Komatsu WA270-3H, Operation & Maintenance Manual

Page 1: ...ating instructions in another language please don t hesitate to ask at your local dealer s Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read thismanualbeforeoperatingormaintainingthismachine This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it WARNING WHEEL LO...

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Page 3: ...A OF TRANSPORT VEHICLE 0 24 SECURING THE MACHINE DURING TRANSPORT 0 25 AFTER TRANSPORT 0 25 DIMENSIONS WEIGHTS AND OPERATING VALUES 0 26 MACHINE RATINGS 0 27 SAFETY 1 1 SAFETY INSTRUCTIONS 1 2 SAFETY DEVICES 1 2 EMERGENCY EXIT 1 2 CLOTHING AND PERSONAL PROTECTION 1 2 MACHINE MODIFICATIONS 1 3 BEFORE YOU LEAVE THE DRIVER S SEAT 1 3 MOUNTING AND DISMOUNTING 1 3 FIRE PREVENTION AND FIRE FIGHTING 1 4 ...

Page 4: ...FUNCTIONAL LEVER IF INSTALLED 2 4 MAIN CONTROL PANEL 2 4 MAINTENANCE CONTROL PANEL 2 4 CONTROL PANELS 2 5 WARNING INDICATORS B AND E 2 6 CONTROL AND MEASUREMENT INDICATORS A C AND D 2 6 WARNING LIGHT AND INDICATOR FOR EMERGENCY STEERING F 2 6 CHECKING THE CONTROL SYSTEM 2 6 WARNING INDICATORS 2 7 1 CENTRAL CONTROL LIGHT CHECK 2 7 2 CENTRAL WARNING LIGHT CAUTION 2 8 3 WARNING LIGHT FOR ENGINE COOLA...

Page 5: ...NCTIONAL LEVER IF INSTALLED 2 21 1 CONTROL LEVER 2 22 ADJUSTING THE LENGTH OF THE GEAR SHIFT LEVER 2 22 2 DRIVING DIRECTION LEVER 2 22 3 SWITCH LEVER LIMIT STOP 2 22 4 LOCKING LEVER FOR THE WORK HYDRAULIC SYSTEM 2 23 5 CONTROL LEVER FOR THE WORK HYDRAULIC SYSTEM 2 24 6 MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAULIC SYSTEM 2 25 7 CONTROL LEVER FOR SPECIAL EQUIPMENT 2 25 ADJUSTING THE ARMREST 2 25 8 B...

Page 6: ...ONTROL LEVER FOR SPECIAL EQUIPMENT 2 51 WORKING WITH THE MACHINE 2 52 EXCAVATING 2 52 LEVELLING 2 54 DOZING 2 54 LOADING AND TRANSPORTING 2 54 LOADING 2 55 LOADING IN DIAGONAL DIRECTION 2 55 V SHAPED LOADING 2 55 ADJUSTING THE WORK UNIT 2 56 LIFT LIMIT SWITCH 2 56 BUCKET RETURN MECHANISM 2 57 BUCKET LEVEL INDICATOR 2 57 PRECAUTIONS FOR SPECIAL OPERATIONS 2 58 WORKING IN WATER 2 58 IF THE WHEEL BRA...

Page 7: ...OIL LEVEL AND OIL CHANGE 3 4 WARNING SIGN 3 4 WELDING INSTRUCTIONS 3 5 FIRE PREVENTION 3 5 GASKETS SEALS 3 5 OBJECTS IN POCKETS 3 5 CHECKING THE TYRES 3 5 PROTECTIVE MEASURES WHEN WASHING THE MACHINE 3 6 MUDDY OR WET ENVIRONMENT 3 6 DUSTY ENVIRONMENTS 3 6 ENGINE HYDRAULIC OIL 3 7 GREASE 3 7 FUEL 3 8 BIOLOGICALLY DEGRADABLE HYDRAULIC OILS AND GREASE 3 8 STORAGE OF OIL AND FUEL 3 8 COOLANT 3 9 FILTE...

Page 8: ...ANGE 3 30 BATTERIES CHECKING THE ACID LEVEL 3 31 BATTERY RECHARGING 3 32 AXLES CHECK OIL LEVELS 3 33 WHEEL NUTS CHECK RETIGHTEN 3 33 LUBRICATION 3 34 MAINTENANCE EVERY 500 OPERATING HOURS 3 35 FUEL FILTER CHANGE FILTER CARTRIDGES 3 35 BLEEDING THE FUEL SYSTEM 3 36 MAINTENANCE EVERY 1000 OPERATING HOURS 3 37 TRANSMISSION CHANGE OIL AND FILTERS 3 37 ENGINE ADJUSTING THE VALVE CLEARANCE 3 39 SERVICE ...

Page 9: ...G FLUID LEVEL TOPPING UP 3 54 TRANSMISSION CHECKING OIL LEVEL TOPPING UP OIL 3 55 REPLACING BUCKET TEETH 3 56 FUEL TANK DRAINING WATER AND DIRT DEPOSITS 3 57 TYRES CHECKING AIR PRESSURE 3 57 AIR CONDITIONING CLEANING CONDENSER 3 57 CHECKING AIR CONDITIONING 3 58 CHECKING THE COOLANT LEVEL 3 58 TECHNICAL DETAILS 4 1 TECHNICAL DETAILS 4 2 NOISE EMISSION LEVELS 4 3 VIBRATION LEVEL 4 3 LIMIT VALUES FO...

Page 10: ...0 8 Contents ...

Page 11: ...INFORMATION ON THESE OPERATING INSTRUCTIONS ...

Page 12: ...0 1 0 Information on these Operating Instructions ...

Page 13: ...ne 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...

Page 14: ...e cab Also the noise level on the ear of the driver is brought down to 74 decibels A The Automatic Load Stabilising electronics ALS is available as a special accessory helping to reduce oscillations and vibrations starting from speeds above 5 k p h thus protecting driver and machine The monitoring system is arranged centrally and consists of the main and the maintenance control panel Around the mo...

Page 15: ...are helping to reduce clearly the time needed for maintenance EDIMOS II the electronic defect diagnosis system and the centrally arranged lubricating points make maintenance much easier for you The integrated mudguard engine shutter units permit easy access to all maintenance locations AND WHAT ABOUT ENVIRONMENTAL CARE The low exhaust engine of the WA 270 3 fulfills the EU standard planned for 199...

Page 16: ...rder 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 The chapter Safety starting on page 1 1 contains a summary of all safety notes applying to this machine We cannot however predict...

Page 17: ... 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 c...

Page 18: ...on 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 co...

Page 19: ...olume m Load capacity kg Hydraulic pressure bar Weight kg Bucket WA270 3H 42Y 70 H2720 2 870 42Y 70 H2730 2 910 42Y 70 H2640 2 1 880 42Y 70 H2650 2 1 920 42Y 70 H2660 2 2 1000 42Y 70 H2741 2 4 988 42Y 70 H2671 2 4 960 42Y 70 H2681 2 4 1000 42Y 71 H2A51 2 4 42Y 71 H2B21 2 4 42Y 71 H2B41 2 5 I dtp BA270GB 270_ALU 270_ALUPM CE 270 TBL ...

Page 20: ...0 1 8 Information on these Operating Instructions CE CONFORMING EQUIPMENT OF THE MANUFACTURER ACCORDING TO DOCUMENT 419 93 H1160 U DTP ZEICHNUN l CEAUS WMF ...

Page 21: ... B2 Distance driver s eye 1 front axle vertical C1 Distance center steering wheel center front axle horizontal C2 Distance center steering wheel center front axle vertical D1 Distance headlights center front axle horizontal D2 Distance headlights center front axle vertical G Weight of the equipment and working load H1 Distance bucket pivoting point upper edge od bucket vertical carrying position H...

Page 22: ...0 2 0 Information on these Operating Instructions ...

Page 23: ...0 2 1 Loading and Transporting the Machine LOADING AND TRANSPORTING THE MACHINE ...

Page 24: ...0 2 2 Loading and Transporting the Machine ...

Page 25: ...rticulated 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...

Page 26: ...RNING Danger of accidents 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 operatin...

Page 27: ...pes 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 th...

Page 28: ...lift at 45 mm 950 1 000 b Dumping height at 45 mm 2 900 2 860 c Lift height hinge pin mm 3 78 3 782 The 2 1 2 4 m standard buckets shown in the table can also be delivered with bolt on cutting edges 2 2 2 5 m d Height at bucket upper edge mm 5 075 5 075 e Digging depth 0 mm 27 27 f Carry height hinge pin mm 460 460 A Overall length mm 7 060 7 120 Special buckets 3 4 m light material bucket B Wheel...

Page 29: ...achine 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 Serial No Machine Serial No Engine Dealer Name Dealer Address Telephone Fax Maintenance Personnel SE NO_75 TBL ...

Page 30: ...0 2 8 Loading and Transporting the Machine ...

Page 31: ... 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 SAFETY 1 1 ...

Page 32: ...of the safety devices Safety devices must be kept in perfect condition EMERGENCY EXIT In an emergency situation you can use the rear window as an emergency exit For this purpose use the emergency hammer 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 I...

Page 33: ...o accidents with injuries or damage 3 Switch off the engine 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 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 cont...

Page 34: ...ve wooden chippings leaves paper and other highly inflammable materials that may have collected in the engine compartment since they could cause a fire A fully operational fire extinguisher must be available at hand Do not operate the machine in the vicinity of naked light FIRE EXTINGUISHER AND FIRST AID KIT The fire extinguisher is located on the rear cab frame on the left inside the operator s c...

Page 35: ...rating the machine the engine coolant the engine oil and the hydraulic oil are extremely hot and under pressure Do not try to unscrew caps drain water or oil or replace filters directly after operating the machine since this may lead to severe burns due to hot fluids or hot machine parts Wait until the temperature has fallen Strictly adhere to the described procedures when performing the required ...

Page 36: ...TACHMENT FOR PROTECTION AGAINST FALLING OBJECTS FOPS IMPORTANT FOPS is a fixed component of the cab When you work on a site where there is danger of falling rocks or other objects the machines must be equipped with a FOPS If the FOPS is modified without permission or damaged its stability is impaired In this case the FOPS must be replaced since its correct function can no longer be guaranteed ATTA...

Page 37: ...your hands after work Batteries produce detonating gas Detonating gas is extremely ex plosive and may be ignited even by the smallest spark Do not disconnect the battery while the engine is still running Prior to start of work on batteries set the start switch to 0 Set the main switch of the battery if installed to Off Avoid any short circuits via the poles or the pole terminals of the battery due...

Page 38: ...company to determine the lines positions Ensure that these facilities will not be damaged When working with water or crossing sand banks first check the subsoil and depth and flow rate of the water Ensure that the permitted water depth will not be exceeded IN THE DRIVER S CAB Do not leave any tools or spare parts lying around in the cab These may actuate damage or block control levers pedals or sw...

Page 39: ...e in engine speed or an exceeding of the engine s maximum rpm This may lead to a fire an explosion and major damage to property It may also happen that the engine cannot be switched off anymore Also refer to chapter Operation in Closed Areas MIRRORS WINDOWS AND LIGHTING Clean the windows and the headlights to ensure maximum sight Adjust the rear view mirror in such a way that you have an excellent...

Page 40: ...ded with a reversing warning system you must ensure that it operates correctly Before you start the machine check that the articulated steering is unlocked position 1 and that the locking bar is attached to the frame by means of bolts and spring bolts Always wear the safety belt when operating the machine REVERSING These rules must be observed for all machines i e also for those machines equipped ...

Page 41: ...r Slopes To keep the centre of gravity as low as possible when driving on slopes embankments and hill flanks you must set the bucket to a position just above the ground approx 200 to 300 mm In an emergency quickly lower the bucket to the ground to stabilise the machine Do not turn on a slope or drive across a slope Turn or cross the section only level ground When driving on slopes avoid driving on...

Page 42: ... off valve in the lift cylinder circuit for the boom slowly in the direction of the arrow 3 Upon completion close shut off valve and return lever to retainer and screw tight for safety reasons LOWERING POSSIBLE FROM CHASSIS NUMBERS FROM WA270H20260 ONWARDS WARNING Danger of accidents While lowering the work unit it is not possible to see the hazardous area below the work unit For this reason ask s...

Page 43: ...r transmission line proceed as follows 1 Do not leave the driver s cab The driver s cab is a Faraday cage protecting you from electric shock 2 Warn other persons and tell them to stay far away from both the power line and your machine 3 Try to move the machine out of the range of influence of the overhead power transmission line by moving it away from the line moving away the work unit etc 4 Have ...

Page 44: ... proceed very carefully when removing snow When driving on hill flanks covered with snow do not brake abruptly to stop the machine To stop the machine lower the bucket onto the ground The load may vary considerably depending on the structure of the snow For this reason reduce the load and pay attention that the machine does not start to skid HEIGHT LIMITATION When working in areas with height limi...

Page 45: ...own the slope Lower the work unit until it firmly touches the ground 1 or let the cutting edge of the bucket sink deeply into the soil Block the wheels with wheel chocks 2 to ensure that the machine cannot roll away When parking the machine on public roads ensure that it does not obstruct traffic Put up signal lamps and required warning signs to ensure that passing traffic can clearly see the mach...

Page 46: ...ed low and drive slowly Do not carry out steering movements on the ramps If required drive off the ramps again correct alignment of the machine and drive up again After loading i e when the machine is on the transport vehicle apply the parking brake Block the wheels of the machine with wheel chocks Set the steering wheel of the machine to straight driving Secure the articulated steering with the l...

Page 47: ...g carried out on the machine 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 SAFETY RELATED PARTS The quality of these parts is subject to normal wear a...

Page 48: ...m proceed with particular care Carry out such measures with two persons with whom you have arranged clear hand signs beforehand One person must be seated on the driver s seat to ensure that the engine can be immediately switched off if required This person must always ask the second person before actuating the control levers The person performing the maintenance measures must take care not to touc...

Page 49: ...ase note 2 support braces are necessary for every machine one for the left hand lifting ram and one for the right hand lifting ram When using the support braces the following procedure is to be adhered to at all times 1 Park the machine on level solid ground 2 Apply the parking brake 3 Place wheel chocks in front of the wheels to prevent the machine from inadvertently rolling away 4 Lift the arm f...

Page 50: ...chine using wheel chocks Do not work under a machine that is not appropriately supported KEEPING THE MACHINE CLEAN Always keep the machine clean and tidy Oil grease and tools lying around involve danger since they may cause slipping or tripping over Do not clean sensors plugs and the interior of the driver s cab with water or steam If water seeps into the electric system there is danger of uncontr...

Page 51: ... according to the relevant environmental regulations If the machine is provided with a fuel sieve in the tank opening do not remove this fuel sieve before you start refuelling COOLANT The machine is provided with an aluminium cooling system Apply only coolants in the prescribed mixing ration Caution antifreeze is highly inflammable To check the coolant level first switch off the engine and wait fo...

Page 52: ... has happened HANDLING OF ALS CONTROL PRESSURE ACCUMULATORS WARNING Danger of injury Pressure accumulators are filled with highly pressurised nitrogen Do not open or damage pressure accumulators Immediately inform your Komatsu dealer if you detect malfunctions or defects of pressure accumulators Filling pressure accumulators with gas or topping up gas in pressure accumulators is strictly limited t...

Page 53: ...an or the belt are cut off or hurled away Do not wear loose clothing neckerchiefs or the like or open long hair that might get caught WASTE MATERIAL Do not pour used oil into the sewage system rivers etc Collect used oil of the machine in appropriate containers Do not let oil flow out onto the ground Adhere to all applicable laws and regulations when disposing of harmful substances such as oil fue...

Page 54: ...e when the tyres are still cold Do not let off pressure when the pressure in a warm tyre has increased Do not light a fire and do not carry out welding near the tyre Keep the working area free of pointed or sharp objects that may damage the tyre Avoid any overload The values for tyre pressure and permitted speed given in this manual correspond to the manufacturers values Please refer to your local...

Page 55: ...SAFETY LABELS 1 25 SAFETY LABELS All labels must be kept clean at all times Missing or damaged labels must be replaced POSITIONS OF SAFETY LABELS ...

Page 56: ...SAFETY LABELS 1 26 ...

Page 57: ...ure articulated joint during transport or when loading P N 421 93 H1330 9 Instructions prior to operation maintenance P N 421 93 H1250 10 Precautionary measures before starting work P N 421 93 H1340 11 Precautionary measures before leaving the machine P N 421 93 H1290 12 Caution when using jump leads P N 421 93 H1310 13 Do not open when engine running P N 09667 A0880 14 Do not stand on fender P N ...

Page 58: ...SAFETY LABELS 1 28 ...

Page 59: ...2 1 Operating and Control Elements OPERATING AND CONTROL ELEMENTS ...

Page 60: ...erating 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 ...

Page 61: ...MAIN CONTROL PANEL 30 Control light for direction indicators 31 Control light for high beam 32 Central control light 33 Preheater control light 34 Switch and control light for front working light 35 Switch and control light for rear working light 36 Switch and control light for transmission cut off 37 Control light for parking brake 38 Central warning light 39 Speedometer 40 Gear shift status indi...

Page 62: ...trol panel MAIN CONTROL PANEL 30 Control light for direction indicator 31 Control light for high beam 32 Central control light 33 Preheater control light 34 Switch and control light for front working light 35 Switch and control light for rear working light 36 Switch and control light for transmission cut off 37 Control light for parking brake 38 Central warning light 39 Speedometer 40 Gear shift s...

Page 63: ...d 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 Control and measurement indicators F Warning light and indicator for emergency steering system All elements which are required for efficient machine operation are described on the following pages ...

Page 64: ...he indicator for the emergency steering system For details see Troubleshooting Emergency steering CHECKING THE CONTROL SYSTEM This check can be performed 30 seconds after the engine has been switched off Turn the start switch to its operating position 1 before starting the engine All instruments and control and warning lights will then light up for approx 3 seconds The speedometer displays the num...

Page 65: ...ures Before the start up do not only rely on the control panels when performing the pre start checks Also carry out the prescribed maintenance steps in time If the coolant level is too low the central control light CHECK goes out when the engine is started The central warning light CAUTION will then start to flash and the alarm buzzer will sound at intervals If an error is detected in the battery ...

Page 66: ...art to flash if the fuel gauge has entered the critical red range while engine is running 3 WARNING LIGHT FOR ENGINE COOLANT LEVEL Park the machine horizontally on level ground before performing this check Check prior to start The warning light and the central control light CHECK start to flash if the coolant level in the cooling system is too low In this case check the coolant level in the equali...

Page 67: ...0 seconds after starting the engine and after the warning has ended If not switch off the engine immediately and let the oil pressure circuit for the brake be checked by a Komatsu Hanomag service technician 6 WARNING LIGHT FOR ENGINE OIL PRESSURE Check prior to start The light must light up With the engine running The lubrication pressure is built up after the engine is started Then the light will...

Page 68: ...the central control light CHECK start to flash if the air filter is dirty In this case clean or replace the filter insert 9 WARNING LIGHT FOR THE TRANSMISSION GEAR SHIFT PRESSURE NOTE You may no longer drive the machine if the transmission gear shift pressure is too low Otherwise consequential damages cannot be ruled out Have any faults immediately repaired At first check the oil level in the tran...

Page 69: ...uring instruments will light up for a moment if they are fully functioning 1 CONTROL LIGHT FOR DIRECTION INDICATOR The control light starts to flash if the direction indicator is switched on 2 CONTROL LIGHT FOR HIGH BEAM HEADLIGHTS This control light light up if the high beam headlights are switched on MAIN CONTROL PANEL MAINTENANCE CONTROL PANEL ...

Page 70: ...n be started after the control light has gone out 4 CONTROL LIGHT FOR PARKING BRAKE This control light lights up if the parking brake has been applied 5 SPEEDOMETER This instrument indicates the speed of the machine 6 GEAR SHIFT STATUS INDICATOR This indicator shows the selected gear If N is displayed on the indicator the driving direction lever has been set to its neutral N position If the drivin...

Page 71: ... temperature of the converter oil During operation the indicator will be in the green range if the temperature is normal The converter oil temperature is too high if the indicator is in the red range The instrument s control light and the central warning light CAUTION start to flash when the indicator enters the first red section An acoustic alarm is also issued if the indicator enters the second ...

Page 72: ...2 14 Operating and Control Elements SWITCHES ...

Page 73: ...ed off Operating position 1 In this position the engine is automatically preheated Leave the key in this position when the engine is running Previously deactivated power supply circuits are again switched on Start position 2 Hold the ignition key in this position until the engine starts up then release it immediately it automatically returns to the operating position 1 IMPORTANT The engine can onl...

Page 74: ...on is only effective in the first or second gear The transmission cut off should be set to ON during normal operation 3 SWITCH FOR FRONT WORKING LIGHTS CAUTION The front working lights may blind oncoming traffic Switch off the front working lights before driving on public roads It is required to switch on the main headlights before the front working lights can be switched on Press the working ligh...

Page 75: ...low beam and high beam 6 DIRECTION INDICATOR LEVER This lever is used to switch on the direction indicators 1 Left direction indicator Push the lever forward 2 Right direction indicator Pull lever to the back The direction indicator control light on the main and maintenance control panel lights up when this lever is activated The direction indicator is automatically reset after the driving manoeuv...

Page 76: ...are driving in 2nd or 4th gear you can increase the thrust for excavation and loading operations by using the kickdown function In 3rd gear kickdown switch can not be operated The transmission changes down to the 1st gear as soon as the kickdown function is activated Kickdown ON In 2nd gear press the button on top of the control lever for the work hydraulic system see arrow If your machine is fitt...

Page 77: ...the selected gear is displayed on the gear shift indicator 3 Press the toggle switch at the front of the multifunctional lever to position 2 The gear shift lock is now switched on and the control lamp for the gear shift lock is lit Switching OFF the gear shift lock You can switch off the gear shift lock by restting the toggle switch at the front of the multifunctional lever to position 2 The gear ...

Page 78: ... interfere with the board electronics 16 SWITCH FOR INTERIOR LIGHTING Switch position 1 Switched OFF Switch position 2 Switched ON by door contact Note The interior lighting can also be switched on if the start switch is in position 0 For this reason set the switch to position 1 OFF when you are leaving the cabin If you operate the machine with open doors set the switch to position 1 OFF 17 BATTER...

Page 79: ...2 21 Operating and Control Elements CONTROL LEVERS PEDALS CONTROL LEVERS PEDALS WITH MULTIFUNCTIONAL LEVER IF INSTALLED ...

Page 80: ...engths positions A B and C To adjust it remove the screw 1 push the lever end section 2 to the required position and retighten the screw 2 DRIVING DIRECTION LEVER Use this lever to change the driving direction The engine can only be started if the driving direction lever or the driving direction switch is in its the neutral position N F Forward N Neutral R Reverse IMPORTANT If your machine is equi...

Page 81: ...rn the locking lever for the work hydraulic system into position 1 The locking lever for the work hydraulic system will then be without function In addition lower the bucket onto the ground and switch off the engine before leaving the driver s cab The work hydraulic system is secured against unintentional operation with this locking lever Lever position 1 Locking lever secured 2 Operating position...

Page 82: ...sition H Raising If the control lever is pulled further in the raising direction H it is locked in that position until the boom has reached the pre set position of the lift limit switch The control lever is then automatically returned to the stop position 0 E Tipping in If the control lever is pulled further in the tip in direction E the lever is locked in that position until the bucket has reache...

Page 83: ...g in If the multifunctional lever is pulled further in the tip in direction E the lever is locked in that position until the bucket has reached the pre set automatic digging angle The multifunctional lever is then returned automatically to the stop position 0 A Dumping Note Never lift heavy with the work unit while the load is balanced only on one side 7 CONTROL LEVER FOR SPECIAL EQUIPMENT Control...

Page 84: ...tch control light is not lit The transmission cut off is switched on or off by pressing the switch T M CUT OFF Operating positions of the transmission cut off OFF The brake pedal can be used as normal brake The switch control light is not lit ON This function can only be used in the 1st and 2nd gear The switch control light is lit If the brake pedal is used for braking the transmission is at the s...

Page 85: ...ill being pulled the warning light CAUTION will start to flash Pulling the brake WARNING Danger of accidents If you are pulling the parking brake during driving the transmission is automatically set to its neutral position and the braking effect of the engine is cannot be applied While driving never brake the machine with the parking brake except for emergencies Pull the parking brake only after t...

Page 86: ... hole 2 in the counterweight 2 Use linch pin 3 to fix the towing pin To remove the pin proceed in reverse order 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 REVERSING AL...

Page 87: ... working light 10A 2 Reverse driving light reversing alarm 10A Rear working light 10A 3 Direction indicator 10A Air conditioning condensator 20A 4 Main headlight right 10A Fan for heating and air conditioning 20A 5 Main headlight left 10A Windscreen wiper and washer front and rear 20A 6 Parking light right instrument illumination 10A Control unit gear shift 10A 7 Parking light left 10A Cigarette l...

Page 88: ...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 1 30A Glow plug 2 30A Battery power supply start switch hazard flasher system 3 100A Main power supply RELAYS ...

Page 89: ...h air circulating air or both fresh and circulating air In the circulating air position external fresh air is blocked so that only the air in the cab is circulated Selector lever for rear window The air jets for the rear window can be continuously opened or closed with this lever 4 Air jets Air is distributed through the air jets 7 and 8 they can be individually opened or closed The direction of t...

Page 90: ...engine speed Switching on the air conditioning 1 Turn the rotary switch 1 of the fan to position 3 2 Set the temperature control lever 2 to cold 3 Set the selector lever 3 to position circulating air 4 Push the switch 6 lock 5 down then hold it in place and press the switch The air conditioning is now switched on and the control light in the switch is lit Maximum cooling is achieved with this sett...

Page 91: ...2 33 Operation OPERATION ...

Page 92: ...ay be prematurely impaired and its service life may be shortened A new machine must be run in and serviced very carefully and thoroughly The following points are particularly important After the engine has been started it must run in idle for 5 minutes Operation with heavy loads or at high speeds is to be avoided Sudden starts sudden acceleration jerky steering and stopping is to be avoided this d...

Page 93: ...k the areas around the engine and radiator for accumulated dirt or dust Check the battery area and the vicinity of hot parts e g exhaust and turbo charger for accumulated inflammable material Remove any dirt or dust 3 Engine and cooling system Pay attention that no oil is leaking out of the engine and that there are no leaks in the fuel supply and cooling system Repair any damages 4 Transmission a...

Page 94: ...catch must not be blocked by paper or similar as this would prevent the belt buckle from locking into place when inserted Keep the belt clean and check whether the belt holder is properly attached Replace the seat belt if either the belt or the belt holder has been damaged or deformed 12 ROPS Check for loose or damaged bolts Bolts may only be retightened or replaced by a Komatsu dealer Loose bolts...

Page 95: ...le of inclination of the seat can be adjusted using levers 3 and 4 The position of the seat front section can be adjusted up or down by raising lever 3 and applying or removing pressure to the front section of the seat cushion The selected seat height angle locks into position when the lever 3 is released The position of the seat rear section can be adjusted up or down by raising lever 4 and apply...

Page 96: ...ion Push the lever 2 down and apply or remove pressure to the rear section of the seat cushion 3 Adjusting the backrest Raise the lever 3 and move the backrest to the required position by moving your body weight Release the lever to lock the backrest in the desired position 4 Weight adjustment The suspension system is adjusted to the driver s weight by pushing button 4 Heavier Push button 4 up Lig...

Page 97: ... immediately in the event of sudden braking or acceleration and while driving on hills or in curves 1 Sit down on the driver s seat and pull out the belt slowly Then push the buckle without interruption into the catch until it locks into place Pull the belt to make sure that the buckle really has locked into place 2 To release the belt press the orange button The belt rewinds automatically IMPORTA...

Page 98: ...osition 1 before you start up the engine 1 Check that parking brake lever is pulled The pilot lamp for the parking brake is on 2 Check that either the directional lever or the directional switch is set to the N position If directional lever or the directional switch is not set to N the engine will not start 3 Insert the key in starter switch 5 turn the key to the ON position and make sure that the...

Page 99: ...ight 2 lights up IMPORTANT The switch on time for the preheating system depends on the ambient temperature 2 Press down lightly the accelerator pedal 3 When the preheating control light goes out turn the ignition key to starting position 2 to start up the engine NOTE Do not apply the starter for longer than 20 seconds If the engine does not start up within this period you must wait for at least 2 ...

Page 100: ...ratures The engine must smoothly after the warm up phase Push either the control lever for the work hydraulic system or the multifunctional lever to position E tip in position and then back again at short intervals to warm up the hydraulic oil This procedure helps to warm up hydraulic oil faster The control lever or the multifunctional lever must not be held in the E tip in position for longer tha...

Page 101: ... If the engine is overheated let it run at medium speed for 5 minutes before switching it off This permits the engine and torque converter to cool down sufficiently 3 Lower the work unit onto the ground Then turn the start switch to position 0 to switch off the engine 4 Remove the key from the start switch AFTER MACHINE OPERATION 1 Walk around the machine and inspect visually the work unit bodywor...

Page 102: ...l lever and move the work unit into the drive position as indicated in the illustration on the right hand side Observe the markings for the transport position arrow 3 Press down the brake pedal and keep it in that position 4 Push down the parking brake lever to release the parking brake 5 Select the desired gear using the gear shift lever 6 Select the required direction using either the directiona...

Page 103: ...itch off the transmission cut off when starting on a slope The control light goes out 2 Start the engine 3 Press down the brake pedal and keep it in that position 4 Push down the parking brake lever to release the parking brake 5 Select the desired gear using the gear shift lever 6 Select the desired direction using either the directional lever or the directional switch F Forward N Neutral R Rever...

Page 104: ...f the 4th gear is selected with the gearshift lever 1 The 1st gear cannot be automatically activated KICK DOWN FUNCTION The kick down function is recommended for driving in the 2nd gear to perform dozing or loading operations The 1st gear can be selected at any time using the kick down switch arrow which is integrated into the work hydraulic control lever by pressing it briefly when the 2nd gear h...

Page 105: ...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 ...

Page 106: ...n can be directly changed in the 1st and 2nd gear 1st gear forward 1st gear reverse 2nd gear forward 2nd gear reverse If the machine is being driven at a speed exceeding the maximum speed of the 2nd gear gear lever 1 position in 4th gear when changing the driving direction the transmission automatically shifts to the 2nd gear first After a brief delay the driving direction is changed first in the ...

Page 107: ...he driving direction lever or the driving direction switch to the neutral position N 3 Pull the parking brake lever up to apply the parking brake 4 Lower the bucket to ground level WARNING Unintentional moving of the bucket may cause accidents Turn the locking lever for the work hydraulic system to position 2 before quitting the driver s cab The control level for the work hydraulic system will the...

Page 108: ...If the control lever is pulled further in raising direction H the lever is locked in this position until the boom has reached the pre set position of the lift limit switch The control lever is then returned automatically to the stop position 0 E Tipping in If the control lever is pulled further in the tip in direction E the lever is locked in this position until the bucket has reached the pre set ...

Page 109: ...lever is pulled further in the tip in direction E the lever is locked in this position until the bucket has reached the pre set automatic digging angle The multifunctional lever is then returned auto matically to the stop position 0 A Dumping NOTE Never lift heavy loads with the work unit with the balance being only on one side Control Lever for Special Equipment Control lever positions A Open 0 N...

Page 110: ... exploded rock drive the machine in the 1st gear Proceed as follows if you are removing loose soil or performing dozing operations 1 While driving forward lower the bucket until it reaches a height of approx 30 cm above the ground Then lower it slowly NOTE If the bucket touches the ground the front wheels may be lifted from the ground resulting in premature wear and tear of the rear wheels 2 Shift...

Page 111: ...it and lower it in order to reduce the load and to prevent that you lose the load during the transport Excavating on Level Ground When excavating and loading on level ground make sure that the bucket is not overloaded on one side since the balance of the machine may be impaired Perform this type of operation in the 1st gear 1 Bend the bucket edge slightly down 2 While driving forward move slightly...

Page 112: ... nobody is in your way while driving backwards DOZING CAUTION The bucket teeth and the bucket will be damaged if you are digging with the bucket being in the dumping position If you are performing digging operations adjust the bucket in such a way that its bottom side is in parallel to the ground Perform dozing operations in the 1st or 2nd gear LOADING AND TRANSPORTING CAUTION The machine may fall...

Page 113: ...ION Align the machine in rectangular position to the heap Drive the machine backwards in straight line after you have filled the bucket Then let the dump truck drive between heap and machine Drive up to the dump truck and unload the material This operation requires not much time and reduces considerably the cycle times V SHAPED LOADING Position the dump truck in such a way that the angle between t...

Page 114: ...s not supported 5 Place wheel chocks in front and behind the wheels 6 Lock the articulated steering with the articulated steering catch 7 Loosen both screws 1 8 Adjust the indicator 2 in such a way that the rear edge is in the centre of the contact area of the switch 3 9 Retighten both screws 10 Loosen both screws 4 permitting to set a gap of 3 to 5 mm between the indicator 2 and the contact area ...

Page 115: ...nd the bracket 4 must be 3 to 5 mm 11 After the adjustment is finished the engine can be restarted WARNING Unintentional moving and opening of the bucket may lead to severe accidents Make sure that there is nobody standing next to the bucket before lifting and opening the bucket Sound the horn immediately before you start to lift the bucket 12 Raise the boom 13 Open the bucket 14 Set either the co...

Page 116: ...nkments and hill flanks you must set the bucket to a position just above the ground approx 200 to 300 mm In the event of an emergency displace the bucket fast on the bottom in order to stabilise the engine Braking on slopes WARNING If the transmission cut off is switched on there is no braking effect of the engine available This may lead to accidents when driving on slopes For this reason switch o...

Page 117: ...sure with the tyres being cold If the tyre pressure is too low the tyres will be overstrained excessive pressure can lead to cracks in the tyres which may result in the tyre bursting under peak loads Set the tyre pressure according to the table to avoid any damage VISUAL INSPECTION As a guideline for visual inspection the compression ratio of the front tyres no load under load should be as follows...

Page 118: ... sure that the working lights and the warning beacon are turned off while driving on public roads Make a break of 30 minutes after driving for one hour Check the tyres and all particularly strained parts during driving on public roads whether they are still fully functioning or damaged TYRES AND TYRE PRESSURES WARNING If a tyre bursts while inflating or if a multipart wheel rim breaks apart the hu...

Page 119: ...0 29 3 75 55 1 5 22 DUNLOP 20 5 25 E91 L 2 1 5 22 1 5 22 2 5 37 1 5 22 DUNLOP 20 5R25 SP T9 L 2 1 5 22 1 75 26 3 0 44 1 5 22 DUNLOP 20 5R25 SP T8S L 2 1 5 22 1 75 26 3 0 44 1 5 22 DUNLOP 20 5 25 PG6S L 3 1 5 22 1 5 22 3 0 44 1 5 22 DUNLOP 20 5R25 SP T7LD L 3 1 5 22 1 75 26 3 0 44 1 5 22 MICHELIN 555 70R25 XHF L 3 2 0 29 1 5 22 3 5 51 2 5 36 MICHELIN 20 5R25 XHA L 3 2 0 29 1 5 22 3 0 44 2 0 29 MICH...

Page 120: ...ow temperatures paraffin deposits of diesel fuel may block the filters and lines see Lubricants and Operating Agents If the injection system the starter the battery and the alternator are in perfect condition it is ensured that the engine can be easily started and that the machine can be operated troublefree even in extremely cold weather Let these important components be checked at an authorised ...

Page 121: ...t park the machine on wooden planks The planks prevent that the wheels are freezing to the ground Drain off collected water from the fuel system The battery capacity drops clearly at low temperatures Therefore dismount the battery in frost periods and store it in a warm place Re install it the next morning before starting to work AFTER THE COLD SEASON If the weather becomes warmer you must fill up...

Page 122: ... dry room which is frost free in winter Add sufficient anti freeze to the coolant if temperatures are expected to drop below 0 C Check whether the coolant is set to a temperature of 37 C Refill antifreeze if necessary DURING SHUTDOWN WARNING Danger of poisoning if the engine is run indoors Open windows and doors before you start the engine indoors Let the engine run once a month Drive the machine ...

Page 123: ...2 65 Troubleshooting TROUBLESHOOTING ...

Page 124: ... is running Alternator belt tension too low Adjust belt tension Battery charging control lamp does not go out when engine is running Faulty electrical connection Faulty alternator Alternator belt tension too low Check repair terminals connecting points and cables Replace alternator or regulator Adjust belt tension Alternator making strange noises Faulty alternator Replace alternator Starter does n...

Page 125: ...mation or dirt in cooling system Radiator dirty outside Thermostat faulty Faulty or loose radiator cap when operating at high altitudes Faulty coolant level sensor Retighten belt Clean inside of cooling system Clean outside of radiator Replace thermostat Replace tighten radiator cap Replace sensor Temperature display in white zone Thermostat faulty Faulty temperature display Replace thermostat Rep...

Page 126: ... because of incorrect valve clearance Turbocharger faulty Clean replace insert Replace injection nozzles Adjust valve clearance Clean replace turbocharger Combustion makes sound like breathing at times Injection nozzle defect Replace injection nozzles Unusual combustion noises Unusual mechanical noises Incorrect fuel Overheating Silencer faulty Valve clearance too large Use recommended fuel See Fa...

Page 127: ...ns Machine only runs slowly and not at full power Oil level too low Top up with oil according to specifications Overheating Oil level too low or too high Machine being driven in a gear which is too high Engine overheating Top up with oil according to specifications Run machine in a lower gear See ENGINE fault Temperature gauge in red zone and respective control lamp flashing Noises Oil level too l...

Page 128: ...not working Brake discs have reached limit of wear Air in the system Hydraulic system faulty Replace brake discs Bleed system Repair PARKING BRAKE Faulty brake action Too much play on brake lever Brake lining worn Adjust brake Replace brake linings STEERING Steering reaction sluggish Faulty hydraulic system Repair Steering wobbles Play on steering cylinder bolts too large Hydraulic system faulty R...

Page 129: ... SYSTEM Fault Fault cause Remedy Insufficient lifting force Lift action too slow Oil level too low Filter insert dirty Top up with oil according to specifications Replace insert Air bubbles in oil Poor oil quality Oil level too low Top up with prescribed oil Top up with oil according to specifications Cylinders jerking Oil level too low Top up with oil according to specifications ...

Page 130: ...matic gear shift 1 Apply the parking brake and set the driving direction lever to its neutral position 2 Push the lock 1 of the emergency switch 2 to the side hold it in this position and press the switch The emergency driving mode is now activated and the control light in the switch lights up 3 Press the brake pedal start the engine and release the parking brake WARNING Careless starting up of th...

Page 131: ...ble and the defective machine have contact with each other and if current is supplied immediately after connecting the positive terminals If a terminal slips off and comes in contact with the machine Attach the terminals firmly and make sure durig connecting and disconnecting the jumper leads that both cable ends neither touch each other nor the machine both machines do not touch each other 1 Turn...

Page 132: ...ead B from the negative pole of the charged battery V 3 Disconnect a terminal of the jumper lead A from the positive pole of the charged battery V 4 Disconnect the other terminal of the jumper lead A from the positive pole of the empty battery TOWING THE MACHINE WARNING If the actively towing machine s weight is too light accidents may occur during towing Always use a machine for towing which has ...

Page 133: ...steering must be locked in place when the machine is transported on a low bed truck by rail or towed by a mobile crane The cardan shaft of the running axle has to be removed when the front axle is to be raised The parking brake does not work if the cardan shafts have been removed WARNING If the machine to be towed has defective brakes it may collide during the towing Use two machines to tow a mach...

Page 134: ...l light 1 for steering goes out The green control light 2 for emergency steering remains unlit 3 Drive with the engine running The red control light 1 for steering remains unlit The green control light 2 for emergency steering lights up If the red control light 1 flashes and the green control light 2 lights up during driving a fault has occurred in the steering s hydraulic circuit and the emergenc...

Page 135: ...nder circuit for the boom slowly in the direction of the arrow 3 Upon completion close shut off valve and return lever to retainer and screw tight for safety reasons Lowering possible from chassis numbers from WA270H20260 onwards WARNING Danger of accidents While lowering the work unit it is not possible to see the hazardous area below the work unit For this reason ask somebody to secure the hazar...

Page 136: ...ng driving the transmission is automatically set to its neutral position so that there will be no braking effect of the engine available While driving never brake the machine using the parking brake with the exception of emergencies Apply the parking brake only after the machine has come to a standstill 1 Start up the engine align the machine for straight driving and drive it with empty bucket up ...

Page 137: ...3 1 MAINTENANCE ...

Page 138: ...3 2 MAINTENANCE BASICS ...

Page 139: ...ndicated in the adjacent illustration 4 Switch all control levers into neutral or stop position 0 5 Turn the locking lever for the work hydraulic system into position 1 6 Remove the ignition key and store it in a safe place 7 Pull the parking brake 8 Attach warning signs to the start switch 9 Place wheel chocks infront and behind the tyres 10 Secure the articulated steering with the articulated st...

Page 140: ...s 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 Relock the tank opening after refuelling You may slip on spilled fuel or oil or spilled fluid may ignite For this reason remove immediat...

Page 141: ... pipes containing fuel or oil FIRE PREVENTION Do not use any inflammable detergents to clean parts Do not allow any naked flames in the vicinity of detergents Do not smoke whilst working GASKETS SEALS Clean contact surfaces after removing gaskets seals Replace gaskets seals and O rings with new ones Do not forget the gaskets seals and O rings when reassembling OBJECTS IN POCKETS Do not carry any l...

Page 142: ...ump the opened bucket completely and lower it with the blade or teeth touching the ground MUDDY OR WET ENVIRONMENT Wash the machine immediately after work to protect the machine against corrosion Perform maintenance measures and lubrication in shorter intervals when working on sites where conditions are often unfavourable The work unit s bolts have to be greased daily when working frequently in wa...

Page 143: ... quantities Functional disturbances can be caused by too much or too little oil If the oil in the work hydraulic system is not clear milky oil or air is probably penetrating the circuit In this case contact you local Komatsu dealer 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 ...

Page 144: ...ce Every 500 Operating Hours Engine oil change periods will have to be reduced by half if fuel is being used with a sulphur content of 0 5 to 1 0 and reduced to one quarter if fuel with a sulphur content of more than 1 0 is being used BIOLOGICALLY DEGRADABLE HYDRAULIC OILS AND GREASE Biologically degradable hydraulic oils and grease on a diester oil basis can be used in Komatsu machines Please con...

Page 145: ... before topping up FILTERS Filters are extremely important safety components They prevent foreign bodies from entering individual circuits and sections of equipment and causing damage there Change all filters regularly Further details in this respect can be found in the operating and maintenance manual The filters will have to be changed more frequently if working under extreme conditions dependin...

Page 146: ...iring or damaged insulation can result in insulation faults in the electrical system and consequently functional faults in the machine When working close to the coast clean the machinery carefully to prevent any corrosion A foreign source of power must never be connected to the fuses the start switch or the battery relay Maintenance of the electrical system consists of 1 Checking the tension of th...

Page 147: ...f nuts or bolts are being changed always use original parts of the same quality and dimension as the part being replaced Thread diameter Wrench of the bolt mm size mm a b Nm kpm M 6 10 10 1 M 8 13 24 2 4 M 10 17 15 48 4 8 M 12 19 83 8 3 M 14 22 130 13 M 16 24 200 20 M 18 27 280 28 M 20 30 390 39 M 22 32 520 52 M 24 36 670 67 M 27 41 980 98 M 30 46 1330 133 M 33 50 1790 179 M 36 55 2310 231 M 39 60...

Page 148: ...e replaced every three years at the latest Hoses should not be used longer than six years under normal loads Hoses must be replaced as soon as any damage becomes apparent Damage includes Damage to the outer layer as far as the intermediate layer Brittleness of the outer layer Deformation in pressurized or non pressurized state which does not conform with the original form of the installed hose Lea...

Page 149: ...er 250 operating hours Service every 500 operating hours Transmission oil filter 42Y 15 H0S92 Cartridge 1 First service after 100 operating hours Service every 1000 operating hours Service brake 42Y 43 H0P01 42X 00 H0190 Insert O ring 1 1 First service after 100 operating hours Service every 1000 operating hours Hydraulic oil filter 42Y 60 H5080 07000 05220 Insert O ring 1 1 First service after 25...

Page 150: ...m 19 22mm 24 27mm 30 32mm 2 Screwdriver 421 98 H1120 3 Screwdriver 421 98 H1110 4 Spanner 09014 10200 5 Pliers 09036 00150 6 Grease gun 424 98 H1010 7 Hose 424 98 H1020 Hose for grease gun 8 Grease cartridge 07950 90403 Lithium grease 400g 9 Hammer 421 98 H1140 10 Bag 421 98 H1130 11 Base 09989 13301 I dtp ba270GB TOOLS TBL ...

Page 151: ...ss D CFPP class E CFPP class F DIN EN 590 up to 0 C up to 10 C up to 15 C up to 20 C 185 Grease nipples central lubrication Multi purpose grease on a lithium basis MPG A KP2N 20 NLGI2 Air conditioning Coolant Refrigerating machine oil NRS NRS R134a CFC free PAG Polyalcohol glycol oil 900 1000 g 150 cm The specified filling quantities are guideline values test equipment values are binding The choic...

Page 152: ...3 16 LUBRICANTS AND OPERATING AGENTS ...

Page 153: ... 100 OPERATING HOURS 3 26 HYDRAULIC SYSTEM CHECKING OIL LEVEL TOPPING UP OIL 3 26 CLEANING THE FRESH AIR FILTER INSERTS 3 27 LUBRICATION 3 27 MAINTENANCE EVERY 250 OPERATING HOURS 3 28 ENGINE CHANGE OIL AND OIL FILTER CARTRIDGE 3 28 CHECKING THE AIR ASPIRATION SYSTEM 3 29 AIR CONDITIONING CHECK TENSION OF THE COMPRESSOR V BELT 3 30 INSPECTION 3 30 ADJUSTMENT 3 30 CHANGE 3 30 BATTERIES CHECKING THE...

Page 154: ...L 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 3 52 CLEANING WITH WATER OR DETERGENT 3 52 CHECKING THE FILTER INSERT 3 52 CHANGING THE SAFETY FILTER 3 53 ASSEMBLING THE AIR FILTER INSERT 3 53 DUST PRE EXTRACTOR TURBO II CHECK CLEAN 3 53 ...

Page 155: ... engine has cooled down sufficiently 1 Open the top cover on the front of the engine hood 2 Check that the coolant level in the expansion tank is between the FULL and LOW markings If the coolant level does not reach up to the LOW marking top up coolant 3 Therefore remove the cover cap of the expansion tank 4 Top up coolant until the level reaches up to the FULL marking 5 After topping up firmly cl...

Page 156: ...OPERATING AGENTS 5 If the oil level is above the marking H the excess oil will have to be drained off at the drain plug P rear frame behind the right wheel and the oil level checked again 6 If the oil level is correct replace and tighten oil filler cap and close engine hood WATER SEPARATOR DRAIN WATER AND DIRT DEPOSITS Open the right engine hood If there is any water or dirt deposit in the water s...

Page 157: ...ECKING DRIVE BELTS Check whether the belt has any signs of cracks Cracks across the width of the belt are permitted Longitudinal cracks along the length of the belt meeting cross cracks missing pieces or damaged fabric layers are not permitted CHECKING THE FAN AND ITS ATTACHMENT CAUTION The fan can be damaged if you turn the engine at the fan Only turn the engine with the engine swivel installatio...

Page 158: ...ecessary 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 Check the fuses for damage paying attention to signs of interruptions or short circuits in the electrical system Retighten any loose connection terminals Check the following carefully Battery Starter Three phase generator IMPORTANT Contact the respon...

Page 159: ...commended oils see section LUBRICANTS AND OPERATING AGENTS 3 Make sure that you reclose the tank tightly after filling up CHECKING CONTROL PANELS 1 Turn the start switch to its operating position 2 2 Ensure that all control lights measuring instruments and warning lights light up for approx 3 seconds and that the alarm buzzer sounds for approx 1 second NOTE If a control lamp does not light up arra...

Page 160: ...ES 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 Checking rear view mirror for alignment dirt and damage ...

Page 161: ...ING HOURS TRANSMISSION CHANGE OIL AND FILTERS OPERATING BRAKE CHANGE OIL FILTER AFTER THE FIRST 250 OPERATING HOURS FUEL TANK DRAIN WATER FUEL FILTER CHANGE CARTRIDGES HYDRAULIC SYSTEM CHANGE OIL FILTER INSERTS AFTER THE FIRST 500 OPERATING HOURS AXLES OIL CHANGE Refer to the following sections for further details on the respective maintenance operation Maintenance as required Maintenance every 50...

Page 162: ...Wait for five minutes then check the oil level in the inspection glass G of the hydraulic tank The oil level must be visible in the centre of the inspection glass 2 If the oil level is too low loosen the screws 1 and open the cover 2 above the hydraulic tank to the front 3 Unscrew the screw plug 3 slowly so that pressure can escape gradually Then unscrew the cap F of the oil filler inlet 4 Pour in...

Page 163: ...x 7 bar Then blow clean the external surfaces Finally clean the interior of the filter inserts again 5 Re insert the filters with the markings pointing to the outside 6 Replace the cover 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 ma...

Page 164: ...ssel Engine oil with the specified quality see section LUBRICANTS AND OPERATING AGENTS Filter wrench NOTE Only perform the oil change with the engine being warm 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 1 Park and secure...

Page 165: ...ead of the cartridge slightly with engine oil or apply a thin coat of grease Re insert the filter cartridge and tighten it 10 The sealing surface of the cartridge must rest lightly against the filter support first when installing Then tighten the filter cartridge as specified in the instructions of the filter manufacturer 11 After replacing the filter cartridge pour fresh engine oil into the fille...

Page 166: ...e in the centre between the belt pulleys It should be possible to depress the V belt by about 10 mm Check the belt pulleys and the compressor V belt for damage wear and tear The belt must not run in the base of the V belt groove The belt must be replaced if excessively worn or cracked ADJUSTMENT Loosen the retaining nuts 1 and 3 by approx 1 turn and adjust the compressor using the adjusting nut 2 ...

Page 167: ...he electric system Overvoltages resulting from disconnecting the battery while the engine is still running may damage parts of the electric system Switch off the engine before disconnecting the battery 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Push the locking lever of the radiator protection to the right hand side into position 1 Then turn it do...

Page 168: ...echarging to ensure that there is sufficient venting and ventilation Keep naked flames and sparks away from the battery to prevent any danger of gas explosion Interrupt the recharging procedure if the temperature of the battery acid exceeds 45 C Switch off the recharging unit as soon as the battery is recharged Overcharging the battery can result in the following conditions 1 Battery overheating 2...

Page 169: ...inspection b Secure the machine c Unscrew the filler plugs 1 of the inspection bore holes The oil level must reach the lower rim of the inspection hole If necessary top up with fresh oil through the inspection hole d Replace the filler plugs with undamaged sealing rings and retighten it 5 Differential transmission The axles must be in horizontal position without any lateral inclination when carryi...

Page 170: ...ribed in chapter Preparing the Machine for Maintenance 2 Clean the grease nipples indicated by arrows 3 Apply sufficient grease using a grease gun 4 Remove the old grease which is pressed out of the bearing 1 Bucket bolts 2 points 2 Tilt rod bolts 2 points 3 Tilt cylinder bolts 2 points 4 Lift cylinder bolts 4 points 5 Boom bolts 2 points 6 Tilt lever bolts 1 point 7 Steering cylinder bolts 4 poin...

Page 171: ...ibed in chapter Preparing the Machine for Maintenance before performing maintenance measures 2 Open the right engine cover 3 Clean the area around the fuel filter 4 Unscrew the filter cartridges using the filter wrench 5 Clean the filter head 6 Change the O rings 7 Fill up new filter cartridges with clean fuel 8 Apply a thin engine oil film on the sealing surfaces of the filter cartridges and the ...

Page 172: ...ew which is bubblefree 4 Retighten the bleed screw 5 Activate pump several times to bleed the injection pump 6 Loosen the injection lines one after the other at the noozle holders 7 Turn the engine using the starter until all air has emerged from the injection lines Do not activate the starter for longer than 20 seconds without interruption 8 Reconnect and retighten all connections WARNING If the ...

Page 173: ...NGER 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 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Place the collecting container below the drain valve P 3 Remove the cap 1 of the drain...

Page 174: ...th a clean cloth 2 Push the dipstick into the filler nozzle F fully and pull out again 3 Read off the oil level Range between markings 1 and 2 operational range oil temperature between 40 C and 80 C Range between markings 2 and 3 operational range oil temperature between ambient temperature and 40 C below marking 3 minimum when the oil is cold 4 If the oil level is below the appropriate marking to...

Page 175: ...ny transmission oil carefully from your skin 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 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Unscrew the filter housing behind the l...

Page 176: ... the belt tensioner down to avoid that the tension spring is breaking 3 Check whether the belt has any signs of cracks Cracks across the width of the belt are permitted Longitudinal cracks along the length of the belt meeting cross cracks missing pieces or damaged fabric layers are not permitted In this case the belt will have to be exchanged 4 Check tension pulley bearing and the fan bearing The ...

Page 177: ...dealer CHECKING THE GAS PRESSURE DANGER Danger of injuries The pressure tanks are filled with nitrogen gas which is put under pressure Never open or damage the pressure tanks 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 Komats...

Page 178: ... and secured Park the machine on firm and level ground and secure it before starting maintenance operations 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Move the machine until the control bore holes 1 of both planetary transmissions of an axle are at their lowest point 3 Place the collecting container below the oil discharge opening 4 Remove the scr...

Page 179: ...ure the machine as described in chapter Preparing the Machine for Maintenance before performing maintenance measures 2 Clean the grease nipples which are indicated by arrows 3 Apply sufficient grease using a grease gun Articulated steering 2 points Universal joints on cardan shafts 5 points Intermediate bearing of the front cardan shaft 1 point 4 Remove old grease which is pressed out of the beari...

Page 180: ... NOTE Antifreeze in the coolant is required in all climates since it does not only lower the freezing point it also raises the boiling point lubricates moving parts and sealing lips and prevents corrosion as well While preparing the coolant make sure to adhere to the prescribed mixing proportions to ensure a freezing protection up to 37 C This is also valid for countries with moderate climate The ...

Page 181: ...e run for 5 minutes with a coolant temperature of approx 80 C 9 After the cleaning switch off the engine and open the drain valve to let the entire cooling system run empty Re lock the drain valve and slowly fill the cooling system with clean water 10 Let the engine run for five minutes with a coolant temperature of approx 80 C 11 Then let the cooling system run empty again If the extruding water ...

Page 182: ...ub B and the flywheel C If these markings are more than 1 6 mm apart the vibration absorber must be exchanged 2 Check the rubber section The shock absorber must be replaced if parts are missing or if the rubber is more than 3 2 mm below the metal surface 3 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...

Page 183: ...lt the responsible dealer for inspection or repair if the carbon brushes are worn or grease is emerging from the bearing seals Have inspections carried out every 1000 operating hours if the engine is being started frequently AIR CONDITIONING CHANGING THE FILTER INSERTS Switch off the air conditioning before changing the filter inserts 1 Loosen the screw 1 and remove the cover 2 2 Loosen the wing n...

Page 184: ...p F Have a collecting container of sufficient capacity ready when carrying out this work 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Remove screws 1 and open the cover 2 to he front via the hydraulic tank 3 Unscrew the venting filter 3 slowly so that the pressure can escape 4 Then unscrew the cap F of the oil filler inlet 5 Place the collecting con...

Page 185: ...ngs will be damaged by the air in the cylinders if the engine is run idle at a too high speed during the extraction or retraction of the cylinders the cylinders are extracted up to the limit stop Therefore let the engine only run at low speed 16 Run the engine idle at low speed and extract and retract the steering bucket and boom cylinders about 5 times each Pay attention that the cylinders are no...

Page 186: ...erformed 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 The outlet hole in the base of the pump housing must not be blocked If something is not in order have the pump repaired by the responsible dealer or have the water pump exchanged ...

Page 187: ...l light A damaged or deformed filter insert must be exchanged immediately If the safety filter is dirty the filter insert is damaged In this case filter insert and safety filter have to be immediately replaced REMOVING THE FILTER INSERT WARNING If the engine is running you may hurt yourself severely on the moving components of the engine compartment Do not perform actions in the engine compartment...

Page 188: ...imum distance of 3 cm You can stop the cleaning if no more dust comes out Do not clean the cartridge by hitting it or by beating it against other objects CLEANING WITH WATER OR DETERGENT After the dust has been blown out the filter cartridge can also be additionally cleaned using warm water with a mild cleaning agent max 50 C to remove adhering oil grease soot etc For this purpose swing the cartri...

Page 189: ... the air filter and pull out the air filter insert 1 and the safety filter 2 2 In order to prevent that dust enters the interior of the engine it is required to block the air aspiration opening of the engine with a clean cloth or similar 3 Clean the interior of the air filter housing and remove the cloth from air aspiration opening 4 Check the new safety filter for damages using a lamp Then re ins...

Page 190: ...er can be used if a sufficient distance is maintained so that the radiator fins are not bent 3 Inspect the rubber hoses at the same time If the hoses show signs of cracks or have hardened they must be replaced by new ones Tighten loose hose clamps WINDSCREEN WASHER CHECKING FLUID LEVEL TOPPING UP 1 Open the cover flap of the engine hood 2 Check the fluid level in the washer tank If it is too low t...

Page 191: ...k G anti clockwise until it is loose Then pull out the dipstick and wipe off the oil with a clean cloth 4 Push the dipstick completely into the filler nozzle F and pull it out again 5 Read off the oil level Range between markings 1 and 2 Operational range oil temperature between 40 C and 80 C Range between markings 2 and 3 Cold range oil temperature between ambient temperature and 40 C Below marki...

Page 192: ...achine before you start maintenance tasks 1 Park and secure the machine as described in chapter Preparing the Machine for Maintenance 2 Raise the bucket slightly and tip it in in such a way that the underside is horizontal 3 Place chocks under the bucket to prevent it from dropping down 4 Knock out the securing pin 1 and remove the tooth 2 5 Clean the mounting surface of the tooth holder 3 6 Inser...

Page 193: ... while the tyres are still cold i e prior to starting work Do not deflate the tyres if the pressure has risen on warm tyres NOTE The appropriate air pressure for tyres depends on the type of work to be performed See also section Handling Tyres AIR CONDITIONING CLEANING CONDENSER NOTE Do not wash the condenser off with a steam cleaner or hot water This could cause the condenser to become too hot an...

Page 194: ... is not enough coolant in the system In this case the system must be checked by a specialist for air conditioning and the coolant is to be topped up IMPORTANT Small bubbles can form temporarily in the coolant in a troublefree system when the system is started up or if the engine speed is changed A slow loss of coolant is also normal even if there are no leaks in the system because of coolant diffu...

Page 195: ...Technical details 4 1 TECHNICAL DETAILS ...

Page 196: ... phase generator 24 V Battery 2 x 12 V 105 Ah Driving speed Forward gears 1 7 2 km h 2 12 7 km h 3 27 2 km h 4 41 8 km h Reverse gears 1 7 2 km h 2 12 7 km h 3 27 2 km h Tractive force max 108 kN Turning radius 40 Over bucket 5 717 mm Over tires 5 240 mm Bucket standard 2 0 m Carrying capacity standard 3 600 kg I DTP BA270GB 270ALU 270_alupm TECHN TBL02 2001 Technical details ...

Page 197: ...tions for the relative machinery class in compliance with ISO 7096 The actual acceleration value of the upper limbs is less than 2 5 m s2 The actual acceleration value for the body is less than 0 76 m s2 These values were determined using a representative machine and with the help of the measurement procedures that are defined in the directives ISO 2631 1 and ISO 5349 LIMIT VALUES FOR SLOPES Maxim...

Page 198: ...Technical details 4 4 NOTES ...

Page 199: ...Special equipment auxiliary equipment 5 1 SPECIAL EQUIPMENT AUXILIARY EQUIPMENT ...

Page 200: ... solenoid valves When the travel damper switch is turned ON the solenoid valves open the circuit at the lift cylinder base end is connected with the hydraulic accumulator PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS ELECTRONICS WARNING If the ALS system is switched on during a journey or when the working attachment is in raised position it may move up or down depending upon the bucket load For ...

Page 201: ...sure nitrogen gas which is extremely dangerous so read the following precautions and be careful to handle the accumulator properly 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...

Page 202: ...Special equipment auxiliary equipment 5 4 ...

Page 203: ... 2001 Komatsu Hanomag Aktiengesellschaft All Rights Reserved Printed in Europe 02 2001 ...