Komatsu WA270-3H Operation & Maintenance Manual
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Komatsu WA270-3H Operation & Maintenance Manual

Komatsu WA270-3H Operation & Maintenance Manual

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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.
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.
WA270H20564
and up
VEAM340200

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Summary of Contents for Komatsu WA270-3H

  • Page 1 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...

  • Page 3: Table Of Contents

    Contents Contents INFORMATION ON THESE OPERATING INSTRUCTIONS ......0-9 WHY YOU SHOULD READ THESE OPERATING INSTRUCTIONS .......... 0-11 THE WA 270-3 - YOUR ECONOMIC MIRACLE ................0-12 THE REMARKABLE ERGONOMICS OF THE WA 270-3 ..............0-12 TECHNOLOGY WHICH INSPIRES ....................0-12 NOTES ON SAFETY REGULATIONS ..................
  • Page 4 Contents DRIVING ............................1-11 DRIVING ON SLOPES ........................1-11 EMERGENCY LOWERING SYSTEM ....................1-12 WORKING CLOSE TO OVERHEAD POWER TRANSMISSION LINES .......... 1-13 LOADING ............................1-13 GOOD VISION ..........................1-14 WORKING ON SNOW ........................1-14 HEIGHT LIMITATION ........................1-14 BRAKES ............................1-14 WORKING ON LOOSE SOIL ......................
  • Page 5 Contents ENGINE COOLANT TEMPERATURE .................. 2-13 TEMPERATURE FOR CONVERTER OIL ................2-13 10. OPERATING HOURS METER ..................... 2-13 SWITCHES ............................2-14 SWITCHES (WITH MULTIFUNCTIONAL LEVER, IF INSTALLED) ..........2-15 START SWITCH ........................2-15 TRANSMISSION CUT-OFF SWITCH .................. 2-16 SWITCH FOR FRONT WORKING LIGHTS ................ 2-16 SWITCH FOR REAR WORKING LIGHTS ................
  • Page 6 Contents ADJUSTING THE STEERING COLUMN ..................2-39 SWITCHING THE ENGINE ON AND OFF ..................2-40 BEFORE STARTING THE ENGINE..................... 2-40 STARTING THE ENGINE ......................2-41 AFTER STARTING THE ENGINE ....................2-42 SWITCHING OFF THE ENGINE ....................2-43 AFTER MACHINE OPERATION ....................... 2-43 DRIVING ............................
  • Page 7 Contents TROUBLESHOOTING ................2-65 TROUBLESHOOTING ........................2-66 EMERGENCY DRIVING MODE ....................... 2-72 STARTING ENGINE WITH JUMPER LEADS ................... 2-73 CONNECTING THE JUMPER LEADS ..................2-73 STARTING THE ENGINE ......................2-74 DISCONNECTING THE JUMPER LEADS .................. 2-74 TOWING THE MACHINE ......................... 2-74 EMERGENCY STEERING .......................
  • Page 8 Contents CHECKING ELECTRICAL CONNECTIONS ..................3-22 CHECKING FUEL LEVEL, TOP UP ....................3-23 CHECKING CONTROL PANELS ..................... 3-23 OTHER PRE-START MAINTENANCE MEASURES ................ 3-24 MAINTENANCE DURING THE RUNNING-IN PERIOD .............. 3-25 AFTER THE FIRST 100 OPERATING HOURS ................3-25 TRANSMISSION, CHANGE OIL AND FILTERS ................3-25 OPERATING BRAKE, CHANGE OIL FILTER ................
  • Page 9 Contents MAINTENANCE AS REQUIRED ....................3-51 AIR FILTER: INSTALLATION AND REMOVAL OF FILTER ELEMENTS CLEANING FILTER INSERTS AND CHANGING SAFETY FILTER ..........3-51 AIR FILTER DESIGN ........................3-51 WHEN IS MAINTENANCE NECESSARY? ................. 3-51 CLEANING OR EXCHANGING THE FILTER INSERT ..............3-52 CLEANING WITH COMPRESSED AIR ..................
  • Page 10 Contents...

  • Page 11: Information On These Operating Instructions

    INFORMATION ON THESE OPERATING INSTRUCTIONS...
  • Page 12 Information on these Operating Instructions 0 - 1 0...

  • Page 13: Why You Should Read These Operating Instructions

    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.

  • Page 14: The Wa 270-3 - Your Economic Miracle

    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.
  • Page 15 Information on these Operating Instructions The fully hydraulic oil-bath brakes cannot freeze and require no longer any draining of the brakes. The service life of the brakes increases considerably. A drum brake is used as parking brake. The WA 270-3 is provided with novelties which are helping to reduce clearly the time needed for maintenance.

  • Page 16: Notes On Safety Regulations

    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...

  • Page 17: Standards And Guidelines

    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...
  • Page 18 Information on these Operating Instructions 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.

  • Page 19: Ce-Conforming Equipment

    Information on these Operating Instructions CE-CONFORMING EQUIPMENT CE-conforming equipment Hydraulic WA 270-3H Type Part No. Volume Load capacity Weight pressure m³ 42Y-70-H2720 42Y-70-H2730 42Y-70-H2640 42Y-70-H2650 42Y-70-H2660 1000 Bucket WA270-3H 42Y-70-H2741 42Y-70-H2671 42Y-70-H2681 1000 42Y-71-H2A51 42Y-71-H2B21 42Y-71-H2B41 I:\dtp\BA270GB\270_ALU\270_ALUPM\CE-270.TBL 0 - 1 7...

  • Page 20: Ce-Conforming Equipment Of The Manufacturer According To Document 419-93-H1160

    Information on these Operating Instructions CE-CONFORMING EQUIPMENT OF THE MANUFACTURER ACCORDING TO DOCUMENT 419-93-H1160 U:\DTP\ZEICHNUN\l\CEAUS.WMF 0 - 1 8...
  • Page 21 Information on these Operating Instructions CE-CONFORMING EQUIPMENT OF THE 419-93-H1160 MANUFACTURER ACCORDING 270-3H DOCUMENT 419-93-H1160 1,187 The responsibility for observing the regulations which are valid for wheel 1,260 loaders with "interchangeable equipment" (e. g. bucket or forklift), which was not supplied from works lies with the supplier of the equipment which were subsequently fitted to the machine.
  • Page 22 Information on these Operating Instructions 0 - 2 0...

  • Page 23: Loading And Transporting The Machine

    Loading and Transporting the Machine LOADING AND TRANSPORTING THE MACHINE 0- 2 1...
  • Page 24 Loading and Transporting the Machine 0- 2 2...

  • Page 25: Securing The Articulated Steering

    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 Operati- on, Transport").

  • Page 26: Driving Machine Onto Loading Area Of Transport Vehicle

    Loading and Transporting the Machine 27 0 _1 52 Information signs attached to the machine mark the attachment points.To avoid damage to the machine, attach the eye hooks only to the attachment points. When selecting the lifting equipment, take the operating weight of the machine into account.

  • Page 27: Securing The Machine During Transport

    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.

  • Page 28: Dimensions, Weights, And Operating Values

    Loading and Transporting the Machine DIMENSIONS, WEIGHTS, AND OPERATING VALUES 270-128 Dimensions, Operating Data Buckets (capacities in m³ accordance with ISO 7546) Specific density t/m³ Bucket weight without teeth 1,050 Static tipping weight, straight 9,800 9,600 Stat. tipping weight, 40° articulated 8,600 8,500 Breakout force, hydraulic...

  • Page 29: Machine Ratings

    Loading and Transporting the Machine MACHINE RATINGS Machine name-plate position Machine name-plate with serial no. Serial no. stamp plate Machine name-plate with serial no. Serial No. and Address of Manufacturer Must be filled in before machine is put into service: ..................
  • Page 30 Loading and Transporting the Machine 0- 2 8...

  • Page 31: Safety

    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.

  • Page 32: Safety Instructions

    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. •...

  • Page 33: Machine Modifications

    Komatsu will not be liable for modifications performed without prior expressed consent by the manufacturer. • Komatsu will not be liable for any injuries or damage resulting from unapproved modifications. BEFORE YOU LEAVE THE DRIVER'S SEAT 1. Lower the work unit onto the ground.

  • Page 34: Fire Prevention And Fire Fighting

    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. •...

  • Page 35: Protection Against Asbestos Dust

    General Safety Measures PROTECTION AGAINST ASBESTOS DUST Asbestos dust is a health hazard if breathed in. This machine is free of any parts containing asbestos. When handling material that may contain asbestos fibres, strictly adhere to all legal instructions and regulations. Furthermore, adhere to the following protective measures for your own protection: •...

  • Page 36: Roll-Over Protection System (Rops)

    • Do not use attachments that have not been approved of by Komatsu Hanomag or the responsible Komatsu dealer. If you use attachments which have not been approved of, safety, correct operation, and service life of the machine may be impaired.

  • Page 37: Battery

    General Safety Measures BATTERY The batteries are filled with sulphuric acid (battery acid). • Always wear safety goggles when handling batteries. • Contact of battery acid with eyes can cause blindness. If acid should get into your eyes, immediately rinse your eyes with ample water and call for medical help.

  • Page 38: Before You Start The Engine

    Safety Measures During Operation BEFORE YOU START THE ENGINE WORKPLACE SAFETY • Before you start operation, check the working area for dangerous working conditions. • Inspect the surface of the soil in the working area and determine the optimum and safest procedure. •...

  • Page 39: In-Door Operation

    Safety Measures During Operation IN-DOOR OPERATION Do not operate machines in-door unless these areas are sufficiently ventilated (e.g. workshops). Caution - Danger of intoxication! GAS, DUST, AND INFLAMMABLE VAPOURS Do not operate combustion engines in an environment that may contain inflammable gases or vapours.

  • Page 40: Machine Operation

    Safety Measures During Operation MACHINE OPERATION BEFORE YOU START THE ENGINE • Walk around the machine to check whether persons or objects are in the way before you get on the machine. • Do not start the engine, if a warning sign has been attached to the control lever or another point.

  • Page 41: Driving

    Safety Measures During Operation DRIVING • When driving, set the bucket to the transport position. The bucket is in its transport position when the transport position markings on frame and boom are aligned. • When driving on uneven ground, drive slowly and avoid sudden steering movements.

  • Page 42: Emergency Lowering System

    Safety Measures During Operation EMERGENCY LOWERING SYSTEM If the engine is switched off, it is possible to lower the work unit with the emergency lowering system. LOWERING FOR CHASSIS NUMBERS UP TO WA270H20259 WARNING Danger of accidents! While lowering the work unit, it is not possible to see the hazardous area below the work unit.

  • Page 43: Working Close To Overhead Power Transmission Lines

    Safety Measures During Operation WORKING CLOSE TO OVERHEAD POWER TRANSMISSION LINES • A voltage overspill may occur, if you or the machine get too close to overhead power transmission lines. For this reason, always heed the required safety distance between the machine and the overhead power transmission lines.

  • Page 44: Good Vision

    Safety Measures During Operation GOOD VISION • When working in dark areas, switch on the working lights of the machine and provide additional lighting for the working area. • If vision is impaired, e.g. due to mist, snow, or rain, interrupt work and wait until vision has improved to such an extent that safe work is ensured again.

  • Page 45: Working On Loose Soil

    Safety Measures During Operation WORKING ON LOOSE SOIL Do not drive the machine too close to edges of hills, overhangs, and deep ditches. If the soil starts to sag at these locations, the machine may tip over, fall down, or roll over, thus injuring you severely. Take into account that the soil is wet and soft after heavy rainfall, or very loose after blasting.

  • Page 46: Transport

    Safety Measures During Operation TRANSPORT LOADING AND UNLOADING THE MACHINE Loading and unloading is potentially dangerous. For this reason, proceed with extreme care. • Load and unload the machine only on solid and level ground. Keep a safety distance to the edge of the road. •...

  • Page 47: Safety Measures During Maintenance

    If required, put up additional warning signs around the machine. You may purchase these warning signs from your Komatsu dealer. TOOLS Only use tools which are suitable for the task you want to carry out. If you use damaged or makeshift tools or tools which are of inferior quality, injuries may occur.
  • Page 48 Safety Measures During Maintenance PRIOR TO START OF INSPECTION AND MAINTENANCE Prior to start of inspection and maintenance operations, park the machine on solid, even ground. Lower the work unit. Switch off the engine (start switch to position '0') and safeguard the machine. If the engine has to be running during maintenance, e.g.
  • Page 49 Safety Measures During Maintenance Securing the working attachment DANGER Risk of injury! The attachment may fall suddenly when in raised position! For safety reasons, a raised attachment must be secured against dropping before you pass or stand under it. The working attachment must be secured against moving if any work is to be carried out under it when it is in a raised position.

  • Page 50: During Maintenance

    Safety Measures During Maintenance DURING MAINTENANCE ATTACHMENTS Attachments removed from the machine must be put down in a safe location in such a way that they cannot tip over. Caution - risk of injury! WORKING UNDER THE MACHINE • Always lower all movable work units onto the ground or set them to their lowest positions before you start to perform maintenance or repair measures under the machine.
  • Page 51 Safety Measures During Maintenance REFUELLING AND TOPPING UP OF OIL • Spilled fuel or oil involves danger of slipping and fire. For this reason, immediately remove any spilled liquid. • Always refuel and top up oil in a place that is sufficiently ventilated. •...
  • Page 52 Have the gas pressure of the pressure accumulators checked either every 1000 operating hours or once every year. NOTE In countries with a hot climate, the responsible Komatsu dealer must check the gas-pressure of the pressure reservoir already every 650 hours.
  • Page 53 Safety Measures During Maintenance FAN AND BELTS • Always keep sufficient distance from rotating parts and pay attention that nothing gets within the operating range of rotating parts. • There is danger that parts getting caught by the fan or the belt are cut off or hurled away.

  • Page 54: Tyres

    Safety Measures During Maintenance TYRES HANDLING OF TYRES (ALSO REFER TO CHAPTER "TYRES") Tyres may burst and the resulting blast wave or parts whirling around may cause severe injury or damage. Make sure that the applicable procedures for servicing and replacing of wheels or tyres are fully understood and that only correct procedures are used.

  • Page 55: Safety Labels

    SAFETY LABELS SAFETY LABELS • All labels must be kept clean at all times. Missing or damaged labels must be replaced. POSITIONS OF SAFETY LABELS 1-25...
  • Page 56 SAFETY LABELS 1-26...
  • Page 57 P/N: 421-93-H1400 Caution, hot water/oil 15 Do not stand too close to the machine P/N: 421-93-H1280 P/N: 421-93-H1360 Use Komatsu oil only 16 Keep a safe distance to the machine’s articulated P/N: 421-93-H1390 joint P/N: 421-93-H1320 17 Keep a safe distance to the attachments...
  • Page 58 SAFETY LABELS 1-28...

  • Page 59: Operating And Control Elements

    Operating and Control Elements OPERATING AND CONTROL ELEMENTS 2 - 1...

  • Page 60: General View Of The Machine

    Operating and Control Elements GENERAL VIEW OF THE MACHINE 1 Tumbler 6 Lifting cylinder V front 2 Bucket cylinder 7 Headlight H rear 3 Bucket Direction indicator R right 4 Boom 8 Rear wheel L left 5 Front wheel 2 - 2...

  • Page 61: Operating And Control Elements

    Operating and Control Elements OPERATING AND CONTROL ELEMENTS GENERAL VIEW Main control panel Horn button Hazard flasher switch Driving direction lever (reversing lever) Gear-shifting lever Switch lever limit-stop Switch for windscreen wipers Switch for emergency driving Switch for parking brake Brake pedal Adjustment lever for steering column Accelerator pedal...

  • Page 62: Operating And Control Elements

    Operating and Control Elements OPERATING AND CONTROL ELEMENTS GENERAL VIEW WITH MULTIFUNCTIONAL LEVER, IF INSTALLED Main control panel Horn button Hazard flasher switch Gear-shift lever Switch lever limit-stop Switch for windscreen wipers Parking brake lever Switch for emergency driving mode Brake pedal Adjustment lever for steering column Accelerator pedal...

  • Page 63: Control Panels

    Operating and Control Elements CONTROL PANELS MAIN CONTROL PANEL MAINTENANCE CONTROL PANEL The monitoring system consists of a main control panel and the maintenance control panel. Depending on the functions, the control system can be divided into the following sections: B and E Warning indicators A, C and D :...

  • Page 64: Warning Indicators (B And E)

    '8'. • In the event of a functional defect, have an inspection performed by your local Komatsu dealer. NOTE When the either driving direction lever or the driving direction switch not being in its neutral position, the central warning light (CAUTION) will start to flash and the alarm buzzer will sound at intervals, if the ignition is turned to position '1'.

  • Page 65: Warning Indicators

    Operating and Control Elements WARNING INDICATORS MAIN CONTROL PANEL MAINTENANCE CONTROL PANEL CENTRAL CONTROL LIGHT (CHECK) If this control lamp starts to flash, it is immediately required to perform the relevant maintenance step. If a functional defect has occurred, the central control light (CHECK) and the respective warning light will start to flash before the engine is started.

  • Page 66: Central Warning Light (Caution)

    Operating and Control Elements CENTRAL WARNING LIGHT (CAUTION) If this warning light starts to flash, switch off the engine immediately or let it run idle. The alarm buzzer sounds at intervals if a fault has occurred (coolant temperature, converter oil temperature, coolant level, brake oil pressure, engine oil pressure) while the engine is running.

  • Page 67: Warning Light For Engine Oil Level

    If not, switch off the engine immediately and let the oil pressure circuit for the brake be checked by a Komatsu-Hanomag service technician. WARNING LIGHT FOR ENGINE OIL PRESSURE Check prior to start: The light must light up.

  • Page 68: Warning Light For Charging Current

    Operating and Control Elements WARNING LIGHT FOR CHARGING CURRENT Check prior to start: The light must light up. With the engine running: When the engine is started, the alternating current generator starts to generate current. After the batteries are recharged, the light goes out. If a fault has occurred, the warning light and the central control light (CHECK) will start to flash.

  • Page 69: Control And Measuring Instruments

    Operating and Control Elements CONTROL AND MEASURING INSTRUMENTS If the start switch is set to its operating position ('ON'), all control and measuring instruments will light up for a moment if they are fully functioning. MAIN CONTROL PANEL MAINTENANCE CONTROL PANEL CONTROL LIGHT FOR DIRECTION INDICATOR The control light starts to flash, if the direction indicator is switched on.

  • Page 70: Control Light For Preheater

    Operating and Control Elements CONTROL LIGHT FOR PREHEATER The control light lights up, if the start switch is set to its operating position ('1') and the preheating is automatically started. The light will go out, when the preheating has been completed. The switch-on time for the preheating system depends on the ambient temperature.

  • Page 71: Fuel Gauge

    Operating and Control Elements FUEL GAUGE E: The tank is empty F: The tank is full During operation, the indicator of the fuel gauge should be in the green range . The control light of the fuel gauge and the central warning light (CAUTION) start to flash, if the indicator enters the critical (red) range.

  • Page 72: Switches

    Operating and Control Elements SWITCHES 2 - 14...

  • Page 73: Switches (With Multifunctional Lever, If Installed)

    Operating and Control Elements SWITCHES (WITH MULTIFUNCTIONAL LEVER, IF INSTALLED) START SWITCH This switch is used to start or switch off the engine. Parking position (P) Not used. Stop position (0) In this position, the ignition key can be removed. The engine and specific power supply circuits are switched off.

  • Page 74: Transmission Cut-Off Switch

    Operating and Control Elements TRANSMISSION CUT-OFF SWITCH WARNING If the transmission cut-off is activated, the braking effect of the engine is not available. This may lead to accidents while driving on slopes or public roads! Before driving on public roads or slopes, set the transmission cut-off switch to its "OFF"...

  • Page 75: Light Switch

    Operating and Control Elements LIGHT SWITCH This switch is used to switch on the main headlights, the sidelights, the taillights and the instrument illumination. position: Sidelights, taillights and instrument illumination are switched on. position: Main headlights and the switch-position illumination (2) are switched on. IMPORTANT The light switch can be operated independent from the lever positions for the direction indicator, low-beam and high-beam.

  • Page 76: Hazard Flasher Switch

    Operating and Control Elements HAZARD FLASHER SWITCH NOTE The hazard flasher may only be activated in an emergency situation. Hazard flasher switched on Hazard flasher switched off If the hazard flasher is switched on, all indicator lights, the direction indicator control light, the switch lights and the warning light of the hazard flasher (1) start to flash.

  • Page 77: Gear-Shift Lock (2) (Only If The Multi-Function Lever Is Installed)

    Operating and Control Elements GEAR-SHIFT LOCK (2) (ONLY IF THE MULTI-FUNCTION LEVER IS INSTALLED) Use the gear-shift lock if you are driving uphill or downhill, or if you are performing works which are to be carried out in a specific gear. As soon as you activate the gear-shift lock, the selected gear is retained, even if you increase engine speed to a level at which the automatic transmission usually would change into a higher gear.

  • Page 78: Rear Windscreen Washer/Wiper Switch

    Operating and Control Elements REAR WINDSCREEN WASHER/WIPER SWITCH Turn lever (D) to activate the rear windscreen wiper. Switch position Window display Operation Washer on Wiper on Washer on Wiper on CIGARETTE LIGHTER If you want to use the cigarette lighter, press it in. After a few seconds, it will return to its original position and can be pulled out to light up a cigarette.

  • Page 79: Control Levers, Pedals

    Operating and Control Elements CONTROL LEVERS, PEDALS CONTROL LEVERS, PEDALS (WITH MULTIFUNCTIONAL LEVER, IF INSTALLED) 2 - 21...

  • Page 80: Control Lever

    Operating and Control Elements CONTROL LEVER This lever is used to select the machine speed. The machine is provided with an automatic gear-shift transmission with four forward gears and three reverse gears. Set the lever to the appropriate position for the required speed range. Position (1): 1st forward and reverse gear Position (2):...

  • Page 81: Locking Lever For The Work Hydraulic System

    Operating and Control Elements LOCKING LEVER FOR THE WORK HYDRAULIC SYSTEM WARNING Unintentional lowering of the bucket may lead to severe accidents! Before you start maintenance operations: Turn the locking lever for the work hydraulic system into position '1'. The locking lever for the work hydraulic system will then be without function.

  • Page 82: Control Lever For The Work Hydraulic System

    Operating and Control Elements CONTROL LEVER FOR THE WORK HYDRAULIC SYSTEM The work unit is controlled with this lever. Swimming position The lever is locked in this position. The switch position 'SW' is for planing (removing subsoil). The work unit lowers to this operating position due to its own weight and can be moved freely by external force.

  • Page 83: Multifunctional Lever For The Work Hydraulic System

    Operating and Control Elements MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAULIC SYSTEM The multifunctional lever is a special equipment and is used to control the work unit. Swimming position The multifunctional lever is locked in this position. The switch position 'SW' is for planing (removing subsoil).

  • Page 84: Brake Pedal

    Operating and Control Elements BRAKE PEDAL CAUTION • If driving downhill, use the engine only when necessary. Frequent use of the brake impairs its braking effect and thus lead to accidents! Let the engine run, if you are driving downhill. Use the brake pedal for additional braking, if required.

  • Page 85: Parking Brake

    Operating and Control Elements PARKING BRAKE The parking brake is a mechanically activated drum brake at the transmission unit. As soon as the parking brake lever is lifted from its normal position, the braking effect is exerted and the transmission is switched off automatically. The machine will drive again, if you loosen the parking brake and insert a gear.

  • Page 86: Traction Device

    Operating and Control Elements ARTICULATED STEERING CATCH DANGER Danger of pinching or squeezing! An unsecured articulated steering may jack-knife all of a sudden. Always secure the articulated steering with the locking bar before you perform maintenance or repair work or if the machine is to be transported.

  • Page 87: Fuses

    Operating and Control Elements FUSES CAUTION Parts of the electrical system can be damaged, if you replace fuses while the ignition is switched on. Set the start switch to position '0' (OFF) before you replace fuses. Fuses with the wrong amperage may cause cable burns or may blow again! Replace defective fuses always with fuses with the same amperage.

  • Page 88: Slow-Blow Fuses

    Operating and Control Elements SLOW-BLOW FUSES If the power supply breaks down, it is possible that one of the slow-blow fuses has blown. Check the electrical system and replace the fuse, if necessary. 30A: Glow plug 30A: Battery power supply (start switch, hazard flasher system) 100A: Main power supply...

  • Page 89: Heating And Ventilation System

    Operating and Control Elements HEATING AND VENTILATION SYSTEM Rotary switch for fan The air flow can be set to three levels using this switch (1). Settings: Fan switched off Low air flow Medium air flow High air flow Temperature selector lever This control lever (2) is used for continuous temperature setting.

  • Page 90: Air-Conditioning

    Operating and Control Elements AIR-CONDITIONING NOTE • Only operate the air-conditioning with the engine running. • Run the air-conditioning for at least 10 minutes every month irrespective of season. This prevents the compressor shaft seal from drying out. Cab windows, doors and ventilation openings must be closed when the air-conditioning is operated, otherwise there is an excessive influx of heat so that the cab can no longer be cooled effectively.

  • Page 91: Operation

    Operation OPERATION 2 - 33...

  • Page 92: Running In The Machine

    Operation RUNNING IN THE MACHINE Before shipment, each machine was carefully checked and adjusted. A machine which is to be run in for the first time has to be treated with utmost care during its first 100 operating hours. If the machine is used for work involving loads exceeding the specified maximum load valid for the running-in period, its performance may be prematurely impaired and its service life may be shortened.

  • Page 93: Inspections Prior To Starting

    Operation INSPECTIONS PRIOR TO STARTING VISUAL INSPECTIONS (see also section "Maintenance Prior to Starting") WARNING Leaking oil or fuel or inflammable material which has collected on or near hot parts, such as the exhaust or turbo-charger may ignite! Before the start, check oil and fuel lines for leaks and repair immediately any damages.
  • Page 94 ROPS Check for loose or damaged bolts. Bolts may only be retightened or replaced by a Komatsu dealer. Loose bolts must only be retightened with the correct torque. Damaged bolts may only be replaced with OEM parts.

  • Page 95: Adjustments Prior To Start-Up

    Operation ADJUSTMENTS PRIOR TO START-UP ADJUSTING THE DRIVER'S SEAT (without pneumatic suspension) Each time, a new driver wants to operate the machine, it is necessary to re-adjust the driver's seat. Before starting operation, you must check whether the seat is adjusted in such a way that the braking pedal can be completely pushed down, with your back touching the seat backrest.

  • Page 96: Adjusting The Driver's Seat (With Pneumatic Suspension)

    Operation ADJUSTING THE DRIVER'S SEAT (with pneumatic suspension) Each time, a new driver wants to operate the machine, it is necessary to re-adjust the driver's seat. Before starting operation, you must check whether the seat is adjusted in such a way that the braking pedal can be completely pushed down, with your back touching the seat backrest.

  • Page 97: Fastening The Seat Belt

    Operation FASTENING THE SEAT BELT WARNING • Danger of injuries! A damaged seat belt or which was overstretched in an accident or whose belt holder or attachment screws are improperly mounted, does no longer protect you when an accident occurs. Replace the seat belt if it is damaged or if the machine had an accident.

  • Page 98: Switching The Engine On And Off

    Operation SWITCHING THE ENGINE ON AND OFF BEFORE STARTING THE ENGINE WARNING Unintentional lowering of the bucket can cause severe accidents! For this reason, turn the locking lever for the work hydraulic system to position '1', before you start up the engine. 1.

  • Page 99: Starting The Engine

    Operation STARTING THE ENGINE CAUTION Unintentional starting up of the machine can cause severe accidents! Make sure that there are no people or obstructions in the vicinity of the machine, before you start up the engine. In addition, sound horn immediately before you start up the engine.

  • Page 100: After Starting The Engine

    Operation AFTER STARTING THE ENGINE The engine must not be abruptly accelerated before the warm- up phase has been completed. Do not run the engine for longer than 20 minutes at lowest or highest idling engine speed. If the engine has to run idle for a longer period of time, rev it up from time to time or let it run at medium speed.

  • Page 101: Switching Off The Engine

    Operation SWITCHING OFF THE ENGINE NOTE Switching the engine off abruptly after heavy loads without allowing it to cool down can severely affect the service life of the engine. For this reason, the engine should only be abruptly switched off in an emergency situation.

  • Page 102: Driving

    Operation DRIVING START-UP CAUTION Careless starting up may lead to accidents! Before starting to drive, make sure that there are no people in the vicinity of the machine. Sound horn immediately before you start to drive. The doors are to be kept closed during a journey. Start the engine.

  • Page 103: Starting Up On Hills And Slopes

    Operation STARTING UP ON HILLS AND SLOPES CAUTION Careless starting up may lead to accidents! Before starting to drive, make sure that there are no people in the vicinity of the machine. Sound horn immediately before you start to drive. The doors are to be kept closed during a journey.

  • Page 104: Gear Shifting

    Operation GEAR SHIFTING CAUTION Never select abruptly a lower gear when driving with high speed, since this may damage the engine and gear mechanism! Always reduce speed first, using the service brake, before you select a lower gear. GEAR SELECTION Select the required or appropriate gear using the gear lever (1).
  • Page 105 Operation Switching off the kick-down function: 1. First, switch the driving direction switch (1) or driving direction switch to the neutral position. 2. Then, set the driving direction switch (1) or driving direction switch to the desired driving direction. 3. Use the gear-shift lever (2) to set the required gear. 2 - 47...

  • Page 106: Changing The Driving Direction

    Operation CHANGING THE DRIVING DIRECTION WARNING Careless changing of the driving direction may lead to severe accidents! If you are changing the driving direction from forward to reverse driving or vice versa, make sure that there is nobody or no obstacle in your way.

  • Page 107: Stopping

    Operation STOPPING WARNING Danger of accidents! If you pull the parking brake while driving, the transmission is automatically set to its neutral position and the braking effect of the engine can no longer be used! During driving, never brake the machine using the parking brake, except for emergencies.

  • Page 108: Control Levers For The Work Hydraulic System

    Operation CONTROL LEVERS FOR THE WORK HYDRAULIC SYSTEM Control lever for the work unit Control lever positions: Swimming position The lever is locked in this position. The switch position 'SW' is for dozing (removing subsoil). The work unit lowers to this operating position through own weight and is moved freely by external force.

  • Page 109: Multifunctional Lever For The Work Hydraulic System

    Operation MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAULIC SYSTEM Positions of the multifunctional lever: Swimming position The multifunctional lever is locked in this position. The switch position 'SW' is for dozing (removing subsoil). The work unit lowers to this operating position through own weight and is moved freely by external force.

  • Page 110: Working With The Machine

    Operation WORKING WITH THE MACHINE Other operation possibilities, in addition to the operations described below, can be performed using other special equipment. EXCAVATING CAUTION If you want to perform excavation operations with the machine being in bent position, you may damage the articulated steering and the cardan shaft! Always drive into the material which you want to remove in straight direction.
  • Page 111 Operation To prevent the bucket from digging in too deep into the material to be removed, you must lift the boom while driving into the material. Lifting the boom ensures a sufficient thrust force. Tip the bucket in. NOTE If the edge of the bucket is moved up and down during driving/ digging into the material to be removed, it can result in the front wheels being lifted from the ground, thus causing the wheels to skid.

  • Page 112: Levelling

    Operation LEVELLING NOTE Drive the machine in reverse for normal levelling operations. Do not tip the bucket by more than 20° if levelling work has to be performed during driving in forward direction. Fill the bucket with soil. Drive the machine in reverse and distribute the soil gradually from the bucket.

  • Page 113: Loading

    Operation LOADING Always select the type of operation with the smallest turning circle and driving effort in order to work as efficiently as possible. WARNING Danger of accidents! If you turn or brake abruptly with the lifted load, the load may fall out of the bucket and cause accidents! Turn slowly with the load lifted and brake cautiously.

  • Page 114: Adjusting The Work Unit

    Operation ADJUSTING THE WORK UNIT LIFT LIMIT SWITCH The lift limit switch provides the possibility of an automatic setting of the required lifting height of the boom. Stop the machine on level ground. Raise the boom to the required lifting height, set either the control lever for work hydraulic system or the multifunctional lever to stop position '0'.

  • Page 115: Bucket Return Mechanism

    Operation BUCKET RETURN MECHANISM The bucket return mechanism permits to set automatically the required digging angle of the bucket. Stop the machine on level ground. Lower the bucket to the ground. Position at required digging angle. Push either the control lever for work hydraulic system or the multi- functional lever to stop position '0'.

  • Page 116: Precautions For Special Operations

    Operation PRECAUTIONS FOR SPECIAL OPERATIONS Working in water While operating in water or on swampy ground, the water must not reach the underside of the axle housing. Wash the machine after the work has been finished and check the lubricating points. If the wheel brake breaks down If the machine does not come to a standstill after pressing the brake pedal, use the parking brake instead.

  • Page 117: Tyres

    Operation TYRES HOW TO HANDLE TYRES 1 Steel belt cord 4 Intermediate layer 2 Radial carcass 5 Diagonal carcass 3 Bead core 6 Bead cores Tyres must be changed for safety reasons, if they have any of the following defects. •...

  • Page 118: Driving Longer Distances

    The required tyre pressure, the driving speed or the tyre type may vary depending on the condition or structure of the road o be used. Contact the responsible Komatsu trader or the tyre dealer to obtain the required information. •...
  • Page 119 Operation RECOMMENDED AIR PRESSURE TYRES For road use For work conditions Front axle Rear axle Front axle Rear axle Make Size Model EM-Code BRIDGE- 20.5R25 STONE BRIDGE- 20.5R25 STONE DUNLOP 555/70R24 SP T9 1.75 3.75 DUNLOP 20.5-25 DUNLOP 20.5R25 SP T9 1.75 DUNLOP 20.5R25...

  • Page 120: Winter Operation

    Operation WINTER OPERATION BEFORE THE COLD SEASON Before the cold season begins, you should perform the following preparatory measures to ensure troublefree operation also in the winter months. • The machine is provided with a aluminium radiator. Therefore, the cooling system must be set to -37°C for the whole year. •...

  • Page 121: After Operation

    Operation AFTER OPERATION Realise the following actions to make sure that the machine can be started the next time without problems: • Remove mud and water from the chassis. This prevents that sealings are damaged due to freezing. • Park the machine on hard and dry ground. If this is not possible, you must park the machine on wooden planks.

  • Page 122: Long-Term Shutdown

    AFTER THE SHUTDOWN NOTE If the machine was not moved once a month, contact the responsible Komatsu dealer to arrange a maintenance appointment. After a longer shutdown period, perform the following works before starting up the machine: • Remove the grease from the piston rods of the hydraulic cylinders.

  • Page 123: Troubleshooting

    Troubleshooting TROUBLESHOOTING 2 - 65...
  • Page 124 Troubleshooting TROUBLESHOOTING If faults or causes of faults are not listed below, have them rectified by the responsible dealer. ELECTRICAL SYSTEM Fault Fault cause Remedy Battery charging control lamp Faulty electrical connection Check/repair terminals, connecting does not light up when the engine points and cables.
  • Page 125 Troubleshooting If faults or causes of faults are not listed below, have them rectified by the responsible dealer. ENGINE Fault Fault cause Remedy Warning lamp for oil pressure Oil level too low Top up with oil. lights up with engine running. Oil filter cartridge dirty Change cartridge.
  • Page 126 Troubleshooting If faults or causes of faults are not listed below, have them rectified by the responsible dealer. ENGINE (continued) Fault Fault cause Remedy Exhaust gases black at times. Air filter insert dirty Clean/replace insert. Injection nozzle faulty Replace injection nozzles. *) Compression too low because of Adjust valve clearance.*) incorrect valve clearance...
  • Page 127 Troubleshooting If faults or causes of faults are not listed below, have them rectified by the responsible dealer. TRANSMISSION Fault Fault cause Remedy Machine does not drive. Parking brake on Release parking brake. Drive direction lever not engaged Engage drive direction lever correctly correctly.
  • Page 128 Troubleshooting If faults or causes of faults are not listed below, have them rectified by the responsible dealer. BRAKES Fault Fault cause Remedy Brakes not working. Brake discs have reached limit of Replace brake discs. *) wear Air in the system Bleed system.
  • Page 129 Troubleshooting If faults or causes of faults are not listed below, have them rectified by the responsible dealer. HYDRAULIC SYSTEM Fault Fault cause Remedy Insufficient lifting force. Oil level too low Top up with oil according to specifications. Lift action too slow. Filter insert dirty Replace insert.

  • Page 130: Emergency Driving Mode

    Troubleshooting EMERGENCY DRIVING MODE The machine is provided with a fully automatic transmission. Gear-shifting and driving the machine is no longer possible, if there is a fault in the control unit. In this case, an emergency driving mechanism can be activated.

  • Page 131: Starting Engine With Jumper Leads

    Troubleshooting STARTING ENGINE WITH JUMPER LEADS NOTE • The current-supplying and the discharged batteries must have the same nominal voltage. • The capacities of the current-supplying batteries must not be significantly less than the capacities of the discharged batteries. • The cross-section of the jumper leads and the cable terminals must be selected according to the size of the batteries.

  • Page 132: Starting The Engine

    Troubleshooting STARTING THE ENGINE Start the engine of the machine with the discharged batteries. If the engine (of the machine with the empty batteries) does not immediately start, wait at least for two minutes before retrying. DISCONNECTING THE JUMPER LEADS CAUTION If the cable ends either touch each other or the machine during disconnecting the jumper lead from the started machine ,a short...
  • Page 133 Troubleshooting Contact your local Komatsu dealer to obtain detailed information on towing. Observe the following instructions if the machine has to be towed with the engine switched off: • Set either the driving direction lever or the driving direction switch to the neutral position.

  • Page 134: Emergency Steering

    Troubleshooting EMERGENCY STEERING CONTROL LIGHTS FOR EMERGENCY STEERING These control lights indicate the hydraulic circuit of the steering and emergency steering system. Always check the function of both lights before starting to drive. Proceed as follows: Turn the start switch to operating position '1' (ON). The red control light (1) for steering starts to flash.

  • Page 135: Emergency Lowering System

    Troubleshooting EMERGENCY LOWERING SYSTEM If the engine is switched off, it is possible to lower the work unit with the emergency lowering system. Lowering for chassis numbers up to WA270H20259 WARNING Danger of accidents! While lowering the work unit, it is not possible to see the hazardous area below the work unit.

  • Page 136: Malfunktion Of Brake

    5 m (16.4 ft). NOTE All repairs on the brake system must be performed by an authorised Komatsu garage. CHECKING PARKING BRAKE TEST CONDITIONS • Tyre air pressure: according to specifications •...

  • Page 137: Maintenance

    MAINTENANCE...
  • Page 138 MAINTENANCE BASICS...

  • Page 139: Maintenance Basics

    OPERATING HOURS METER Check operating hours meter reading every day so that you know when maintenance work is due. SPARE PARTS Only use Komatsu original spare parts. FLUID FOR THE WASHER SYSTEM Use clean washer fluid as prescribed for use in cars.

  • Page 140: Keep The Machine Clean

    After changing oil or filter, check oil and filter for metal particles and foreign bodies. If larger quantities of metal particles or foreign bodies are found, contact your local Komatsu dealer. TOPPING UP FUEL OR OIL; FUEL SIEVE Always top up fuel or oil in a sufficiently ventilated place. If the machine is provided with a fuel sieve in the tank opening, do not remove this fuel sieve before you start refuelling.

  • Page 141: Welding Instructions

    MAINTENANCE BASICS WELDING INSTRUCTIONS • Turn the engine start switch to the OFF position. • Do not apply a constant voltage of more than 200 V. • Connect the ground cable in a distance of max. 1 m from the area in which the welding is to be performed.

  • Page 142: Protective Measures When Washing The Machine

    MAINTENANCE BASICS PROTECTIVE MEASURES WHEN WASHING THE MACHINE • Never spray steam or water at high pressure onto the radiator. • Make sure that no water comes into contact with the electric al components. WARNING If the bucket is accidentally lowered during cleaning the machine, severe accidents may occur! For this reason, support the bucket below the boom or lower the bucket to the ground while cleaning.

  • Page 143: Engine / Hydraulic Oil

    If changing oil, change corresponding oil filter as well. • We recommend to have an engine oil and hydraulic oil analysis to be performed by your local Komatsu dealer on a regular basis to check the condition of the machine. GREASE •...

  • Page 144: Fuel

    BIOLOGICALLY DEGRADABLE HYDRAULIC OILS AND GREASE • Biologically degradable hydraulic oils and grease - on a diester oil basis - can be used in Komatsu machines. Please contact our works dealers for the products approved by us and most suitable for your requirements.

  • Page 145: Coolant

    When using anti-freeze, always observe the instructions in the operating and maintenance manual. • Our machines are supplied with original antifreeze from Komatsu. This antifreeze prevents corrosion in the cooling system, among other things, lubricates moving parts, raises the boiling point of the coolant and must therefore also be used at hot working sites.

  • Page 146: Specifications Of The Electrical System

    Never remove or alter electrical components which is installed in the machine. • Never install any other electrical components other than those approved by Komatsu Hanomag. • Pay attention that no water enters the electrical system when was- hing the machine or working in the rain.

  • Page 147: Starting Torques For Standard Nuts And Bolts

    MAINTENANCE BASICS STARTING TORQUES FOR STANDARD NUTS AND BOLTS Unless stated otherwise, metric bolts of strength class 8.8 and nuts of strength class 8 are to be tightened to torque settings as quoted in the table below. The starting torque depends on the diameter of the thread (a) and wrench size (b) for the nuts and bolts.

  • Page 148: Regular Replacement Of Safety-Related Parts

    MAINTENANCE BASICS REGULAR REPLACEMENT OF SAFETY-RELATED PARTS The user must service the machine regularly to ensure troublefree operation of the machine. CAUTION Worn safety-related parts may cause accidents! Replace all parts which are relevant for the security of the machine and for fire prevention on a regular basis. The following parts must be replaced regularly - even if they appear to be fully functioning: •...

  • Page 149: Wearing Parts

    MAINTENANCE BASICS WEARING PARTS NOTE Wearing parts must be replaced when performing maintenance work on a regular basis or if they are excessively worn or soiled. Parts indicated in brackets are to be exchanged at the same time. Position Part no. Part designation Replacement interval Engine oil filter...
  • Page 150 MAINTENANCE BASICS TOOLS Designation Part No. Comments Spanner sizes: 8/10mm 12/14mm Spanner set 09000-30006 13/17mm 19/22mm 24/27mm 30/32mm Screwdriver 421-98-H1120 Screwdriver 421-98-H1110 Spanner 09014-10200 Pliers 09036-00150 Grease gun 424-98-H1010 Hose 424-98-H1020 Hose for grease gun Grease cartridge 07950-90403 (Lithium grease: 400g) Hammer 421-98-H1140 421-98-H1130...

  • Page 151: Lubricants And Operating Agents

    LUBRICANTS AND OPERATING AGENTS LUBRICANTS AND OPERATING AGENTS LUBRICANTS AND OPERATING EQUIPMENT BI abbreviations *), specifications and filling quantities WA270-3 Filling Lubricants and Temperature quantity in operating BI abbreviation Quality class Viscosity class range litres equipment (approx.) CCMC D4 EO 1540 A -10°...
  • Page 152 LUBRICANTS AND OPERATING AGENTS 3-16...

  • Page 153: Maintenance Schedule

    MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE PRIOR TO STARTING UP ................3-19 COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING UP COOLANT ....3-19 CHECKING ENGINE OIL LEVEL, TOP UP ..................3-20 WATER SEPARATOR, DRAIN WATER AND DIRT DEPOSITS ............3-20 FUEL FILTER, DRAIN WATER ....................... 3-21 CHECKING DRIVE BELTS ......................
  • Page 154 MAINTENANCE SCHEDULE DRAINING OFF THE COOLANT .................... 3-45 CLEANING THE COOLING SYSTEM ..................3-45 FILLING UP COOLANT ......................3-45 MAINTENANCE EVERY 2000 OPERATING HOURS ..............3-46 CHECK SHOCK ABSORBER ......................3-46 CHECKING THE COOLING SYSTEM ................... 3-46 CHECKING AND CLEANING THE TURBOCHARGER ..............3-47 CHECK THREE-PHASE GENERATOR AND STARTER ..............

  • Page 155: Maintenance Prior To Starting Up

    MAINTENANCE PRIOR TO STARTING UP MAINTENANCE PRIOR TO STARTING UP COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING UP COOLANT CAUTION • A wrong water/coolant mixing ratio will damage the radiator! Always mix water and coolant in the ratio 50:50. This also applies to countries with a hot climate.

  • Page 156: Checking Engine Oil Level, Top Up

    MAINTENANCE PRIOR TO STARTING UP CHECKING ENGINE OIL LEVEL, TOP UP NOTE Check the engine oil level after waiting at least 5 minutes after switching off the engine. The machine must be parked on level ground. Open the right engine hood. Pull out the dipstick (G) and wipe off oil with a clean cloth.

  • Page 157: Fuel Filter, Drain Water

    MAINTENANCE PRIOR TO STARTING UP FUEL FILTER, DRAIN WATER If dirt or water has been detected in the water separator, place a clean container beneath the fuel filter. Open the drain valve on the base of the fuel filter and drain off the water. Close the drain valve again as soon as clean fuel emerges.

  • Page 158: Checking Electrical Connections

    MAINTENANCE PRIOR TO STARTING UP CHECKING ELECTRICAL CONNECTIONS CAUTION Accumulated inflammable material (leaves, twigs, grass, etc.) in the electrical system represents a fire danger. For this reason, always check this area for inflammable material and remove it, if necessary. NOTE If a fuse blows regularly or if there are signs of a short-circuit in the electrical system, find the cause of the trouble and repair it.

  • Page 159: Checking Fuel Level, Top Up

    MAINTENANCE PRIOR TO STARTING UP CHECKING FUEL LEVEL, TOP UP WARNING Danger of fire! Spilled fuel may ignite! Remove thoroughly any fuel which has spilled during filling Turn the start switch to its operating position (2) and check the fuel level on the fuel gauge (G). Reset the switch to switch position (1).

  • Page 160: Other Pre-Start Maintenance Measures

    MAINTENANCE PRIOR TO STARTING UP OTHER PRE-START MAINTENANCE MEASURES • Checking lighting for function, dirt and damage • Checking exhaust, exhaust fumes colour and noise • Checking measuring instruments • Checking steering wheel play and function • Checking lighting for function, dirt and damage •...

  • Page 161: Maintenance During The Running-In Period

    MAINTENANCE DURING THE RUNNING-IN PERIOD MAINTENANCE DURING THE RUNNING-IN PERIOD The following maintenance operations are to be performed in the running-in period of the machine, in addition to the regular maintenance steps: AFTER THE FIRST 100 OPERATING HOURS TRANSMISSION, CHANGE OIL AND FILTERS OPERATING BRAKE, CHANGE OIL FILTER AFTER THE FIRST 250 OPERATING HOURS FUEL TANK, DRAIN WATER...

  • Page 162: Maintenance Every 100 Operating Hours

    MAINTENANCE EVERY 100 OPERATING HOURS MAINTENANCE EVERY 100 OPERATING HOURS HYDRAULIC SYSTEM, CHECKING OIL LEVEL, TOPPING UP OIL NOTE The hydraulic tank is under pressure. Oil can spurt out when the oil filler cap (F) is removed. Switch the engine off and allow the oil to cool down sufficiently. Then, unscrew the screw plug (3) slowly so that the pressure can escape gradually.

  • Page 163: Cleaning The Fresh-Air Filter Inserts

    MAINTENANCE EVERY 100 OPERATING HOURS CLEANING THE FRESH-AIR FILTER INSERTS CAUTION • Whirled up dust particles may hurt the eyes! Always wear protective goggles if you are cleaning the filter inserts with compressed air. • Dangerous dust particles may irritate the lung! Always wear a protective mask if you are cleaning the filter inserts with compressed air.

  • Page 164: Maintenance Every 250 Operating Hours

    Open the drain plug (P) and drain oil. Inspect the drained oil: if it contains too many metal particles or foreign bodies, contact your local Komatsu dealer. Retighten the drain plug. 3-28...

  • Page 165: Checking The Air Aspiration System

    MAINTENANCE EVERY 250 OPERATING HOURS Using a filter wrench, unscrew the filter cartridge anti-clockwise on the left-hand side of the machine. Clean the filter support. Fill up the new filter cartridge with engine oil. Oil the seal and thread of the cartridge slightly with engine oil (or apply a thin coat of grease).

  • Page 166: Air-Conditioning, Check Tension Of The Compressor V-Belt

    MAINTENANCE EVERY 250 OPERATING HOURS AIR-CONDITIONING, CHECK TENSION OF THE COMPRESSOR V-BELT The performance of the air-conditioning system and the service life of the V-belt depend on the correct tension. DANGER You can be severely injured, if you touch the running V-belt or the rotating fan! Never reach into or in the vicinity of the V-belt or fan when the engine is running.

  • Page 167: Batteries, Checking The Acid Level

    MAINTENANCE EVERY 250 OPERATING HOURS BATTERIES, CHECKING THE ACID LEVEL WARNING • Danger of injury! The battery contains strongly aggressive battery acid which may spill and burn your eyes! Carry goggles and rubber gloves if you work on the battery. Immediately wash off battery acid from eyes or skin using plenty of water and go to see a doctor.

  • Page 168: Battery Recharging

    MAINTENANCE EVERY 250 OPERATING HOURS Temperature Battery 20°C 5°C -10°C -25°C Charge Specific density (kg/l) full 1,28 1,29 1,30 1,31 half 1,20 1,21 1,22 1,23 empty 1,12 1,13 1.14 1,15 Lock the cells with the cleaned plugs. BATTERY RECHARGING Recharging an installed battery. •...

  • Page 169: Axles, Check Oil Levels

    MAINTENANCE EVERY 250 OPERATING HOURS AXLES, CHECK OIL LEVELS The machine must be parked on solid, even ground for this work. Inspection of an axle must be carried out on all three inspection bore holes in one complete maintenance cycle. DANGER Severe accidents may happen, if you perform maintenance operations on machines which are not properly parked and...

  • Page 170: Lubrication

    MAINTENANCE EVERY 250 OPERATING HOURS LUBRICATION DANGER Severe accidents may happen, if you perform maintenance operations on machines which are not properly parked and secured! Park the machine on firm and level ground and secure it, before starting maintenance operations. Park and secure the machine as described in chapter "Preparing the Machine for Maintenance".

  • Page 171: Maintenance Every 500 Operating Hours

    MAINTENANCE EVERY 500 OPERATING HOURS MAINTENANCE EVERY 500 OPERATING HOURS This maintenance cycle automatically includes all maintenance operations to be performed every 100 and 250 operating hours. FUEL FILTER, CHANGE FILTER CARTRIDGES DANGER Fuel may ignite on hot surfaces! Wait until the engine has sufficiently cooled down, before replacing the filter cartridges.

  • Page 172: Bleeding The Fuel System

    MAINTENANCE EVERY 500 OPERATING HOURS DANGER The fuel inside the injection system is under pressure. Fuel which is splashing out can penetrate the skin and lead to blood poisoning. Wear protective goggles and rubber gloves, when working on the injection pump. If you are hit by a high-pressure stream of fuel, immediately go to see a doctor and describe what has happened.

  • Page 173: Maintenance Every 1000 Operating Hours

    MAINTENANCE EVERY 1000 OPERATING HOURS MAINTENANCE EVERY 1000 OPERATING HOURS This maintenance cycle automatically includes all maintenance operations to be performed every 100, 250 and 500 operating hours. TRANSMISSION, CHANGE OIL AND FILTERS WARNING • Frequent skin contact with used transmission oil may cause skin damages and other injuries! Carry rubber gloves for exchanging the filter.
  • Page 174 MAINTENANCE EVERY 1000 OPERATING HOURS Pour the prescribed quantity of oil in the oil filler inlet (F). Information on the recommended oil, see section "LUBRICANTS AND OPERATING AGENTS". After filling up oil, check the oil level: NOTE The oil level in the transmission can rise considerably when the engine is not running.

  • Page 175: Engine, Adjusting The Valve Clearance

    MAINTENANCE EVERY 1000 OPERATING HOURS ENGINE, ADJUSTING THE VALVE CLEARANCE NOTE The valve clearance may only be adjusted by a competent garage. Refer to the workshop and training manual for the required actions and settings. SERVICE BRAKE, CHANGE OIL FILTER Run the engine for approx.

  • Page 176: Drive Belts, Check Tension Pulley And Fan Bearing

    MAINTENANCE EVERY 1000 OPERATING HOURS DRIVE BELTS, CHECK TENSION PULLEY AND FAN BEARING DANGER Severe accidents may happen, if you perform maintenance operations on machines which are not properly parked and secured! Park the machine on firm and level ground and secure it, before starting maintenance operations.

  • Page 177: Turbocharger, Checking The Attachment And Play

    Have the gas pressure of the pressure tank checked by your local dealer when maintaining or replacing important, safety-related components at the prescribed intervals. NOTE In countries with a hot climate, the responsible Komatsu dealer must check the gas-pressure of the pressure reservoir already every 650 hours. 3-41...

  • Page 178: Axles, Oil Change

    MAINTENANCE EVERY 1000 OPERATING HOURS AXLES, OIL CHANGE The oil change procedure for the front and the rear axle is identical. WARNING • Frequent skin contact with used oil may cause skin damages and other injuries! Carry rubber gloves for exchanging the filter. Wash any oil carefully from your skin.

  • Page 179: Lubrication

    MAINTENANCE EVERY 1000 OPERATING HOURS LUBRICATION Perform the lubrication thoroughly and in time. DANGER Severe accidents may happen, if you perform maintenance operations on machines which are not properly parked and secured! Park the machine on firm and level ground and secure it, before starting maintenance operations.

  • Page 180: Cooling System, Exchanging Coolant And Cleaning The System

    MAINTENANCE EVERY 1000 OPERATING HOURS COOLING SYSTEM, EXCHANGING COOLANT AND CLEANING THE SYSTEM WARNING Danger of being burnt! The coolant is under pressure if the engine is hot. Hot coolant may squirt out during opening. Do not open the radiator until the engine has cooled down somewhat.

  • Page 181: Draining Off The Coolant

    MAINTENANCE EVERY 1000 OPERATING HOURS Draining off the coolant 1. Switch off the engine and let it cool down. 2. Use a suitable aid (e.g. ladder) to climb up the back of the machine and undo the cover screws on the engine hood. 3.

  • Page 182: Maintenance Every 2000 Operating Hours

    The shock absorber must also be exchanged if the flywheel (C) can be moved on the absorber hub (B). CHECKING THE COOLING SYSTEM NOTE Let the cooling system check be performed at a garage which is authorised by Komatsu. 3-46...

  • Page 183: Checking And Cleaning The Turbocharger

    MAINTENANCE EVERY 2000 OPERATING HOURS CHECKING AND CLEANING THE TURBOCHARGER Accumulation of oil carbon or oil sludge on the blower wheel reduces the performance of the turbocharger and can lead to damage. Therefore, have it cleaned by your local dealer. CHECK THREE-PHASE GENERATOR AND STARTER Consult the responsible dealer for inspection or repair, if the carbon brushes are worn or grease is emerging from the bearing seals.

  • Page 184: Hydraulic System, Oil Change, Changing The Filter Insert

    MAINTENANCE EVERY 2000 OPERATING HOURS HYDRAULIC SYSTEM, OIL CHANGE, CHANGING THE FILTER INSERT DANGER • Frequent skin contact with used hydraulic oil may cause skin damages and other injuries! Wear rubber gloves for changing the oil. Wash any hydraulic oil carefully from your skin.
  • Page 185 MAINTENANCE EVERY 2000 OPERATING HOURS Remove the screws (4) from the filter cap (5) and remove the cap. Remove the filter insert (6). Clean the interior of the filter. Before cleaning, check whether there are any foreign particles inside the filter. Insert a new filter insert.

  • Page 186: Maintenance Every 4000 Operating Hours

    WARTUNG ALLE 4000 BETRIEBSSTUNDEN MAINTENANCE EVERY 4000 OPERATING HOURS This maintenance cycle includes all maintenance operations to be performed every 100, 250, 500, 1000 and 2000 operating hours. CHECK WATER PUMP Open the left engine hood. Check the water pump for belt pulley play, emerging grease and leaks.

  • Page 187: Maintenance As Required

    MAINTENANCE AS REQUIRED MAINTENANCE AS REQUIRED AIR FILTER: INSTALLATION AND REMOVAL OF FILTER ELEMENTS CLEANING FILTER INSERTS AND CHANGING SAFETY FILTER AIR FILTER DESIGN The air filter consists of the air filter housing with cover and dust extractor valve, the filter insert and the safety filter. WHEN IS MAINTENANCE NECESSARY? If the control light (1) for the air filter on the maintenance control panel starts to flash, the air filter insert is dirty.

  • Page 188: Cleaning Or Exchanging The Filter Insert

    MAINTENANCE AS REQUIRED CLEANING OR EXCHANGING THE FILTER INSERT The air filter insert can be cleaned with compressed air or water with mild detergent, depending on the type of dirt. The filter insert must be exchanged if the control light lights up again only short time after cleaning, if it was already cleaned six times or after 2000 operating hours.

  • Page 189: Changing The Safety Filter

    MAINTENANCE AS REQUIRED CHANGING THE SAFETY FILTER NOTE Always insert a new safety filter. You must not clean the safety filter and re-use it. It must be replaced if the filter insert is exchanged for the third time. Open the air filter and pull out the air filter insert (1) and the safety filter (2).

  • Page 190: Cleaning The Radiator

    MAINTENANCE AS REQUIRED CLEANING THE RADIATOR If the radiator is dirty, it has to be cleaned. Otherwise, the engine may overheat. Push the locking lever of the radiator protection to the right-hand side into position '1'. Then, turn it downwards into positon '2' and open up the radiator protection.

  • Page 191: Transmission, Checking Oil Level, Topping Up Oil

    MAINTENANCE AS REQUIRED TRANSMISSION, CHECKING OIL LEVEL, TOPPING UP OIL NOTE The oil level in the transmission can rise considerably when the engine is not running. For this reason, only check the transmission oil level with the engine idling. The gear-shift must be in the neutral position.

  • Page 192: Replacing Bucket Teeth

    MAINTENANCE AS REQUIRED REPLACING BUCKET TEETH Worn bucket teeth have to be replaced as follows: DANGER Any movement of the bucket during replacing the bucket teeth can lead to severe accidents. For this reason, park the machine on firm and level ground and secure the machine, before you start maintenance tasks.

  • Page 193: Fuel Tank, Draining Water And Dirt Deposits

    MAINTENANCE AS REQUIRED FUEL TANK, DRAINING WATER AND DIRT DEPOSITS This work has to be carried out if dirt or water is found in the pre-separating glass. Place a clean collecting container below the drain and open the drain plug on the left front side of the tank a few turns and drain off the water and dirt deposit.

  • Page 194: Checking Air-Conditioning

    MAINTENANCE AS REQUIRED CHECKING AIR-CONDITIONING Check the air-conditioning twice a year, in spring and in autumn. WARNING Fluid spraying in the eyes or on the hands can lead to blindness or symptoms of frostbite. Wear safety goggles and protective gloves when working on the air-conditioning.

  • Page 195: Technical Details

    Technical details TECHNICAL DETAILS 4 - 1...
  • Page 196 Technical details Technical details SPECIFICATIONS Model Komatsu S6D102E-1 Engine output (ISO 9249) 103,5 kW (141 PS) / 2,200 min-1 Torque, max. (DIN 70020) 566 Nm / 1,600 min-1) Engine Starter 24 V Three-phase generator 24 V Battery 2 x 12 V 105 Ah 7.2 km/h...

  • Page 197: Noise Emission Levels

    Technical details NOISE EMISSION LEVELS Two rating plates with details of the machine's noise level must be mounted on the machine: In compliance with EC directive 95/27/EEC: 1 plate for sound pressure level 76 dB/A 1 plate for sound power level = 106 dB/A No alterations may be made to the machine which could have an influence on the noise emission levels.
  • Page 198 Technical details NOTES 4 - 4...

  • Page 199: Special Equipment, Auxiliary Equipment

    Special equipment, auxiliary equipment SPECIAL EQUIPMENT, AUXILIARY EQUIPMENT 5 - 1...

  • Page 200: Als - Electronic

    Special equipment, auxiliary equipment ALS - ELECTRONIC Always read this section before installing and operating the ALS- Electronics as safe as possible. STRUCTURE AND FUNCTIONING PRINCIPLE OF THE ALS-ELECTRONICS • The ALS-Electronics uses the hydraulic spring effect of the hydraulic accumulator installed to the circuit at the lift cylinder base end to absorb the vibration of the chassis when the machine is travelling.

  • Page 201: Operating The Als-Electronics

    If any problem or failure occurs with the accumulator, contact immediately your Komatsu dealer. • The gas must be charged only by a serviceman from your Komatsu dealer or by a person licensed to handle high pressure gas. • Do not strike or bring any flame or heat close to the accumulator when it is charged with gas.
  • Page 202 Special equipment, auxiliary equipment 5 - 4...
  • Page 203 © 2001 Komatsu Hanomag Aktiengesellschaft All Rights Reserved Printed in Europe 02.2001...

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