Komatsu SK818-5 Operation & Maintenance Manual

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Operation & Maintenance

Manual

WARNING

Unsafe use of this machine may cause serious injury

or death. Operators and maintenance personnel

must read this manual before operating or

maintaining this machine.

This manual should be kept inside the cab for

reference and periodically reviewed by all personnel

who will come into contact with the machine.

SK818

SKID-STEER LOADER

SERIAL NUMBER

SK818-5 37BF50111

WEAM004502

-5

and up

Table of Contents

Summary of Contents for Komatsu SK818-5

Page 1 Operation & Maintenance WEAM004502 Manual SK818 SKID-STEER LOADER SERIAL NUMBER SK818-5 37BF50111 and up WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3: Foreword 1.1 Foreword
Over the years Komatsu Dealers have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Utility Dealer: he always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to con- form the machine to the safety standards and traffic rules.
Page 4: Information On Safety
This gives information that is useful to know. Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation or maintenance of the machine; for this reason, the safety messages included in this manual and applied on to the machine plates may not include all possible safety precautions.
Page 5 INFORMATION ON SAFETY WARNING It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held liable for any damage to persons, property or the machine, if this has been tampered with by modi- fying the standard setting of the hydraulic system.
Page 6: Introduction
1.3 INTRODUCTION 1.3.1 INTENDED USES The Komatsu MACHINES described in this manual have been designed and constructed to be used by duly trai- ned personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS. If provided with suitable safety devices, they can be used with authorized optional equipment having the characte- ristics illustrated at point "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
Page 7: Running-In
INTRODUCTION 1.3.4 RUNNING-IN Every machine is scrupulously adjusted and tested before delivery. A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the various components. If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its functio- nality will be untimely reduced.
Page 8: Product Identification
PRODUCT IDENTIFICATION 1.4 PRODUCT IDENTIFICATION The Komatsu COMPACT LOADER and its main components are identified by serial numbers stamped on the identification plates. The serial number and the identification numbers of the components are the only numbers that must always be in- dicated to the Dealer when requiring assistance and ordering spare parts.
Page 9: Engine Serial Number And Exhaust Gas Emission Plate
PRODUCT IDENTIFICATION 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE The plate (1) indicating the engine serial number and the exhaust gas emission plate are positioned on the upper side of the tappet cover. RWAA9660 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER The serial number of the travel reduction gear is stamped on the plate positioned on the hydraulic motor cover.
Page 10: Serial Numbers And Dealer's Address
PRODUCT IDENTIFICATION 1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS Machine N° Model Engine N° Product identification number (PIN) Travel reduction gear N° Cab N° Excavator (if installed) N° Dealer: Address: Tel. Person to contact: NOTES:...
Page 11: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD FOREWORD............................INFORMATION ON SAFETY ........................ INTRODUCTION ........................... 1.3.1 INTENDED USES ........................1.3.2 IMPROPER OR UNAUTHORIZED USES................1.3.3 MAIN CHARACTERISTICS...................... 1.3.4 RUNNING-IN ..........................PRODUCT IDENTIFICATION ....................... 1.4.1 MACHINE SERIAL NUMBER....................1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ........
Page 12 TABLE OF CONTENTS PRECAUTIONS TO BE TAKEN WHEN WORKING................2.4.1 STARTING THE ENGINE......................2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS ..........2.4.3 CHECKS FOR TRAVELLING IN REVERSE ................2.4.4 MOVING THE MACHINE ......................2.4.5 WORKING ON SLOPES ......................2.4.6 PREVENTING ELECTROCUTION...................
Page 13 TABLE OF CONTENTS DESCRIPTION AND USE OF THE MACHINE SAFETY LOCKS ........................... 3.1.1 LOADER LOCKS ........................3.1.2 EXCAVATOR LOCKS (if installed) ................... 3.1.3 ASPHALT CUTTER LOCKS (if installed) ................. GENERAL VIEWS..........................3.2.1 FRONT GENERAL VIEW ......................3.2.2 REAR GENERAL VIEW ......................3.2.3 CAB INSIDE GENERAL VIEW ....................
Page 14 TABLE OF CONTENTS TRANSPORTING THE MACHINE ON OTHER VEHICLES ..............3.9.1 LOADING AND UNLOADING THE MACHINE................. 3.9.2 TRANSPORT..........................3.10 HOW TO LIFT THE MACHINE......................3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON ..............3.11.1 FUEL AND LUBRICANTS ......................3.11.2 COOLANT ..........................3.11.3 BATTERY ..........................
Page 15 TABLE OF CONTENTS MAINTENANCE GUIDE TO MAINTENANCE ........................MAINTENANCE NOTES ........................4.2.1 NOTES REGARDING THE ENGINE ..................4.2.1.1 ENGINE OIL......................4.2.1.2 COOLANT ....................... 4.2.1.3 FUEL ........................4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM..............4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM ............... 4.2.4 NOTES REGARDING LUBRICATION ..................
Page 16 TABLE OF CONTENTS 4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION ............4.8.8.a CHANGING THE FUEL FILTER ................4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER ..........4.8.8.c CLEANING THE WATER SEPARATOR..............4.8.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES) ....4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION ............
Page 17: Safety And Accident Prevention
SAFETY AND ACCIDENT PREVENTION...
Page 18: Safety, Noise And Vibration Plates
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer. In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on the new part.
Page 19 SAFETY, NOISE AND VIBRATION PLATES RWA37020 RWA00010...
Page 20: Safety Plates For Machines With Excavator
SAFETY, NOISE AND VIBRATION PLATES 2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR RWA37030 RWA00020 RWA00030...
Page 21 SAFETY, NOISE AND VIBRATION PLATES RWA37040 RWA00020 RWA00010...
Page 22: Pictograms And Relevant Meanings
SAFETY, NOISE AND VIBRATION PLATES 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS The warning and danger plates applied on to the machine are accompanied or represented by pictograms. The personnel in charge with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly;...
Page 23 SAFETY, NOISE AND VIBRATION PLATES BIOLOGICAL HYDRAULIC OIL TOPPING UP BIO-OIL RWA34380 REFUELLING RWA00040 ENGINE LUBRICATING OIL FILTER RWA00080 FUEL FILTER RWA00060 ENGINE AIR SUCTION FILTER RWA00090 ENGINE COOLANT RWA00130...
Page 24 SAFETY, NOISE AND VIBRATION PLATES ENGINE COOLANT PRESSURE RWA00110 HYDRAULIC OIL LEVEL RWA00100 HYDRAULIC OIL FILTER RWA00070 ELECTRIC OUTLET 12 V RWA00120 ANCHORAGE POINT RWA00200 EMERGENCY EXIT RWA00190 LIFTING POINT RWA04920...
Page 25: Position Of The Noise Plates
Do not use fuel, petrol or solvents. If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer. In case of replacement of a component provided with a noi-...
Page 26: General Precautions
GENERAL PRECAUTIONS 2.2 GENERAL PRECAUTIONS 2.2.1 GENERAL SAFETY RULES Only trained and authorized personnel can use the machine and perform maintenance operations. When using the machine or performing maintenance operations, follow all the safety rules, precautions and in- structions. When working with other operators or when the work site is often occupied by other operators, make sure that everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as to be able to see the machine and to be visible to the operator.
Page 27: Unauthorized Modifications
GENERAL PRECAUTIONS 2.2.4 UNAUTHORIZED MODIFICATIONS Any modification made without the authorization of Komatsu can involve hazards. Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injuries or damage caused by unauthorized modifications. 2.2.5 LEAVING THE OPERATORS SEAT When leaving the operatorís seat, even if temporarily, make...
Page 28: Getting On And Off The Machine
GENERAL PRECAUTIONS 2.2.6 GETTING ON AND OFF THE MACHINE Do not jump on or off the machine, either when it is at rest and when it is moving. When getting on or off the machine, always use the appro- priate handles and footboards; get on and off the machine very carefully.
Page 29: Preventing Fires Due To Fuel And Oil
GENERAL PRECAUTIONS 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL Fuel, oil and some types of antifreeze can be easily ignited if they get in contact with a flame. Fuel is particularly flammable and therefore extremely hazardous. Keep any naked flame away from flammable fluids. Stop the engine and do not smoke when refuelling.
Page 30: Preventing Damage Due To Asbestos Powder
GENERAL PRECAUTIONS 2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER Asbestos powder can be hazardous to your health if it is inhaled. If you handle materials containing asbestos fibers, keep to the instructions given below contenga fibre di amianto, utiliz- zare le seguenti precauzioni: 1 - Do not use compressed air, but only aspirators to clean the machine and make sure that the room in which you are working is properly ventilated.
Page 31: Fire Extinguishers And First Aid Kit
If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent reduction of its stiffness and of the safety that must be guaranteed to the operator. Consult Komatsu or your Komatsu Dealer to have the cab structure and resistance checked in case of impact or damage.
Page 32: Precautions To Be Taken Before Starting The Engine
Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as far as the floor is concerned, remove any excess dirt (earth, stones, etc.). Check the safety belt and change it if it is broken or damaged. Replace any component only with homologated parts supplied by Komatsu or its Dealers.
Page 33: Room Ventilation
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 2.3.4 ROOM VENTILATION Before starting the machine in confined or poorly ventilated places, make sure that there is proper ventilation or connect the engine exhaust pipe to a suction duct. The engine exhaust gases can be deadly.
Page 34: Precautions To Be Taken When Working
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.1 STARTING THE ENGINE Before getting on the machine, walk around it and check for people and objects that might be in the way. Do not start the engine if warning plates have been attached to the control levers. When starting the engine, sound the horn to give an alert signal to the persons in the vicinity.
Page 35: Checks For Travelling In Reverse
PRECAUTIONS TO BE TAKEN WHEN WORKING 3 - Lock the equipment control by shifting the safety device lever (4) to the lock position. When travelling on roads, keep to the traffic rules and opera- te the flashing light. IMPORTANT If the machine is provided with optional equipment, ap- ply all the locks required according to the homologation and the traffic safety rules (see "3.1 SAFETY LOCKS").
Page 36: Moving The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.4 MOVING THE MACHINE IMPORTANT The use of the speed increase function is allowed only for the fast speed transfers of the machine. When moving the machine, lower the arm and fold the buc- ket completely;...
Page 37 PRECAUTIONS TO BE TAKEN WHEN WORKING Travel up or down slopes with the heaviest part of the loader facing the top of the slope. Do not travel on wet grass or thick layers of leaves: if the machine moves obliquely in these conditions, it may slip. Before carrying out any operation on a slope, always check the functionality of the parking brake.
Page 38: Preventing Electrocution
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.6 PREVENTING ELECTROCUTION Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to electrocution; for this reason, when working near overhead electrical lines, always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.
Page 39: Visibility
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.7 VISIBILITY Switch on the working lights as soon as visibility starts decreasing. If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the wea- ther to improve until visibility becomes accepta.
Page 40: Parking The Machine
PRECAUTIONS TO BE TAKEN WHEN WORKING 2.4.11 PARKING THE MACHINE Park the machine on firm and level ground. If this is not pos- sible and it is necessary to park on a slope, position the ma- chine with the bucket directed downwards and carry out the following operations: 1 - Rotate the bucket forward and rest it on the ground.
Page 41: Transporting The Machine On Other Vehicles
TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES 2.5.1 LOADING AND UNLOADING THE MACHINE Ramps Loading and unloading the machine on/from another vehicle always involve potential hazards. Proceed with extreme ca- Perform loading and unloading on firm, level ground. Main- tain a safety distance from the edges of ditches or from road sides.
Page 42: Battery
BATTERY 2.6 BATTERY 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES Electrolytic batteries contain sulphuric acid which can cause burns. It can also corrode clothing and make holes in it. If you inadvertently splash battery acid on yourself or on so- meone else, immediately wash the affected part with plenty of water.
Page 43: Precautions For Emergency Recovery
PRECAUTIONS FOR EMERGENCY RECOVERY 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY The removal hooks are to be used exclusively for emergen- cy recovery and not for towing vehicles. Before moving the machine, make sure that all the controls are in neutral. Release the parking brake of the travel hydraulic motors (see "4.8.1.d RELEASING THE PARKING BRAKE").
Page 44 PRECAUTIONS FOR EMERGENCY RECOVERY Move the machine just far enough to permit the required re- pairs. Do not remove the machine in any way other than that indi- cated in paragraph "3.15.1 HOW TO REMOVE THE MACHI- NE". CAUTION The maximum pulling force for the emergency recovery is the following F=2600 kg.
Page 45: Precautions To Be Taken During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.1 WARNING PLATES Before starting any maintenance operation, position the ma- chine on a firm and level surface, rest the equipment on to the ground, engage the safety locks of either the equipment and the controls and stop the engine.
Page 46: Personnel
If one or more plates should be damaged, request for spare ones to Komatsu or to your Komatsu Dealer and provide for replacing them. Water into the electrical system provokes the oxidation of the contacts and may hinder the start of the machine or even make it start suddenly and abruptly.
Page 47: Use Of The Engine During Maintenance
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.7 USE OF THE ENGINE DURING MAINTENANCE During maintenance operations, run the engine only when indispensable. If it is necessary to have the engine running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator should constantly remain in the cab, in order to be able to stop the engine whenever this is required.
Page 48: Rules For Refuelling And Adding Oil
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.10 RULES FOR REFUELLING AND ADDING OIL Keep away from naked flames while refuelling or adding oil. Spilled fuel or oil make the ground slippery and may cause accidents; clean any dirty area immediately and carefully. Always tighten the fuel tank and the hydraulic circuit oil sa- fety caps securely.
Page 49: Precautions Concerning The Battery And The Alternator
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.13 PRECAUTIONS CONCERNING THE REMOVAL BATTERY AND THE ALTERNATOR When repairing the electrical system, disconnect the battery in order to stop the flow of current. IMPORTANT Disconnect first the negative earth cable (-) and then the positive cable (+).
Page 50: Precautions Concerning High-Pressure Hoses
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES Do not bend high-pressure hoses or rub them with sharp or abrasive objects. Do not use bent or cracked rigid tubes or hoses that were previously rejected because of leaks or fastening de- fects, since they may burst during use.
Page 51: Cooling Fan And Fan Belt
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.18 COOLING FAN AND FAN BELT Be careful to the rotating parts and do not allow anyone to get too close to these parts, since clothes or parts of the bo- dy may get caught into them. If hands, clothes, or tools get entangled in the fan blades or the fan belt, they may be cut, torn or seriously damaged;...
Page 52: Precautions To Be Taken When Using The Synthetic Biodegradable Oil Type "Hees
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE 2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODE- GRADABLE OIL TYPE «HEES» It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
Page 53 THE MACHINE AND ITS OPERATIONS...
Page 54: Safety Locks
SAFETY LOCKS 3.1 SAFETY LOCKS DANGER If it is necessary to stop the machine with raised loader arm, always engage the mechanical safety lock on the arm and lock the equipment and travel control by lifting the safety bars (see "3.3.5 pos. 1 - SA- FETY BARS").
Page 55 SAFETY LOCKS The safety bars (4) positioned in front of the operator seated in the driving position make it possible to lock the equipment and travel control. For the operation of the safety bars (see "3.3.5 pos. 1 - SA- FETY BARS".
Page 56: Excavator Locks (If Installed)
SAFETY LOCKS 3 - Locking of the safety device (8) for the inhibition of the equipment control. RWAA13200 3.1.2 EXCAVATOR LOCKS (if installed) IMPORTANT When travelling on roads, always position the excavator following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment control by shifting the safety device lever to the lock position.
Page 57 SAFETY LOCKS If the machine is equipped with rear stabilizers, raise the supports completely and engage the relevant safety chainsza (5). RWAA4140 RWAA4150 RWAA4160 RWAA4170 RWA37420...
Page 58: Asphalt Cutter Locks (If Installed)
SAFETY LOCKS 3.1.3 ASPHALT CUTTER LOCKS (if installed) IMPORTANT When travelling on roads, always position the asphalt cutter following the longitudinal axis of the vehicle, ap- ply the safety locks and lock the equipment control by shifting the safety device lever to the lock position. If the machine is equipped with asphalt cutter, besides ap- plying the antirotation lock already described for the stand- ard machine (see "3.1.1 LOADER LOCKS"), it is also...
Page 59: General Views
GENERAL VIEWS 3.2 GENERAL VIEWS 3.2.1 FRONT GENERAL VIEW RWA37430 Bucket Frame Bucket cylinder Wheels...
Page 60: Rear General View
GENERAL VIEWS 3.2.2 REAR GENERAL VIEW RWA37440 Rear panel Lifting cylinder Engine hood Exhaust silencer...
Page 61: Cab Inside General View
GENERAL VIEWS 3.2.3 CAB INSIDE GENERAL VIEW RWA31880 1 - Safety bars 2 - Left servo control lever - (ISO PATTERN) - travel and steering - (OPTION PATTERN) - left wheel travel and loader arm control 3 - Right servo control lever - (ISO PATTERN) - loader arm and bucket control - (OPTION PATTERN) - right wheel travel and bucket con- trol...
Page 62 GENERAL VIEWS 10 - Left console switches 11 - Right console switches RWAA11260 RWAA9720...
Page 63: Instruments And Controls
INSTRUMENTS AND CONTROLS 3.3 INSTRUMENTS AND CONTROLS 3.3.1 INSTRUMENTS RWA31900 Hour meter Fuel level indicator Engine coolant temperature indicator 1 - HOUR METER This instrument indicates the total number of operating hours of the engine. The count is continuous and the number is in- creased by 1 when the engine has run for one hour, independ- ently of its speed.
Page 64 INSTRUMENTS AND CONTROLS 2 - ENGINE COOLANT TEMPERATURE INDICATOR This instrument indicates the temperature of the engine cool- ant, which in normal conditions should be 80-85°C. After starting the engine and before starting work, let it warm up until the temperature indicator reaches the green range. If the indicator exceeds the limit values while the engine is run- ning and reaches the overheating red range, let the engine idle until the indicator returns to the normal temperature green...
Page 65: Warning Lights
INSTRUMENTS AND CONTROLS 3.3.2 WARNING LIGHTS 9 10 RWA31890 Generator warning light Speed increase warning light Preheating warning light Floating device warning light Engine oil pressure warning light Direction indicator warning light Air cleaner clogging warning light Working light warning light Hydraulic oil filter clogging warning light Safety device functionality control unit Parking brake warning light...
Page 66 INSTRUMENTS AND CONTROLS 2 - PREHEATING WARNING LIGHT This warning light comes on when the ignition key is turned to position « » to start the engine at low temperatures and goes out automatically after approximately 13 seconds (see "3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLI- MATES").
Page 67 INSTRUMENTS AND CONTROLS 6 - PARKING BRAKE WARNING LIGHT This warning light comes on when the parking brake circuit isn't pressurised (brake applied). If the warning light comes on during routine operations, stop the machine and try to locate the cause of the malfunction. RWA20230 7 - SPEED INCREASE WARNING LIGHT It comes on when the high speed is selected (see "3.3.3 pos.
Page 68 INSTRUMENTS AND CONTROLS 10 - WORKING LIGHT WARNING LIGHT It comes on when the working lights are turned on with the switch positioned on the dashboard (see "3.3.3 pos. 5 - WORKING LIGHT SWITCH"). RWA07180 11 - SAFETY DEVICE FUNCTIONALITY CONTROL UNIT This control unit is positioned on the dashboard and checks the condition of the safety devices installed on the machine.
Page 69 INSTRUMENTS AND CONTROLS C - GREEN WARNING LIGHT LED on - This means that the safety bars are down and therefore safety is ensured. LED off - (With the red warning light coming on at the same time) This means that the safety bars are not com- pletely down and therefore the work equipment and the travel function cannot be used.
Page 70: Switches Und Push Buttons
INSTRUMENTS AND CONTROLS 3.3.3 SWITCHES UND PUSH BUTTONS 1 - Parking brake push button 2 - Revolving light switch 3 - Left stabilizer button (if installed) 4 - Right stabilizer button (if installed) 5 - Working light switch 6 - Emergency switch (HAZARD) 7 - Parking light and low beam switch 8 - Direction indicator switch RWAA10590...
Page 71 INSTRUMENTS AND CONTROLS 12 - “Super flow" hydraulic system switch (5 lines) for front equipment (if installed) 13 - Speed increase button 14 - Floating device button (if installed) 15 - Available for other functions RWAA11950 RWAA11960 1 - PARKING BRAKE PUSH BUTTON When pressed, this button comes on and applies the parking brake.
Page 72 INSTRUMENTS AND CONTROLS 3 - LEFT STABILIZER BUTTON (if installed) This is a button with two temporary positions and the neutral position at its centre. Press the button forward or backward to lower or raise the sta- bilizer. For use, see "3.3.5 pos. 14 - LEFT STABILIZER CONTROL (IF INSTALLED)".
Page 73 INSTRUMENTS AND CONTROLS 7 - PARKING LIGHT AND LOW BEAM SWITCH This is a two-position switch: The 1 click enables the circuit of the instrument lights and the parking lights. The 2 click enables the general circuit of the low beam or working lights, according to the position of the switch (2).
Page 74 INSTRUMENTS AND CONTROLS 11 - FRONT EQUIPMENT «HIGH-FLOW» HYDRAULIC SYS- TEM SWITCH (3 LINES) (if installed) This switch allows the oil delivery of the hydraulic pump to be constantly increased. For use, see "3.3.5 pos. 9 - "HIGH FLOW" HYDRAULIC SY- STEM CONTROL (3 LINES) (IF INSTALLED)".
Page 75: Electrical Accessories
INSTRUMENTS AND CONTROLS 3.3.4 ELECTRICAL ACCESSORIES 1 - Acoustic alarm 2 - Electric outlet 3 - Accumulator disconnection switch (if provided) RWAA9760 RWAA11570 RWAA12480 1 - ACOUSTIC ALARM This acoustic alarm sounds when the circuits are energized with the ignition key (rotation to position ìIî) and is automatical- ly disconnected when the engine is started.
Page 76 INSTRUMENTS AND CONTROLS 2 - ELECTRIC OUTLET An electric outlet is positioned on the right side of the cab inner wall for the connection of a lighting device for routine and maintenance operations. It is a two-pole outlet and is in compliance with the ISO 4165- 1979 standard.
Page 77: Machine Controls
INSTRUMENTS AND CONTROLS 3.3.5 MACHINE CONTROLS CAUTION The procedures to be followed to use any control systems different from the ISO and OPTION PATTER- NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine. RWA31880 1 - Safety bars 2 - Left servo control lever...
Page 78 INSTRUMENTS AND CONTROLS 11 - Floating device control (if installed) 12 - Pattern shifting control (if installed) 13 - Right stabilizer control (if installed) 14 - Left stabilizer control (if installed) 15 - Optionals RWAA10490 RWAA11590 RWA36000 RWAA11610...
Page 79 Therefore, before modifying or replacing wirings and electrical components, which may result in malfunc- tions of the devices, contact your Komatsu Dealer. RWAA13210 The locking of the servo control safety device is obtained by lifting the bars (1) in vertical position.
Page 80 INSTRUMENTS AND CONTROLS ISO PATTERN CONTROL SYSTEM CAUTION The procedures to be followed to use any control systems different from the ISO and OPTION PATTER- NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine. 2 - LEFT SERVO CONTROL LEVER (TRAVEL AND STEERING) WARNING Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with...
Page 81 INSTRUMENTS AND CONTROLS If the lever is operated in directions that are inclined with re- spect to the machine axis, simultaneous steering movements proportional to the angle of inclination are obtained, since the two hydraulic pumps corresponding to each single function are engaged at the same time.
Page 82 INSTRUMENTS AND CONTROLS 3 - RIGHT SERVO CONTROL LEVER (LOADER ARM AND BUCKET) WARNING Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with fastened safety belt; before any manoeuvre he must perform the operations described in"3.13 USING THE WORK EQUIPMENT".
Page 83 INSTRUMENTS AND CONTROLS If the lever is operated in directions that are inclined with re- spect to the machine axis, simultaneous movements propor- tional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time.
Page 84 INSTRUMENTS AND CONTROLS OPTIONAL PATTERN CONTROL SYSTEM CAUTION The procedures to be followed to use any control systems different from the ISO and OPTION PATTER- NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine 2 - LEFT SERVO CONTROL LEVER (LEFT WHEEL TRAVEL AND LOADER ARM CONTROL) WARNING Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with...
Page 85 INSTRUMENTS AND CONTROLS N - Neutral A - Forward right steering B - Loader arm lowering C - Reverse right steering D - Loader arm lifting RWA32220 CAUTION Always travel at moderate speed, in order to obtain maximum precision and maximum efficiency during work.
Page 86 INSTRUMENTS AND CONTROLS 3 - RIGHT SERVO CONTROL LEVER (RIGHT WHEEL TRAVEL AND BUCKET FOLDING) WARNING Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with fastened safety belt; before every manoeuvre the operator must take all the precautions indicated in "3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)"...
Page 87 INSTRUMENTS AND CONTROLS CAUTION Always travel at moderate speed, in order to obtain maximum precision and maximum efficiency during work. During work, the use of the lever must be proportional to the required effort and such as to obtain con- stant engine speed.
Page 88 INSTRUMENTS AND CONTROLS 4 - AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED) CAUTION The procedures to be followed to use any control sy- stems different from the ISO and OPTION PATTERNS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine.
Page 89 INSTRUMENTS AND CONTROLS 5 - FOOT ACCELERATOR The accelerator pedal (1) is positioned on the operator’s right and serves to control the engine speed and power. Use the accelerator pedal with care, especially when the ma- chine is under strain or is working in difficult conditions. Avoid useless accelerations, in order to reduce consumption and extend the life of both the engine and the machine.
Page 90 INSTRUMENTS AND CONTROLS 7 - PARKING BRAKE WARNING The parking brake must be applied whenever the opera- tor leaves the driving position, even if for a short time. The machine must be positioned with the wheels resting firmly on the ground. If one of the wheels is unstable or is resting on a small obstacle, the machine may move.
Page 91 INSTRUMENTS AND CONTROLS 9 - STANDARD FLOW HYDRAULIC SYSTEM CONTROL (2 LINES) WARNING Avoid connecting any equipment to the hydraulic lines before said equipment has been correctly installed from a mechanical point of view and secured to the machine front coupling. Avoid connecting any manually-controlled equipment or tool (for example, hand hammer) to the hydraulic lines while the equipment/tool is working.
Page 92 INSTRUMENTS AND CONTROLS 9 - "HIGH FLOW" HYDRAULIC SYSTEM CONTROL (3 LINES) (IF INSTALLED) WARNING Avoid connecting any equipment to the hydraulic lines before said equipment has been correctly installed from a mechanical point of view and secured to the machine front coupling.
Page 93 INSTRUMENTS AND CONTROLS 9 - “SUPER FLOW” HYDRAULIC SYSTEM CONTROL (5 LINEE) (IF INSTALLED) WARNING Avoid connecting any equipment to the hydraulic lines before said equipment has been correctly installed from a mechanical point of view and locked to the machine front coupling.
Page 94 INSTRUMENTS AND CONTROLS 10 - SPEED INCREASE CONTROL The button (1) that allows the machine travel speed to be in- creased is positioned on the left joystick grip. When the button is pressed, the speed increases; release the button to return to normal speed. CAUTION The speed increase function should be used only for the fast speed transfers of the machine;...
Page 95 INSTRUMENTS AND CONTROLS 12 - PATTERN SHIFTING CONTROL (IF INSTALLED) WARNING Before changing the setting of the pattern change valve, lower the equipment to the ground, engage the safety locks and stop the engine. After changing the control operating pattern, carry out the first manoeuvres slowly and very carefully, in order to understand the new controls correctly and avoid any damage or fatal injury that may be caused by incorrect movements.
Page 96 INSTRUMENTS AND CONTROLS 13 - RIGHT STABILIZER CONTROL (IF INSTALLED) WARNING Before moving the machine in any way, make sure that the stabilizer feet are completely raised. Before travelling on roads, make sure that the safety locks of the stabilizer feet have been applied. The right stabilizer is operated by means of the button (1) in- stalled on the left console and according to the indicated posi- RWA36010...
Page 97: Fuses And Relays
FUSES AND RELAYS 3.4 FUSES AND RELAYS CAUTION When changing a fuse, make sure that the ignition key is in position « ». If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity.
Page 98: Main Fuse
FUSES AND RELAYS VERSION WITH OPTIONALS POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT Violet Left parking lights, number plate light Violet Control panel lights, right parking lights Light blue Horn, low beam or front working lights Switch, direction indicator lights Light blue Rear working lights, stop lights Power supply of joystick switches, floating device, pattern shifting 12 V electric outlet, revolving light, emergency lights (HAZARD)
Page 99: Relays
FUSES AND RELAYS 3.4.3 RELAYS The relays are positioned inside the engine compartment and can be reached by raising the cab (see "3.5.3.1 RAISING THE CAB"). Some relays are grouped inside the container fixed to the right side of the machine frame and can be reached by removing the cover (A).
Page 100 FUSES AND RELAYS POSITION DESCRIPTION Safety unit RWA36050 POSITION DESCRIPTION Relay board: A - Stop lights B - 1 way C - 3 way D - Momentary high-flow E - 2 way F - Blinking G - Detent high-flow RWA36060 POSITION DESCRIPTION Parking brake relay...
Page 101: Guards And Driver's Seat
GUARDS AND DRIVER’S SEAT 3.5 GUARDS AND DRIVER’S SEAT 3.5.1 ENGINE HOOD WARNING Do not open the engine hood when the engine is run- ning. Do not use the machine without engine hood and do not start the engine when the hood is open, unless this is expressly prescribed for certain maintenance opera- tions.
Page 102: Rear Panel
GUARDS AND DRIVER’S SEAT 3.5.2 REAR PANEL WARNING Do not open the rear panel when the engine is running. Do not use the machine without the rear panel and do not start the engine with open panel if this is not ex- pressly prescribed for certain maintenance operations.
Page 103: Cab
The cab is ROPS and FOPS homologated - level I; if the cab is subjected to an impact, or if the machine over- turns, immediately contact your Komatsu Dealer, who will check the stiffness of the cab and make sure that the operatorís safety is guaranteed.
Page 104: Raising The Cab
GUARDS AND DRIVER’S SEAT 3.5.3.1 RAISING THE CAB WARNING Raise the cab only with the machine parked on a firm and level surface and with arm lowered to the ground complete with bucket or any other optional equipment. Make sure that the surface on which the machine is parked is not slippery.
Page 105 GUARDS AND DRIVER’S SEAT CAUTION When lowering the cab, be careful to the hold points and carry out the operation with the help of another person. 1 - Remove the safety split pin (2) of the cab overturning pro- tection lock (3) and put it in the appropriate seat (4). 2 - Lower the cab until it touches the support surface.
Page 106: Standard Seat
GUARDS AND DRIVER’S SEAT 3.5.4 STANDARD SEAT The seat can be adjusted longitudinally and the operator can choose the driving position that is most suitable for his phy- sique. The longitudinal adjustment of the seat is obtained by operat- ing the lever (1) and making the seat slide on the guides; once the desired position has been found, release the lever and car- ry out slight movements, in order to make sure that the lock pin is engaged in its seat.
Page 107: Safety Belt
GUARDS AND DRIVER’S SEAT 3.5.6 SAFETY BELT WARNING Before starting the engine, fasten the safety belt. The safety belt must be changed when it is frayed, dam- aged or worn and in any case every 4 years. The safety belt (1) is of the type with two coupling points and adjustable length (2);...
Page 108: Technical Documentation Case
GUARDS AND DRIVER’S SEAT 3.5.8 TECHNICAL DOCUMENTATION CASE CAUTION The operation manual and the spare parts catalogue are integral parts of the machine and must accompany it even in case of resale. The operation and maintenance manual must be handled with RWAA11420 care and kept aboard, so that it can be easily consulted at any moment;...
Page 109: Use Of The Machine
Dirt, oil and fuel in the engine compartment near its hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your Komatsu Dealer. Before starting the engine, check around and under the machine to verify: 1 - if there are loose screws or nuts;...
Page 110: Operational Checks
USE OF THE MACHINE 3.6.1.3 OPERATIONAL CHECKS WARNING All the checks must be carried out by the operator while seated, with fastened safety belt. If the machine has been stopped after use or in order to carry out maintenance operations, the safety devices may have been inadvertently disconnected;...
Page 111: Starting The Engine
USE OF THE MACHINE 3.6.2 STARTING THE ENGINE WARNING Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls perfectly. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong manoeuvres and non-compliance with the safety regulations in force.
Page 112: Starting With Cold Engine Or In Cold Climates
USE OF THE MACHINE 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES WARNING Do not use any fluids or products that facilitate the cold starting of the engine, since these are ether-based and may cause explosions. 1 - Pull the accelerator lever until reaching half of its stroke and turn the ignition key to the preheating position «...
Page 113: Warming The Engine
USE OF THE MACHINE 3.6.3 WARMING THE ENGINE 1 - After starting the engine, let it warm up before starting work. 2 - The ideal warming up of the engine is achieved by making the engine run at idling speed by means of the hand accelerator.
Page 114 USE OF THE MACHINE Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety device of the controls is released (safety bars down) and the bucket is folded; the equipment control lever must be in neutral position.
Page 115: Steering (Changing Direction)
USE OF THE MACHINE 3.6.5.1 STEERING (CHANGING DIRECTION) WARNING If possible, avoid any abrupt change of direction. Counterrotations should be carried out with the ma- chine running at moderate speed. When travelling on roads, avoid carrying out counterrotations, since they may create dangerous situa- tions;...
Page 116 USE OF THE MACHINE CHANGING DIRECTION WHEN THE MACHINE IS MOVING To turn to the LEFT, rotate the travel lever anticlockwise by ap- proximately 45°. RWA31960 To turn to the RIGHT, rotate the travel lever clockwise by ap- proximately 45°. RWA31970 HOW TO CARRY OUT A COUNTERROTATION (with the machine not moving)
Page 117: How To Move The Machine (Optional Pattern Control System)
USE OF THE MACHINE 3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYS- TEM) CAUTION The procedures to be followed to use any control systems different from the ISO and OPTION PATTER- NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine.
Page 118 USE OF THE MACHINE 2 - Operate the joysticks (1) and (2) at the same time, shifting them forward or backward to move the machine. RWAA13340 RWA32270...
Page 119: Steering (Changing Direction)
USE OF THE MACHINE 3.6.6.1 STEERING (CHANGING DIRECTION) WARNING If possible, avoid any abrupt change of direction. Counterrotations should be carried out with the ma- chine running at moderate speed. When travelling on roads, avoid carrying out counterrotations, since they may create dangerous situa- tions;...
Page 120 USE OF THE MACHINE CHANGING DIRECTION WHEN THE MACHINE IS MOVING (THE TWO JOYSTICKS ARE IN THE SAME POSITION) To turn to the LEFT, shift the left joystick to the NEUTRAL posi- tion (N): the machine will turn to the LEFT. RWA32300 To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N): the machine will turn to the RIGHT.
Page 121: Moving On Slopes
USE OF THE MACHINE 3.6.7 MOVING ON SLOPES WARNING Before working on slopes, always check the functionali- ty of the parking brake. Always go up or down slopes at moderate speed and with the heavier end of the loader always directed towar- ds the top of the slope.
Page 122: Maximum Immersion Depth
USE OF THE MACHINE 3.6.8 MAXIMUM IMMERSION DEPTH WARNING If it is necessary to work with the machine immersed in water on river banks or sea shores, always check the water depth and the current flownte. Make sure that the surface on which you are working is sufficiently firm. If it is necessary to work with the machine immersed in water, make sure that the maximum immersion depth does not exceed 21 cm and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.
Page 123: Parking The Machine
PARKING THE MACHINE 3.7 PARKING THE MACHINE 3.7.1 PARKING ON LEVEL GROUND WARNING Park the machine on firm and level ground, in a suffi- ciently wide space, so that checks, daily lubrication and refuelling can be carried out without problems. Lower the work equipment to the ground.
Page 124: Parking On Slopes
PARKING THE MACHINE 3.7.2 PARKING ON SLOPES WARNING The movement of the machine when the operator is not on board may cause serious accidents and even death; to prevent this, carry out the operations described be- low. Park on slopes only when it is absolutely necessary. Park only with the bucket directed downwards.
Page 125: Stopping The Engine
STOPPING THE ENGINE 3.8 STOPPING THE ENGINE IMPORTANT Do not stop the engine suddenly, except in case of emergency; the sudden stop of the engine while it is running shortens its life. It is likewise recommended not to stop the engine sud- denly if it has been running for a long period and is still hot;...
Page 126: Transporting The Machine On Other Vehicles
TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES 3.9.1 LOADING AND UNLOADING THE MACHINE CAUTION The procedures to be followed to use any control sy- stems different from the ISO and OPTION PATTERNS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND &...
Page 127: Transport
TRANSPORTING THE MACHINE ON OTHER VEHICLES 1 - The machine with empty bucket or without optional accessories must get on the ramps with the bucket (1) at the back and raised from the ground. 2 - Once the machine has been loaded, lower the work equipment to the ground and shift the safety bars to the lock position.
Page 128: How To Lift The Machine
IMPORTANT The owner of the machine is responsible for installing the eyebolts correctly on the cab roof. Use only eyebolts homologated by Komatsu for this specific type of machine. Homologated eyebolts must be requested to Komatsu Spare Parts Dpt., specifying the machine model and se- rial number.
Page 129: Precautions To Be Taken In The Cold Season
PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON During the cold season or in areas where the temperature is particularly low, especially during the night, it is ne- cessary to take some countermeasures meant to limit the damage deriving from low temperatures. 3.11.1 FUEL AND LUBRICANTS 1 - Change the fuel and use the winter fuel ASTM D975 No.
Page 130: Battery
PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 3.11.3 BATTERY WARNING To avoid explosions due to the presence of gas, do not provoke sparks and do not use naked flames near the battery. The battery electrolyte is dangerous. If it comes in contact with the eyes or the skin, immediately rinse with plenty of water and consult a doctor without delay.
Page 131: Precautions To Be Taken In The Warm Season
PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 1 - At the end of the cold season, change the lubricants, the coolant and the fuel. IMPORTANT The coolant must be changed only if it is not permanent. For the relevant specifications, see "4.3 FUEL, COOLANT AND LUBRICANTS".
Page 132: Using The Work Equipment
USING THE WORK EQUIPMENT 3.13 USING THE WORK EQUIPMENT CAUTION The procedures to be followed to use any control systems different from the ISO and OPTION PATTER- NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read and be sure to understand the contents of this section before using the machine.
Page 133: Organizing The Work Are
USING THE WORK EQUIPMENT 3.13.2 ORGANIZING THE WORK ARE CORRECT If after a first inspection the area results to be uneven, encum- bered with big obstacles or characterized by considerable hei- ght differences, before starting work it is advisable to level the ground as much as possible, both for the machine and for the vehicles to be loaded.
Page 134: Loading Material On Heaps And On Level Surfaces
USING THE WORK EQUIPMENT 3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES The efficiency of the bucket depends on how the operator be- gins to load; keep to the following rules: 1 - Start moving with the arm completely lowered and direct the bucket toward the base of the heap.
Page 135: Loading Material On Slopes
USING THE WORK EQUIPMENT 3.13.4 LOADING MATERIAL ON SLOPES WARNING The loading of material on slopes is to be carried out on- ly if absolutely necessary, always going up with the bucket directed forward. Go down slopes in reverse, with the loader directed forward and lowered bucket.
Page 136: Digging Method
USING THE WORK EQUIPMENT 3.13.5 DIGGING METHOD 1 - At the beginning of work, keep the bucket at the correct penetration angle. 2 - Once the desired digging depth has been reached, position the bucket with its back parallel to bottom of the excavation and then start filling.
Page 137: Changing The Bucket Or The Equipment With Standard Rapid Coupling
USING THE WORK EQUIPMENT 3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING WARNING Stop the machine on a firm and level surface and lower the equipment to the ground. Before getting off the machine, stop the engine, release the residual pressure by moving the equipment control lever more than once in all directions and lock the controls (safety bars lifted in vertical posi- tion).
Page 138: Releasing The Bucket
USING THE WORK EQUIPMENT 3.13.6.1 RELEASING THE BUCKET 1 - Lower the arm completely and rest the bucket on to the ground in horizontal position. 2 - Stop the engine, release the residual pressures and lock the safety bars. 3 - Rotate the lever (1) to the left to release the coupling pins (2).
Page 139 USING THE WORK EQUIPMENT 3 - Slowly raise the arm and at the same time fold the tool- holder until it is completely engaged in its seat. 4 - Fold the bucket completely. 5 - Stop the engine, release the residual pressures and lock the safety bars.
Page 140: Changing The Bucket Or The Equipment With Optional Rapid Coupling
USING THE WORK EQUIPMENT 3.13.7 CHANGING THE BUCKET OR THE EQUIPMENT WITH OPTIONAL RAPID COUPLING WARNING Stop the machine on a firm and level surface and lower the equipment to the ground. Before getting off the machine, stop the engine, release the residual pressure by moving the equipment control lever more than once in all directions and lock the controls (safety bars lifted in vertical posi- tion).
Page 141: Removing The Bucket Or The Equipment
USING THE WORK EQUIPMENT 3.13.7.1 REMOVING THE BUCKET OR THE EQUIPMENT WARNING Do not remove the bucket or the equipment when they are lifted or when a suitable support is not available: if they fall down, they may cause serious damage and even death.
Page 142: Connecting The Bucket
USING THE WORK EQUIPMENT 3.13.7.2 CONNECTING THE BUCKET WARNING Avoid using your fingers to align the holes, since they may be cut in case of sudden or uncontrolled movemen- 1 - Make sure that the lever (1) is rotated completely to the left and that the coupling pins (2) have moved completely backward.
Page 143: Checking The Position Of The Locking Pins
USING THE WORK EQUIPMENT 3.13.7.3 CHECKING THE POSITION OF THE LOCKING PINS The position of the pins (1) must be checked with the levers in locked or horizontal position. The length of the protruding part of the pins must be in compliance with the prescribed values, as indicated in the figure.
Page 144: Adjusting The Locking Pins
USING THE WORK EQUIPMENT 3.13.7.4 ADJUSTING THE LOCKING PINS The pins must be adjusted with the bucket resting flat on the ground and the levers (1) of the rapid coupling in horizontal or locking position, proceeding as indicated below: 1 - Check the protrusion of the locking pins, proceeding as in- dicated in paragraph "3.13.7.3 CHECKING THE POSI- TION OF THE LOCKING PINS".
Page 145: Long Periods Of Inactivity
LONG PERIODS OF INACTIVITY 3.14 LONG PERIODS OF INACTIVITY 3.14.1 BEFORE THE PERIOD OF INACTIV- WARNING When draining the fuel, do not smoke or bring naked flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around.
Page 146: During The Period Of Inactivity
IMPORTANT If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your Komatsu Dealer. When using the machine after a long period of inactivity, proceed as follows: 1 - Free the exhaust pipe from the sealing covers.
Page 147: Troubleshooting
TROUBLESHOOTING 3.15 TROUBLESHOOTING 3.15.1 HOW TO REMOVE THE MACHINE DANGER When removing the machine, use a wire rope suitable for the weight of the machine to be removed. If the machine gets stuck in mud and cannot get out using only its motive power, or in case of breakdown, use a wire rope as shown in the figure on the right.
Page 148: If The Battery Is Depleted
TROUBLESHOOTING 3.15.3 IF THE BATTERY IS DEPLETED WARNING When checking or carrying out any operation on the bat- tery, stop the engine and make sure that the ignition key is in position « ». The battery produces hydrogen, which may explode. Do not use naked flames and do not smoke near the batte- ry, and avoid producing sparks.
Page 149: Starting With Booster Cables
TROUBLESHOOTING 3.15.3.1 STARTING WITH BOOSTER CABLES WARNING When starting the engine with the aid of another machine, connect the batteries in parallel. When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (-). When starting the engine with booster cables, always wear safety goggles. Take care to avoid any contact between the machine to be started and the machine used as starting aid, in order to avoid sparks and therefore the explosion of the hydrogen produced by the batteries.
Page 150: Other Troubles
(•) Always contact your Komatsu Dealer when you have to carry out this operation. • If the anomaly or its cause are not included in the failures indicated below, contact your Komatsu Dealer for the necessary repair. 3.15.4.1 ELECTRICAL CIRCUIT...
Page 151: Engine
TROUBLESHOOTING 3.15.4.3 ENGINE TROUBLE CAUSE REMEDY • Oil level in oil pan too low. • Top up.. Oil pressure warning light remains on • Oil filter clogged. • Change filter. even with engine at high speed • Oil unsuitable for the season. •...
Page 152: Hydrostatic Transmission
TROUBLESHOOTING 3.15.4.4 HYDROSTATIC TRANSMISSION TROUBLE CAUSE REMEDY • Oil level insufficient. • Top up. • Suction filter clogged. • Change. • Faulty flexible coupling. (•) Change coupling. Machine moves neither forward, nor • Max. pressure valves faulty or dirty. (•) Clean or change valves. backward: •...
Page 153 TROUBLESHOOTING TROUBLE CAUSE REMEDY • Engine power drop. (•) Check clogging of diesel oil filter, injection pump and valves. Machine accelerates slowly • Pressure relief valve setting incor- (•) Set to rated value. rect. • Sealing rings faulty. (•) Change. Oil leakages from engine propeller •...
Page 154 PAGE INTENTIONALLY LEFT BLANK...
Page 155: Maintenance
MAINTENANCE...
Page 156: Guide To Maintenance
Raise the cab taking all the precautions indicated in "3.5.3.1 RAISING THE CAB". Use Komatsu genuine oils and greases; choose oils suitable for the ambient temperature. Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases.
Page 157 GUIDE TO MAINTENANCE Never mix oils of different brands. Do not top up with any oil different from the oil used in the machine. If necessary, drain all the oil and fill the tank with oil of the available brand. WARNING Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the regulations in force.
Page 158: Maintenance Notes
4.2 MAINTENANCE NOTES Use only Komatsu genuine spare parts. Do not mix different types of oil. Unless specified otherwise, the oils and the coolant used by Komatsu to fill the tanks before the delivery of the machine are the following: ITEM...
Page 159: Fuel
3 - check of the battery electrolyte level. Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component with characteristics different from those specified and approved by Komatsu. Be careful to keep the electrical system dry.
Page 160: Notes Regarding Lubrication
The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic maintenan- ce intervals prescribed or when they reach the wear limit. The timely change of these parts ensures an economic use of the machine. Use only Komatsu genuine parts, which alone can guarantee excellent quality and interchangeability. FREQUENZA PARTICOLARE...
Page 161: Fuel, Coolant And Lubricants
FUEL, COOLANT AND LUBRICANTS 4.3 FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY (l) RESERVOIR FLUID 50°C filling Change 104 122°F SAE 10W SAE 30 Engine oil pan SAE 40 API CD SAE 10W-30 SAE 5W-30 SAE 10W Hydraulic system hydrostatic API CD transmission SAE 5W-30...
Page 162 Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half. Use Komatsu genuine products whose characteristics have been specifically formulated and approved for use in the engine, in the equipment hydraulic circuit, in the reduction gears and in the transmission.
Page 163: Homologated Synthetic Biodegradable Lubricants Type Hees
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin and therefore the use of the oils indicated in the following table is authorized and recommended: SUPPLIER HEES SYNTHETIC BIODEGRADABLE OIL KOMATSU BO 46 G4 (KES 07.872) AGIP —...
Page 164: Driving Torques For Screws And Nuts
DRIVING TORQUES FOR SCREWS AND NUTS 4.4 DRIVING TORQUES FOR SCREWS AND NUTS 4.4.1 STANDARD DRIVING TORQUES 10.9 Thread Pitch Spanner size diameter (mm) (mm) (mm) 0.96 ± 0.1 9.5 ± 1 1.3 ± 0.15 13.5 ± 1.5 1.25 2.3 ± 0.2 23 ±...
Page 165: Lubrication
LUBRICATION 4.5 LUBRICATION 4.5.1 LUBRICATION DIAGRAM IMPORTANT For the lubrication procedures for the single points, see "4.7 MAINTENANCE PLAN". The type of lubricant to be used is indicated in the lubricant table (see "4.3 FUEL, COOLANT AND LUBRI- CANTS"). 2000 h 1000 h 500 h 250 h...
Page 166: Periodical Change Of The Components Connected With Safety
PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY To ensure safety at any moment while driving and using the machine, the operator must carry out all the periodic maintenance operations prescribed. Furthermore, the operator must periodically change the components indica- ted in the table in the following page, which are especially related to safety and fire-prevention rules.
Page 167: Critical Parts For Safety
PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 4.6.1 CRITICAL PARTS FOR SAFETY FUEL SUPPLY SYSTEM Components related to safety that periodically need changing Q.ty Change interval Fuel pipe (Fuel tank - Precleaner) Fuel pipe (Precleaner - Fuel pump) Fuel pipe (Fuel pump - Fuel filter) Fuel pipe (Fuel filter - Injection pump) Every 2 years or 4000 hours, whichever oc-...
Page 168 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY STANDARD HYDRAULIC SYSTEM Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Travel pump delivery) Every 2 years or 4000 hours, whichever oc- Hydraulic pipe (Machine function pump delivery) curs first For the serial numbers and the quantity of the components that periodically need changing, consult the spare parts catalogue section regarding the components connected with safety and the components that must be pe-...
Page 169 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Lifting cylinder) Every 2 years or 4000 Hydraulic pipe (Bucket cylinder) hours, whichever oc- curs first Hydraulic pipe (Auxiliary hydraulic kit) RWA37630...
Page 170 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY HIGH-FLOW AND SUPER FLOW HYDRAULIC SYSTEM Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Travel pump delivery) Every 2 years or 4000 Hydraulic pipe (Machine function pump delivery) hours, whichever oc- curs first Hydraulic pipe (Flow rate increase pump delivery)
Page 171 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY Components related to safety that periodically need changing Q.ty Change interval Hydraulic pipe (Lifting cylinder) Every 2 years or 4000 Hydraulic pipe (Bucket cylinder) hours, whichever oc- curs first Hydraulic pipe (Auxiliary hydraulic kit) RWA37640...
Page 172 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY OPERATORíS SAFETY Components related to safety that periodically Q.ty Change interval need changing Safety belt Every 4 years RKAB0320...
Page 173: Maintenance Plan
MAINTENANCE PLAN 4.7 MAINTENANCE PLAN WHEN REQUIRED CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE ..............173 TYRE ROTATION ................................174 DRAINING THE FUEL TANK............................175 RELEASING THE PARKING BRAKE ..........................176 CHECKING THE BATTERY CHARGE LEVEL ........................ 177 CHECKS BEFORE STARTING VARIOUS CHECKS .................................
Page 174 MAINTENANCE PLAN MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (only for machines filled with synthetic biodegradable oil type HEES) (Operations to be carried out together with those prescribed at point "4.8.8 MAINTENAN- CE EVERY 500 HOURS OF OPERATION") CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER..........198 MAINTENANCE EVERY 500 HOURS OF OPERATION CHANGING THE FUEL FILTER ............................
Page 175: Maintenance Procedure
MAINTENANCE PROCEDURE 4.8 MAINTENANCE PROCEDURE 4.8.1 WHEN REQUIRED 4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE WARNING Remove the air cleaner only after stopping the engine and do not start the engine if the air cleaner is open. Always wear goggles while cleaning the filter. IMPORTANT The air filtering system comprises a primary filtering RWA32410...
Page 176: Tyre Rotation
MAINTENANCE PROCEDURE To change the safety cartridge after removing the primary ele- ment, proceed as follows: 1 - Remove the used safety cartridge (5) and replace it with a new one. IMPORTANT In case of doubts on the efficiency of the gasket, imme- diately change it.
Page 177: Draining The Fuel Tank
MAINTENANCE PROCEDURE 4.8.1.c DRAINING THE FUEL TANK WARNING When draining the fuel tank, avoid spilling fuel, since this may cause fires. If some fuel is accidentally spilled, clean the dirty area immediately, in order to prevent it from getting slippery and to avoid fires.
Page 178: Releasing The Parking Brake
MAINTENANCE PROCEDURE 4.8.1.d RELEASING THE PARKING BRAKE WARNING In case of failure of the hydraulic system and before re- moving the machine, release the negative brake in- stalled on the travel motors. The release of the parking brake is obtained by acting on the negative brake installed on the travel motors, according to the following procedure.
Page 179: Checking The Battery Charge Level
MAINTENANCE PROCEDURE 4.8.1.e CHECKING THE BATTERY CHARGE LEVEL WARNING Check the battery charge level only with the engine at rest. To prevent gas explosions, do not use naked flames, do not smoke and avoid producing sparks due to short circuits. The battery electrolyte is dangerous: in case of contact with the eyes or the skin, wash with plenty of running water and consult a doctor.
Page 180: Checks Before Starting
Dirt, oil and fuel spread in the engine compartment near the hot areas may cause fires and damage the machine. Check if there are leakages frequently and carry out the necessary repairs immediately; if this occurs re- peatedly, contact your Komatsu Dealer. Before starting the engine, check: 1 - if there are loose screws or nuts;...
Page 181: Checking The Fuel Level
MAINTENANCE PROCEDURE 4.8.2.c CHECKING THE FUEL LEVEL WARNING When refuelling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately. Fuel is flammable; neither use naked flames, nor smoke while refuelling.
Page 182: Checking The Engine Oil Level
MAINTENANCE PROCEDURE 4.8.2.d CHECKING THE ENGINE OIL LEVEL MAX. WARNING Soon after the machine has been stopped the engine is MIN. very hot and may cause burns; let the engine cool down before carrying out any check. The dipstick can be reached by raising the engine hood (see "3.5.1 ENGINE HOOD").
Page 183: Checking The Oil Level In The Hydraulic Circuit
MAINTENANCE PROCEDURE 4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT WARNING The oil level in the hydraulic circuit must be checked with cold oil and the machine positioned on a level sur- face with the bucket resting on the ground. Top up after stopping the engine and eliminating the re- sidual pressures from the equipment circuit (by operat- ing the controls more than once) and from the tank (by...
Page 184: Checking The Water Separator For Sediments And Water
« ». If there are signs of short circuit on the cables, find out the cause and repair them; always contact your Komatsu Dealer for the troubleshooting. Before checking the wiring, take all the necessary precautions to ensure safety.
Page 185: Maintenance After The First 50 Hours Of Operation
If the fluid level in the radiator is low and the expansion tank is full of coolant, check the tightness of the radiator and make sure that there is no air leakage from the radi- ator-expansion tank coupling. If this inconvenience occurs repeatedly, contact your Komatsu Dealer.
Page 186: Maintenance After The First 250 Hours Of Operation
MAINTENANCE PROCEDURE 4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION These maintenance operations must be carried out after the first 250 hours of operation, together with those to be carried out “EVERY 250 HOURS”. HYDRAULIC OIL DRAIN FILTER For details on the various maintenance operations, see section "4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION".
Page 187: Checking The Gearing Chain Tension
Repeat this operation also for the opposite wheel. IMPORTANT Check the tension on the front and rear wheels and if the slack exceeds 6 mm, contact your Komatsu Dealer. RWA37600 Max. 6mm (0.24 in) RWAA13440...
Page 188 MAINTENANCE PROCEDURE ADJUSTING THE CHAINS WARNING The adjustment must be carried out with the machine parked on a firm, level and not slippery surface. Before carrying out the adjustment, take all the neces- sary safety precautions. CAUTION RWAA10190 When adjusting the hub-holding plate, do not loosen the fastening nuts by giving them more than 2 turns, in or- der to prevent any oil leakage.
Page 189: Cleaning The Outside Of The Radiators
MAINTENANCE PROCEDURE 4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS WARNING If compressed air, steam or water are directed against a person, they may cause injuries. Always wear an eye shield and safety shoes. The radiators can be cleaned after opening the rear panel (see "3.5.2 REAR PANEL"), using a compressed air jet and, if ne- RWAA13450 cessary, carrying out a washing cycle with low pressure water...
Page 190: Checking The Oil Level In The Final Transmissions
MAINTENANCE PROCEDURE 4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS This check must be carried out on each transmission, with the machine at rest on level ground. The check is visual and serves to verify that the lubricant rea- ches the height of the hole (1);...
Page 191: Lubricating The Joints
MAINTENANCE PROCEDURE 4.8.6.f LUBRICATING THE JOINTS IMPORTANT Clean the grease nipples before applying the greasing pump. After lubrication, remove any excess grease. If the machine is used in difficult conditions, perform these maintenance operations more frequently. These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground.
Page 192: Changing The Engine Oil
MAINTENANCE PROCEDURE 4.8.6.g CHANGING THE ENGINE OIL WARNING Soon after the machine has been stopped the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40-45ºC before draining the oil. The oil that may be spilled during the change makes the ground slippery, therefore, use anti-slip shoes and im- mediately remove any trace of oil from the floor.
Page 193: Changing The Engine Oil Filter
MAINTENANCE PROCEDURE Some versions of the machine come with special safety drain plugs and to change the oil it is necessary to proceed as fol- lows. Remove the plug (7), apply the special union provided and screw manually until the oil flows out. At the same time, carry out the change procedures prescribed for the standard version.
Page 194: Maintenance After The First 500 Hours Of Operation
MAINTENANCE PROCEDURE 4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES) These maintenance operations must be carried out after the first 500 hours of operation, together with those to be carried out “EVERY 500 HOURS”.
Page 195 MAINTENANCE PROCEDURE BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to position « » and wait for approximately 15-20 seconds, in such a way as to ble- ed the fuel supply circuit. IMPORTANT After bleeding the circuit, turn the ignition key to posi- tion «...
Page 196: Changing The Hydraulic Oil Drain Filter
MAINTENANCE PROCEDURE 4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER WARNING Soon after the machine has been stopped the hydraulic oil is very hot; let it cool down until it reaches a temper- ature of 40-45ºC before changing the filter. The hydraulic system is pressurized; loosen the filling cap slowly to release the residual pressure.
Page 197: Cleaning The Water Separator
MAINTENANCE PROCEDURE 4.8.8.c CLEANING THE WATER SEPARATOR WARNING Change the precleaner at the end of work, when the engine has cooled down to 40-45º C. When these operations are carried out, fuel may be spilled; clean the dirty areas immediately, in order to prevent any risk of slipping or fire.
Page 198: Draining The Hydraulic Oil Tank (Only For Machines Filled With Synthetic Biodegradable Oil Type Hees)
MAINTENANCE PROCEDURE 4.8.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES) WARNING Lower the loader arm completely, rest the bucket on to the ground and, after stopping the engine, eliminate the residual pressures that may be present in the equip- ment (by operating the controls more than once) and lock the safety bars (see "3.3.5 pos.
Page 199: Maintenance Every 1000 Hours Of Operation
MAINTENANCE PROCEDURE 4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION These operations must be carried out together with those to be carried out EVERY 50, 250, 500 HOURS. 4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION WARNING Oils, filters, coolants and batteries are considered spe- cial waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.
Page 200: Changing The Hydraulic System Oil And Cleaning The Suction Filter
MAINTENANCE PROCEDURE 4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL- CAUTION On machines filled with synthetic biodegradable hy- draulic oil type HEES the oil must be changed after the first 500 hours of operation and successively every 1000 hours, and in any case at least once a year.
Page 201: Checking And Adjusting The Engine Valve Clearance
RWAA12570 RWAA12580 4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE Since the check and adjustment of the engine valve clearance require the use of special tools, have these opera- tions carried out by your Komatsu Dealer.
Page 202: Manutenzione Ogni 2000 Ore
MAINTENANCE PROCEDURE 4.8.10 MANUTENZIONE OGNI 2000 ORE Carry out these operations together with those to be performed EVERY 50, 250, 500 and 1000 HOURS. 4.8.10.a CHANGING THE COOLANT WARNING Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns;...
Page 203: Changing The Suction Filter
MAINTENANCE PROCEDURE 4.8.10.b CHANGING THE SUCTION FILTER WARNING Lower the loader arm completely, rest the bucket on to the ground, stop the engine, eliminate the residual pres- sures that may be present in the equipment (by operat- ing the controls more than once) and lock the safety bars (see "3.3.5 pos.
Page 204: Checking The Alternator And The Starter
RWA36400 4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER For any inspection and/or repair, contact your Komatsu Dealer. If the engine is started frequently, the alternator and the starter should be inspected every 1000 hours of operation.
Page 205: Technical Specifications
TECHNICAL SPECIFICATIONS...
Page 206: Technical Data
TECHNICAL DATA 5.1 TECHNICAL DATA 5.1.1 STANDARD MACHINE OVERALL DIMENSIONS IMPORTANT The weight of the machine increases by 200 kg when it is equipped with solid tyres. If the bucket is provided with teeth, the machine length increases by 100 mm. With extended bucket the machine length increases by 130 mm.
Page 207 TECHNICAL DATA OVERALL DIMENSIONS WITH BUCKET L 1550 AND TYRES (10x16.5) 1070 1380 1290 1060 3420 1550 RWA36810 OVERALL DIMENSIONS WITH BUCKET L 1800 AND TYRES (10x16.5) 1380 1070 1670 1290 1060 3420 1800 RWA36830...
Page 208: Machine Overall Dimensions With Optional Equipment
TECHNICAL DATA 5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT IMPORTANT The weight of the machine increases by 200 kg when it is equipped with solid tyres. MACHINE OVERALL DIMENSIONS WITH EXCAVATOR (E30) 1380 2160 1060 1070 1640 1670 4290 RWA36840 MACHINE OVERALL DIMENSIONS WITH ASPHALT CUTTER 1380 1060...
Page 209 TECHNICAL DATA OVERALL DIMENSIONS WITH PALLET FORKS 1600 1060 1070 1380 3730 1670 RWA36860 OVERALL DIMENSIONS WITH SNOW BLADE 1380 1060 1070 1340 1670 3470 1700 RWA36870...
Page 210 TECHNICAL DATA OVERALL DIMENSIONS WITH MIXING BUCKET 1400 1060 1070 1380 3530 1670 RWA36880 OVERALL DIMENSIONS WITH SWEEPER 1380 1550 1060 1070 1920 1670 4050 1680 RWA36890...
Page 211 TECHNICAL DATA OVERALL DIMENSIONS WITH GRAPPLE FORK 1380 1320 1060 1070 1460 3450 1670 RWA36900...
Page 212: Technical Characteristics
Komatsu diesel engine model ........
Page 213 TECHNICAL DATA SOLID TYRES SIZE MAKE 10x16.5 AIR BOSS...
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Page 215 AUTHORISED OPTIONAL EQUIPMENT...
Page 216: Authorized Optional Equipment
The installation of optional accessories or equipment other than those authorized by Komatsu shortens the life of the machine and may also cause problems concerning safety. It is advisable to contact a Komatsu Dealer before installing any accessory not indicated in this operation and maintenance manual.
Page 217: Precautions Regarding The Installation Of Equipment
AUTHORIZED OPTIONAL EQUIPMENT 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT WARNING The use of lengthened work equipment reduces the stability of the machine. If it is necessary to go up or down a slope, be particularly careful, since the machine may lose its bal- ance and overturn.
Page 218: Characteristics Of The Standard Machine Optional Equipment
AUTHORIZED OPTIONAL EQUIPMENT 6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT (Specific weight of the handled material = 1,8 t/m MAX. DIMENSIONS MAX. MAX. SAE MAX. OPERA- MAX. FLOW WEIGHT CAPACITY TING PRESSURE EQUIPMENT RATE Width Height (l/min.) (kg) (cu m) (bar) (mm) (mm)
Page 219: Characteristics Of The Optional Equipment Of The Machine Version With High-Flow And Super-Flow Hydraulic System
AUTHORIZED OPTIONAL EQUIPMENT 6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH-FLOW AND SUPER-FLOW HYDRAULIC SYSTEM (Specific weight of the handled material = 1,8 t/m MAX. DIMENSIONS MAX. MAX. SAE MAX. OPERA- MAX. FLOW WEIGHT CAPACITY TING PRESSURE EQUIPMENT RATE Width...
Page 220: Changing The Authorized Equipment
CHANGING THE AUTHORIZED EQUIPMENT 6.2 CHANGING THE AUTHORIZED EQUIPMENT WARNING Stop the machine on a firm and level surface and lower the equipment to the ground. Before getting off the machine, stop the engine, release the residual pressures by moving the equipment control lever more than once in all directions and lock the safety bars (see "3.3.5 pos.
Page 221: Connecting The Hydraulic Circuit
(2). See B,C and D The rapid coupling must be in compliance with the ISO 8434-3 standard. IMPORTANT In case of doubts regarding the connection of the hy- draulic circuit to the equipment, contact your Komatsu Dealer RWAA12680 RWAA11790 1" UNS 1"...
Page 222 CHANGING THE AUTHORIZED EQUIPMENT RWAA11830 1"3/16 UN 1"3/16 UN RWA36110 RWAA11840 1" UNS 1" UNS RWA36090...
Page 223: Connecting The Return Circuit With Direct Drainage Into The Tank
The return system is positioned on the left side of the loader arm and the equipment drain pipe must be connected to the union (1). IMPORTANT In case of doubts regarding the connection of the hy- draulic circuit to the equipment, contact your Komatsu Dealer. RWAA11810 1" UNS RWA36100...
Page 224: Preparing The Machine For The Use Of The Excavator
CHANGING THE AUTHORIZED EQUIPMENT 6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR After the installation of the excavator, make sure that the mechanical and hydraulic connections have been carried out correctly and proceed as follows. 1 - Press the auxiliary kit control pedal with your toe until en- gaging it in position (B);...
Page 225: Pallet Forks
PALLET FORKS 6.3 PALLET FORKS CAUTION Before using the forks for any operation, the operator must get acquainted with the increased dimen- sions of the machine and must also practise the use of the swinging movements. After grasping the material with the forks and before lifting the load, swing the equipment in such a way as to lift the points and prevent the load from slipping.
Page 226: Changing The Operating Pattern
CHANGING THE OPERATING PATTERN 6.4 CHANGING THE OPERATING PATTERN WARNING Before changing the setting of the pattern change valve to modify the operating pattern of the machine, lower the equipment to the ground, stop the engine and lock the controls by lifting the safety bars in ver- tical position (see "3.3.5 pos.
Page 227 CHANGING THE OPERATING PATTERN The lever (2) controlling the pattern change valve has two po- sitions: A - Position for the ISO PATTERN CONTROL SYSTEM RKAB1390 ISO PATTERN RKA10390 B - Position for the OPTION PATTERN CONTROL SYSTEM RKAB1400 OPTION PATTERN RKA10400...
Page 228: How To Change The Operating Pattern
CHANGING THE OPERATING PATTERN 6.4.1 HOW TO CHANGE THE OPERAT- ING PATTERN After stopping the machine on a firm and level surface, lower the equipment to the ground, stop the engine and lock the con- trols by lifting the safety bars in vertical position. Open the engine hood and proceed as follows: 1 - Loosen the safety screw (3) that holds the selection lever (2) in position.
Page 229: Hand & Foot Control System
HAND & FOOT CONTROL SYSTEM 6.5 HAND & FOOT CONTROL SYSTEM 6.5.1 MACHINE CONTROLS CAUTION The controls represented in the figure and not described in this section remain unchanged and are the same present on the standard version. For details on how to use them, see "3.3.5 MACHINE CON- TROLS".
Page 230: Travel And Steering Control Levers
HAND & FOOT CONTROL SYSTEM 6.5.1.1 TRAVEL AND STEERING CONTROL LEVERS WARNING Before carrying out any manoeuvre with the levers, the operator must be seated in driving position with fastened safety belt and lowered safety bars; before any manoeuvre it is important to take all the precau- tions indicated in "6.5.2 HOW TO MOVE THE MACHINE (HAND &...
Page 231 HAND & FOOT CONTROL SYSTEM The lever (2) is used to control the right wheels and also to control the auxiliary hydraulic kit according to the movements indicated in the following diagram: N - Neutral A - Right wheel forward travel B - Right wheel reverse travel C - Oil delivery from the male coupling of the auxiliary hydrau- lic kit...
Page 232: Work Equipment Control Pedals (Loader Arm And Bucket)
HAND & FOOT CONTROL SYSTEM 6.5.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET) WARNING Before carrying out any manoeuvre with the pedals, the operator must be seated in driving position with fastened safety belt and lowered safety bars; before any manoeuvre it is important to take all the precau- tions indicated in "3.13 USING THE WORK EQUIPMENT".
Page 233 HAND & FOOT CONTROL SYSTEM The pedal (1), positioned on the operator's left, controls the lift- ing and lowering of the loader arm, as indicated in the follow- ing diagram: RKAB1470 N - Neutral A - Loader arm up B - Loader arm down IMPORTANT On machines provided with floating device, press the pedal to position B (arm down) and press the switch po-...
Page 234 HAND & FOOT CONTROL SYSTEM The pedal (2), positioned on the operator's right, controls the folding and dumping of the bucket, as indicated in the follow- ing diagram: RKAB1480 N - Neutral A - Bucket folding B - Bucket dumping RKA10460 RKA10470...
Page 235: Auxiliary Hydraulic Kit Control
HAND & FOOT CONTROL SYSTEM 6.5.1.3 AUXILIARY HYDRAULIC KIT CONTROL WARNING Before carrying out any manoeuvre with the control lever, the Operator must be seated in driving posi- tion with fastened safety belt and lowered safety bars. The control lever (1) is positioned on the operator's right and controls the movement of the right wheels and the auxiliary hy- draulic kit, according to the movements indicated on the plate (2) and in the following diagram:...
Page 236 HAND & FOOT CONTROL SYSTEM The auxiliary hydraulic kit control starts and stops the oil flow to any optional equipment and has four positions (neutral, left, right and coupling position). 1 - Neutral position (N) (CLOSED HYDRAULIC CIRCUIT) This position doesn't allow the optional equipment to be used.
Page 237 HAND & FOOT CONTROL SYSTEM 3 - Coupling position (E) (OPEN HYDRAULIC CIRCUIT). This position is used to obtain a continuous unidirectional oil flow for the operation of equipment such as excavator, demolition hammer, sweeper, etc. To hold the lever (1) in coupling position (E), rotate the lever further to the left.
Page 238: How To Move The Machine (Hand & Foot Control System)
HAND & FOOT CONTROL SYSTEM 6.5.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM) WARNING Before moving the machine, make sure that you know the control functions and all the relevant safety regulations perfectly. The operator must be seated in driving position with fastened safety belt and lowered safety bars. Before moving the machine, check the position of the rear-view mirrors (if installed) and make sure that there is no one within the operating radius of the machine and that there are no obstacles in the sur- rounding area.
Page 239 HAND & FOOT CONTROL SYSTEM 2 - Shift the joysticks (1) and (2) forwards or backwards at the same time to move the machine. RWAA13340 RWA32270...
Page 240: Steering (Changing Direction)
HAND & FOOT CONTROL SYSTEM 6.5.2.1 STEERING (CHANGING DIRECTION) WARNING Avoid abrupt changes of direction as much as possible. Carry out counter-rotations at moderate speed. Avoid carrying out counter-rotations when travelling on roads, since these manoeuvres may cause dangerous situations; make counter-rotations only during work. Do not use the speed increase function when changing direction or carrying out a counter-rotation.
Page 241 HAND & FOOT CONTROL SYSTEM CHANGING DIRECTION WITH MACHINE IN MOVEMENT (THE TWO JOYSTICKS ARE SHIFTED TO THE SAME PO- SITION) To turn to the LEFT, shift the left joystick to the NEUTRAL posi- tion (N) and the machine will turn to the LEFT. RWA32300 To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N) and the machine will turn to the RIGHT.
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