KOMATSU WA95-M, WA95-3 Maintenance Manual
Operation & Maintenance
Manual
VEAM980500
WA95-3
WHEEL LOADER
SERIAL NUMBERS
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
HA980376
and up
NOTICE
Komatsu has had the operating and maintenance instructions translated into all the languages of the
member states in the European Union. Should you
wish to have a version of the operating instructions
in another language, please don’t hesitate to ask at
your local dealer’s.
Contents
Contents
Information on these Operating Instructions .............................................................. 1-1
Why You Should Read these Operating Instructions .................................................................... 1-3
Notes on Safety Regulations ......................................................................................................... 1-4
Correct Use .................................................................................................................................................................1-4
Safety Notes in the Operating Instructions ................................................................................................................. 1-4
Standards and Guidelines ........................................................................................................................................... 1-6
CE-Conforming Equipment ............................................................................................................ 1-8
CE-Conforming Equipment of the Manufacturer According to Document 42W-93-11130 ....................................... 1-10
Loading and Transporting the Machine........................................................................ 2-1
Loading and Transporting the Machine.......................................................................................... 2-3
Securing the Articulated Steering ............................................................................................................................... 2-3
Lifting the Machine ......................................................................................................................................................2-3
Driving Machine Onto Loading Area of Transport Vehicle ..........................................................................................2-4
Securing the Machine During Transport...................................................................................................................... 2-5
After Transport ............................................................................................................................................................. 2-5
Dimensions, Weights, and Operating Values ................................................................................ 2-6
Technical Data ................................................................................................................................ 2-7
Safety............................................................................................................................... 3-1
General Safety Measures .............................................................................................................. 3-2
Safety Instructions ....................................................................................................................................................... 3-2
Safety Devices ............................................................................................................................................................ 3-2
Emergency Exit ...........................................................................................................................................................3-2
Clothing and Personal Protection ............................................................................................................................... 3-2
Machine Modifications ................................................................................................................................................. 3-3
Before You Leave the Driver's Seat ............................................................................................................................ 3-3
Mounting and Dismounting ......................................................................................................................................... 3-3
Fire Prevention and Fire Fighting ................................................................................................................................ 3-4
Protection Against Asbestos Dust ............................................................................................................................... 3-5
Protection Against Injuries .......................................................................................................................................... 3-5
Working at High Temperatures .................................................................................................................................... 3-5
Roll-Over Protection System (ROPS) ......................................................................................................................... 3-6
Attachment for Protection Against Falling Objects (FOPS) ........................................................................................ 3-6
Attachments ................................................................................................................................................................ 3-6
Battery .........................................................................................................................................................................3-7
Before You Start the Engine .......................................................................................................... 3-8
Workplace Safety ........................................................................................................................................................ 3-8
In the Driver's Cab....................................................................................................................................................... 3-8
In-Door Operation ....................................................................................................................................................... 3-9
Gas, Dust, and Inflammable Vapours .........................................................................................................................3-9
Mirrors, Windows, and Lighting................................................................................................................................... 3-9
Machine Operation ....................................................................................................................... 3-10
Before You Start the Engine .....................................................................................................................................3-10
Reversing .................................................................................................................................................................. 3-10
Driving ....................................................................................................................................................................... 3-10
Driving On Slopes ..................................................................................................................................................... 3-11
Emergency Lowering System ................................................................................................................................... 3-11
Working Close to Overhead Power Transmission Lines...........................................................................................3-12
Loading......................................................................................................................................................................3-12
Good Vision ............................................................................................................................................................... 3-13
Working On Snow .....................................................................................................................................................3-13
Height Limitation .......................................................................................................................................................3-13
Brakes ....................................................................................................................................................................... 3-13
0-1
Contents
Working On Loose Soil .............................................................................................................................................3-13
Working with the Forklift Truck Attachment...............................................................................................................3-14
Parking the Machine ................................................................................................................................................. 3-15
Transport ...................................................................................................................................... 3-16
Loading and Unloading the Machine ........................................................................................................................ 3-16
Transport ................................................................................................................................................................... 3-16
Safety Measures During Maintenance ......................................................................................... 3-17
Personnel ..................................................................................................................................................................3-17
Prior to Start of Maintenance Measures.................................................................................................................... 3-17
During Maintenance ..................................................................................................................................................3-19
Tyres .........................................................................................................................................................................3-23
Labeling........................................................................................................................................ 3-24
Positions of Safety Labels ......................................................................................................................................... 3-24
Information Labels.....................................................................................................................................................3-25
Controls and Indicators .................................................................................................4-1
Overall View of the Machine .......................................................................................................... 4-3
Controls and Indicators .................................................................................................................. 4-4
Overall View ................................................................................................................................................................ 4-4
Instrument Panel .........................................................................................................................................................4-5
Warning Lights ............................................................................................................................................................ 4-6
Control Lamps ............................................................................................................................................................. 4-8
Measuring Indicators ................................................................................................................................................. 4-11
Switches ....................................................................................................................................................................4-13
Control Levers, Pedals ..............................................................................................................................................4-19
Articulated Steering Catch ........................................................................................................................................4-23
Traction Device..........................................................................................................................................................4-23
Socket .......................................................................................................................................................................4-23
Door Unlocking System............................................................................................................................................. 4-23
Alarm Horn for Reverse Driving (Option) ..................................................................................................................4-23
Operation ........................................................................................................................ 5-1
Running in the Machine ................................................................................................................. 5-3
Preparing the Machine Start .......................................................................................................... 5-4
Visual Checks (also refer to chapter "Maintenance Prior to Machine Start") .............................................................. 5-4
Adjustments Prior to Machine Start ............................................................................................... 5-6
Adjusting the Driver’s Seat .......................................................................................................................................... 5-6
Adjusting the Steering Column ................................................................................................................................... 5-7
Adjusting the Armrest ..................................................................................................................................................5-7
Adjusting the Rear-View Mirrors .................................................................................................................................5-7
Adjusting the Heating and Ventilation System ............................................................................................................5-8
Operating the Air Conditioning .................................................................................................................................... 5-9
Putting on the Safety Belt .......................................................................................................................................... 5-10
Starting and Switching Off the Engine ......................................................................................... 5-11
Starting the Engine.................................................................................................................................................... 5-11
Switching Off the Engine ........................................................................................................................................... 5-12
Driving .......................................................................................................................................... 5-13
Start-Up .....................................................................................................................................................................5-13
Driving with the high-speed gear...............................................................................................................................5-14
Changing the Driving Direction ................................................................................................................................. 5-15
Reverse Driving ......................................................................................................................................................... 5-15
Turning ......................................................................................................................................................................5-16
Braking ......................................................................................................................................................................5-17
Stopping ....................................................................................................................................................................5-18
Longer-Distance Driving............................................................................................................................................ 5-19
Operating the Machine................................................................................................................. 5-20
Tyre-Appropriate Operation ...................................................................................................................................... 5-22
Adjusting the Bucket Positioner ................................................................................................................................5-23
Loading......................................................................................................................................................................5-24
Transporting .............................................................................................................................................................. 5-26
0-2
Contents
Dumping/Unloading................................................................................................................................................... 5-26
Planing ...................................................................................................................................................................... 5-27
Working With the Forklift Truck Attachment..............................................................................................................5-28
Precautions For Special Operations .........................................................................................................................5-29
After the work is finished ...........................................................................................................................................5-29
Instructions for Winter Operation ..............................................................................................................................5-30
Longer Standstill Periods of the Machine ................................................................................................................. 5-31
Troubleshooting ............................................................................................................. 6-1
Troubleshooting.............................................................................................................................. 6-3
Warning Lights and Indicators ....................................................................................................................................6-3
Electrical System ......................................................................................................................................................... 6-4
Engine ......................................................................................................................................................................... 6-5
Hydraulic System ........................................................................................................................................................ 6-8
Brakes ....................................................................................................................................................................... 6-10
Axles .......................................................................................................................................................................... 6-11
Driver's cab ............................................................................................................................................................... 6-11
Emergency Steering Characteristics ......................................................................................................................... 6-12
Emergency Lowering System ................................................................................................................................... 6-12
Starting the Engine with a Battery Jumper Cable ..................................................................................................... 6-13
Towing the Machine ................................................................................................................................................... 6-15
Inadequate Braking Effect ......................................................................................................................................... 6-17
Maintenance.................................................................................................................... 7-1
Maintenance Basics ....................................................................................................................... 7-3
Cleaning the Machine ................................................................................................................................................. 7-4
Working-Area-Dependent Maintenance .....................................................................................................................7-5
Lubricants and Operating Agents ............................................................................................................................... 7-6
Replacing Safety-Related Parts ................................................................................................................................ 7-11
Spare Parts and Consumable Components ............................................................................................................. 7-12
Electrical System ....................................................................................................................................................... 7-13
Tyres .........................................................................................................................................................................7-15
Tools...........................................................................................................................................................................7-17
Torque for Standard Nuts and Bolts .......................................................................................................................... 7-18
Maintenance Schedule................................................................................................................. 7-21
Maintenance Prior to Start ........................................................................................................... 7-23
Cooling System, Checking the Coolant Level, Topping Up Coolant..........................................................................7-23
Engine, Checking the Oil Level, Topping Up Oil........................................................................................................ 7-24
Engine, Draining Off Oil ............................................................................................................................................7-24
Checking the Fuel Level, Refuelling ......................................................................................................................... 7-25
Checking the Controls ............................................................................................................................................... 7-25
Checking the Electrical Connections ........................................................................................................................ 7-26
Heater / Air conditioning: checking rate of air flow .................................................................................................... 7-26
Other Maintenance Measures Prior to Start.............................................................................................................. 7-26
Maintenance upon Demand ......................................................................................................... 7-27
Checking the Air Conditioning System...................................................................................................................... 7-27
Maintenance Every 10 Operating Hours ...................................................................................... 7-28
Lubrication ................................................................................................................................................................. 7-28
Maintenance After the First 50 Operating Hours ......................................................................... 7-29
Engine, Changing Oil and Replacing the Oil Filter Cartridge....................................................................................7-29
Replacing the Oil Filter Cartridge ..............................................................................................................................7-30
V-Belt, Checking the Condition .................................................................................................................................7-31
V-Belt, Checking and Adjusting the Tension..............................................................................................................7-31
Hydraulic System, Replacing the Filter Insert ...........................................................................................................7-32
Checking and Tightening the Wheel Nuts.................................................................................................................7-32
Front and Rear Axle, Oil Change ..............................................................................................................................7-33
Transfer Box Gearing - Changing Oil ........................................................................................................................7-34
Maintenance Every 50 Operating Hours ...................................................................................... 7-35
Checking the Cooling System, Coolant Level in the Radiator and expanion tank....................................................7-35
Draining Off Water and Dirt Deposits From the Fuel Tank ........................................................................................7-36
Checking the Service Brake and Oil Level, Refilling Oil ........................................................................................... 7-36
0-3
Contents
Checking the Battery and Acid Level ........................................................................................................................7-37
Re-Charging the Battery ...........................................................................................................................................7-38
Lubrication ................................................................................................................................................................. 7-39
Maintenance Every 100 Operating Hours .................................................................................... 7-40
Draining the Water Separator, Removing Water and Dirt Deposits .........................................................................7-40
Maintenance Every 250 Operating Hours .................................................................................... 7-41
Changing the Engine Oil and Oil Filter Cartridge ...................................................................................................... 7-41
Checking the V-Belt Condition ..................................................................................................................................7-41
Checking and Adjusting the V-belt Tension ............................................................................................................... 7-41
Front and Rear Axle, Checking the Oil Level ............................................................................................................ 7-42
Air Filter, Removing and Re-Installing the Filter Insert, Checking and Cleaning the Filter Insert............................. 7-43
Cleaning the Radiator Segments ..............................................................................................................................7-45
Lubrication ................................................................................................................................................................. 7-45
Maintenance Every 500 Operating Hours .................................................................................... 7-46
Changing the Fuel Filter and Filter Element ............................................................................................................. 7-46
Changing the Filter Cartridge of the Hydraulic System ............................................................................................. 7-47
Cleaning the Water Separator .................................................................................................................................. 7-48
Lubrication ................................................................................................................................................................. 7-49
Transfer Box Gearing, Checking the Oil Level and Refilling Oil................................................................................7-49
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter .............................................................................7-50
Heater/Air Conditioning: cleaning/replacing Filter Fleece
or cleaning Condenser ............................................................................................................................................. 7-51
Checking the ALS-Accumulator Gas Pressure (Option) ........................................................................................... 7-52
Maintenance Every 1000 Operating Hours .................................................................................. 7-53
Cooling System, Exchanging Coolant and Cleaning the System ............................................................................7-53
Front Axle, Oil Change ..............................................................................................................................................7-55
Rear Axle, Oil Change...............................................................................................................................................7-55
Transfer Box Gearing, Oil Change ............................................................................................................................7-55
Service Brake ............................................................................................................................................................7-55
Checking and Adjusting System Pressures .............................................................................................................. 7-55
Checking and Adjusting the Valve Play .................................................................................................................... 7-55
Checking and Adjusting the Injection Nozzles, Nozzle Pressure and Fuel-Jet Pattern............................................ 7-55
Checking the Accumulator Gas Pressure of third Control Circuit .............................................................................7-55
Maintenance Every 2000 Operating Hours .................................................................................. 7-56
Hydraulic System, Oil Change ..................................................................................................................................7-56
Ventilating the Hydraulic Oil Tank ..............................................................................................................................7-57
Cooling System, Checking the Antifreeze Content of the Coolant ........................................................................... 7-57
Checking the Cooling System ...................................................................................................................................7-57
Checking the Fuel Pump ........................................................................................................................................... 7-57
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if required) ...............................................................7-57
Checking the Water Pump ........................................................................................................................................ 7-57
Checking and Adjusting the Fuel Injection and Injection time .................................................................................. 7-58
Technical Data................................................................................................................. 8-1
Technical Data ................................................................................................................................ 8-2
Noise Emission Levels ................................................................................................................................................ 8-3
Vibration Level ............................................................................................................................................................ 8-3
Limit Values for Slopes ............................................................................................................................................... 8-3
Special Equipment and Attachments ........................................................................... 9-1
ALS-Electronics.............................................................................................................................. 9-3
Structure and Functioning Principle of the ALS-Electronics .......................................................................................9-3
Precautionary Measures for Switching on the ALS-Electronics .................................................................................. 9-3
Operation of the ALS-Electronics ................................................................................................................................ 9-3
Handling of the Pressure Accumulator ....................................................................................................................... 9-4
Index .............................................................................................................................. 10-1
0-4
Information on these Operating
Instructions
Information on these Operating Instructions
1 - 2
Information on these Operating Instructions
Why You Should Read these Operating Instructions
The machine must be operated, cleaned, and maintained very carefully
to ensure safe and troublefree operation. If you operate the machine
correctly, these operating instructions will help you to avoid injuries and
damage to property. To ensure this, these operating instructions take
into account all applicable legal regulations and directives; the operating
instructions comprise the following information:
• Notes on the Operating Instructions
• Notes on Transport
• Notes on Safety Regulations
• Operating Instructions
• Troubleshooting
• Maintenance Instructions
• Technical Data
• Notes on Lubricants and Operating Agents
The operating instructions are part of the machine and must always be
available at hand in the machine. If the operating instructions have been
lost or if they have become unreadable, because they are dirty, you may
receive a new copy from Komatsu or your local Komatsu dealer. If the
machine is resold, the operating instructions, the EU Declaration of
Conformity (CE), and the licence are to be handed over to the new owner.
The owner of the machine has to ensure that
• all persons driving the machine have the legally required
minimum age and are physically and mentally fit to perform the
tasks they are charged with.
• all persons in charge with operating or maintaining the machine
are appropriately instructed before operation or maintenance
is started. They must have completely read and understood
these operating instructions. In particular, this applies to the
following section "Notes on Safety Regulations" and the chapter
"Safety".
• all persons driving the machine have read the accompanying
leaflet "Notes on Operation of Komatsu Construction Machines in Public Traffic" - applying to operation of construction
machines with a speed of more than 20 km/h on German public
roads.
• the machine is correctly operated.
• the machine is not improperly modified.
Please note:
If the owner modifies safety-related parts of the machine, the certificate
of conformity of the manufacturer will lapse and the person who has
performed the modification has to issue a new certificate. Should you
have any questions concerning this point, please do not hesitate to ask
Komatsu.
1 - 3
Information on these Operating Instructions
Our continuous effort to improve the machine's design may lead to
changes of machine details. However, the introduction of these
improvements does not oblige us to perform them on machines which
have already been delivered and are already in use.
If these improvements result in minor changes, these minor changes will
not be described in the operating instructions. Should you require new
available information about your machine or have any questions
concerning the information given in the operating instructions, please do
not hesitate to contact either Komatsu or your responsible Komatsu dealer.
These operating instructions may refer to attachments and special
equipment not available from your local Komatsu dealer. Should you
require attachments or special equipment, ask your responsible Komatsu
dealer.
Notes on Safety Regulations
The procedures and precautionary measures concerning operation and
maintenance only apply on the provision that the machine is used as
intended.
Correct Use
A loader is a machine which has its own drive and which is moving on
either tracks or wheels. By moving in forward direction, a loader can load
material or cut the ground with the work unit (use of bucket) provided for
loading which is attached to its front.
The standard working cycle of a loader comprises filling and lifting the
loading bucket, transporting material, and emptying the loading bucket.
If you use the machine for any other purpose than specified above, we
will not accept any responsibility for safety. All considerations concerning
safety will then be up to the owner or the operating and maintenance
personnel. In any case, neither you nor any other person are/is authorised
to perform work and functions explicitly prohibited in these operating
instructions.
Safety Notes in the Operating Instructions
Most accidents are caused by disregard of basic safety regulations during
operation and maintenance of machines. In order to avoid accidents and
thus damage to persons and property, read all applicable safety notes
and warnings in these operating instructions and on the machine, before
you start operation or maintenance of the machine and always adhere to
these safety notes and warnings.
1 - 4
Information on these Operating Instructions
The chapter "Safety" starting on page 1-1 contains a summary of all
safety notes applying to this machine. We cannot, however, predict all
circumstances resulting in potentially dangerous situations when operating
and maintaining the machine. For this reason, it may be possible that the
safety notes in these operating instructions and on the machine do not
comprise all possible safety measures. If procedures or measures are
required which are not recommended or approved, you must ensure that
performing them is neither dangerous nor involving potential damage to
the machine. Should you have any doubt concerning safety of a procedure,
either directly contact Komatsu or your responsible Komatsu dealer.
The following signal words are used to indicate safet notes in these
operating instructions and on the labels attached to the machine:
DANGER This word is used in the safety notes and on
safety labels in situations or places where severe
injuries cannot be ruled out, if the danger is not
avoided. The safety notes or labels contain
precautionary measures which must be heeded
to avoid this danger.
WARNING This word is used in the safety notes and on
safety labels, if there is a potentially dangerous
situation which may lead to severe injury, if the
danger is not avoided. The safety notes or labels
contain precautionary measures that must be
realised to avoid this danger.
CAUTION This word is used in the safety notes and on
safety labels in dangerous situations which may
lead to minor injury, if the danger is not avoided.
It may also refer to dangers which may lead to
damage of the machine.
NOTE This word is used for precautionary measures
which must be realised to exclude processes
which would shorten the service life of the
machine.
IMPORTANT This word is used for important additional
information.
1 - 5
Information on these Operating Instructions
Standards and Guidelines
This machine is labelled with the CE mark indicating that it meets all
basic requirements concerning safety and protection of health of the EU
Machinery Directive 89/392/EEC, its supplements 91/368 EEC and
93/44 EEC for Europe, and the regulation 95/27/EEC. In addition, the
harmonised European standards EN 292-2 and EN 474/1 of 1994, and
EN 474-3 of 1996 were applied for manufacture of the machine. This
fact is documented in the EU Declaration of Conformity (CE) which is
supplied together with the machine.
This means that in those cases in which the machine is modified in such
a way that safety of the machine is affected, the person responsible for
safety of the machine is the one who has arranged for the machine to be
modified. If you use the machine for any other purpose than that defined
as correct use, you are the person who has to ensure that safety is
maintained. Modifications of the machine or use of the machine for any
other purpose than that specified as correct use may require a new CE
mark and thus new issuing of an EU Declaration of Conformity.
If a machine is used in other countries than Germany, it may be possible
that special national safety devices and specifications are missing which
may be required for the application in the relevant country. For example,
for Komatsu machines, the manufacturer has to design the cab roof in
such a way that a warning beacon can be attached to the roof. However,
when driving the machine on roads, this warning beacon must be covered.
Should you have any questions concerning standards and guidelines in
the respective country the machine is to be used in, please ask your
Komatsu dealer before you start commissioning the machine.
In addition to the operating instructions, you must also adhere to all legal
regulations on public traffic and all applicable regulations on prevention
of accidents. A corresponding leaflet "Notes on Operation of Komatsu
Construction Machines in Public Traffic" - applying to operation of
construction machines with a speed of more than 20 km/h on German
public roads - has been handed over to the dealer together with the
machine papers.
The expert inspection for earthmoving machines has to be performed
according to VBG 40 § 50 (VBG: German Administrative Professional
Association). The requirements for this expert inspection are defined in
the paragraphs 1 to 3 as follows:
1) Prior to first commissioning and after major modifications, earthmoving
machines must be inspected by an expert before they are put into service
again.
2) Earthmoving machines must be inspected by an expert at least once
every year. Moreover and depending on the respective operating and
local conditions, they must additionally be inspected by an expert, when
required.
3) The inspection results must be recorded in writing and stored at least
until the next inspection is due.
1 - 6
Information on these Operating Instructions
Notes on Later Installation of Electrical and Electronical Devices
and Components
Electrical or electronical devices and/or components installed later emit
electromagnetic radiation which may influence the proper function of
electronic components and parts of the machine. This may impair safety
of the machine and endanger persons. For this reason, strictly adhere to
the following safety notes.
If you later install electrical and electronical devices and/or components
in the machine and connect them to the vehicle electrical system, you
are responsible for any malfunctions of the vehicle electronics or other
components resulting from this installation. Above all, check that all
electrical and electronical components which you install later comply with
the valid version of the EMC directive 89/336/EEC and that they are
labelled with the CE mark.
The following requirements must additionally be met for a later installation
of mobile communication systems (e.g. radio, telephone):
• Only install devices which have a licence referring to valid national
regulations (e.g. BZT-licence in Germany).
• The device must be stationary.
• Only use portable or mobile devices in the cab, if they are connected
to a stationary external aerial.
• Install the sender in such a way that it is physically separated from
the vehicle electronics.
• When installing the aerial, make sure that it is installed correctly with
a good chassis earth connection between the aerial and the chassis
of the vehicle.
In addition, adhere to all information about installation and connection of
cables and maximum power input indicated in the manufacturer's
installation instructions of the machine.
1 - 7
Information on these Operating Instructions
CE-Conforming Equipment
CE-conforming equipment
1 2 3 4 –
WA 95-3
Bucket
Type Part No.
42W-70-12021 1,1 --- 387
42W-70-12030 1,1 --- 411
42W-70-12090 0,9 185 670
42W-70-12100 0,9 185 620
42W-70-12210 1,0 185 700
WA95-3
42W-70-12240 1,0 185 640
42W-70-12051 1,25 --- 410
Volume
m³
Hydr.
pressure
bar
Weight
kg
42W-70-12061 1,6 --- 420
42W-70-12120 1,0 185 540
42W-70-12080 1,5 185 770
42W-70-12110 1,0 185 615
CE_1WA95.TBL
1 - 8
Information on these Operating Instructions
CE-conforming equipment
1 2 3 4 –
WA 95-3
Type Part No.
Fork carrier
*) Standing security 80% of the tipping load on firm and level ground
**) Standing security 60% of the tipping load on uneven ground
STD Machine in standard version
CTW Machine with counterweight
WA95-3 42U-70-12080
Work load of fork
carrier STD
kg / pair
*) 2500
**) 1870
Work load of fork
carrier with CTW
*) 2600
**) 1950
CE-conforming equipment
1 2 3 4 –
WA 95-3
Type Part No.
Carrying capacity
mm / kg
Carrying capacity
kg / pair
mm / kg
Weight
kg
121
Weight
kg
crane boom
WA95-3 42U-70-12530 500 / 1500 1000 / 1300 100
CE_2WA95.TBL
1 - 9
Information on these Operating Instructions
CE-Conforming Equipment of the Manufacturer
According to Document 42W-93-11130
1 -10
U:\DTP\BA75\CEAUS75.WMF
Information on these Operating Instructions
CE-Conforming Equipment of the
Manufacturer According to Document 42W-9311130
The responsibility for observing the regulations which are valid for wheel
loaders with "exchangeable equipment/attachments" (e. g. bucket or
forklift truck attachment), which is supplied by other manufacturers
lies with the supplier of the relevant parts which were subsequently
fitted to the machine.
The guidelines for CE Conformity and road-traffic registration are
deemed to have been fulfilled when the manufacturer of the equipment
confirms fulfilment of the document 42W-93-11130.
The certificate must be sent to the customer and the manufacturer of
the wheel loader. Only then will the CE conformity declaration for the
specific wheel loader be valid.
The dimensions X1, X2, Y1 and Y2 must be provided by the
manufacturer of the equipment for approval for use on public roads. *)
It is required to add the dimension Sh to the dimension D2 (smallest
tyre radius).
The figure G (in kg) represents the maximum load (equipment and
operating load) permitted to act at this point.
*) valid in Germany
A1 Distance bucket pivoting point - front axle, horizontal
A2 Distance bucket pivoting point- front axle, vertical
B1 Distance driver's eye - front axle, horizontal
B2 Distance driver's eye - front axle, vertical
D1 Distance front axle- lower edge of headlights, horizontal
D2 Distance front axle- lower edge of headlights, vertical
G Weight of the equipment and carrying load without additional
counterweight
H1 Distance bucket pivoting point - upper edge of bucket, vertical
(carrying position)
H2 Distance bucket pivoting point - to visual line, vertical
(carrying position)
J Distance road level - lower edge of bucket in carrying position
(to be considered during driving on public roads)
Sh Distance road level - front axle
X1 Distance cutter protection - front axle, horizontal
X2 Distance cutter protection - road level, vertical
Y1 Distance teeth protection - front axle, horizontal
Y2 Distance teeth protection - road level, vertical
a tip-in angle
b1 Bucket connection dimension boom width, interior
c Bucket connection dimension between d1 and d2, vertical
d1 Bucket connection dimension bolts for boom
d2 Bucket connection dimension bolt for tip-in rod
e Bucket connection dimension d1- d2 horizontally displaced
h Distance lower edge of bucket - drill hole of boom bolt
WA 95 42W-93-11130
A1 1,670
A2 1,180
Sh 545
B1 1,980
B2 1,860
C1 1,490
C2 1,490
D1 285
D2 1,075
G 2,480
H1 1,030
H2 1,400
J 270
X1
X2
Y1
Y2
a 52
b1 860
c 312
d1 40
d2 40
e 15
h 200
Tyre Dunlop 455/70 R20
Bucket
42W-70-12030
1.1 m³
CEDok95.TBL
1 -11
Information on these Operating Instructions
1 -12
Loading and Transporting the Machine
Loading and
Transporting the
Machine
2- 1
Loading and Transporting the Machine
2- 2
Loading and Transporting the Machine
Loading and Transporting the Machine
If you have to transport the machine over far distances, either use a low
bed loader or a railway wagon. You may lift the machine onto the transport
vehicle. Optionally, you may drive it onto the low bed loader or railway
wagon via loading ramp (also refer to "Safety Measures During Operation, Transport"). Before you start driving, check that the following
requirements are fulfilled: the roads are broad enough, the bridges are
wide enough, the clearance heights of tunnels and the like are sufficient,
the carrying capacities of roads and bridges are sufficient.
Securing the Articulated Steering
Secure the articulated steering before you lift up the machine or start to
perform repair measures.
1. Set the machine to straight driving.
2. Loosen the spring bolt and remove the bolt.
3. Turn the locking bar from position '1' to position '2'.
'1' Articulated steering unlocked
'2' Articulated steering locked
4. Insert the bolt and secure it with the spring bolt.
Lifting the Machine
DANGER
• Danger of pinching! An unlocked articulated steering may
suddenly move!
Secure the articulated steering before you lift up the
machine.
• Danger of accidents! Carrying ropes with insufficient
carrying capacities may tear so that the machine may fall
down!
Only lift up the machine using carrying ropes with sufficient
carrying capacities.
• Hoisting equipment with insufficient carrying capacities may
suddenly bend and cause severe accidents!
Only use hoisting equipment capable of carrying the
machine's operating weight.
• Objects lying on the machine may fall down and cause
injuries when the machine is lifted up!
Remove all loose objects from the machine before you lift
up the machine.
CAUTION
Incorrectly attached ropes may damage the machine!
Only fasten the eye hooks of the carrying ropes at the marked
attachment points.
There are two attachment points each at the front part and the rear part
of the machine. These attachment points are shown in the following figure.
2- 3
Loading and Transporting the Machine
“
X
„
75_162a
Information signs attached to the machine indicate the attachment points.To
avoid damage to the machine, attach the eye hooks only to the attachment
points.
X = Machine accessories:
- 2 brackets, order no. 42U-98-12A10
- 4 screws M16 x 40
+ strength 10.9, order no. 01016-51640
+ screws in rear frame, inside, screwed in.
+ torque: 280 Nm
When selecting the lifting equipment, take the operating weight of the
machine into account. Insufficient carrying capacities of the lifting equipment may cause severe accidents. Also use carrying ropes with
appropriate carrying capacities for the operating weight of the machine.
Carrying ropes with insufficient carrying capacities may tear when the
machine is lifted up and cause severe accidents. The operating weight
of the machine depends on the attached bucket. You find the operating
weights of the machine in the chapter "Dimensions, Weights, and
Operating Values".
Driving Machine Onto Loading Area of Transport Vehicle
WARNING
If the transport vehicle or the loading ramp starts skidding while
you are driving up the loading ramp, the machine may fall off
the ramp and cause severe accidents!
Secure the transport vehicle against accidental movement.
Secure the wheels of the low bed loader with wheel chocks or
wedges.
The transport vehicle for the machine must have an appropriate work
load. The operating weight of the machine depends on the attached
equipment. The operating weights of the machine can be found in the
respective table in the chapter "Dimensions, Weights, and Operating
Values".
The articulated steering must be unlocked before the machine is driven
onto the transport vehicle to ensure that the machine remains steerable.
Remove any mud, snow, or ice adhering to the wheels to ensure that you
can drive onto the ramps without danger of skidding. Do not load the
machine via landing stage unless you have checked that the landing
stage is broad enough and that its strength is sufficient to carry the load.
2- 4
1
75_269
Loading and Transporting the Machine
The loading ramps (3) must be aligned to the wheel tracks (5) of the
machine. The loading ramps must be secured in such a way that they
cannot slip while the machine is being loaded. Support the loading ramps
by placing support blocks (2) under both ramps. Make sure that the
transport vehicle may neither tip over, start to skid, or roll away while you
are driving it onto the transport vehicle. Secure the wheels of the low bed
loader with wheel chocks (1) or wedges.
Position the machine straight in front of the loading ramp and slowly
drive up the loading ramp. Do not perform steering movements on the
ramp. If required, drive off the ramp, correct the position of the machine
on the ground and drive up the ramp again.
Securing the Machine During Transport
DANGER
If the machine is insufficiently secured, it may start to skid or
fall off the transport vehicle and cause severe accidents!
Always secure the machine with ropes and wheel chocks or
wedges to avoid falling down and skidding.
CAUTION
Stay ropes that are incorrectly attached may damage the
machine!
Only fasten the eye hooks of the stay ropes at the marked
attachment points.
When the machine is on the loading area of the transport vehicle, secure
the articulated steering as described in the chapter "Securing the
Articulated Steering". Then, block the wheels of the machine with wheel
chocks or wedges and secure the machine with ropes in such a way that
it will neither start to skid nor tip over during transport. To avoid damage
to the machine, only fasten the eye hooks of the stay ropes at the marked
attachment points. The attachment points to be used are the two eye
hooks at the front frame and the tie bolt at the rear frame of the machine.
The positions of the attachment points are shown in the figure on the
previous page.
After Transport
After transport, remove all securing devices, such as wheel chocks or
wedges and ropes. Remove the catch of the articulated steering before
you drive the machine off the transport vehicle. For this purpose, reverse
the steps 1 through 4 described in the chapter "Securing the Articulated
Steering".
2- 5
Loading and Transporting the Machine
g
g
g
gkg
g
g
g
g
y
g
g
g
Dimensions, Weights, and Operating Values
Dimensions, Operating Values
Bucket capacity according to
ISO 7546
Loose weight t/m³ 2.0
Stat. tipping load, straight k
Stat. tipping load, bent by 40° k
Working load without CTW
Workin
load with CTW
Tear-out force, hydraulic kN 72.5
Hydr. lifting capacity on ground kN 57.0
Operating weight k
Turning radius over bucket mm 4455
Bucket length in transport position mm 5550
L
Bucket length during planin
A
Width with bucket mm 2150
T1
Width without bucket (above wheels) mm 2060
T2
Height, including ROPS mm 2750
G
Track (front section)
D
Track (rear section)
Width over tyres mm 2150
B
m³ 1.1
k
mm 5580
mm
mm
4860
4200
2500
2600
5830
1590
1590
The 1.1 m³ standard bucket given in
the table is also available with blade
125 m³ li
m³ li
attachment.
Special buckets:
ht weight material bucket 1.6
ht weight material bucket
0.9 m³ multi-purpose bucket
Distance articulated steer. - front axle mm 1035
H
Ground clearance, axle /
transfer
E
Centre of gravity,
F
hei
Centre of gravity, distance to front axle mm 1440
I
ear
round clearance, cardan shaft
ht above axle centre
mm
mm
mm 420
395
505
These values apply to machines with
455/70 R20 t
*) CTW = additional counterweight
res
ABM_95E.TBL
2- 6
Technical Data
Machine name-plate position
(see enlargement)
Serial no. stamp marking (1)
Machine name-plate with serial no.
Loading and Transporting the Machine
Engine name-plate (1) with serial no.
EPA label (2)
Serial no. and address of manufacturer
Must be filled in before machine is put into service:
Serial No. Machine
Serial No. Engine
Dealer Name
..................................................................................
..................................................................................
..................................................................................
Dealer Address
Telephone
Fax
Maintenance Personnel
..................................................................................
..................................................................................
..................................................................................
..................................................................................
..................................................................................
SE-NO_75.TBL
2- 7
Loading and Transporting the Machine
2- 8
Safety
DANGER
Failure to adhere to these safety instructions can lead to
accidents with serious injuries!
Read and adhere to all safety instructions.
This chapter also contains safety instructions for special equipment
and attachments.
General Safety Measures
General Safety Measures
Safety Instructions
• Do not operate or service the machine unless you have been trained
and are authorised to do so.
• Always adhere to all instructions, measures, and safety instructions
when operating or servicing the machine.
• When working together with other persons, agree beforehand on all
hand signals that you want to use to avoid accidents due to
misunderstandings.
Safety Devices
• Check that all safety devices and covers of the machine are correctly
installed.
• Ensure that damaged safety devices and covers are repaired before
you start the machine.
• Use all safety devices as prescribed, e.g. the safety lever for the work
hydraulic system (see opposite figure) and the safety belt.
• Do not remove any of the safety devices e.g. the protective grid above
the fan (see opposite figure). Safety devices must be kept in perfect
condition.
Emergency Exit
In an emergency situation, you can use the door on the right-hand side
of the driver's cab (seen from the driving direction) as an emergency
exit.
Clothing and Personal Protection
• Do not wear loose-fitting clothing, jewellery, or open long hair. There
is danger that you get caught by control elements or moving parts
leading to serious injuries.
• Immediately replace clothing stained with highly inflammable
substances.
• When operating and servicing the machine, wear the appropriate
protective equipment, e.g. safety helmet, safety goggles, safety shoes,
dust protection mask, and safety gloves.
• Always wear safety goggles, safety helmet, and protective clothing, if
it is likely that chippings or splinters will be produced while operating
the machine (e.g. when removing or driving in bolts or cleaning with
compressed air).
• Ensure that no unauthorised person is within the danger zone.
3- 2
Machine Modifications
• Komatsu will not be liable for modifications performed without prior
expressed consent by the manufacturer.
• Komatsu will not be liable for any injuries or damage resulting from
unapproved modifications.
Before You Leave the Driver's Seat
1. Lower the work unit onto the ground.
2. Switch off the engine.
3. Press slowly the multi-function lever to the front into position 'S'. The
remaining hydraulics pressure will be reduced.
4. Remove the ignition key before you leave the driver's seat. Store the
ignition key in a safe place.
5. Close the cabin door.
General Safety Measures
75_016
Mounting and Dismounting
• Do not jump on or off the machine. Do not mount on or dismount from
a moving machine.
• Always use the handle bars and tread steps for mounting or
dismounting the machine. Do not hold onto the control levers while
mounting and dismounting.
• To ensure safe hold, hold the handle bar with one hand and stand on
the tread steps with both feet. Optionally, stand on the tread steps
with one foot and hold the handle bars with both hands.
• To reach the left rear mudguard for checking of the coolant level, set
one foot into the driver's cab and use it as the fourth step. Dismount
backwards.
3- 3
General Safety Measures
Fire Prevention and Fire Fighting
• Fuel, oil, and antifreezing compound are highly inflammable and could
cause a fire.
• Do not approach inflammable material with naked light.
• Prior to refuelling, switch off the engine and stop smoking.
• Refuelling and refilling of oil are to be performed in sufficiently ventilated
places.
• Store oil and fuel in special places appropriate for this purpose. Ensure
that unauthorised persons do not have access to these places.
• Tightly close all cover caps.
• Check the fuel system, the lubrication system, and the hydraulic system
for leaks. Have leaks repaired. Remove any excess oil, fuel, or other
inflammable substances.
• Carefully and completely remove wooden chippings, leaves, paper,
and other highly inflammable materials that may have collected in the
engine compartment, since they could cause a fire.
• Do not operate the machine in the vicinity of naked light.
Fire Extinguisher and First-Aid Kit
• A fire extinguisher can be stored in the compartment under the driver's
seat. Two appropriate fastening points are already attached to the
back of the compartment.
• A fully operational fire extinguisher must be available at hand.
• If, in the course of certain operations, there is danger of fire, fire
extinguishers must be at hand. Familiarise with the use of the fire
extinguishers.
• Inform yourself on measures to be taken in the event of a fire.
• The first-aid kit can be stored in the compartment under the driver's
seat next to the fire extinguisher.
• Make sure that you know all telephone numbers of the persons that
you need to contact in an emergency.
3- 4
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