Komatsu SK818-5 User Manual
WEAM004502
Operation & Maintenance
Manual
SK818-5
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.
This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
FOREWORD
1.1 FOREWORD
q This manual is supplied by Komatsu Utility S.p.A. in order to provide customers with all the necessary informa-
tion on the machine and the safety regulations related to it, together with the use and maintenance instructions
that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
q The operation manual, together with the spare parts catalogue, is an integral part of the machine and must ac-
company it, even when it is resold, until its final disposal.
q The manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment, where also the ownership documents and the logbook are usually kept.
q This manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu or to your Komatsu Dealer.
q The illustrations contained in this manual may represent machine configurations that are available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent techniques applied at the moment in which the machine is
marketed.
For any updated information, contact your Komatsu Dealer.
q Punctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan
frequently.
q 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 conform the machine to the safety standards and traffic rules.
Furthermore, Komatsu Dealers also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability.
q The table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
q Improper use and maintenance of this machine may be hazardous and cause serious injuries and even
death.
q Operators and maintenance personnel must carefully read this manual before using the machine or per-
forming maintenance operations.
q Some actions involved in the operation and maintenance of the machine may cause serious injuries or
even death, if they are not performed in compliance with the instructions given herein.
q The procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
INFORMATION ON SAFETY
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates applied on to the machine.
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
q Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This signal word is to be limited to most extreme situations.
WARNING
q Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
q Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is are useful to know.
IMPORTANT
q This word is used for precautions that must be taken to avoid actions which could shorten the life of the
machine.
NOTE
q 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.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity of the machine will work in total safety, with no risk of injuries or damage. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu or your local Dealer.
DANGER
q Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and of the controls and stop the engine.
DANGER
q To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine hood is
open, unless this is expressly prescribed for some specific maintenance operations.
2
INFORMATION ON SAFETY
WARNING
q 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 modifying the standard setting of the hydraulic system.
WARNING
q Before carrying out any electrical welding, disconnect the battery and the alternator (see "2.8.13 PRE-
CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR").
WARNING
q Install only authorized additional equipment (see "6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIP-
MENT OF THE MACHINE VERSION WITH HIGH-FLOW AND SUPER-FLOW HYDRAULIC SYSTEM").
WARNING
q Travel on roads is allowed only if the machine is provided with appropriate lighting, signalling and safety
devices and properly authorized by the relevant papers.
Before travelling on roads, make sure that the equipment installed on the machine is homologated and
that the safety locks are correctly engaged.
DANGER
q It is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.
3
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 trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
q This paragraph describes some of the improper or unauthorized uses of the machine; since it is impos-
sible to predict all the possible improper uses, if the machine happens to be used for particular applications, contact your Komatsu Dealer before carrying out the work.
IMPORTANT
q The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are attached to this
manual.
q The instructions regarding the assembly of the authorized equipment, the controls requiring special ar-
rangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.
Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials;
therefore, the following uses are absolutely forbidden:
q USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
q USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
q TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
q USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
q USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
q Simple and easy operation.
q Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors opera-
ting epicyclic reduction gears.
q Four driving wheels always engaged through oil-immersed roller chains.
q Main equipment and travel control through servo levers ensuring also combined movements that can be modu-
lated proportionally and continually.
q Foot control for the optional equipment (if installed).
q Foot accelerator.
q Lever accelerator.
q Parking brake control.
q Complete series of instruments visible from the operating position.
q Easy maintenance with simplified intervals.
q Road travel (on request).
4
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 functionality will be untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
q After starting the engine, let it idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
q Avoid operating the machine with the limit loads allowed or at high speed.
q Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
q After the first 50 hours of use, carry out the following operations, in addition to those to be performed every 50
hours:
1 - Check the gearing chain tension.
2 - Check the wheel nut tightening.
q After the first 250 hours of use, carry out the following operations, in addition to those to be performed every 250
hours:
1 - Change the hydraulic circuit drain filter.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
On machines in which the synthetic biodegradable oil type HEES is used, carry out the following operations in addition to the routine maintenance:
q After the first 50 hours of operation, change the hydraulic circuit drain filter.
q After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
q When changing the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits can be observed, find out what may have caused them before restarting the machine.
q The number of operating hours is indicated by the hour meter.
5
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 indicated to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the inner wall of the
rear right pillar.
RWAA13090
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu MACHINES described in this manual are provided with the CE mark, which certifies that they are in compliance with the CE harmonized standards.
The plate with the mark is applied on to the inner wall of the rear right pillar.
MODELLO - MODEL
TYP - MODELE
MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.
ANNO - YEAR
BAUJAHR - ANNEE
MASSA TOTALE - TOTAL WEIGHT
GESAMTGEWICHT - POIDS TOTAL
POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR
Product Identification Number
PIN
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
MODEL
SERIAL N˚
YEAR
TOTAL WEIGHT
ENGINE POWER
Product Identification Number
PIN
RWAA13100
kg
kw
37A-98-11820
RWA39300
kg
kw
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
6
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.
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.
PRODUCT IDENTIFICATION
2
1
RWAA9660
1.4.5 CAB SERIAL NUMBER
The cab serial number is stamped on the plate positioned on
the right side of the base cross member.
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)
The excavator identification number is stamped on the plate
positioned on the left side of the control panel.
RWAA9670
RWAA9680
RWAA2520
7
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:
Person to contact:
NOTES:
Te l.
8
TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USES .................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER................................................................................................... 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 CAB SERIAL NUMBER ........................................................................................................... 7
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed) .............................................................. 7
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 8
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 16
2.1.1 POSITION OF THE SAFETY PLATES .................................................................................... 16
2.1.1.1 SAFETY PLATES ................................................................................................... 16
2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR ..................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 20
2.1.3 POSITION OF THE NOISE PLATES ...................................................................................... 23
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 23
2.2 GENERAL PRECAUTIONS .................................................................................................................. 24
2.2.1 GENERAL SAFETY RULES .................................................................................................... 24
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 24
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 24
2.2.4 UNAUTHORIZED MODIFICATIONS ....................................................................................... 25
2.2.5 LEAVING THE OPERATORS SEAT ....................................................................................... 25
2.2.6 GETTING ON AND OFF THE MACHINE ................................................................................ 26
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed) ........................................................... 26
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL ..................................................................... 27
2.2.9 PREVENTING BURNS ............................................................................................................ 27
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER .................................................... 28
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 28
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT ........................................................................ 29
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 29
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT ............................................................... 29
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE................................................. 30
2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 30
2.3.2 FIRE PREVENTION ................................................................................................................ 30
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB ............................................. 30
2.3.4 ROOM VENTILATION ............................................................................................................. 31
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)............................................. 31
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING
THE WINDSHIELD WIPER BLADES (if installed) ................................................................... 31
9
TABLE OF CONTENTS
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 32
2.4.1 STARTING THE ENGINE......................................................................................................... 32
2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS ............................................. 32
2.4.3 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 33
2.4.4 MOVING THE MACHINE ........................................................................................................34
2.4.5 WORKING ON SLOPES .........................................................................................................34
2.4.6 PREVENTING ELECTROCUTION........................................................................................... 36
2.4.7 VISIBILITY ................................................................................................................................ 37
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 37
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 37
2.4.10 WORKING ON LOOSE GROUND ........................................................................................... 37
2.4.11 PARKING THE MACHINE ....................................................................................................... 38
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 39
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 39
2.5.2 THE ROUTE ............................................................................................................................. 39
2.6 BATTERY .............................................................................................................................................. 40
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ........................................................ 40
2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 40
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY ............................................................................... 41
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ................................................................. 43
2.8.1 WARNING PLATES ................................................................................................................. 43
2.8.2 TOOLS ..................................................................................................................................... 43
2.8.3 PERSONNEL............................................................................................................................ 44
2.8.4 EQUIPMENT ........................................................................................................................... 44
2.8.5 WORKING UNDER THE MACHINE ........................................................................................ 44
2.8.6 KEEPING THE MACHINE CLEAN .......................................................................................... 44
2.8.7 USE OF THE ENGINE DURING MAINTENANCE ................................................................... 45
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 45
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 45
2.8.10 RULES FOR REFUELLING AND ADDING OIL ...................................................................... 46
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ....................................................... 46
2.8.12 USING LAMPS ........................................................................................................................ 46
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR ......................... 47
2.8.14 PRECAUTIONS CONCERNING THE STARTER ................................................................... 47
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES.................................................. 48
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS ........ 48
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES
AND PRESSURES ..................................................................................................................48
2.8.18 COOLING FAN AND FAN BELT ............................................................................................. 49
2.8.19 WASTE MATERIALS ............................................................................................................... 49
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES .......................................... 49
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE
OIL TYPE «HEES»................................................................................................................... 50
10
TABLE OF CONTENTS
DESCRIPTION AND USE OF THE MACHINE
3.1 SAFETY LOCKS ................................................................................................................................... 52
3.1.1 LOADER LOCKS ..................................................................................................................... 52
3.1.2 EXCAVATOR LOCKS (if installed) ........................................................................................... 54
3.1.3 ASPHALT CUTTER LOCKS (if installed) ................................................................................. 56
3.2 GENERAL VIEWS................................................................................................................................. 57
3.2.1 FRONT GENERAL VIEW .........................................................................................................57
3.2.2 REAR GENERAL VIEW ........................................................................................................... 58
3.2.3 CAB INSIDE GENERAL VIEW ................................................................................................ 59
3.3 INSTRUMENTS AND CONTROLS ....................................................................................................... 61
3.3.1 INSTRUMENTS........................................................................................................................ 61
3.3.2 WARNING LIGHTS .................................................................................................................. 63
3.3.3 SWITCHES UND PUSH BUTTONS......................................................................................... 68
3.3.4 ELECTRICAL ACCESSORIES ............................................................................................... 73
3.3.5 MACHINE CONTROLS ............................................................................................................ 75
3.4 FUSES AND RELAYS........................................................................................................................... 95
3.4.1 MACHINE FUNCTION FUSES ............................................................................................... 95
3.4.2 MAIN FUSE ............................................................................................................................. 96
3.4.3 RELAYS .................................................................................................................................. 97
3.5 GUARDS AND DRIVER’S SEAT .......................................................................................................... 99
3.5.1 ENGINE HOOD ........................................................................................................................ 99
3.5.2 REAR PANEL .......................................................................................................................... 100
3.5.3 CAB .......................................................................................................................................... 101
3.5.3.1 RAISING THE CAB ................................................................................................ 102
3.5.4 STANDARD SEAT .................................................................................................................. 104
3.5.5 CUSHIONED SEAT ................................................................................................................. 104
3.5.6 SAFETY BELT.......................................................................................................................... 105
3.5.7 EMERGENCY EXIT ................................................................................................................. 105
3.5.8 TECHNICAL DOCUMENTATION CASE.................................................................................. 106
3.5.9 FIRE EXTINGUISHER ............................................................................................................ 106
3.5.10 FIRST AID KIT ......................................................................................................................... 106
3.6 USE OF THE MACHINE........................................................................................................................ 107
3.6.1 CHECKS BEFORE STARTING THE ENGINE......................................................................... 107
3.6.1.1 VISUAL CHECKS ................................................................................................... 107
3.6.1.2 DAILY CHECKS ...................................................................................................... 107
3.6.1.3 OPERATIONAL CHECKS ...................................................................................... 108
3.6.2 STARTING THE ENGINE ........................................................................................................ 109
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES ................... 109
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................ 110
3.6.3 WARMING THE ENGINE ......................................................................................................... 111
3.6.4 HEATING THE HYDRAULIC OIL ............................................................................................. 111
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEMERN) ........................ 111
3.6.5.1 STEERING (CHANGING DIRECTION) .................................................................. 113
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM).................... 115
3.6.6.1 STEERING (CHANGING DIRECTION) .................................................................. 117
3.6.7 MOVING ON SLOPES ............................................................................................................. 119
3.6.8 MAXIMUM IMMERSION DEPTH ............................................................................................. 120
3.7 PARKING THE MACHINE .................................................................................................................... 121
3.7.1 PARKING ON LEVEL GROUND ............................................................................................. 121
3.7.2 PARKING ON SLOPES............................................................................................................ 122
3.8 STOPPING THE ENGINE ..................................................................................................................... 123
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TABLE OF CONTENTS
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 124
3.9.1 LOADING AND UNLOADING THE MACHINE ......................................................................... 124
3.9.2 TRANSPORT............................................................................................................................ 125
3.10 HOW TO LIFT THE MACHINE.............................................................................................................. 126
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON ................................................................... 127
3.11.1 FUEL AND LUBRICANTS ........................................................................................................ 127
3.11.2 COOLANT ................................................................................................................................ 127
3.11.3 BATTERY ................................................................................................................................. 128
3.11.4 OTHER PRECAUTIONS .......................................................................................................... 128
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK ...................................................... 128
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON .................................................................. 129
3.13 USING THE WORK EQUIPMENT......................................................................................................... 130
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE ........................................ 130
3.13.2 ORGANIZING THE WORK ARE .............................................................................................. 131
3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES .......................................... 132
3.13.4 LOADING MATERIAL ON SLOPES ........................................................................................ 133
3.13.5 DIGGING METHOD.................................................................................................................. 134
3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING ... 135
3.13.6.1 RELEASING THE BUCKET .................................................................................... 136
3.13.6.2 COUPLING THE BUCKET ...................................................................................... 136
3.13.7 CHANGING THE BUCKET OR THE EQUIPMENT WITH OPTIONAL RAPID COUPLING .... 138
3.13.7.1 REMOVING THE BUCKET OR THE EQUIPMENT ................................................ 139
3.13.7.2 CONNECTING THE BUCKET ................................................................................ 140
3.13.7.3 CHECKING THE POSITION OF THE LOCKING PINS .......................................... 141
3.13.7.4 ADJUSTING THE LOCKING PINS ......................................................................... 142
3.14 LONG PERIODS OF INACTIVITY ........................................................................................................ 143
3.14.1 BEFORE THE PERIOD OF INACTIVITY ................................................................................ 143
3.14.2 DURING THE PERIOD OF INACTIVITY .................................................................................. 144
3.14.3 AFTER THE PERIOD OF INACTIVITY .................................................................................... 144
3.15 TROUBLESHOOTING .......................................................................................................................... 145
3.15.1 HOW TO REMOVE THE MACHINE......................................................................................... 145
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED ............................................................ 145
3.15.3 IF THE BATTERY IS DEPLETED ............................................................................................ 146
3.15.3.1 STARTING WITH BOOSTER CABLES .................................................................. 147
3.15.4 OTHER TROUBLES................................................................................................................. 148
3.15.4.1 ELECTRICAL CIRCUIT........................................................................................... 148
3.15.4.2 HYDRAULIC SYSTEM ............................................................................................ 148
3.15.4.3 ENGINE................................................................................................................... 149
3.15.4.4 HYDROSTATIC TRANSMISSION ......................................................................... 150
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TABLE OF CONTENTS
MAINTENANCE
4.1 GUIDE TO MAINTENANCE .................................................................................................................. 154
4.2 MAINTENANCE NOTES ....................................................................................................................... 156
4.2.1 NOTES REGARDING THE ENGINE ....................................................................................... 156
4.2.1.1 ENGINE OIL............................................................................................................ 156
4.2.1.2 COOLANT ............................................................................................................... 156
4.2.1.3 FUEL ....................................................................................................................... 157
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM................................................................. 157
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM ............................................................... 157
4.2.4 NOTES REGARDING LUBRICATION ..................................................................................... 158
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.............................. 158
4.3 FUEL, COOLANT AND LUBRICANTS................................................................................................. 159
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES ................... 161
4.4 DRIVING TORQUES FOR SCREWS AND NUTS ................................................................................ 162
4.4.1 STANDARD DRIVING TORQUES ........................................................................................... 162
4.4.2 SPECIFIC DRIVING TORQUES .............................................................................................. 162
4.5 LUBRICATION ...................................................................................................................................... 163
4.5.1 LUBRICATION DIAGRAM........................................................................................................ 163
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY.............................. 164
4.6.1 CRITICAL PARTS FOR SAFETY............................................................................................. 165
4.7 MAINTENANCE PLAN.......................................................................................................................... 171
4.8 MAINTENANCE PROCEDURE ............................................................................................................ 173
4.8.1 WHEN REQUIRED................................................................................................................... 173
4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE ....... 173
4.8.1.b TYRE ROTATION .................................................................................................. 174
4.8.1.c DRAINING THE FUEL TANK ................................................................................. 175
4.8.1.d RELEASING THE PARKING BRAKE .................................................................... 176
4.8.1.e CHECKING THE BATTERY CHARGE LEVEL ....................................................... 177
4.8.2 CHECKS BEFORE STARTING................................................................................................ 178
4.8.2.a VARIOUS CHECKS ................................................................................................ 178
4.8.2.b CHECKING THE COOLANT LEVEL ...................................................................... 178
4.8.2.c CHECKING THE FUEL LEVEL............................................................................... 179
4.8.2.d CHECKING THE ENGINE OIL LEVEL ................................................................... 180
4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT ............................... 181
4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER .......... 182
4.8.2.g CHECKING THE WIRING SYSTEM ....................................................................... 182
4.8.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION ........................................ 183
4.8.4 MAINTENANCE EVERY 50 HOURS OF OPERATION ........................................................... 183
4.8.4.a CHECKING THE TYRE PRESSURE ..................................................................... 183
4.8.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................... 183
4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ...................................... 184
4.8.6 MAINTENANCE EVERY 250 HOURS OF OPERATION ......................................................... 184
4.8.6.a ADJUSTING THE FAN BELT TENSION................................................................. 184
4.8.6.b CHECKING THE GEARING CHAIN TENSION ...................................................... 185
4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS................................................. 187
4.8.6.d CHECKING THE WHEEL NUT DRIVING TORQUE............................................... 187
4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS .......................... 188
4.8.6.f LUBRICATING THE JOINTS .................................................................................. 189
4.8.6.g CHANGING THE ENGINE OIL ............................................................................... 190
4.8.6.h CHANGING THE ENGINE OIL FILTER.................................................................. 191
4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines filled with synthetic biodegradable oil type HEES) .................................... 192
13
TABLE OF CONTENTS
4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 192
4.8.8.a CHANGING THE FUEL FILTER ............................................................................. 192
4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER .............................................. 194
4.8.8.c CLEANING THE WATER SEPARATOR................................................................. 195
4.8.8.d DRAINING THE HYDRAULIC OIL TANK
(Only for machines filled with synthetic biodegradable oil type HEES) ................... 196
4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION ....................................................... 197
4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION ......................................... 197
4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION
FILTER .................................................................................................................... 198
4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ..................... 199
4.8.10 MANUTENZIONE OGNI 2000 ORE ......................................................................................... 200
4.8.10.a CHANGING THE COOLANT .................................................................................. 200
4.8.10.b CHANGING THE SUCTION FILTER ...................................................................... 201
4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER ......................................... 202
TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA ............................................................................................................................... 204
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS ................................................................... 204
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT.................................... 206
5.1.3 TECHNICAL CHARACTERISTICS .......................................................................................... 210
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 214
6.1.1 PRECAUTIONS REGARDING SAFETY .................................................................................. 214
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 215
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT.................. 216
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION
WITH HIGH-FLOW AND SUPER-FLOW HYDRAULIC SYSTEM ............................................ 217
6.2 CHANGING THE AUTHORIZED EQUIPMENT .................................................................................... 218
6.2.1 CONNECTING THE EXCAVATOR .......................................................................................... 218
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT............................................................................ 219
6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK ........ 221
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR .................................... 222
6.2.5 USING THE MACHINE WITH THE EXCAVATOR ................................................................... 222
6.3 PALLET FORKS ................................................................................................................................... 223
6.4 CHANGING THE OPERATING PATTERN ........................................................................................... 224
6.4.1 HOW TO CHANGE THE OPERATING PATTERN .................................................................. 226
6.5 HAND & FOOT CONTROL SYSTEM ...................................................................................................227
6.5.1 MACHINE CONTROLS ............................................................................................................ 227
6.5.1.1 TRAVEL AND STEERING CONTROL LEVERS..................................................... 228
6.5.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET).......... 230
6.5.1.3 AUXILIARY HYDRAULIC KIT CONTROL ............................................................... 233
6.5.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM) ............................... 236
6.5.2.1 STEERING (CHANGING DIRECTION) .................................................................. 238
14
SAFETY AND
ACCIDENT PREVENTION
15
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
q The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made of water and detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer.
q In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on
the new part.
q The machine can be provided with other plates in addition to those indicated below; in any case, keep also to the
instructions given in the additional plates.
2.1.1.1 SAFETY PLATES
RWA37010
16
RWA00030
RWA37020
SAFETY, NOISE AND VIBRATION PLATES
RWA00010
17
SAFETY, NOISE AND VIBRATION PLATES
2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR
RWA37030
RWA00020
RWA00030
18
RWA37040
SAFETY, NOISE AND VIBRATION PLATES
RWA00020
RWA00010
19
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; the following description illustrates what they look like and their respective meanings.
DANGER IN THE WORK AREA
(Only for machines with excavator)
q Do not approach or stand within the equipment operating ra-
dius when the boom and the bucket of the excavator are raised.
RWA00020
DO NOT OPEN THE HOOD
q Do not open or remove the hood while the engine is running.
CONSULT THE MANUAL
q Carefully read the contents of the manual before using the
machine or performing maintenance operations.
HYDRAULIC OIL TOPPING UP
RWA00010
RWA00030
20
RWA00050
BIOLOGICAL HYDRAULIC OIL TOPPING UP
SAFETY, NOISE AND VIBRATION PLATES
REFUELLING
ENGINE LUBRICATING OIL FILTER
FUEL FILTER
BIO-OIL
D
RWA00040
RWA00080
RWA34380
ENGINE AIR SUCTION FILTER
ENGINE COOLANT
D
RWA00060
RWA00090
RWA00130
21
SAFETY, NOISE AND VIBRATION PLATES
ENGINE COOLANT PRESSURE
HYDRAULIC OIL LEVEL
HYDRAULIC OIL FILTER
RWA00110
RWA00100
ELECTRIC OUTLET
ANCHORAGE POINT
EMERGENCY EXIT
RWA00120
RWA00070
12 V
RWA00200
LIFTING POINT
22
RWA00190
RWA04920
2.1.3 POSITION OF THE NOISE PLATES
q The noise plates must always be legible and in good condi-
tions; for this reason, if they are dirty with dust, oil or grease,
it is necessary to clean them with a solution made of water
and detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or
to your Komatsu Dealer.
q In case of replacement of a component provided with a noi-
se plate, make sure that this plate is applied also on the new
part.
NOISE OUTSIDE THE CAB
q This value indicates the noise level outside the machine and
refers to the noise perceived by the persons who are in the
vicinity of the work area.
SAFETY, NOISE AND VIBRATION PLATES
RWA37050
10
NOISE INSIDE THE CAB
q This value indicates the maximum noise level perceived by
the operatorís ears inside the cab.
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
q According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is
subjected to vibrations lower than 0.5 m/sq sec.
1
2000/14/EC
8
6
ISO 6396
dB
RWA37060
dB
RWA36350
23
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
q Only trained and authorized personnel can use the machine and perform maintenance operations.
q When using the machine or performing maintenance operations, follow all the safety rules, precautions and in-
structions.
q 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.
2.2.2 SAFETY DEVICES AND GUARDS
q Make sure that all the guards and covers are in the correct position. Have guards and covers changed or repai-
red if damaged. Neither use the machine without guards, nor remove the guards when the engine is running.
q Always use the proper safety devices to lock the machine when parking and remember to fasten the safety belt.
q For the safety devices, see "3.1 SAFETY LOCKS".
q For the safety belt, see "3.5.6 SAFETY BELT".
q Do not remove the safety devices and always keep them in good operating conditions.
q Improper use of the safety devices may lead to serious injuries or even death.
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
q Do not wear large or loose clothes, rings and watches and do
not approach the machine with loose long hair, since they
can get entagled in the moving parts of the machine and cause serious injuries and damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
q Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing
maintenance operations.
q Always wear safety goggles, a hard hat and heavy gloves if
your job involves scattering metal chips or minute materials;
these precautions are particularly useful when driving the
equipment connection pins with a hammer and when blowing
compressed air into the air filter and the radiator to clean
them.
During these operations, make also sure that no one is standing or working near the machine without the necessary protections.
q When working for 8 hours with a noise level exceeding 90
dBA, it is necessary to use headphones or ear plugs and to
be particularly careful, especially at the end of the work shift.
RWA00960
24
GENERAL PRECAUTIONS
P
2.2.4 UNAUTHORIZED MODIFICATIONS
q Any modification made without the authorization of Komatsu can involve hazards.
q 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
q When leaving the operatorís seat, even if temporarily, make
sure that the machine is in a safe position (see "2.4.11
PARKING THE MACHINE").
q Before leaving the operatorís seat, carry out the following
operations in the sequence indicated below:
1 - Rest the equipment on the ground.
RWA37070
2 - Apply the parking brake.
3 - Engage the safety device of the optional equipment con-
trol pedal (if installed).
4 - Lock the equipment and travel control by shifting the safe-
ty bars to the lock position.
5- Stop the engine (see "3.8 STOPPING THE ENGINE").
If you have to go so far away that you will not be able to see
the machine, extract the ignition key.
RWAA11160
RWAA12610
RWAA13110
25
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
q Do not jump on or off the machine, either when it is at rest
and when it is moving.
q When getting on or off the machine, always use the appro-
priate handles and footboards; get on and off the machine
very carefully.
q Never hold or rest on the control levers.
q Either when getting on and when getting off the machine,
always maintain three points of contact (holding or resting
points), in order to avoid losing your balance and falling
down.
q Clean the handles and footboards if they are dirty with oil or
grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud
or rubble.
RWA37080
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)
q Make sure that the rear-view mirrors are clean and correctly
directed; the operator must be able to check the area behind
the machine with no need to move the trunk with respect to
his normal operating position.
q If the rear-view mirrors should move or break during the ope-
rations, stop the machine immediately and fix or change
them.
q Working without checking the area behind the machine in-
volves the risk of running over persons who have incautiously approached the machine or colliding with fixed obstacles
or manoeuvring vehicles.
RWA18670
RWA37090
26
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.
q Keep any naked flame away from flammable fluids.
q Stop the engine and do not smoke when refuelling.
q Top up with fuel and oil only after stopping the engine and in
well ventilated areas.
q Top up with fuel and oil in a well delimited area and do not al-
low unauthorized persons to approach.
q When refuelling, hold the fuel gun firmly and keep it constan-
tly in contact with the filler until you have finished, in order to
avoid sparks due to static electricity.
q After topping up, tighten the safety caps of the fuel and oil
tanks securely.
q Do not fill the tank completely, in order to leave room for the
fuel to expand.
q In case some fuel is spilled, wipe it up immediately.
GENERAL PRECAUTIONS
RWA00970
2.2.9 PREVENTING BURNS
q If the engine coolant, the engine oil and the hydraulic oil are
hot, use heavy cloths and wear gloves, heavy clothing and
safety goggles before carrying out any check or touching the
hot parts.
q Before checking the coolant level, stop the engine and let
the fluid cool down.
If a check is necessary due to the overheating of the engine,
slowly loosen the radiator cap to release any residual pressure before removing it. The hot fluid that spurts out may
cause serious burns.
q Before checking the engine oil and the hydraulic circuit oil le-
vels, stop the engine and let the oil cool down. The hot oil
that can be sprayed out of the tank may cause serious burns.
RWA00980
RWA00990
27
GENERAL PRECAUTIONS
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
q Asbestos powder can be hazardous to your health if it is
inhaled.
q If you handle materials containing asbestos fibers, keep to
the instructions given below contenga fibre di amianto, utilizzare 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.
2 - Use low-pressure water to keep down the dust when clea-
ning.
3 - If there is danger that there may be asbestos powder in
the air, operate the machine with the wind to your back
whenever possible.
4 - Even if the cab provides suitable protection, use an ap-
proved and homologated respirator.
5 - The powder gathered during the cleaning operations must
be dampened and put in a sealed and marked container,
so that it can be safely disposed of according to the regulations in force.
RWA01000
RWA01010
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
q Do not stand within or approach the operating radius of the
work equipment, even when the operator is on board the
machine and the engine is running.
q Do not stand or work under the arms or the articulated joints
when the arms are lifted, if you are not sure that the safety
locks have been duly engaged.
q Do not carry out any operation requiring the lifting of the ar-
ms, if you are not sure that the locks are correctly positioned
and coupled to the arms.
RWA21910
28
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