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MAINTENANCE EVERY 100 OPERATING HOURS

7-44

MAINTENANCE EVERY 100 OPERATING HOURS

All maintenance operations to be performed after 10 and 50

hours of operation fall also into this maintenance category.

DRAINING THE WATER SEPARATOR, REMOVING WATER AND DIRT DE-

POSITS

Keep a container ready for collecting the liquid from the water

separator (1).

1. Screw out the drain plug (2).

2. Let the water run off.

3. Screw in the drain plug and tight it.

4. Check for tightness.

75_231

Default Chapter4
- Table of Contents4
Introduction12
Forword13
Safety Information14
Introduction16
- Features16
- Breaking in a New Machine16
Location of Plates, Table to Enter Serial No. and Distributor17
- Machine Serial No. Plate Position17
- Engine Serial No. Plate Position17
Emission Control Warranty18
- Emission Control Warranty Statement (Applies to Canada Only)18
Engine Data Plate19
Garantie Sur le Contrôle des Émissions20
- Énoncé de Garantie Sur le Contrôle des Émissions (Applicable au Canada Seulement)20
Engine Data Plate22
Why You Should Read These Operating Instructions23
Notes on Safety Regulations25
- Correct Use25
- Safety Notes in the Operating Instructions25
Equipment26
Loading and Transporting the Machine28
- Securing the Articulated Steering29
- Lifting the Machine29
- Driving Machine Onto Loading Area of Transport Vehicle31
- Securing the Machine During Transport32
- After Transport32
Safety34
General Safety Measures36
- Safety Instructions36
- Safety Devices36
- Emergency Exit36
- Clothing and Personal Protection37
- Machine Modifications37
- Before You Leave the Driver's Seat37
- Mounting and Dismounting38
- Fire Prevention and Fire Fighting39
- Fire Extinguisher and First-Aid Kit40
- Protection against Asbestos Dust40
- Protection against Injuries41
- Working at High Temperatures41
- Roll-Over Protection System (Rops)42
- Attachment for Protection against Falling Objects (Fops)42
- Attachments42
- Battery43
Safety Measures During Operation44
- Before You Start the Engine44
- Machine Operation46
- Transport53
  - Loading and Unloading the Machine53
  - Transport54
Safety Measures During Maintenance55
- Personnel55
- Prior to Start of Maintenance Measures55
- During Maintenance58
- Tires62
  - Storing Tires63
Labeling64
- Position of Safety Labels64
- Information Labels66
Controls and Indicators68
Overall View of Machine69
Controls and Indicators70
- Switches and Controls71
- Instrument Panel72
- Warning Lights73
- Control Lamps76
- Measuring Indicators80
- Switches82
- Control Levers, Pedals89
- Articulated Steering Catch95
- Traction Device95
- Socket95
- Door Unlocking System96
- Alarm Horn for Reverse Driving96
Operation99
Running in the Machine99
Preparing the Machine Start100
- Visual Checks100
  - Before You Start the Engine100
  - Before Starting Working with the Machine100
Adjustments Prior to Machine Start103
- Adjusting the Driver's Seat103
- Adjusting the Steering Column104
- Adjusting the Armrest104
- Adjusting the Rear-View Mirrors104
- Adjusting the Heating and Ventilation System105
  - Adjusting the Ventilation System105
  - Adjusting the Heating System106
- Operating the Air Conditioning107
  - Switching on the Air-Conditioning107
- Putting on the Safety Belt109
  - Taking off the Safety Belt109
Starting and Switching off the Engine110
- Starting the Engine110
- Warming up the Engine111
- Switching off the Engine112
Driving113
- Start-Up113
  - Starting the Machine on Slopes115
- Changing the Driving Direction115
- Reverse Driving116
- Turning116
  - Turning on Slopes, Embankments or Hill Flanks116
Braking117
- Pulling the Parking Brake117
- Stopping119
  - Parking the Machine on a Slope119
- Longer-Distance Driving120
Operating the Machine121
- Preparing the Work Equipment121
- Tire Service Life125
- Level Indicator for the Bucket125
- Adjusting the Bucket Positioner126
- Loading127
  - Removing Piled up Soil127
  - Excavation Works129
- Transporting130
- Dumping / Unloading130
- Planing132
- Working with the Forklift Truck Attachment134
  - Picking up the Load134
- Precautions for Special Operations135
- After the Work Is Finished135
Instructions for Winter Operation136
- Before the Cold Season136
- After Operation136
- After the Cold Season137
- Longer Standstill Periods of the Machine138
Troubleshooting140
- Warning Lights and Indicators141
- Electrical System142
- Engine143
- Hydraulic System146
- Brakes148
- Axles149
- Driver's Cab149
- Emergency Steering Characteristics150
- Emergency Lowering System150
- Starting the Engine with a Battery Jumper Cable151
- Towing the Machine153
  - Towing a Machine with Defective Brakes154
- Inadequate Braking Effect155
  - Checking the Parking Brake155
  - Checking the Service Brake156
Maintenance Basics159
- Preparing the Machine for Maintenance159
- Cleaning the Machine160
  - Precautionary Measures When Cleaning the Machine160
  - Fire Prevention160
- Working-Area-Dependent Maintenance161
  - Muddy or Wet Working Areas161
  - Dusty Working Areas161
- Lubricants and Operating Agents162
- Axles169
  - Released Axle Oil Brands169
- Replacing Safety-Related Parts169
- Welding Instructions170
- Spare Parts and Consumable Components171
- Electrical System172
- Tires175
- Torque for Standard Nuts and Bolts177
Maintenance Schedule179
Maintenance Prior to Start181
- Visual Checks181
- Cooling System, Checking the Coolant Level, Topping off Coolant181
- Engine, Checking the Oil Level, Topping off Oil182
- Engine, Draining off Oil183
- Checking the Fuel Level, Refueling184
- Checking the Controls185
- Checking the Electrical Connections185
- Heater / Air Conditioning: Checking Rate of Air Flow186
- Other Maintenance Measures Prior to Start186
Maintenance Upon Demand187
- Checking the Air-Conditioning System187
  - Checking the Coolant Level187
Maintenance Every 10 Operating Hours188
- Lubrication188
Maintenance after the First 50 Operating Hours189
- Engine, Changing Oil and Replacing the Oil Filter Cartridge189
  - Replacing the Oil Filter Cartridge190
- V-Belt, Checking the Condition191
- V-Belt, Checking and Adjusting the Tension191
- Hydraulic System, Replacing the Filter Insert192
- Checking and Tightening the Wheel Nuts193
- Front and Rear Axle, Changing Oil194
  - Planet Gear194
  - Differential194
- Transfer Gear - Changing Oil195
Maintenance Every 50 Operating Hours196
- Checking Cooling System, Coolant Level in the Radiator and Expansion Tank196
- Draining off Water and Dirt Deposits from the Fuel Tank197
- Checking the Service Brake and Oil Level, Refilling Oil197
- Checking the Battery and Acid Level198
  - Re-Charging a Built-In Battery199
- Lubrication200
  - Lubricating Points of the Work Equipment200
Maintenance Every 100 Operating Hours201
- Draining the Water Separator, Removing Water and Dirt Deposits201
Maintenance Every 250 Operating Hours202
- Changing the Engine Oil and Oil Filter Cartridge202
- Checking the V-Belt Condition202
- Checking and Adjusting the V-Belt Tension202
- Front and Rear Axle, Checking the Oil Level203
  - Planet Gear203
  - Differential204
- Air Filter, Removing/Re-Installing and Checking/Cleaning the Filter Insert205
- Cleaning the Radiator Segments207
- Lubrication208
Maintenance Every 500 Operating Hours209
- Changing the Fuel Filter and Filter Element209
  - Bleeding the Fuel System210
- Changing the Filter Cartridge of the Hydraulic System211
- Cleaning the Water Separator211
- Lubrication212
- Transfer Gear, Checking the Oil Level and Refilling Oil212
- Air Filter, Replacing the Filter Insert, Replacing the Safety Filter213
  - Replacing the Filter Insert213
  - Replacing the Safety Filter213
- Heater/Air Conditioning: Clean Filter Fleece of Heater Unit214
- Heater/Air Conditioning: Cleaning the Condenser215
Maintenance Every 1000 Operating Hours216
- Cooling System, Exchanging Coolant and Cleaning the System216
- Front Axle, Oil Change218
- Rear Axle, Oil Change218
- Transfer Gear, Oil Change218
- Service Brake218
- Checking and Adjusting System Pressures218
- Checking and Adjusting the Valve Clearance218
- Checking/Adjusting the Injection Nozzles, Nozzle Pressure/Fuel-Jet Pattern219
- Checking the Accumulator Gas Pressure219
Maintenance Every 2000 Operating Hours220
- Hydraulic System, Oil Change220
- Bleeding the Hydraulic Oil Tank221
- Cooling System, Checking the Antifreeze Content of the Coolant221
- Checking the Cooling System221
- Checking the Fuel Pump221
- Checking the Fuel and Coolant Tubes, Replacing the Tubes (if Required)221
- Checking the Water Pump222
- Checking and Adjusting the Fuel Injection and Injection Time222
Technical Data224
- Noise Emission Levels226
- Vibration Level226
- Limit Values for Slopes226
  - Maximum Slope Angle for Operating the Machine226
Special Equipment and Attachments228
Als-Electronics229
- Structure and Functioning Principle of the Als-Electronics229
- Precautionary Measures for Switching on the Als-Electronics229
- Operation of the Als-Electronics230
  - Switching on the Als-Electronics230
  - Switching off the Als-Electronics230
- Handling of the Pressure Accumulator231

Brand	Komatsu
Model	HA940549
Category	Compact Loader
Language	English

Komatsu HA940549 User Manual

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