an oil change.
7- 8
Maintenance Basics
Coolants
7- 9
Maintenance Basics
Table of Lubricants and Operating Agents
Lubricants and Operating Agents
BI-Codes*), Specifications, and Filling Volumes
WA95-3
Lubricants and
Operating
Agents
BI-Codes
Quality Classes
Temperature
Ranges
Engine
Engine Oil EO
EO 1540 A
EO 1030 A
NRS
CCMC D4
or, if not available:
API CE oder
API CF -4)
-15 to 45 C
-20 to 30 C
-15 to 20 C
Gear Oil GO
GO 90 LS
API-GL5 +LS
or
MIL-L-2105D +LS
Viscosity
Classes
SAE 15W-40 )
SAE 10W-30
SAE 05W-30
12.5
SAE 90LS
1.0
3.0
SAE 90 LS
)
SAE 85W-90LS
SAE 80W-90LS
Planet Gear:
2 x 1.0
Differential:
4.5
SAE 90 LS
)
SAE 85W-90LS
SAE 80W-90LS
Planet Gear:
2 x 1.0
Differential:
7.5
Front Axle
Gear Oil GO
GO 90 LS
API-GL5 +LS
or
MIL-L-2105D +LS
Rear Axle
Gear Oil GO
GO 90 LS
API-GL5 +LS
or
MIL-L-2105D +LS
Hydraulic Oil
HYD
HYD 0530
HYD 1030
HYD 1540
HVLP
HVLP D
or
Engine Oil EO
EO 1540 A
EO 1030 A
NRS
CCMC D4
or, if not available:
API CE oder
API CF -4)
-15 to 45 C
-20 to 30 C
-15 to 20 C
SAE 15W-40 )
SAE 10W-30
SAE 05W-30
or
Hydraulic Oil
BIO-E-HYD
BIO-E-HYD 0530
HEES
(acc. to VDMA fluid
technology)
-15 to 20 C
ISO VG 46
Service Brake
Automatic
Transmission
Gear Oil
ATF
ATF, Type A,
Suffix A
Cooling System
Long-Time
Coolant
SP-C
Antifreeze and
Corrosion Protection
Hydraulic System,
Steering
Filling
Volume in
Litres
approx.
15 to 20 C
-20 to 30 C
-15 to 45 C
ISO VG 46 )
ISO VG 68
ISO VG 100
94.0
0.6
Proportion of Mixture:
50% Coolant : 50% Water
17.0
Fuel Tank
Diesel Fuel)
CFPP Class B
CFPP Class D
CFPP Class E
CFPP Class F
DIN-EN 590
up to 0 C
up to -10C
up to -15C
up to -20C
Grease Nipple
LithiumsoapBased
Multi-Purpose
Grease
MPG-A
KP2N-20
NRS
R134a (CFC-free)
1200 g
Air conditioning
Coolant
Refrigerating
machine oil
NRS
PAG
(polyalkyleneglycol)
180 cm
130.0
NLGI 2
The specified filling volumes represent approximate values; the testing devices are binding. The selection of a viscosity class depends on
the ambient temperature prevailing over a longer period of time. The temperature limits are to be regarded as guiding values; for a brief
period, the actual temperature may be higher or lower than these guiding values.
) Factory filling
) If engine oil of either the API CE or the API CF - 4 specification is not available, engine oil of either the API CC or the API CD
specification may be used. In these cases, the oil change intervals must be cut in halves.
) If fuels with a sulphur content between 0.5 and 1.0 % are used, the oil change intervals for the engine must be cut in halves; if the
sulphur content exceeds 1.0 %, the oil change intervals must be quartered.
*) BI-codes are the "standard lubricants" (Regelschmierstoffe) for construction machinery and vehicles of the Hauptverband der
Deutschen Bauindustrie e.V. (BI) (head association of the German construction industry). The brochure "Regelschmierstoffe fr
Baumaschinen- und Fahrzeuge" (standard lubricants for construction machinery and vehicles" can be obtained from bookstores or the
German Bauverlag GmbH Wiesbaden und Berlin under the ISBN-No. 3-7625-3102-1.
FIL95MC.TBL 04.2001
7- 1 0
Maintenance Basics
Replacing Safety-Related Parts
WARNING
Worn safety-related parts may cause accidents!
Have parts which are important for machine safety and fire
protection replaced in a Komatsu garage at regular intervals.
Have the following parts replaced in the Komatsu garage at regular
intervals, even if they are not visibly worn:
Have the safety belt replaced at least every three years.
Do not use hoses longer than six years under normal operating
conditions. Have hoses replaced, if you detect one of the following
damages:
damage to the outer layer reaching down to the lining,
embrittlement of the outer layer,
deformations that do not correspond to the normal shape of the
installed hose, when the hose is pressurised and depressurised,
leaks,
damage to hose fittings or connections between fittings and hoses,
damage due to storage (the storage time for hoses should not
exceed two years).
When replacing hoses, do not forget to replace also all accessory Orings, gaskets, and similar parts.
Welding Instructions
7- 1 1
Maintenance Basics
Spare Parts and Consumable Components
Replace parts which are subjected to wear and tear, such as filter
elements, air filter insert, etc., when performing the regular
maintenance work or when the limiting value for wear and tear and
contamination is reached.
Perform this work at regular intervals and as prescribed to ensure an
efficient use of the machine.
Only use original Komatsu spare parts.
After removing the gaskets, clean the sealing surfaces. Replace
gaskets and O-rings by new ones. Pay attention not to forget any
gaskets and O-rings when re-assembling the parts.
Use the part numbers specified in the spare parts catalogue for
ordering of spare parts.
Position
Part No.
Part
Designation
Quant.
Replacement Interval
First maintenance
after 50 operating hours
Engine Oil Filter
YM119005-35100
Cartridge
1
Maintenance every 250 operating
hours
Maintenance every 500 operating
hours
Fuel Filter
YM119000-55600
Cartridge
Hydraulic Oil
Filter
42U-62-13150
(42U-62-H0P01)
(42U-62-H0P02)
Filter Element
(O-Ring)
(O-Ring)
1
(1)
(1)
Engine Valve
Cover Gasket
YM123900-11310
YM24311-000120
Gasket
O-Ring
1
4
Air Filter
42U-01-H0P02
42U-01-H0P01
Filter Insert
Safety Filter
1
1
First maintenance
after 50 operating hours
Maintenance every 500 operating
hours
SPAREP95.TBL
7- 1 2
Maintenance Basics
Electrical System
Fuses
CAUTION
7- 1 3
Maintenance Basics
Fuse Assignment
Starter
stop magnet,
socket
10A
Inside lighting,
radio
10A
Direction indicator,
horn
10A
Hazard flasher
10A
20A
Brake light,
reversing warning
system, warning beacon
10A
Fan,
ventilation,
heating
10A
10A
Tank sensor,
solenoid valves
high-speed motor,
ALS (option)
10A
10A
fuses75.tbl
Slow-Blowing Fuses
If the power supply fails, the reason for this may be that one of the slowblowing fuses (1) has blown. Check the electrical system and replace
defective fuses.
75 _ 2 65
F3
F4
F5
F6
80A:
50A:
30A:
70A:
Front of machine
7- 1 4
Maintenance Basics
Tyres
Tyre Components
1 Steel Cord Belt
2 Radial Carcass
3 Bead Core
4 Liner
5 Diagonal Carcass
6 Bead Cores
7- 1 5
Maintenance Basics
NOTE
Check that the machine is unloaded before you check the tyre
pressure.
Prior to start of work, measure the tyre pressure of the cold tyres.
If the tyre pressure is too low, the tyre will be overloaded. If the tyre
pressure is too high, this will lead to formation of notches in the tyre
resulting in bursting of the tyre when it is subjected to shock load. To
avoid such damage, set the pressure of the tyres according to the values
given in the following table. If you are not sure, ask your tyre dealer.
Do not deflate the tyre when the tyre pressure increases due to a rise in
temperature. For this reason, check and set the tyre pressure before you
start work, i.e. when the tyres are still cold.
Size
for operation
Front axle
Rear axle
Front axle
Rear axle
bar
psi
bar
psi
bar
psi
bar
psi
Type
DUNLOP
405/70 R24
SP T9
1.5
22
2.0
29
2.5
37
2.0
29
DUNLOP
16/70- 20
E 91-2
1.5
22
1.5
22
2.0
29
1.5
22
DUNLOP
455/70 R20
SP T9
1.5
22
2.0
29
2.25
33
2.0
29
DUNLOP
14.5 - 20
E91
1.5
22
2.25
33
3.5
51
2.25
33
DUNLOP
405/70 R20
SP T9
1.5
22
2.25
33
2.75
40
2.25
33
MICHELIN
425/75 R20
XM 27
1.5
22
1.25
18
2.0
29
1.25
18
BARUM
405/70 - 24
NB 38
1.75
26
1.75
26
2.5
37
1.75
26
BARUM
14.5 - 20
NB 38
1.75
26
2.25
33
3.0
44
2.25
33
TYRE95.TBL
If the tyres are too soft, increase the tyre pressure accordingly.
The following degree of resilience (tyre loaded/unloaded) of the front
tyres can be used as the guideline for the visual check.
approx. 15 - 25%.
Digging
(rear wheels lifted off the ground): approx. 25-30%.
7- 1 6
Maintenance Basics
Tools
No.
Designation
Part No.
Remark
42T-09-H0450
42T-09-H0460
42T-09-H0470
42T-09-H0440
Spanner Openings:
8/10 mm
13/15 mm
17/19 mm
24/27 mm
Screwdriver
421-98-H1120
Screwdriver
421-98-H1110
Hammer
421-98-H1140
Bag
421-98-H1130
424-98-H1010
TOOLS75.TBL
7- 1 7
Maintenance Basics
Torque for Standard Nuts and Bolts
Provided that no other values are given, tighten the metric screws with a
strength value of 10.9 and the nuts with a strength value of 10 applying
the torques given in the tables.
The torque that must be applied depends on the diameter of the thread
(a) and the size of the spanner (b) of both the nut and the screw.
Always replace nuts and screws by original parts. Dimensions and quality
of replaced parts and original parts must be identical.
NOTE
Do not apply excessive torque to plastic parts. Tighten plastic parts
only manually.
Wrench Size
(mm)
(a)
(b)
Nm
kpm
Nm
kpm
M6
10
14
1.4
7.7
0.77
M8
13
35
3.5
19.0
1.9
M10
17 (15)
70
7.0
37.0
3.7
M12
19
115
11.5
64.0
6.4
M14
22
185
18.5
101.5
10.15
M16
24
280
28.0
158.0
15.8
M18
27
390
39.0
218.0
21.8
M20
30
560
56.0
306.5
30.65
M22
32
750
75.0
416.0
41.6
M24
36
960
96.0
528.5
52.85
M27
41
1400
140.0
774.0
77.4
M30
46
1900
190.0
1053.0
105.3
M33
50
2600
260.0
M36
55
3300
330.0
M39
60
4300
430.0
Steel
Aluminium Cast
TORQU75A.TBL
7- 1 8
Maintenance Basics
Metric Fine Screw Thread - Strength Class 10.9
Thread diameter of the
bolt
(mm)
Wrench Size
(mm)
(a)
(b)
Nm
kpm
Nm
kpm
M8 x 1
13
35
3.5
20.0
2.0
M10 x 1
17 (15)
75
7.5
42.0
4.2
M10 x 1.25
17 (15)
70
7.0
39.0
3.9
M12 x 1.25
19
125
12.5
70.0
7.0
M12 x 1.5
19
120
12.0
67.0
6.7
M14 x 1.5
22
200
20.0
110.0
11.0
M16 x 1.5
24
300
30.0
167.5
16.75
M18 x 1.5
27
440
44.0
243.0
24.3
M18 x 2
27
420
42.0
230.0
23.0
M20 x 1.5
30
620
62.0
338.5
33.85
M20 x 2
30
322.5
32.25
M22 x 1.5
32
820
82.0
454.5
45.45
M22 x 2
32
436.0
43.6
M24 x 1.5
36
1090
109.0
596.0
59.6
M24 x 2
36
1040
104.0
573.0
57.3
M27 x 2
41
1500
150.0
832.0
83.2
M30 x 2
46
2120
212.0
1158.0
115.8
M33 x 2
50
2800
280.0
M36 x 3
55
3500
350.0
M39 x 3
60
4600
460.0
Steel
Aluminium Cast
TORQU75B.TBL
7- 1 9
Maintenance Basics
7- 2 0
Maintenance Schedule
Maintenance Schedule
Maintenance Prior to Start ........................................................................................................... 7-23
Cooling System, Checking the Coolant Level, Topping Up Coolant .................................................................. 7-23
Engine, Checking the Oil Level, Topping Up Oil ................................................................................................ 7-24
Engine, Draining Off Oil .................................................................................................................................... 7-24
Checking the Fuel Level, Refuelling ................................................................................................................. 7-25
Checking the Controls ....................................................................................................................................... 7-25
Checking the Electrical Connections ................................................................................................................ 7-26
Heater / Air conditioning: checking rate of air flow ............................................................................................ 7-26
Other Maintenance Measures Prior to Start ...................................................................................................... 7-26
7-21
Maintenance Shedule
7-22
CAUTION
3.
4.
5.
6.
7-23
Pull out the oil dipstick (1) and wipe off the oil with a clean cloth.
Completely re-insert the oil dipstick and pull it out again after a few
seconds. The oil level must be between the (H) and (L) markings on
the oil dipstick.
If the oil level does not reach up to the (L) marking, top up engine oil.
For detailed information on recommended oils, see section
"Lubricants and Service Fluids".
3.
NOTE
Do not fill in too much oil in one go via the filler!
4.
5.
Wait three minutes before you check the oil level again.
If the oil level is above the (H) marking, drain off some oil (see "Engine,
Draining Off Oil").
Close the oil filler (2).
2
7 5 _ 20 6
7-24
0
I
P
II
WARNING
Danger of fire! Fuel that has spilled over may ignite!
Immediately remove fuel that has spilled over.
1.
2.
3.
4.
75_209
Turn the start switch to the operating position 'I' and check the fuel
level indicated on the fuel level indicator.
A - fuel tank full
B - fuel tank half-full
Then, return the start switch to the stop position '0'.
If required, refuel via the filler (1).
For detailed information on fuels, see section "Lubricants and Service Fluids".
After refuelling, firmly close the filler.
75 _ 2 11
3.
0
I
P
II
75_209
NOTE
Contact your responsible Komatsu dealer, if one or several of the
indicators do not light up.
Do not only use the indicators to perform the checks prior to start. Always
perform the work described as regular maintenance, too.
7-25
CAUTION
Danger of ignition! Inflammable material (leaves, twigs, grass,
etc.) may ignite within the electrical system!
Remove inflammable material from the electrical system.
NOTE
If a fuse blows, or if there are any signs of a short-circuit within the
electrical system, inform your responsible Komatsu dealer.
Regularly check that the terminals are fastened tightly, retighten loose
terminals.
4.
If insufficient air is coming out of the jets, either the filter fleece in the
heating/air conditioning unit is dirty and will have to be cleaned or
replaced or the condenser in the air conditioning system is dirty and
will have to be cleaned; see "Maintenance every 500 operating
hours" .
Check that the contacts at the float of the brake oil container are
tightened correctly.
7-26
Check the function of the rear-view mirror; check it for dirt and
damage.
DANGER
If the liquid gets into your eyes or on your hands, it may cause
loss of sight or frostbite: Therefore never loosen any part of the
refrigerant circuit.
6 5_ 15
Cooler condition
Normal
Abnormal
Temperature of high
and low
pressures pipes
Amost no difference in
temperature between high
and low pressure pipes.
Sight glass
Opaque substance is
visible in the fluid.
Pipe connections
Properly connected
General condition of
cooler
7- 2 7
DANGER
There is danger of severe accidents, if you perform maintenance
work at a machine that has not been parked and secured
correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
1.
2.
3.
Before you start maintenance work, park and secure the machine
as described in the chapter "Preparing the Machine for Maintenance".
Clean the grease nipples marked by arrows.
Use a grease gun to fill the grease nipples with a sufficient volume
of lubricating grease.
Articulated steering (3 points)
4.
7- 2 8
WARNING
Frequent skin contact with used engine oil may cause skin
lesions!
Thoroughly remove any engine oil adhering to your skin.
NOTE
Do not perform an oil change, unless the engine is switched off and
at operating temperature.
DANGER
There is danger of severe accidents, if you perform maintenance
work at a machine that has not been parked and secured
correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
1.
2.
3.
4.
5.
6.
7.
8.
9.
9.
Before you start maintenance work, park and secure the machine
as described in the chapter "Preparing the Machine for Maintenance".
Loosen the screw (1) at the bottom cover plate (2) and swivel the
cover plate to the side.
Put the oil trough under the drain screw (4).
Remove the cover cap (3) from the drain valve.
Screw on the drain hose (5) on the drain valve (4). This will cause
the drain valve to open.
Drain the oil.
Check the removed oil for metal parts or undesired material. If the
oil contains such particles, inform the responsible Komatsu dealer.
Remove the cover cap (3) from the drain valve.
Remove the drain hose (5) from the drain valve (4). This will cause
the drain valve to close.
Fasten the bottom cover plate with the screw.
7-29
2
7 5 _ 20 6
7-30
OK
OK
75_219
DANGER
There is danger of severe accidents, if you perform maintenance
work at a machine that has not been parked and secured
correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
1.
Before you start maintenance work, park and secure the machine
as described in the chapter "Preparing the Machine for Maintenance".
WARNING
Danger of injuries! When the engine is in operation, there is
danger of severe injuries by moving parts within the engine
compartment!
Do not work within the engine compartment, while the engine is
in operation.
2. Press down the V-belt in the middle of the longest straight part. You
should be able to press the V-belt down about 10-15 mm.
If you can press down the V-belt more than 10-15 mm, adjust the
tension as follows:
3. Loosen the fastening screw (1) at the generator.
4. Loosen the connecting screw (2) between the generator and the
guide rail.
5. Loosen the fastening screw (3) at the guide rail.
6. Tilt the generator to adjust the tension of the V-belt.
7. Fasten the generator and the guide rail.
8. Check the tension of the V-belt and re-adjust it, if required.
7-31
WARNING
Frequent contact between used hydraulic oil and skin may cause
skin lesions and other physical damage!
Wear rubber gloves when changing the filter. Thoroughly wash
off any hydraulic oil adhering to your skin.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
WARNING
Loose wheel nuts may cause severe accidents!
Regularly check and tighten the wheel nuts.
Tightening of loose nuts. Nut torque: 450 - 500 Nm
NOTE
If a threaded bolts breaks, replace all threaded bolts of the respective
wheel.
7-32
7 5 _1 59
WARNING
Frequent contact between used hydraulic oil and skin may
cause skin lesions and other physical damage!
Wear rubber gloves when changing the oil. Thoroughly wash
off any hydraulic oil adhering to your skin.
DANGER
There is danger of severe accidents, if you perform maintenance work at a machine that has not been parked and
secured correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
Planetary gearing
1.
2.
3.
4.
5.
6.
7.
8.
Start engine. Raise work unit and drive the machine until the drain
plug (1) for the planetary gearing on the wheel where you want to
change the oil has reached its lowest point. Switch off engine. Lower
work unit and apply parking brake.
Place drip pan or container underneath the drain plug (1).
Unscrew drain plug (1) and drain oil into container.
Drive machine until the planetary gearing drain plug hole (1) is in a
horizontal ("3 o'clock") position.
Fill planetary gearing with oil until the oil reaches the lower lip of the
drain plug hole (1).
Clean drain plug and attach clean, undamaged (or new) washer.
Screw drain plug in tight.
Change oil in other wheels of the front and rear axle following the
same procedure as described under no. 1 - 7 above.
Differential
1.
2.
3.
4.
5.
Place a drip pan or container underneath the oil drain opening (2).
Remove the filler screw (1), the 3 drain plugs of the drain holes (2)
and the 2 inspection hole screws (3). Drain off oil.
Clean drain plugs and attach clean, undamaged (or new) washers.
Screw drain plugs (2) in tight.
Pour oil in through the filler hole (1) until it reaches the lower lip of
the inspection holes (3).
Insert filler screw (1) and inspection hole screws (3) and screw tight.
7-33
WARNING
Frequent contact between used hydraulic oil and skin may
cause skin lesions and other physical damage!
Wear rubber gloves when changing the oil. Thoroughly wash
off any hydraulic oil adhering to your skin.
DANGER
There is danger of severe accidents, if you perform
maintenance work at a machine that has not been parked and
secured correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
Have an oil trough with a sufficient capacity ready.
Perform an oil change with the gear unit at operating temperature.
1. Before you start maintenance work, park and secure the machine
as described in the chapter "Preparing the Machine for
Maintenance".
2. Unscrew the screw plugs (1) and (2) .
3. Drain the oil.
4. Clean the screw plugs and replace the gaskets.
5. Tightly screw in the screw plug (2).
6. Fill in oil via the check drill hole (1), until the oil reaches up to the
bottom edge of the check drill hole.
7. Tightly screw in the screw plug (1).
7-34
Checking the Cooling System, Coolant Level in the Radiator and expanion tank
WARNING
Danger of being burnt! The coolant is under pressure if the
engine is hot. Hot coolant may squirt out during opening.
Check the coolant level only after the engine has sufficiently
cooled down. Open the cover of the radiator (arrow) by turning
it slowly so that the pressure can escape.
DANGER
Danger of fire! Antifreeze may ignite at the hot engine!
Wait until the engine has cooled down, before refilling antifreeze.
1.
2.
3.
4.
5.
6.
7.
8.
7.
7 5_ 2 0 2
NOTE
If coolant has been toppe up regualry in the radiator or expansion
tank, then the system should be checkesd by your local Komatsu
dealer an repaired if required.
7-35
Place a container under the drain plug of the fuel tank (see arrow).
Open the drain plug, drain off water and dirt.
Close the drain plug when clean fuel starts to leak out.
WARNING
Danger of accidents! If the oil level is too low, the service brake
may break down!
If the brake fluid supply control lamp (1) lights up, you must
immediately stop and check the oil level.
CAUTION
Danger of accidents! If you use usually available brake fluid
for filling up, the operational efficiency of the brake system
may be impaired!
Use only the prescribed oil for filling up! Do not use brake fluid!
Pay attention to utmost cleanness!
1.
2.
3.
4.
7-36
75_238
WARNING
5.
Measure the specific density of the battery acid and read off the
battery charging using the following conversion table.
Temperature
Battery
20 C
Charge
full
half
empty
6.
7.
5 C
-10 C
-25 C
1.29
1.21
1.13
1.30
1.22
1.14
1.31
1.23
1.15
7-37
7-38
DANGER
If you perform maintenance operations at a machine which is
not properly parked and secured, severe accidents may occur!
ark the machine on firm, level ground and secure it before
starting the maintenance operations.
1.
2.
3.
4.
(2 locations each)
(1 location)
(2 locations)
(2 locations)
(3 locations)
(3 locations)
NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.
7-39
7-40
7- 4 1
DANGER
There is danger of severe accidents, if you perform maintenance
work at a machine that has not been parked and secured
correctly!
Park the machine on a solid, even surface and secure it, before
you start to perform maintenance work.
Before you start maintenance work, park and secure the machine as
described in the chapter "Preparing the Machine for Maintenance".
Planet gear
1.
2.
3.
4.
5.
6.
Start engine, raise work unit and drive the machine until the oil level
marking at the planetary gearing of the wheel which you are checking
is in horizontal position. Switch off engine. Lower work unit and apply
parking brake.
Unscrew the locking screw (1) of the drill hole.
Check the oil level. The oil level must reach up to the bottom edge of
the check drill hole.
If the oil level is too low, top up oil via the check drill hole of the screw
plug.
For details on recommended oils, see section "Lubricants and
Operating Agents".
Tightly screw in the screw plug.
Check the oil level at the other wheel of the front and rear axle. For
this purpose, proceed as described under points 2 through 5.
Differential
1.
2.
Unscrew the locking screw (2) of the drill hole at the front axle. Check
the oil level as described under points 3 through 5 in section "Planet
gear".
Unscrew the locking screw (2) of the drill hole at the rear axle. Check
the oil level as described under points 3 through 5 in section "Planet
gear".
7- 4 2
WARNING
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine room!
Do not perform any operation in the engine room with the engine
running!
1.
2.
3.
4.
5.
7- 4 3
b)
Cleaning with water and cleaning agents
After the dust has been blown out, the filter cartridge can also be
additionally cleaned using warm water with a mild cleaning agent (max.
50 C) to remove adhering oil, grease, soot, etc. For this purpose, swing
the cartridge back and forth in the solution.
Then, rinse the filter cartridge with clean water starting with the inside
and then proceeding to the outside (max. 3 bars) and let it dry at a
temperature of max. 50 C.
Checking the filter cartridge
Usually, it is required to check each air filter cartridge before it is reinstalled. For this purpose, insert a 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 insert is defective and must be
replaced.
Check filter cartridges for damaged seals.
NOTE
Also new filter cartridges must be checked before they are
assembled.
Assembling the air filter cartridge
1.
2.
3.
7- 4 4
Lubrication
DANGER
If you perform maintenance operations at a machine which is
not properly parked and secured, severe accidents may occur!
Park the machine on firm, level ground and secure it before
starting the maintenance operations.
1.
2.
3.
4.
(1 location each)
(1 location each)
(1 location)
(1 location)
NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.
7- 4 5
DANGER
Danger of fire! Fuel may ignite on hot surfaces!
Only change the filter elements if the engine has sufficiently
cooled down. Stay away with open fire or sparks while handling
with fuel. Do not smoke.
1.
2.
3.
4.
5.
6.
7.
8.
9.
7-46
75 _ 2 5 1
DANGER
Fuel in the injection system is under pressure.
Carry goggles and rubber gloves if you work on the injection
pump. If you are hit by a high-pressure fuel beam, immediately
go into medical treatment.
1.
2.
3.
4.
5.
6.
7.
8.
9.
3
2
7 5 _2 3 4
WARNING
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine room.
Do not perform any operation in the engine room with the engine
running.
10. Start up the engine and purge the lines, one after the other, with the engine
running until the engine is running regularly.
IMPORTANT
If the fuel system has run empty during driving, or if repairs or
maintenance operations are to be performed, it is necessary to
purge the system.
7-47
7-48
DANGER
If you perform maintenance operations at a machine which is
not properly parked and secured, severe accidents may occur!
Park the machine on firm, level ground and secure it before
starting the maintenance operations.
1.
2.
3.
4.
Transfer Box Gearing, Checking the Oil Level and Refilling Oil
NOTE
If the engine is not running, the oil level in the transfer box can
significantly rise. Therefore, only check the gear oil level with the
engine running idle at operating temperature. The gearshift
assembly must be in neutral position.
DANGER
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine room!
Do not perform any operation in the engine room with the engine
running.
1.
2.
3.
4.
5.
6.
7.
7-49
2.
3.
Open the air filter and remove the air-filter insert (1). Proceed as
described in chapter "Air Filter, Removing and Re-Installing the Filter
Insert, Checking and Cleaning the Filter Insert".
Use a source of light (e.g. torch) to check the new air filter for damages.
Re-install the air-filter insert as described in chapter "Air Filter,
Removing and Re-Installing the Filter Insert, Checking and Cleaning
the Filter Insert".
2.
3.
4.
5.
6.
7-50
Open the air filter and remove the air-filter insert (1). Proceed as
described in chapter "Air Filter, Removing and Re-Installing the Filter
Insert, Checking and Cleaning the Filter Insert".
Pull out the safety filter (2).
In order to prevent that dust enters the interior of the engine, it is
required to the air aspiration opening of the engine with a clean cloth
or similar.
Clean the interior of the air-filter enclosure and remove the cloth
from the air aspiration opening.
Use a source of light (e.g. torch) to check the new safety filter for
damages. If it is in perfect condition, press it firmly into place.
Re-install the air-filter insert as described in chapter "Air Filter,
Removing and Re-Installing the Filter Insert, Checking and Cleaning
the Filter Insert".
4.
5.
6.
7.
8.
Remove screws on the front cover (1) on the driver's cab (4 screws).
Withdraw filter (2) from the heater unit (3).
Clean the filter in warm water (30 - 40 C) which has had a little
household cleaning solvent added to it.
Caution: Neither rub the filter fleece nor wring it out.
Allow the filter fleece to dry.
Insert dried filter fleece (2) back into the heater unit (3).
Switch on the blower and check the air flow at the air-outlet nozzles
(4) and (5) to the right and left of the steering column.
Caution: The circulating air jets (arrow) must be open.
If the air flow is still too weak the filter fleece must be replaced.
Screw front cover (1) back on.
2
3
6 5 -11
DANGER
Do not wash the condenser with a steam cleaner. Otherwise,
the condenser will get hot and may break down.
7-51
7-52
WARNING
Danger of being burnt! The coolant is under pressure if the
engine is hot. Hot coolant may squirt out during opening.
Check the coolant level only after the engine has sufficiently
cooled down. Open the cover of the radiator (arrow) by turning
it slowly so that the pressure can escape.
DANGER
7 5_ 2 0 2
NOTE
The coolant must be exchanged after max. two years.
NOTE
While preparing the coolant, make sure to adhere to the prescribed
mixing proportions to ensure a freezing protection up to -37C! This
is also valid for countries with moderate climate.
The coolant has to consist of 50 vol.% coolant additive and 50 vol.%
water. Only monoethylene glycol and dieethylene glycol are permitted as
coolant additives which are both contained in commercially available
standard coolants.
If the water contains too much lime, the cooling system may be impaired.
In this case, use a mixture of potable water and distilled or deionized
water.
7- 5 3
3.
4.
5.
Filling Up Coolant
12. Empty and clean the expansion tank.
13. Prepare the coolant as prescribed.
14. Fill up the coolant slowly into the cooling system up to the overflow
shoot of the radiator.
15. To purge the cooling system while the radiator cap is removed, let
the engine run idle for five minutes with its lower speed (rpm) and
then for another five minutes with its top speed. Fill up with coolant
if the coolant level in the radiator is dropping.
16. Switch off the engine, wait approx. three minutes and then refill
coolant up to overflow shoot of the radiator. Re-lock the radiator.
17. Fill up coolant into the expansion tank, until the coolant level is
between the FULL and LOW markings.
7- 5 4
7 5_ 2 0 2
Service Brake
NOTE
All repairs on the brake system must be performed by a garage
which is authorised by Komatsu.
Changing oil
Checking tubes and lines
Checking the brake disks for wear and tear
Adjusting the clearance of the brake disks
7- 5 5
WARNING
7- 5 6
7- 5 7
7- 5 8
Technical Data
Technical Data
Technical Data
Specifications
Engine
Model
Komatsu 4D 106E - 2 HC
Torque, max.(DIN
70020)
Starter
12 V - 3.0 kW
Three-Phase Generator 12 V - 60 A
Battery
12 V - 92 Ah
Driving Speed
forward and backwards
5.7 km/h
20.0 km/h
5.4 km/h
14.0 km/h
11.6 km/h
30.0 km/h
Turning radius
Bucket, Standard
48.9 kN
Outside
Counterweight
4100 mm
Outer Edge
Bucket, Standard
4455 mm
1.1 m
Data95_s.TBL/26.6.99
8 -2
Technical Data
Noise Emission Levels
Two rating plates with details of the machine's noise level must be
mounted on the machine:
In compliance with EC directive 95/27/EC
1 plate for sound pressure level
1 plate for sound power level
LpA = 73 dB/A
LWA = 98 dB/A
Vibration Level
When used for its intended purpose, levels of vibration for the earthworking
machine transmitted from the operator's seat are lower or equal to the
test vibrations for the relative machinery class in compliance with ISO
7096. The actual acceleration value of the upper limbs is less than 2.5
m/s2. The actual acceleration value for the body is less than 0.76 m/s2.
These values were determined using a representative machine and with
the help of the measurement procedures that are defined in the directives
ISO 2631/1 and ISO 5349.
uphill
downhill
sideways
30
30
30
8 -3
Technical Data
8 -4
9- 1
9- 2
ALS-Electronics
Always read this section before installing and operating the ALSElectronics as safe as possible.
WARNING
If the ALS system is switched on during a journey, or when the
working attachment is in raised position, it may move up or
down depending upon the bucket load.
For this reason, extreme caution is advised when operating the
switch.
When inspecting and servicing the machine, also lower the work
equipment to the ground then turn the ALS-Electronics switch OFF
before beginning to service.
NOTE
The ALS system is activated when the transmission is shifted into
2nd gear and the machine is traveling at a speed higher than 5 km/h.
9- 3
NOTE
To ensure that the ALS system can remain fully effective
when the machine is underway, do not tilt the bucket all the
way through till it touches the limit stops.
Do not support the boom when on the road.
WARNING
Danger of injury! Pressure accumulator is filled with highly
pressurised nitrogen.
Do not open or damage the pressure accumulator.
9- 4
Index
Index
10 - 2
Index
A
Air conditioning 4-10, 4-18, 5-9
Checking 7-27
checking rate of air flow 7-26
cleaning Condenser 7-51
cleaning/replacing Filter Fleece 7-51
Switching 5-9
Air ventilation nozzles 5-8, 5-9
Alarm horn 4-23
ALS-Electronics 9-3
Application fields 1-4
Articulated steering
Lock 2-3
Securing 2-3
Attachments. See Equipment
B
Batteries
Connection/disconnection 3-7
Re-charge 7-38
Topping up battery acid 3-7
Battery jumper cable
Connecting 6-13
Disconnecting 6-14
Brake 6-17
Checking the Parking Brake 6-17
Checking the Service Brake 6-17
Inadequate Braking Effect 6-17
Brakes
Brake pedal 4-20
Parking brake 4-20, 5-17
Service brake 5-17
Braking on slopes 5-17
Bucket
Adjusting the Bucket Positioner 5-23
Dumping 4-21
Floating position 4-21
Level indicator 5-22
Lifting 4-21
Lowering 4-21
Bucket reset guiding
Adjustment 5-27
C
Components
Subjected to wear and tear. See Ersatzteile
Control lamps 4-8
air conditioning 4-10
Air preheater control lamp 4-9
ALS-Electronics 4-10
Direction indicator control lamp 4-9
Driving direction switch indicators 4-9
Heated rear windscreen indicator 4-9
High beam control lamp 4-9
High-speed gear 4-10
in ALS-Electronics switch 4-10
Low beam control lamp 4-9
D
Dimensions 2-6
Direction indicator 5-15
Door unlocking system 4-23
Driver's seat
Adjustment 5-6
Driving direction
Changing 5-15
Driving direction lever 5-15
Driving speed 8-2
Dumping 5-26
E
Emergency exit 3-2
Emergency lowering system 6-12
Emergency steering 6-12
Engine
Checking the oil level 7-24
Start-up 5-11. See also Engine: Start-up
Topping up coolant 3-5
Equipment 3-6
CE-conforming 1-8, 1-10
EU directives
CE Conformity 1-6
Machinery Directive 1-6
Excavation works 5-25
F
Faults
Axles 6-11
Brakes 6-10
Inadequate Braking Effect 6-17
Parking brake 6-8
Service brake breaks down 5-17
Control lights 6-3
Electric system 6-4
Electronics 6-3
Engine 6-5
Hydraulics
Hydrostat drive unit 6-8
10 - 3
Index
Work hydraulics system 6-9
Steering 6-8
Warning indicators 6-3
Filling up 5-27
Filter. See Spare parts
Fire extinguisher 3-4
Fire prevention 3-4
First-aid kit 3-4
Fuel. See Operating agents
Fuses
Slow-blow fuses 7-14
H
Heater
checking rate of air flow 7-26
cleaning Condenser 7-51
cleaning/replacing Filter Fleece 7-51
Heating
Adjustment 5-8
Hydraulic system
Hydraulic oil
Topping up 3-5
Hydraulics
Hydraulic oil 7-7
I
Information labels 3-25
Instrument panel 4-4
L
Labeling 3-24
Information labels 3-25
Safety labels 3-24
Liability 1-6
Loading 5-24, 5-26
In diagonal direction 5-26
Lubricants
Grease 7-7
Hydraulic oils 7-7
Oils 7-6, 7-8
Table 7-10
M
Machine
Braking 5-17
Cleaning 3-5, 5-30
Loading 2-3, 2-4, 3-16
Operation 5-20
Overall view 4-3
Parking 3-15
Quitting 3-3
Reverse driving 5-16
Running in 5-3
Start up
After standstill 5-31
Start-up 5-13
Stopping 5-18
10 - 4
Index
Pressure Accumulator 7-52, 7-55
Prior to start 5-4, 7-23
Rear axle
Oil change 7-33, 7-55
Service brake 7-55
Checking the oil level 7-36
Refilling oil 7-36
Transfer box gearing
Checking the oil level 7-49
Refilling oil 7-49
Transfer gearing box
Oil change 7-55
upon Demand 7-27
V-belt
Checking the condition 7-31, 7-41
Checking the tension 7-31, 7-41
Ventilation
check blower 7-26
cleaning blower filter 7-51
Water pump
Check 7-57
Water separator 7-40
Windshield washer assy 7-9
Measuring indicators 4-11
Coolant temperature indicator 4-12
Fuel level indicator 4-12
Operating hour meter 4-12
O
Oils. See Lubricants
Operating agents
Coolant 7-9
Fuel 7-8
Table 7-10
Operating conditions
Asbestos containing material 3-5
Turning 5-16
Working
High temperatures 3-5
Near overhead lines 3-12
On loose soil 3-13
Operating elements
Overall view 4-4
Operating instructions
Working
On snow 3-13
Operating values 2-6
Operation
Adjusting the Bucket Positioner 5-23
Adjusting the driver's seat
Without air-cushioning 5-6
Ajsting the work unit
Bucket reset guiding 5-27
Changing the driving direction 5-15
Digging 5-25
Driving 5-13
On slopes 5-14
Driving with high-speed gear 5-14
Filling up with soil 5-27
In water 5-29
Loading 3-12, 5-24
Loading in diagonal direction 5-26
Mining operations 5-27
Near overhead lines 5-29
On loose soil 5-29
On slopes 5-29
On snow 5-29
On steep slopes 5-29
Piling up material 5-27
Planing 5-27
Preparing the standstill 5-31
Prospecting 5-27
Removing piled up soil 5-24
Securing the articulated steering 4-23
Stopping 5-18
Transporting 5-26
Unloading 5-26
V-shaped loading 5-26
With fork tines 5-28
Working Conditions
Long-distance driving 7-16
Works
Loading in diagonal direction 5-26
Planing 5-29
V-shaped loading 5-26
Operation elements
Air Conditioning 5-9
Heating system 5-8
Overall view 4-4
Control elements 4-4
Controls and indicators 4-4
Machine 4-3
P
Parking brake
Pulling 5-17
Releasing 5-17
Pedals 4-19
Accelerator pedal 4-21
Piling up material 5-27
Planing 5-29
Pressure accumulator 3-21, 7-52, 7-55, 9-4
Prospecting 5-27
R
Rear mirror
Adjustment 5-7
Removing
Piled up soil 5-24
Roll-over protection 3-6
ROPS. See Roll-over protection
S
Safety belt
Putting on 5-10
Releasing 5-10
Safety devices
10 - 5
Index
Fire extinguisher 3-4
Roll-over protection 3-6
Safety equipment
First-aid kit 3-4
Safety instructions
Appearance 1-4
Asbestos dust 3-5
Attachments 3-1
Battery 3-7
Driver's cab 3-8
Driving 3-10
Engine coolant 3-5
Engine oil 3-5
Fire prevention 3-4
General notes 3-1
Hydraulic oil 3-5
Loading operations 3-12
Maintenance operations 7-4
Pressure accumulator 3-21, 9-4
Quitting the machine 3-3
Special equipment 3-1
Transporting the machine 3-16
Vision 3-9
Workplace 3-8, 3-13
Safety labels 3-24
Socket 4-23
Spare parts
Parts subjected to wear and tear 7-9, 7-12
Special equipment
ALS-Electronics 9-3
Specifications. See Dimensions
Standards
EU directives 1-6
Start
Pre-start settings 5-6
Start-up 5-13
On slopes 5-14
Preparation 3-10, 5-4
Steering column adjustment 5-7
Switches 4-13
Air conditioning switch 4-18
ALS-Electronics 4-18
Battery main switch 4-17
Direction indicator lever 4-14
Driving direction switch 4-15
Fan rotary switch (ventilation/heating) 4-16
Front windscreen wiper and washer 4-14
Hazard flasher switch 4-14
Heated rear windscreen 4-16
High-speed gear 4-18
Horn button 4-14
Light switch 4-15
Rear windscreen wiper and washer 4-14
Start switch 4-16
Switch for driving range up to 20 km/h 4-17
Switch for inside lighting 4-17
Temperature rotary switch 4-16
Warning beacon 4-18
Working lights switch 4-17
10 - 6
T
Taking off soil 5-27
Technical data 8-2
Tilt angle
Maximum angle 8-3
Towing the machine 6-15
Traction device 4-23
Tractive force 8-2
Transporting
Machine 2-3, 3-16
Turning
On dams 5-16
On hills 5-16
On slopes 5-16
Turning radius 8-2
Tyre pressure
Long-distance routes 7-16
Tyres
Driving long distances 5-19
Tyre-appropriate operation 5-22
U
Usage of the machine 1-4
V
Ventilation system 5-8
W
Warning lights 4-6
Air filter warning light 4-7
Brake fluid warning light 4-7
Charging current warning light 4-7
Engine oil-pressure warning light 4-7
Faults 6-3
Parking brake warning light 4-7
Weights 2-6
Windshield washer assy 7-9
Winter operation
Diesel fuel 5-30
Work unit
Adjustment 5-22
Dumping 4-21
Floating position 4-21
Lifting 4-21
Lowering 4-21
Multifunctional lever 4-21
Removal 5-20
Workplace
Safety at the 3-8, 3-12, 3-13