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Komatsu
Compact Loader
HA940549
Komatsu HA940549 User Manual
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MAINTENANCE
BASICS
7-13
W
ELDING
INSTRUCTIONS
•
Set
the
e
ngine
star
t
s
witch
to
switching
pos
itio
n
'0'
(OF
F).
•
Apply
onl
y
br
iefly
a
voltage
of
mo
re
than
20
0
V
.
•
Conne
ct
the
e
ar
th
ing
c
able
a
t
a
dista
nce
of
max.
3.28
f
t
(1
m
)t
ot
h
ea
r
e
a
t
ob
ew
e
l
d
e
d
.
•
There
must
b
e
no
gaskets
or
bear
ings
between
the
welding
area
and
t
he
mass
poi
nt.
•
There
must
be
a
minimum
distanc
e
of
3
.28
f
t
(1
m)
between
the
welding
area
and
the
batt
er
y
.
•
Do
not
weld
lines
or
pipes
c
ontain
ing
fuel
o
r
oil.
169
171
Table of Contents
Default Chapter
4
Table of Contents
4
Introduction
12
Forword
13
Safety Information
14
Introduction
16
Features
16
Breaking in a New Machine
16
Location of Plates, Table to Enter Serial No. and Distributor
17
Machine Serial No. Plate Position
17
Engine Serial No. Plate Position
17
Emission Control Warranty
18
Emission Control Warranty Statement (Applies to Canada Only)
18
Engine Data Plate
19
Garantie Sur le Contrôle des Émissions
20
Énoncé de Garantie Sur le Contrôle des Émissions (Applicable au Canada Seulement)
20
Engine Data Plate
22
Why You Should Read These Operating Instructions
23
Notes on Safety Regulations
25
Correct Use
25
Safety Notes in the Operating Instructions
25
Equipment
26
Loading and Transporting the Machine
28
Securing the Articulated Steering
29
Lifting the Machine
29
Driving Machine Onto Loading Area of Transport Vehicle
31
Securing the Machine During Transport
32
After Transport
32
Safety
34
General Safety Measures
36
Safety Instructions
36
Safety Devices
36
Emergency Exit
36
Clothing and Personal Protection
37
Machine Modifications
37
Before You Leave the Driver's Seat
37
Mounting and Dismounting
38
Fire Prevention and Fire Fighting
39
Fire Extinguisher and First-Aid Kit
40
Protection against Asbestos Dust
40
Protection against Injuries
41
Working at High Temperatures
41
Roll-Over Protection System (Rops)
42
Attachment for Protection against Falling Objects (Fops)
42
Attachments
42
Battery
43
Safety Measures During Operation
44
Before You Start the Engine
44
Workplace Safety
44
In the Driver's Cab
44
In-Door Operation
45
Gas, Dust, and Inflammable Vapours
45
Mirrors, Windows, and Lighting
45
Machine Operation
46
Before You Start the Engine
46
Reversing
46
Driving
47
Driving on Slopes
47
Emergency Lowering System
48
Working Close to Overhead Power Transmission Lines
48
Loading
49
Good Vision
49
Working on Snow
49
Height Limitation
50
Brakes
50
Working on Loose Soil
50
Working with the Forklift Truck Attachment
51
Parking the Machine
52
Transport
53
Loading and Unloading the Machine
53
Transport
54
Safety Measures During Maintenance
55
Personnel
55
Prior to Start of Maintenance Measures
55
Warning Sign
55
Tools
55
Safety-Related Parts
55
Prior to Start of Inspection and Maintenance
56
Securing the Articulated Steering
56
Supporting the Boom
57
During Maintenance
58
Attachments
58
Working under the Machine
58
Keeping the Machine Clean
58
Specific Measures
58
Refueling and Topping off Oil
59
Coolant
59
Use of Lighting
60
High-Pressure Hoses
60
Handling High-Pressure Oil
60
Handling of the Pressure Accumulator
61
Fan and Belts
61
Waste Material
61
Tires
62
Storing Tires
63
Labeling
64
Position of Safety Labels
64
Information Labels
66
Controls and Indicators
68
Overall View of Machine
69
Controls and Indicators
70
Switches and Controls
71
Instrument Panel
72
Warning Lights
73
Control Lamps
76
Measuring Indicators
80
Switches
82
Control Levers, Pedals
89
Articulated Steering Catch
95
Traction Device
95
Socket
95
Door Unlocking System
96
Alarm Horn for Reverse Driving
96
Operation
99
Running in the Machine
99
Preparing the Machine Start
100
Visual Checks
100
Before You Start the Engine
100
Before Starting Working with the Machine
100
Adjustments Prior to Machine Start
103
Adjusting the Driver's Seat
103
Adjusting the Steering Column
104
Adjusting the Armrest
104
Adjusting the Rear-View Mirrors
104
Adjusting the Heating and Ventilation System
105
Adjusting the Ventilation System
105
Adjusting the Heating System
106
Operating the Air Conditioning
107
Switching on the Air-Conditioning
107
Putting on the Safety Belt
109
Taking off the Safety Belt
109
Starting and Switching off the Engine
110
Starting the Engine
110
Warming up the Engine
111
Switching off the Engine
112
Driving
113
Start-Up
113
Starting the Machine on Slopes
115
Changing the Driving Direction
115
Reverse Driving
116
Turning
116
Turning on Slopes, Embankments or Hill Flanks
116
Braking
117
Pulling the Parking Brake
117
Releasing the Parking Brake
117
Braking with the Service Brake
117
If the Service Brake Breaks down
118
Braking on Slopes
118
Stopping
119
Parking the Machine on a Slope
119
Longer-Distance Driving
120
Operating the Machine
121
Preparing the Work Equipment
121
Selecting a Work Unit
121
Picking up the Work Unit (Except Multi-Purpose Bucket)
121
Removing the Work Unit
122
Picking up the Multi-Purpose Bucket
122
Removing the Multi-Purpose Bucket
124
Tire Service Life
125
Level Indicator for the Bucket
125
Adjusting the Bucket Positioner
126
Loading
127
Removing Piled up Soil
127
Excavation Works
129
Transporting
130
Dumping / Unloading
130
Loading in Diagonal Direction
130
V-Shaped Loading
131
Piling up Material
131
Planing
132
Filling up
132
Taking off Soil
132
Cutting the Ground
133
Working with the Forklift Truck Attachment
134
Picking up the Load
134
Precautions for Special Operations
135
Working in Water
135
Working on Snow
135
Dumping on Steep Slopes
135
Working in the Vicinity of Electrical Overhead Lines
135
Operation on Slopes
135
Working on Loose Soil
135
After the Work Is Finished
135
Instructions for Winter Operation
136
Before the Cold Season
136
After Operation
136
After the Cold Season
137
Longer Standstill Periods of the Machine
138
Before the Standstill
138
During the Standstill
138
After the Standstill
139
Troubleshooting
140
Warning Lights and Indicators
141
Electrical System
142
Engine
143
Hydraulic System
146
Brakes
148
Axles
149
Driver's Cab
149
Emergency Steering Characteristics
150
Emergency Lowering System
150
Starting the Engine with a Battery Jumper Cable
151
Connecting the Jumper Cable
151
Starting the Engine
152
Disconnecting the Battery Jumper Cable
152
Towing the Machine
153
Towing a Machine with Defective Brakes
154
Inadequate Braking Effect
155
Checking the Parking Brake
155
Checking the Service Brake
156
Maintenance Basics
159
Preparing the Machine for Maintenance
159
Cleaning the Machine
160
Precautionary Measures When Cleaning the Machine
160
Fire Prevention
160
Working-Area-Dependent Maintenance
161
Muddy or Wet Working Areas
161
Dusty Working Areas
161
Lubricants and Operating Agents
162
Draining Hot Lubricants and Fluids
162
Checking the Oil Level and Changing Oil
162
Changing Filters
162
Refuelling and Topping off Oil
162
Oil
163
Lubricating Grease
163
Biodegradable Hydraulic Oil and Lubricating Grease
163
Fuel
164
Storage of Oil and Fuel
164
Coolants
165
Windscreen Washer Liquid
165
Table of Lubricants and Operating Agents
167
Lubrication Chart
168
Axles
169
Released Axle Oil Brands
169
Replacing Safety-Related Parts
169
Welding Instructions
170
Spare Parts and Consumable Components
171
Electrical System
172
Fuses
173
Fuse Assignment
173
Slow-Blowing Fuses
174
Tires
175
Tire Components
175
Checking the Tires
175
Checking the Tire Pressure
175
Torque for Standard Nuts and Bolts
177
Maintenance Schedule
179
Maintenance Prior to Start
181
Visual Checks
181
Cooling System, Checking the Coolant Level, Topping off Coolant
181
Engine, Checking the Oil Level, Topping off Oil
182
Engine, Draining off Oil
183
Checking the Fuel Level, Refueling
184
Checking the Controls
185
Checking the Electrical Connections
185
Heater / Air Conditioning: Checking Rate of Air Flow
186
Other Maintenance Measures Prior to Start
186
Maintenance Upon Demand
187
Checking the Air-Conditioning System
187
Checking the Coolant Level
187
Maintenance Every 10 Operating Hours
188
Lubrication
188
Maintenance after the First 50 Operating Hours
189
Engine, Changing Oil and Replacing the Oil Filter Cartridge
189
Replacing the Oil Filter Cartridge
190
V-Belt, Checking the Condition
191
V-Belt, Checking and Adjusting the Tension
191
Hydraulic System, Replacing the Filter Insert
192
Checking and Tightening the Wheel Nuts
193
Front and Rear Axle, Changing Oil
194
Planet Gear
194
Differential
194
Transfer Gear - Changing Oil
195
Maintenance Every 50 Operating Hours
196
Checking Cooling System, Coolant Level in the Radiator and Expansion Tank
196
Draining off Water and Dirt Deposits from the Fuel Tank
197
Checking the Service Brake and Oil Level, Refilling Oil
197
Checking the Battery and Acid Level
198
Re-Charging a Built-In Battery
199
Lubrication
200
Lubricating Points of the Work Equipment
200
Maintenance Every 100 Operating Hours
201
Draining the Water Separator, Removing Water and Dirt Deposits
201
Maintenance Every 250 Operating Hours
202
Changing the Engine Oil and Oil Filter Cartridge
202
Checking the V-Belt Condition
202
Checking and Adjusting the V-Belt Tension
202
Front and Rear Axle, Checking the Oil Level
203
Planet Gear
203
Differential
204
Air Filter, Removing/Re-Installing and Checking/Cleaning the Filter Insert
205
Structure of the Air Filter
205
Maintenance Demand
205
Removing the Filter Cartridge
205
Cleaning or Exchanging the Filter Cartridge
206
Checking the Filter Cartridge
207
Assembling the Air Filter Cartridge
207
Cleaning the Radiator Segments
207
Lubrication
208
Maintenance Every 500 Operating Hours
209
Changing the Fuel Filter and Filter Element
209
Bleeding the Fuel System
210
Changing the Filter Cartridge of the Hydraulic System
211
Cleaning the Water Separator
211
Lubrication
212
Transfer Gear, Checking the Oil Level and Refilling Oil
212
Air Filter, Replacing the Filter Insert, Replacing the Safety Filter
213
Replacing the Filter Insert
213
Replacing the Safety Filter
213
Heater/Air Conditioning: Clean Filter Fleece of Heater Unit
214
Heater/Air Conditioning: Cleaning the Condenser
215
Maintenance Every 1000 Operating Hours
216
Cooling System, Exchanging Coolant and Cleaning the System
216
Draining off the Coolant
217
Cleaning the Cooling System
217
Filling off Coolant
217
Front Axle, Oil Change
218
Rear Axle, Oil Change
218
Transfer Gear, Oil Change
218
Service Brake
218
Changing Oil
218
Checking Tubes and Lines
218
Checking the Brake Disks for Wear and Tear
218
Adjusting the Clearance of the Brake Disks
218
Checking and Adjusting System Pressures
218
Checking and Adjusting the Valve Clearance
218
Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern
219
Checking the Accumulator Gas Pressure
219
Maintenance Every 2000 Operating Hours
220
Hydraulic System, Oil Change
220
Bleeding the Hydraulic Oil Tank
221
Cooling System, Checking the Antifreeze Content of the Coolant
221
Checking the Cooling System
221
Checking the Fuel Pump
221
Checking the Fuel and Coolant Tubes, Replacing the Tubes (if Required)
221
Checking the Water Pump
222
Checking and Adjusting the Fuel Injection and Injection Time
222
Technical Data
224
Noise Emission Levels
226
Vibration Level
226
Limit Values for Slopes
226
Maximum Slope Angle for Operating the Machine
226
Special Equipment and Attachments
228
Als-Electronics
229
Structure and Functioning Principle of the Als-Electronics
229
Precautionary Measures for Switching on the Als-Electronics
229
Operation of the Als-Electronics
230
Switching on the Als-Electronics
230
Switching off the Als-Electronics
230
Handling of the Pressure Accumulator
231
4
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Komatsu HA940549 Specifications
General
Brand
Komatsu
Model
HA940549
Category
Compact Loader
Language
English
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