Komatsu SK1020-5NA, SK1020-5N Skid Steer Loader Operation & Maintenance Manual - DOWNLOAD by www.heydownloads.com

CEAM013902

Operation & Maintenance Manual

SK1020-5NA SK1020-5N SKID STEER LOADER SERIAL NUMBERS

ENGINE

SK1020-5NA SK1020-5N S4D98E-2

A60001 A70001

and UP

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. September 2010

0INTRODUCTION

SK1020-5N/SK1020-5NA

0-1

INTRODUCTION

FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU distributor for those items that you may require.

Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine. This manual should be kept near or with the machine for reference and periodically reviewed by all personnel who operate it. Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual. The procedures and precautions given in this manual apply only to the intended uses of this machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine. The safety description is given in SAFETY INFORMATION and in SAFETY Section 1.

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INTRODUCTION

SAFETY INFORMATION Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations. The following signal words are used to inform you that there is a potentially hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, different signal words are used to express the potential level of hazard. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Remark This word is used for precautions that must be taken to avoid actions, which could shorten the life of the machine. Safety precautions are described in SAFETY section 1. KOMATSU AMERICA CORP. cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your local distributor or KOMATSU AMERICA CORP.

SK1020-5N/SK1020-5NA

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INTRODUCTION

APPROVED AND NON-APPROVED USES The SKID STEER LOADERS described in this manual have been designed and constructed to be used mainly for the following functions, any non-approved use may void the warranty, damage the machine or possibly injure the operator.

Approved • •

LOADING, SCRAPING OR GRADING OPERATIONS EXCAVATING

Installation of optional equipment can also be used in the following applications. • • • • • •

HANDLING OF MATERIALS (MP BUCKET - PALLET FORKS - LOG FORK GRAPPLE) SNOW REMOVAL (SNOWBLOWER - SNOW BLADE) DEMOLITION (HAMMER ON BACKHOE UNIT) DITCH CLEANING AND DIGGING (SPECIAL BUCKETS) LANDSCAPING (TILLER - POWER RAKE - PREPARATOR SCARIFIER) ROAD REPAIR (COLD PLANER)

Non-approved This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is important to contact your distributor before carrying out the work operations. • • • • • • •

0-4

USE OF MACHINE FOR LIFTING OR TRANSPORTING PERSONNEL IN ANY MANNER TRANSPORTATION OF FLAMMABLE LIQUIDS LIFTING, MOVING OR TRANSPORTING OTHER MACHINES WITH THE WORK EQUIPMENT TOWING OTHER EQUIPMENT WITH THE TRACTOR UNIT OR WORK EQUIPMENT USING THE WORK EQUIPMENT AS A HAMMER OR FOR STRIKING OR DRIVING OBJECTS TOWING THE MACHINE AT HIGH SPEEDS TRAVELING AT HIGH SPEEDS

SK1020-5N/SK1020-5NA

INTRODUCTION

PRODUCT INFORMATION Listed are features and machine identification locations. Komatsu skid steer loaders and main components are identified by serial numbers stamped on identification plates or decals attached to the machine or component.

Main Features • • • • • • • • • • •

Simple and easy operation Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors operating epicyclic reduction gears Four driving wheels always engaged through oil-immersed roller chains Main equipment and travel control through servo levers ensuring combined movements that can be modulated proportionally and continually Foot control for the optional equipment (if installed) Foot accelerator Lever accelerator Parking brake control Complete series of instruments visible from the operating position Easy maintenance with simplified intervals Road travel (on request)

Break-in Period Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for the first 100 hours to ensure proper run-in time for the various components. If the machine is subjected to excessive or severe work loads at the beginning of its operation, its functions will be greatly reduced or damaged. Every new machine must be used carefully, paying special attention to the following indications: • • • •

After start up, let the engine idle at a low RPM for five minutes, to warm up the machine gradually before beginning actual operation. Avoid operating the machine with excessively heavy loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt reversals or sudden stops. After the first 50 hours, perform the following maintenance, in addition to normal maintenance performed at 50 hours: A. Check the drive chain tension. B. Check the wheel nut torque.

•

After the first 250 hours, perform the following maintenance, in addition to normal maintenance performed at 250 hours perform: C. Change the hydraulic system filter.

Synthetic Biodegradable Oil Types On machines in which synthetic biodegradable types of oils are used, the following operations are to be performed, besides the standard maintenance operations: • •

After the first 50 hours of operation, change the hydraulic system filter. After the first 500 hours of operation, change the hydraulic system oil and filter.

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INTRODUCTION

PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your distributor will need when requiring assistance or ordering replacement parts. It is a good idea to record this information in this manual, see “SERIAL NUMBERS AND DISTRIBUTOR INFORMATION” on page 0-8. All views indicated below are viewed from the operator’s position.

Machine Serial Number The machine serial number is stamped on the inner wall of the right rear pillar.

Machine Identification Plate The PIN plate is located on the inner wall of the right rear pillar.

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INTRODUCTION

Engine Serial Number and Emission Plate The plate (1) indicating the engine serial number and the exhaust gas emission plate (2) are positioned on the top of the valve cover.

Travel Reduction Gear Serial Number The serial number of the travel reduction gear is stamped on the plate positioned on the hydraulic motor cover.

Cab Serial Number The cab serial number is stamped on the plate positioned on the right side of the base cross member.

Excavator Identification Plate (if installed) The excavator identification number is stamped on the plate positioned on the left side of the control panel.

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INTRODUCTION

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION Model: SK1020-5N or SK1020-5NA Machine # Engine # Travel reduction gear # Cab # Excavator (if installed)

Distributor:

Address:

Phone # Contacts:

NOTES:

0-8

SK1020-5N/SK1020-5NA

INTRODUCTION

CONTENTS INTRODUCTION FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPROVED AND NON-APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Break-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synthetic Biodegradable Oil Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number and Emission Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Reduction Gear Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excavator Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model: SK1020-5N or SK1020-5NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-2 0-3 0-4 0-4 0-4 0-5 0-5 0-5 0-5 0-6 0-6 0-6 0-7 0-7 0-7 0-7 0-8 0-8 0-9

SAFETY SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Example of Safety Label Using Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Example of Safety Label Using Pictogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Location of the Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Location of the Pictogram Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Decals Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Vibrations to Which the Operator is Subjected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 General Safety at Job Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Working on Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Fire Extinguisher and First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Checking the Rearview Mirrors (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Precautions for ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Leaving the Operatorâ&#x20AC;&#x2122;s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 Fire Prevention for Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Preventing Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Dust Hazard Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 SK1020-5N/SK1020-5NA

0-9

INTRODUCTION Crush or Pinch Point Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Extinguisher and First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions Concerning the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety on the Work Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for the Operatorâ&#x20AC;&#x2122;s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Room Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for the Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Windows and the Rearview Mirrors - Checking the Windshield Wiper Blades . . . PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for Traveling in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing Electrocution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working on Icy or Snow-covered Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing Damage Caused by the Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working on Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading and Unloading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Under the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keeping the Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Operation During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop Engine Before Maintenance Operation or Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for Refueling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions Concerning the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions Concerning High-Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Working on High-Pressure Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Maintenance Work Involving High Temperatures and Pressures . . . . . . . . . . . . 0-10

1-33 1-33 1-34 1-34 1-34 1-34 1-35 1-36 1-36 1-36 1-36 1-36 1-37 1-37 1-37 1-37 1-38 1-39 1-40 1-40 1-40 1-40 1-41 1-42 1-42 1-42 1-43 1-43 1-44 1-44 1-45 1-47 1-47 1-47 1-48 1-48 1-48 1-48 1-49 1-49 1-49 1-50 1-50 1-50 1-51 1-51 1-52 1-52 1-52

SK1020-5N/SK1020-5NA

INTRODUCTION Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 Disposal of Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 Inflating Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 Hydraulic Environmental Ester Synthetic (HEES) Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 OPERATION SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Loader Arm Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Backhoe Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cold Planer Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Front View of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Rear View of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Inside View of Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Engine Coolant Temperature Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Alternator Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Preheating Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Engine Oil Pressure Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Air Cleaner Clogging Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hydraulic Oil Filter Clogging Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Parking Brake Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Speed Increase Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Floating Device Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Direction Indicator Light (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Working Light Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Safety Device Functionality Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Switches and Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Parking Brake Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Rotating Beacon Light Switch (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Left Stabilizer Button (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Right Stabilizer Button (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Working Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Emergency (Hazard) Switch (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Parking Light and Low Beam Switch (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Direction Indicator Switch (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Starting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Front Equipment Super Flow Hydraulic System Momentary Switch (If Installed) . . . . . . . . 2-22 Front Equipment Super Flow Hydraulic System Continuous Switch (If Installed) . . . . . . . . 2-22 Speed Increase Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Floating Device Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Available for Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 SK1020-5N/SK1020-5NA

0-11

INTRODUCTION 12V Electric Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ISO Pattern Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left PPC Control Joystick (Travel and Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right PPC Control Joystick (Loader Arm and Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Pattern Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left PPC Control Joystick (Left Wheel Travel, Steering, and Loader Arm Control) . . . . . . . Right PPC Control Joystick (Right Wheel Travel, Steering and Bucket Control) . . . . . . . . . Auxiliary Hydraulic Kit Control Pedal (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Control Locking Lever (If Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Flow Hydraulic System Control (Two Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Super Flow Hydraulic System Control (Five Lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Increase Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floating Device Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pattern Shifting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Stabilizer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Stabilizer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Function Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Version with Optional Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUARDS AND OPERATORâ&#x20AC;&#x2122;S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Documentation Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with a Warm Engine or in Warm Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting in Cold Weather or in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12

2-24 2-24 2-25 2-27 2-28 2-28 2-29 2-30 2-31 2-33 2-35 2-36 2-36 2-37 2-37 2-38 2-39 2-40 2-40 2-41 2-43 2-43 2-43 2-44 2-44 2-44 2-45 2-45 2-46 2-48 2-48 2-49 2-50 2-51 2-53 2-53 2-54 2-54 2-55 2-55 2-55 2-56 2-56 2-56 2-56 2-57 2-58 2-58 2-59

SK1020-5N/SK1020-5NA

INTRODUCTION Warming the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Heating the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Hydraulic Oil Travel Circuit Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Moving the Machine (ISO Pattern Control System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 Steering (Changing Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 How to Move the Machine (Optional Pattern Control System) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 Steering (Changing Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Hand and Foot Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Travel and Steering Control Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 Work Equipment Control Pedals (Loader Arm and Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Auxiliary Hydraulic Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 How to Move the Machine (Hand and Foot Control System) . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 Steering (Changing Direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Moving on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Maximum Immersion Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Parking on Level Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Parking on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 HOW TO LIFT THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 Front Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Rear Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 COLD WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Fuel and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Hydraulic Oil Travel Circuit Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Precautions at the End of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 WARM WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 OPERATING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Lowering the Equipment in Case of Machine Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Organizing the Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Loading Heaped and Level Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 Loading Operations on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93 Digging Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 Changing the Bucket or Attachment with Standard Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . 2-95 Removing the Bucket or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 Installing the Bucket or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 Checking the Position of the Locking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 Adjusting the Locking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 Long Periods of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 Before the Period of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 During the Period of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 SK1020-5N/SK1020-5NA

0-13

INTRODUCTION After the Period of Inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Move the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel is Completely Depleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discharged Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-101 2-101 2-101 2-101 2-102 2-103 2-103 2-105 2-105 2-106 2-107 2-108

MAINTENANCE GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Notes Regarding the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Notes Regarding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Notes Regarding the Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Notes Regarding Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Wear Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Selection According to the Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES . . . . . . . . . . . . . . . . 3-9 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Critical Parts for Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Standard Flow Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Super Flow Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Operatorâ&#x20AC;&#x2122;s Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Standard Torque for Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Specific Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 When Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Air Cleaner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Draining the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Releasing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Checking the Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Checks Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Various Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 0-14

SK1020-5N/SK1020-5NA

INTRODUCTION Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Checking the Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Hydraulic System Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Draining Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Checking the Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Maintenance After the First 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Maintenance Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Checking Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Checking the Coolant Level in the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Maintenance After the First 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Maintenance Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Fan Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Checking the Drive Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Adjusting the Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Cleaning the Outside of the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Checking the Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Checking the Oil Level in the Chain Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Lubricating the Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Changing the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Changing the Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Maintenance After the First 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Maintenance Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Changing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Changing the Hydraulic Oil Drain Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Cleaning the Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Draining Condensation from the Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Maintenance Every 1000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Changing the Oil in the Chain Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Changing the Hydraulic System Oil and Cleaning the Suction Filter . . . . . . . . . . . . . . . . . . . 3-47 Checking and Adjusting the Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Maintenance Every 2000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Changing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Changing the Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Checking the Alternator and the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Machine Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Overall Dimensions with Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-2 4-4 4-6

OPTIONAL ATTACHMENTS OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions Regarding the Installation of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Equipment Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Equipment Measurements with the Super-flow Hydraulic System . . . . . . . . . . . . . . . . . SK1020-5N/SK1020-5NA

5-2 5-2 5-3 5-3 5-4

0-15

INTRODUCTION Changing the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Return Circuit with Direct Drainage into the Tank . . . . . . . . . . . . . . . . . . . . . . . . Preparing the Machine for the Use of the Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Machine with the Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pallet Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-16

5-5 5-5 5-6 5-8 5-8 5-9 5-9

SK1020-5N/SK1020-5NA

1SAFETY

Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine. Read and follow all safety precautions. Failure to do so may result in serious injury or death.

SK1020-5N/SK1020-5NA

1-1

SAFETY

SAFETY LABELS Safety labels are affixed to the machine to inform the operator or maintenance worker when operation or maintenance of the machine may involve a hazard. This machine uses safety labels using words and safety labels using pictograms to indicate safety procedures.

Example of Safety Label Using Words

Example of Safety Label Using Pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the single word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside the circle.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual. The explanations, values and illustrations in this manual were prepared on the latest information available at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or for any questions regarding information in this manual.

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SAFETY AND WARNING DECALS Location of the Safety Decals ★ The safety decals must always be legible and in good condition. If they are dirty with dust, oil, or grease, clean them with a solution of water and detergent. Do not use fuel, petroleum based products, or solvents. ★ If the decals are damaged they must be replaced before operating the machine. ★ When a component provided with a safety decal is replaced, make sure the decal is also applied to the replacement component. ★ The machine may be provided with other decals, in addition to those shown below, which must be followed for safe operation.

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SAFETY

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SAFETY 1.

Warning Decal 37C-98-11211 Improper operation and maintenance can cause serious injury or death. Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual.

Height Decal 37C-98-11211 Hazardous voltage hazard. Serious injury or death can occur if machine or attachments are not kept safe distance away from electrical lines.

Line Voltage 6.6 kV

Safe Distance At least 10 ft (3 m)

66.0 kV

At least 16 ft (5 m)

275.0 kV

At least 33 ft (10 m)

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SAFETY 3.

Warning Decal 37C-98-11211 Before moving machine or its attachments: • Honk horn to alert people nearby. • Be sure no one is on or near machine or in area of operation. • Use spotter if view is obstructed. Follow above instructions even if machine is equipped with travel alarm and mirrors. Do not risk serious injury or death.

Pinch Point Danger CRUSH HAZARD; KEEP CLEAR

37A-98-12120

- OPERATE MACHINE FROM OPERATOR’S SEAT ONLY. DO NOT RISK SERIOUS INJURY.

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SAFETY During operations, never place any part of your body near the swing area of the machine.

Warning Decal KEEP OUT OF THIS AREA

37C-98-11211

Do not risk serious injury or death.

Block wheels 37C-98-11211 Block wheels to prevent machine movement. Do not risk serious injury or death.

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SAFETY 7.

Do Not Operate Tag 312614667 DO NOT OPERATE When this tag is not being used, keep it in the storage compartment.

Hydraulic Oil HYDRAULIC OIL

37A-98-12140

Hot oil hazard. To prevent the sudden release of hot oil: • Turn off engine. • Allow oil to cool. • Slowly loosen cap to relieve pressure before removing. DO NOT RISK SERIOUS INJURY.

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Battery Decal 37A-98-12180 EXPLOSIVE GASES • When attaching booster cables, always make last connection on machine frame away from battery to avoid sparks at the battery. • Keep cigarettes, flames, and sparks away from battery to avoid explosion. • Always shield eyes and face from battery. • Do not charge, use booster cables, or adjust port connections without proper instruction and training. POISON CAUSES SEVERE BURNS Contains Sulfuric Acid • Avoid contact with skin, eyes, or clothing. • In the event of contact, flush affected area with water and call a physician immediately. DO NOT RISK SERIOUS INJURY.

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SAFETY 10. ROPS Structure 37C-98-11211 DO NOT WELD ONTO ROPS STRUCTURE. If any damage is sustained to ROPS structure, contact your local Komatsu dealer immediately.

11. Accumulator (OPTIONAL EQUIPMENT) 37A-98-12110 HIGH PRESSURE AND BURN HAZARD 1. When breakdown or trouble develops in the accumulator, do not attempt to disassemble or repair. Always contact your nearest authorized service station. 2. Do not attempt to fill or re-fill with gas. Authorized servicemen, or persons licensed to handle high pressure gases, are the only persons allowed. 3. Never hammer a gas filled accumulator, or place one close to a fire. 4. Never attempt to attach a part to or bore a hole in the accumulator’s wall. 5. Always completely exhaust the accumulator of all contaminated gas when disassembling or discarding the accumulator. 6. To exhaust the gas, use the air relief valve mounted on the accumulator. When there is no such valve, remove the accumulator’s gas filling valve cap and release the gas by depressing the valve core (pin) with a suitable tool (screwdriver). (1) Type of gas Nitrogen (2) Maximum Working Pressure 210 bar (3) Testing Pressure 315 bar DO NOT RISK SERIOUS INJURY OR DEATH. 12. Hot Coolant Hazard Hot Water Hazard.

37A-98-12370

To prevent the sudden release of hot water: • Turn off engine. • Allow water to cool. • Slowly loosen cap to relieve pressure before removing. DO NOT RISK SERIOUS INJURY.

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SAFETY 13. Running Engine Warning While engine is running: 1. Do not open cover. 2. Keep away from fan and fan belt.

37A-98-12170

DO NOT RISK SERIOUS INJURY.

14. Do Not Use Ether DO NOT USE ETHER

37A-98-12150

Engine equipped with electric heater. Using ether as a starting aid may cause explosion. Do not risk serious injury or death.

15. Fuel Tank DIESEL FUEL ONLY

37A-98-12130

Refer to your Operation and Maintenance Manual for instructions on draining fuel tank.

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SAFETY 16. Seat Belt Warning ALWAYS USE SEAT BELT

37C-98-11211

Avoid being crushed - DO NOT jump if machine tips. Do not risk serious injury or death.

17. Warning Decal Do not risk serious injury or death.

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SAFETY 18. Warning Decal 37A-98-11271 To remove arm safety bar check operator manual.

19. Loader Raised Warning 37A-98-11172 ALWAYS INSTALL LOADER ARM SAFETY SUPPORT WHEN WORKING UNDER RAISED ARM. ALWAYS HAVE TWO PEOPLE PRESENT WHEN INSTALLING OR REMOVE LOADER ARM SAFETY SUPPORT. TO INSTALL LOADER ARM SAFETY SUPPORT 1. Park machine on level ground. Slowly raise loader arm to maximum height and stop engine. 2. Have second person remove split pin from loader arm support retaining pin: then remove retaining pin. 3. Lower loader arm safety support onto cylinder rod. 4. Slowly lower loader arm until safety support fully engages cylinder and stops arm movement. 5. Install retaining pin inside loader arm safety support lock hole and secure it with split pin. TO REMOVE LOADER ARM SAFETY SUPPORT 1. Start engine. Raise loader arm to maximum height. 2. Have second person remove split pin and retaining pin from inside loader arm safety support locking hole. 3. Place loader arm support in its rest position and secure it with retaining pin. 4. Slowly lower arm.

20. Air Filter 37A-98-12160 IMPORTANT • Element must be kept free of cracks and oil. • For cleaning and replacement of elements, refer to the Operator’s Manual. • Do not put oil into this cleaner.

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SAFETY 21. Diesel Engine Exhaust CALIFORNIA Proposition 65 Warning

37A-98-12330

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

22. Battery Warning CALIFORNIA Proposition 65 Warning

37A-98-12220

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. 23. Attaching Bucket 37A-98-11232 BEFORE OPERATING VEHICLE • Do not operate machine without confirmation that coupling pins are fully engaged and the levers are in horizontal position. • Do not use your fingers to center the pins. • Read Operation Manual before removing or installing bucket or attachment. • Failure to follow these instructions may cause serious injury or death.

24. Cab Lifting 37A-98-11342 EVERY TIME LIFT THE CABIN Remove the split pin from its slot and put it in the hole indicated by the arrow.

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SAFETY N/I Lifting Points

25. Pattern Change 37A-98-11281 Change between Komatsu control pattern and optional control pattern.

26. Floating Device Control Button 37A-98-11931 (Right Joystick) Controls the loader arm floating function (if installed).

27. Machine Speed Increase Button 37A-98-11211 (Left Joystick) Controls the increase of the machine travel (if installed).

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SAFETY 28. Optional Attachment Electrical Connections 37A-98-11321 (Right Joystick) Controls the electrohydraulic functions of optional attachments if connected.

29. NOT APPLICABLE 30. Super-flow (Left Joystick) 37A-98-11311 Controls Super-flow Auxiliary Hydraulics functions for optional attachments.

31. Foot Control for the Optional Attachments Controls standard auxiliary hydraulic functions if optional attachment is installed.

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SAFETY 32. Lever Controls

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37A-98-11251

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SAFETY 33. Lubrication Chart

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37A-98-11961

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SAFETY 34. Equipment Fuse Decal

37A-98-11162

Standard Version POS

COLOR

AMP

Violet

Optional Version POS

COLOR

AMP

Left side lights

Violet

Left side lights, plate light

Control panel lights

Violet

Control panel lights, right side lights

Blue

15A

Horn, low beam, or front work light

Blue

15A

Horn, low beam, or front work light

Brown

7.5A

Switch lights

Red

10A

Switch lights, direction lights

Blue

15A

Rear work light

Blue

15A

Rear work light, Stop lights

Red

10A

Lever switch power supply, Float, Pattern change

Red

10A

Lever switch power supply, Float, Pattern change

Red

10A

Current intake 12V, Beacon light

Red

10A

Current intake 12V, hazard, Beacon light

Red

10A

Control panel, safety box, fuel shut off, safety bar proximity, safety seat switch, Brake switch

Red

10A

Control panel, safety box, fuel shut off, safety bar proximity safety seat switch, Brake switch

Brown

7.5A

Back-up alarm

Red

10A

Back-up alarm, Attachment 3-way HIFLOW, Stabilizer ENPI valve

Brown

7.5A

Fuel pump, safety engine relay, generator

Brown

7.5A

Fuel pump, safety engine relay, generator

Green

30A

Pull engine solenoid PPC safety pressure switch

Green

30A

Pull engine solenoid PPC safety pressure switch

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INVOLVED CIRCUIT

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SAFETY 35. Radiator Door Warning

37A-98-11361

36. Engine Hood Safety Release Lever 37A-98-11370 - Lift the hood until the safety lock is engaged - Remove the safety lock before closing the hood

37. Warm Up Travel Circuit Oil 2939-98-1150 (Chart Location a - Canopy Model, Chart Location b - Cab Model) Warm-up travel circuit oil prior to machine operation when unit has been parked at temperatures below 32Â°F (0Â°C). Travel circuit oil warm-up procedure since the date of last use. - Start engine and place drive in high gear. - Release and re-apply park brake. - Hold PPC control in full forward position for 4-6 minutes. - Confirm the braking controls are operating normally. - Consult operation and maintenance manual for details of this procedure.

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SAFETY 38. Emergency Exit 37A-98-11290 In case of emergency, pull the safety tag and remove the rear window weather strip, then push window out.

N/I Jump Start Prohibited 09842-A0481 Do not start the engine by tampering with the starter terminals.

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Location of the Pictogram Decals • • •

Your distributor can supply you with new replacement pictogram decals if the ones on the machine are damaged or missing. When replacing damaged or missing pictogram decals, be sure they are placed in the proper location. Additional safety or warning decals may be added to your machine if desired.

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SAFETY

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Decals Defined The warning and danger decals applied to the machine are accompanied or represented by pictograms. The personnel charged with the operation and maintenance of the machine must know the symbols contained in the pictograms perfectly; the following descriptions illustrate what they look like and their respective meanings. DANGER IN THE WORK AREA . . . . . . . . . . . . . . . 306421689 (Only for machines with the excavator) Do not approach or stand near the work equipment operating radius when the boom and the bucket of the excavator are raised.

MOVING PARTS IN THE ENGINE . . . . . . . . . . . . . 312614646 Keep clear of moving parts inside engine compartment.

CONSULT THE MANUAL . . . . . . . . . . . . . . . . . .37C-98-11210 Carefully read the contents of the manual before using the machine or performing maintenance operations.

HYDRAULIC OIL FILL

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SAFETY DO NOT LOOSEN BOLT TO TILT CAB . . . . . . . 37A-98-11390 This bolt is not to be loosened when the cab needs to be tilted.

FOLLOW INSTRUCTIONS ACCORDING TO OPERATION AND MAINTENANCE MANUAL . . . . . . . . . . . . .37A-98-12390

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Vibrations to Which the Operator is Subjected According to tests used to determine the vibrations transmitted to the operator by the machine, the upper limbs are subjected to vibrations lower than 2.5m/sq sec (8.2 ft/sq sec), while the lower part of the body is subjected to vibrations lower than 0.5 m/ sq sec (1.7 ft/sq sec).

SAFETY RULES AND PRECAUTIONS General Safety Rules • • • •

• • •

• • • • • • •

•

Only trained and authorized personnel shall be allowed to operate and service this machine. Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy reference. Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating condition. Always perform a pre-operational check on your machine before operating it. The machine is equipped with a seat belt and rollover protective structure (ROPS). The operator must remain within the confines of the ROPS with the seat belt fastened snugly around the waist while operating the machine. See “Seat Belt Inspection” on page 1-35. If your equipment is designed for operation by one person, it is for one person only, never allow other personnel to ride on your machine. Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment. Be sure that all personnel are outside the working radius of the machine before moving or operating the machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more restricted your visibility will be. If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded or smaller machine has the right away over an unloaded machine. Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result. Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine. It is the owner and/or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the machine. Think before you act, study the job carefully. Careful operator and service personnel are the best insurance against accidents. The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that might affect their eyesight, hearing, or reactions. When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used. When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel. Never drive up to anyone standing in your travel path. Always be sure all personnel are standing to the side when you approach them and acknowledge your approach. Follow all rules relating to safety as outlined in this manual and by your company. Never get involved in horseplay.

General Safety at Job Site • • • • • •

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Know your location to report an accident or fire. In case of an emergency, have a local emergency phone number available. Be careful when operating around or near open-burning operations. Maintain the fire extinguisher on the machine and a second one at the job site. Keep the machine clean, especially from flammable materials such as trash, grease, oil or fuel. Keep all safety equipment in good working condition.

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SAFETY • • • • • • •

Check the terrain and condition of the ground at the work site, and determine the safest method of operation. Do not operate where there is a danger of landslides or falling rocks. If water lines, gas lines, or high-voltage electrical lines may be buried under the work site, contact each utility company and have them identify their locations. Take action to prevent unauthorized people from approaching the job site. When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians. When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations. Conduct periodic safety training and familiarize all personnel with emergency procedures.

Working on Loose Ground •

• • •

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is danger that the machine may fall or tip over. Remember that the soil is loose after heavy rain, blasting or after earthquakes. When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

Safety Features • • • •

Be sure all guards and covers are in place especially after servicing the machine. Have guards or covers repaired immediately if they are damaged. See “PRECAUTIONS BEFORE STARTING THE ENGINE” on page 1-34. Use safety equipment such as safety locks and seat belt properly. Never remove any safety features. Always keep them in good operating condition. See “Seat Belt Inspection” on page 1-35. Always secure the machine in a safe position; see “Parking the Machine” on page 1-41. See “Seat Belt” on page 2-54. Improper use of safety features could result in serious bodily injury or death. Be sure the machine has the correct equipment required by local rules and regulations.

Personal Protective Equipment •

•

If your machine is equipped with safety equipment, use the safety equipment when operating your machine. Check to be sure all personal protective equipment are in good condition before using. Avoid loose fitting clothing, jewelry and loose long hair. These can catch on controls or in moving parts and cause serious injury. Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety glasses, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air. Check to be sure no one is near your work area.

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Fire Extinguisher and First Aid Kit Always follow the precautions below to prepare for action if any injury or fire should occur. •

Be sure that fire extinguishers are provided and read the labels to ensure that you know how to use them in emergencies.

•

Perform periodic inspection and maintenance to ensure that the fire extinguisher is always ready for use.

•

Provide a first aid kit at the storage point. Perform periodic checks and add to the contents if necessary.

Checking the Rearview Mirrors (If Installed) •

Make sure that the rearview mirrors are clean and correctly directed; the operator must be able to check the area behind the machine with no need to twist his trunk with respect to his normal operating position.

•

If the rearview mirrors should move or break during the operations, stop the machine immediately and fix or change them.

•

Working without checking the area behind the machine involves the risk of running over persons who have carelessly approached the machine or colliding with fixed obstacles or maneuvering vehicles.

Mounting and Dismounting •

Do not jump on or off the machine, either when it is at rest or when it is moving.

•

When getting on or off the machine, always use the appropriate handles and footrests; get on and off the machine very carefully.

•

Never hold or rest on the control levers.

•

Either when getting on and when getting off the machine, always maintain three points of contact (holding or resting points), to avoid losing your balance and falling down.

•

Clean the handles and footboards if they are dirty with oil or grease. Carefully clean the cab floor if it is dirty with oil, grease, mud or rubble.

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SAFETY

Precautions for ROPS

Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation.

The operator’s compartment is equipped with a Roll Over Protective Structure (ROPS) to protect the operator. ROPS is designed to support the load if the machine rolls over and also to absorb the impact of the energy. The ROPS fulfills all the regulations and standards for all countries. If the machine weight (mass) exceeds the certified value (shown on the Roll Over Protective Structure (ROPS) certification plate), ROPS will not be able to fulfill its function. Do not increase machine weight beyond the certified value by modifying the machine or by installing attachments to the machine. If the function of the protective equipment is impeded, the protective equipment will not be able to protect the operator and the operator may suffer injury or death. If the cab is inadvertently impacted or the machine overturns, the cab may be damaged with consequent reduction of sturdiness and of the safety that must be guaranteed to the operator. Consult Komatsu or your Komatsu distributor to have the cab structure and resistance checked for damage in this case. Always observe the following rules: • •

•

Do not remove the protective structure and carry out operations without it. If the protective structure is welded, or holes are drilled in it, or if it is modified in any other way, its strength may decrease. Never drill, cut, weld on, or modify the ROPS structure. If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. If the ROPS structure is damaged in any way, replace it immediately. Do not make repairs to the ROPS structure itself. Even if the protective structure is installed, always fasten your seat belt properly when operating the machine. If you do not fasten your seat belt properly, it cannot provide full protection. For details on seat belt safety see “Seat Belt Inspection” on page 1-35.

Unauthorized Modification • •

Komatsu will not be responsible for any injuries, accidents, product failures, or other property damages resulting from modifications made without authorization from Komatsu. Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.

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Leaving the Operator’s Seat •

When leaving the operator’s seat, even if temporarily, make sure that the machine is in a safe position.

•

Before leaving the operator’s seat, carry out the following operations in the sequence indicated below: 1.

Rest the equipment on the ground.

Apply the parking brake.

Engage the safety device of the optional equipment control pedal (if installed).

Lock the equipment and travel control by shifting the safety bars to the lock position.

Stop the engine. See “STOPPING THE ENGINE” on page 284.

Remove the starting key if the machine will be out of your sight for any period of time.

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SAFETY

Fire Prevention for Fuel and Oil Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following: • Keep any open flames away from flammable fluids. • Stop the engine and do not smoke when refueling. • Refueling or adding oil should be made in well-ventilated areas and only after stopping the engine. • Keep oil and fuel in its proper place.

•

• • •

When refueling, hold the nozzle firmly and keep it constantly in contact with the filler until you have finished, to avoid sparks due to static electricity. After refueling, tighten the fuel and oil safety caps securely. Do not fill the tank completely to leave room for the fuel to expand. In case some fuel is spilled, wipe it up immediately.

Preventing Burns • •

Wear gloves and safety glasses when checking any fluid levels: engine oil, hydraulic oil, engine coolant, transmission fluid. Before checking the engine coolant, engine oil, or hydraulic oil, stop the engine and let the fluids cool down before attempting to check the level. If you don’t, the hot fluids may spurt out and cause burns. If the coolant level in the radiator needs to be checked due to overheating, slowly loosen the radiator cap to release the internal pressure or the hot coolant may spurt out and cause burns.

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Dust Hazard Precautions Asbestos dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fiber during demolition operations, always do as follows. • Never use compressed air for cleaning. • Use water to keep down the dust when cleaning. • If there is a danger there may be asbestos dust in the air, operate the machine with the wind to your back whenever possible. Use an approved respirator. • Do not allow any other person into the area during operation. • There may be a danger that non-genuine Komatsu parts may contain asbestos, use only genuine Komatsu parts. • Always observe rules and regulations related to the job site and working environment.

Crush or Pinch Point Dangers Never stand under or place any part of your body between the movable components such as the work equipment and cylinders or between the machine and work equipment. Keep in mind when the work equipment is operated, the clearance will change and this may lead to serious personal injury or death. Never drive up to any one standing in front of a solid object or your path of travel. The brakes could fail or the machine could slide on a slippery surface causing injury or even death.

Fire Extinguisher and First Aid Kit As a precaution if a fire or an injury should occur, always keep a fire extinguisher and first aid kit on your machine and do as follows: •

Make sure that fire extinguishers have been provided and check their position.

•

Be sure that fire extinguisher is in good condition and read the label on it to ensure you know how to use it.

•

Keep a first aid kit in the storage area. Check the kit periodically and replace any bandages, disinfectants, etc. as necessary.

•

Keep a list of emergency phone numbers in case of an accident.

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SAFETY

Precautions Concerning the Equipment •

When installing and using optional equipment, carefully read the relevant instruction manual and operate the machine accordingly.

•

Do not use optional or special equipment without the authorization of Komatsu or your Komatsu distributor. The installation and use of unauthorized equipment may create safety problems and adversely affect the efficiency and life of the machine.

•

Komatsu cannot be held liable for any damage, accident, product failure resulting from the installation and use of unauthorized equipment.

Precautions for Attachments • • •

When installing and using an optional attachment, read the instruction manual for the attachment and information related to the attachments. Do not use attachments that are not authorized by your distributor. Use of unauthorized attachments could create a safety problem and adversely affect proper operation and useful life of the machine. Any injuries, accidents, product failures resulting from use of unauthorized attachments will not be the responsibility of Komatsu.

PRECAUTIONS BEFORE STARTING THE ENGINE Before starting your work operations, it is important to perform several procedures to be sure your equipment is in a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.

Safety on the Work Site Before starting your machine and preceding with any work operations, it is important to be sure your machine is safe to operate. •

Before starting the engine, thoroughly check the area for any unusual ground conditions that may cause the work to be dangerous.

•

Check the conditions of the work site and before starting the engine define the work plan and the best and safest operating procedure.

•

Make the ground surface as level as possible before carrying out any operation.

•

If working on the road, protect pedestrians and cars by designating a person for work site traffic duty and install fences around the work site.

•

If water lines, gas lines, telephone or high-voltage electrical lines are located under the work site, contact the relevant utility company to find out their exact locations or to make them inoperative until the end of the operations. Be careful not to sever or damage any of these lines.

•

Check the depth and flow of water before operating in water or on river banks.

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SAFETY

Seat Belt Inspection

Seat belts must be replaced immediately if there are any signs of wear or damage, no matter how recently they were last replaced. A thorough inspection of the entire seat belt system should occur before starting the engine. •

Inspect the full length and both sides of the seat belt webbing for wear, abrasion, dirt, oil, mildew, paint or other damage. Replace immediately if worn or damaged. • If the webbing is cut, fraying, snagging, kinking, or roping, the seat belt must be replaced. Any of these conditions may limit belt retraction.

•

There may be internal and/or external tethers mounted on the suspension mechanism. Inspect these for fatigue as well as the integrity of the mounting hardware.

•

Inspect the seat belt attachment and adjustment hardware for wear or damage. • Retractable and non-retractable buckle housings with damage from abrasions, rubbing, forceful impacts and age, must be replaced. These conditions may weaken the strength of the buckle. • Examine the seat belt buckle and retractor housing(s) for proper function. • Dirt, debris, lint, leaves, etc. may become encased inside of the retractor housing. With time, this condition may cause a seat belt malfunction. • Check the mounting structure integrity. Verify that the mounting bolts are secure. Tighten to specified torque, if necessary. • Check your records or the seat belt “Date of Installation” label (if equipped). Even if there are no signs of damage, the seat belt must be replaced either five years after the date of manufacture, or every three years after the start of usage, whichever comes first. • The manufactured date and “Install By” (if equipped) date may be found on the back of the buckle housing and/or on the seat belt webbing. • The location of the “Date of Installation” label (if equipped) may vary slightly, but most frequently it will be found on the plastic molding of the seat belt. If your machine is equipped with a shoulder harness also, inspect the webbing, the shoulder loop web guide and the height adjuster for wear, damage and proper function capabilities

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SAFETY

Fire Prevention •

•

Completely remove all wood chips, rubbish, paper and other flammable materials that may have accumulated inside the engine compartment, since they can cause fires. Check the fuel and hydraulic system pipes for leaks and if necessary repair them. Wipe up any excess oil, fuel or other flammable fluids. Make sure that fire extinguishers are available in the work area.

Precautions for the Operator’s Cab • • •

Do not keep objects or tools in the operator’s cab. They may hinder the operation of the controls and cause serious accidents. Keep the cab floor and the controls (pedals and levers) clean by removing any trace of oil and grease and as far as the floor is concerned, remove any excess dirt (earth, stones, etc.). Check the seat belt system and replaced any parts that are broken or damaged. Replace any component only with approved parts supplied by your distributor. See “Seat Belt Inspection” on page 1-35.

Room Ventilation Exhaust gases are deadly. If starting the machine inside a building, connect a suction duct to the exhaust pipe to vent fumes outside.

Precautions for the Lights • •

Remove any trace of dirt from the lights, in such a way as to ensure perfect visibility of the work area. Make sure that all the bulbs and the working lights are functioning properly. If necessary, replace any faulty bulbs with new ones, making sure that their power is correct.

Cleaning the Windows and the Rearview Mirrors - Checking the Windshield Wiper Blades •

Remove any trace of dirt from the cab windows and clean the rearview mirrors, to ensure perfect visibility on the work area.

•

Adjust the rearview mirrors that may have moved, so that the operator seated in the driving position can clearly see the area behind the machine. If any glass is damaged, replace it with new.

•

Check the condition of the windshield wiper blades; the scraping edge must be smooth, with no indentations and attached to the rubber back of the blade. In case of doubts about the efficiency of the edge, change the blade.

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SAFETY

PRECAUTIONS TO BE TAKEN WHEN WORKING Starting the Engine •

Before operating the machine, walk around it and check for people or objects that might be in the way.

•

Do not start the engine if warning tags have been attached to the steering wheel or control levers.

•

Sound your horn to warn others in the area before starting the engine or moving the machine.

•

Start the engine only when seated and with the seat belt fastened snugly around your waist. See “Seat Belt Inspection” on page 1-35.

•

Do not allow anyone in the cab or on the machine during operations.

Rules for Traveling in Reverse •

•

• •

When operating in areas that may be hazardous or where visibility is poor, designate a person to direct the movements of the machine and the traffic on the work site. Make sure that no unauthorized person is standing within the machine operating radius or in its travel direction. If necessary, put up appropriate fences. Before moving the machine, sound the horn to warn persons near the work area. There are blind spots behind the machine, which cannot be seen by the operator and where someone may be standing. Therefore, it is necessary to make sure that there is no one behind the machine before traveling in reverse.

Moving the Machine

The use of the speed increase button is allowed only for the high speed transfers of the machine. •

When moving the machine, lower the arm and roll the bucket completely; this position makes it possible to evaluate the space required for movement more precisely and at the same time ensures the stability of the machine.

•

If the equipment control levers must be used during travel, avoid moving them abruptly; sudden maneuvers change the position of the machine and make driving difficult.

•

When traveling on rough ground, keep the speed low and avoid sudden movements of the bucket arm.

•

If possible, avoid moving on obstacles. If the machine has to travel over an obstacle, keep the equipment as close to the ground as possible and travel at low speed. Never move on obstacles that may considerably tip the machine (over 10°).

•

If one of the two wheels goes over an obstacle or gets into a hole in the ground, the machine may overturn. In terrain of rocks and holes, reduce the speed to a minimum and be very careful of the balance of the machine.

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SAFETY

Working on Slopes • • •

•

• • • • • •

•

Operations on slopes, rivers or lake banks with damp ground may result in the machine sliding or tipping over. Do not operate the bucket while the machine is on a slope. On hills, banks or slopes, keep the arm lowered and the bucket rolled and in case of emergency quickly lower it to the ground to help the machine stop. Do not change direction and if possible avoid traveling sideways when working on slopes. It is advisable to go down or up to a flat surface before performing these maneuvers. Travel up or down slopes with the heaviest part of the loader facing the top of the slope. Do not travel on wet grass or thick layers of leaves; the machine may slide. Before carrying out any operation on a slope, always check the functionality of the parking brake. Do not go down slopes at high speed; you may lose control of the machine and cause serious damage and even death. Do not move on slopes with inclination exceeding 15°, since the machine may overturn. When the fuel level indicator reaches the red reserve area during work on a slope, immediately refuel. Due to the inclination of the machine, the engine may suck in air and stop suddenly, which represents a grave risk for the safety of the operator and of the persons in front of the machine. If the engine should stop suddenly, immediately lower the bucket to the ground and apply the parking brake.

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SAFETY .

Preventing Electrocution •

Digging operations near overhead electric lines are extremely dangerous and may also cause death due to electrocution. For this reason, when working near overhead electrical lines, always respect the minimum safety distances prescribed by the competent authorities and by the accident-prevention rules in force.

•

As far as underground long-distance lines are concerned, the minimum distance depends on the covering of the ducts in which the cables are laid. •

Wear shoes with thick rubber or leather soles.

•

Request the aid of another person who can warn you if the machine gets too close to the electric wires.

•

Operate at low speed.

•

Learn what is to be done first in case of electrocution.

•

Keep the phone number of the electricity company and of the nearest first aid station at hand.

•

If the work equipment accidentally gets entangled in the cables, the operator must remain still and must not leave the cab until the utility company has shut off the power.

•

When carrying out this kind of operation, warn everyone standing in the work area to keep at the minimum distance prescribed from the machine and the work equipment.

•

Ask the power company in advance the voltage of the cables and the minimum safety distance.

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SAFETY

Visibility •

Switch on the working lights as soon as visibility starts decreasing. If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.

Working on Icy or Snow-covered Surfaces • •

If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sideways. Therefore it is advisable to move at low speed and to avoid abrupt starts, stops or turns. When it has snowed heavily, the road shoulders and obstacles are buried in the snow and are not visible; therefore proceed with care when clearing snow.

Preventing Damage Caused by the Work Equipment •

When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.

Working on Loose Ground •

•

Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches. These areas may collapse, making the machine fall down or tip over and this could result in serious injuries or even death. Remember that after heavy rain or earthquakes these dangerous conditions usually get worse. The earth near ditches is loose and can easily collapse due to the weight or vibrations of the machine. Be extremely careful and remember to fasten your safety belt. See “Seat Belt Inspection” on page 1-35.

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SAFETY

Parking the Machine •

•

• •

Park the machine on firm and level ground. If this is not possible and it is necessary to park on a slope, position the machine with the bucket directed downwards and carry out the following operations: • Rotate the bucket forward and rest it on the ground. • Apply the parking brake. • Stop the engine. • Put wedges or safety blocks under the wheels. Always rest the work equipment on the ground; if it is necessary to park with raised arms, make sure that the safety locks are engaged (see “SAFETY LOCKS” on page 2-2). Always lock the equipment and travel control by shifting the safety bars to the lock position (see “SAFETY LOCKS” on page 2-2). When leaving the machine, always apply the parking brake and remove the starting key. If it is necessary to park on public roads, signal the presence of the machine according to the local regulations in force (signalling fires, fences, road works ahead, alternated direction and direction signs, etc.).

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SAFETY

TRANSPORTING THE MACHINE Loading and Unloading the Machine • • • • •

• • •

• •

Loading and unloading the machine on or off another vehicle always involves potential hazards. Proceed with extreme care. Perform loading and unloading on firm, level ground. Maintain a safe distance from the edges of ditches or road sides. If the vehicles used have not been appropriately equipped, put support blocks under the ramps, to avoid any bending. Always lock the wheels of the transporting vehicle with chocks. Always use ramps that are sufficiently wide and can support the weight of the machine. The longitudinal axis of the ramps must be parallel to each other and perpendicular to the loading board and their distance from each other must be sufficient to accommodate the tread of the machine. Make sure that the ramps are securely positioned and anchored to the loading board and that they are the same length. Position the ramps with a maximum angle of 15°. Make sure that the ramp surface is clean and there is no trace of grease, oil, soil and ice; remove any dirt from the wheels of the machine before starting to load it on the vehicle. If the bucket is empty or no optional accessories are fitted to the machine, this end must face the rear. Do not reposition the machine on the ramps. If necessary, go down the ramps and start the operation again. After loading the machine, block the wheels with chocks and secure it with tie-downs or chains that prevent any shifting (see “TRANSPORTING THE MACHINE” on page 2-85).

The Route • • •

Define the route to be followed, taking into account the width, height and weight of the transporting vehicle plus the machine. Make sure that the overall dimensions of the vehicle and its load are compatible with the roads and any tunnel, underpass, bridge, power and telephone line, etc. along the route. Adhere to the regulations in force regarding the permissible width, height, weight and speed of heavy vehicles.

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SAFETY

BATTERY Safety Precautions •

•

• •

•

Electrolytic batteries contain sulfuric acid which can cause burns. It can also corrode clothing and make holes in it. If you inadvertently splash battery acid on yourself or on someone else, immediately wash the affected part with plenty of water. Battery acid may cause blindness if it comes into contact with the eyes. If acid accidentally gets into your eyes, wash them immediately with plenty of water and consult a doctor right away. If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg white, or vegetable oil and in any case antacid substances like magnesia, bicarbonate, etc. Call a doctor or a poison treatment center immediately. Always wear safety glasses and rubber gloves when working with batteries. Batteries produce hydrogen, which is highly explosive and can be easily ignited with small sparks or exposed flames. Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around or near the battery. Before working with batteries, first turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch to the UNLOCK position, and remove the battery disconnect switch key. Avoid short-circuiting the battery terminals through accidental contact with metal objects, tools or through the inversion of the terminals. Tighten the battery terminals securely. Loose terminals may generate sparks and even cause the battery to explode.

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SAFETY

Removing Battery Cables Turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch on to the UNLOCK position, and take out the battery disconnect switch key. Then, begin the cable removal at the ground (negative -) cable side. When installing the battery cables, be sure to begin with the positive (+) cable side and finish at the ground cable side.

Booster Cables Connecting the booster cables incorrectly may cause the battery to explode. Follow the directions carefully. • Wear safety glasses and rubber gloves when starting the engine with booster cables. •

When starting the engine by means of another machine, the working machine must have the same battery voltage of the problem machine. Avoid any contact between the two machines.

•

When connecting two machines with booster cables, turn the problem machine’s starting switch and battery disconnect switch to the OFF position, then turn the working machine’s starting switch to the OFF position. There is a danger that the problem machine may move when the power is connected.

•

Be sure to connect the positive cable (+) first and then the negative or ground cable (-) when connecting the booster cables.

•

When connecting the ground cable to the frame of the machine to be started, operate as far as possible from the battery (see “Discharged Battery” on page 2-102). For details to start engine with booster cables see “Discharged Battery” on page 2-102.

•

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SAFETY

PRECAUTIONS FOR EMERGENCY RECOVERY • • • • •

•

The removal hooks are to be used exclusively for emergency recovery and not for towing vehicles. Before moving the machine, make sure that all the controls are in neutral. Release the parking brake of the travel hydraulic motors (see “Releasing the Parking Brake” on page 3-25). Incorrect maneuvers may result in serious injuries or even death. To move the machine, use properly dimensioned steel cables; do not use worn cables or cables with broken strands (A), twisted cables (B), or deformed cables (C). During the recovery operation, no one is allowed to approach the machines or the cable.

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SAFETY • •

Move the machine just far enough to permit the required repairs. Do not remove the machine in any way other than that indicated in paragraph (see “How to Move the Machine” on page 2-101).

Never stand next to the tow lines when towing the machine. The cable or chain could break causing injury. Always stay clear of the towing equipment. • • •

The maximum pulling force for the emergency recovery is the following: F = 2750 kg. Use cables of the same length and pull continuously, without jerks. Arrange and connect the machine to be removed by positioning it on the same axis as the towing vehicle; the force must be parallel to the axis of movement.

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SAFETY

PRECAUTIONS DURING MAINTENANCE All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

Warning Tags • • •

•

Before performing any maintenance operations on this machine, position the machine on a level and firm surface. Lock the equipment controls, remove the starting key and tag the steering wheel. Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine around specific points to warn others that this machine is down for maintenance. If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.

Tools • •

•

Use only the tools provided with the machine and high-quality tools suitable for the tasks to be performed. Do not use worn, damaged, low-quality tools or tools that are not suitable for the tasks to be performed, to avoid any personal injury. After use, always put the tools in the appropriate compartment (1) behind the driver’s seat.

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SAFETY

Personnel • •

Only authorized and trained personnel can service and repair the machine. Additional precautions must be taken when grinding, welding, using a sledge hammer or heavy hammers. When assembling the equipment or cylinder connection pins, use wooden, plastic or other soft tools to check the centering of the holes. Do not use your fingers since you run the risk of cutting them.

Equipment Storage •

•

The normal or special equipment that must be installed on the machine or that has been removed, must be stored in a safe place. Be especially careful to prevent them from falling down; if they fall on someone, they can cause serious bodily harm. When assembling or removing any equipment, make sure that the ropes and the lifting hook are in good condition and properly dimensioned for the load to be lifted.

Working Under the Machine •

•

Always use approved jack stands to support the machine when performing maintenance under the chassis. Never rely on hydraulic jacks or the machine’s work equipment to support the machine when working under or on the machine. Always lower the work equipment to the ground or to their lowest position before performing service or repairs under the machine. Always lock the machine tires securely. Do not work under the machine if it is not sufficiently supported.

Keeping the Machine Clean •

•

• • •

Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts of the machine itself. Avoid using high-pressure steam cleaners or caustic soaps to wash the machine, if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components. Never use high-pressure water or flood the inside of the operator’s cab. Doing so may damage sensitive electrical components. When pressure-washing, use high-pressure, hot water, and mild grease-cutting soaps. Always grease the machine after cleaning to force any water out of the pivot point connections.

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SAFETY

Engine Operation During Maintenance • • •

•

If the engine must run during maintenance, be sure all work equipment is locked. Have someone remain in the operator’s seat while the engine is running. This is so the engine may be shut down quickly. During maintenance operations with the engine running, never disengage the safety locks of the controls from the LOCK position. Service personnel must not move any control lever.

Critical Parts Some parts must be replaced for safety purposes periodically. Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or pedestrian. Listed are some of the systems containing these components that may fail under extended use: • Fuel supply and delivery hoses • Hydraulic system: main delivery hoses and tubing • Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment For additional information: see “Critical Parts for Safety” on page 3-13.

Stop Engine Before Maintenance Operation or Inspection • •

•

Stop the machine only on firm, level ground and stop the engine before carrying out any maintenance operation or inspection. If the engine must be running during a maintenance operation, shift the safety bars to the LOCK position and carry out the maintenance operation with the help of another person; one operator must remain on the machine and the words and signs to be used must be agreed upon in advance. The person who carries out the maintenance operations must be very careful not to touch any moving part of the engine.

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SAFETY

Rules for Refueling the Machine • • • • • •

•

Keep away from exposed flames while refueling or adding oil. Spilled fuel or oil makes the ground slippery and may cause accidents; clean any dirty area immediately and carefully. Always tighten the fuel tank and the hydraulic circuit oil safety caps securely. Do not use fuel to clean any part of the machine that is dirty with oil or dust. Always top off the fuel and oil tanks in properly-ventilated areas and refrain from smoking. When refueling, hold the fuel nozzle firmly and keep it constantly in contact with the filler until you have finished, to avoid sparks from static electricity. Do not fill the tank completely, to leave room for the fuel to expand.

Cooling System Precautions •

•

Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap. If it is necessary to remove the cap with the engine still hot, wear suitable clothes and protection before loosening the cap. Loosen the cap slowly to relieve pressure gradually. Never dump used coolant on the ground, in a lake, stream or in a sewer system.

Using Lamps When checking the fuel, oil, coolant or battery electrolyte levels, always use approved explosion-proof lamps. If such lighting equipment is not used, there is a danger of fire and/or explosion.

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Electrical Precautions • • • •

•

When repairing the electrical system, disconnect the battery to stop the flow of electricity. When working on the electrical system, disconnect the negative (-) battery cable b first, then the positive (+) battery cable c last. Upon completion of work, reconnect the positive (+) cable c first, then the negative (-) cable b last. If electrical welding operations are to be performed on the machine, it is necessary to disconnect the battery and also the alternator. Be aware that the fuel injector harness contains high voltage and high amperage.

Precautions Concerning the Starter • •

Do not start the engine by tampering with the terminals of the starter, since the machine may move. Sudden or accidental movements of the machine may cause serious injuries or even death.

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SAFETY

Precautions Concerning High-Pressure Hoses •

•

Do not use bent, cut or cracked tubing or hoses which have been previously rejected because of leaks or other defects. Faulty hoses can burst during operation causing injury or fire. Repair or replace any loose or faulty fuel or hydraulic lines immediately. Do not operate the machine with damaged or leaking hoses or lines.

Precautions for Working on High-Pressure Systems •

•

Remember that working hydraulic systems are always under pressure. If you have to add or drain hydraulic fluid, service or inspect the hydraulic system, lower the equipment to the ground and release system pressure and residual tank pressure before starting any work. Leaks from pressurized hydraulic lines are extremely dangerous since the spray from them can penetrate your skin and enter the bloodstream, or the eyes. Always wear thick gloves and protective glasses when working on the hydraulic systems Use a sheet of cardboard or plywood to search for leaks. If you are struck by a jet of hydraulic fluid under pressure, or if you are injured even slightly, consult a doctor immediately for appropriate treatment

Precautions for Maintenance Work Involving High Temperatures and Pressures When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system is still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns. Carry out maintenance procedures described in this manual only when the machine has had time to cool down.

Rotating Parts Take particular care near rotating parts. Keep your body at a safe distance. If hands, clothing, or tools become entangled in the fan blades or fan belt, severe injury may result. Keep well away from all rotating parts.

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Disposal of Waste Materials •

•

Never dump waste fluids in a sewer system, on the ground, in rivers, etc. Always drain fluids from your machine into the appropriate containers. Never drain fluids directly onto the ground. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil.

Inflating Tires Always bear in mind that tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions: • Before inflating tires, always check the wheel rims, tire walls and tread for cuts, broken cords, or other damage. Have a tire expert perform checks and tire maintenance. • When inflating tires, use a protective cage, and a compressed airgun with extension hose and pressure gauge. • Make sure there is nobody in the vicinity before starting to inflate a tire. Stand at the tread side of the tire to inflate it. • Never exceed the inflation pressures specified for each type of tire. Always check the tire pressures on both sides of the machine.

Hydraulic Environmental Ester Synthetic (HEES) Oil HEES is a synthetic, biodegradeable oil intended for use in the hydraulic system only. • Never use HEES in the engine, transmission, axle, braking system or mix HEES with organic hydraulic oil. Doing so could clog the hydraulic oil filter. When switching to HEES for the hydraulic system: 1. Drain the organic oil from the tank completely. Disconnect the hydraulic lines and drain the oil from the lines and the cylinders. 2.

Replace the hydraulic oil filter with a new one. Reconnect the hydraulic oil lines.

Fill the hydraulic oil tank with HEES type oil.

Start the engine and let it idle until the hydraulic oil reaches 40°C. Operate all the work equipment to fill the hydraulic circuits.

Stop the engine and check the hydraulic oil level. Add oil as needed.

After completing the conversion to HEES, change the hydraulic oil after 1000 hours of operation. Thereafter, change the hydraulic oil every 2000 hours of operation.

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SAFETY

MEMORANDUM

1-54

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2OPERATION

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2-1

OPERATION

SAFETY LOCKS

If it is necessary to stop the machine with the loader arm raised, always engage the mechanical loader arm support on the loader arm and lock the equipment and travel control by lifting the safety bars. See â&#x20AC;&#x153;Safety Barsâ&#x20AC;? on page 2-27.

Loader Arm Support

The loader arm support must always rest against the hydraulic cylinder rod. The loader arm support must be brought to its final position by moving the contact surfaces slowly and continuously, in such a way as not to damage the cylinder head surface. The loader arm is provided with a loader arm support b to be used to keep the arm raised when the machine is serviced or routine operations are carried out. The engagement of the loader arm support must be carried out by two people, one seated in the driving position to check the movements of the machine and the other standing on the ground to engage the support correctly. It is important to remember that under operating conditions the loader arm support b must be positioned against the arm and kept in this position by means of the safety pin c.

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OPERATION

After engaging the loader arm support b, hold it in position with the safety pin c. Do not perform any work under the raised loader arm if the loader arm support c is not in the locked position.

The safety bars d located in front of the operator seated in the driving position make it possible to lock the equipment and travel controls. See â&#x20AC;&#x153;Safety Barsâ&#x20AC;? on page 2-27 for the operation of the safety bars.

The safety guard e locks the optional equipment control pedal in the neutral position.

Rotate the locking lever clockwise to lock the equipment controls.

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2-3

OPERATION

Backhoe Locks

When traveling on roads, always position the backhoe following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment controls by shifting the safety device lever to the lock position. The backhoe safety locks must be used for traveling on roads and applied by proceeding as follows:

â&#x20AC;˘

2-4

After rolling back the bucket completely, apply the lock b between boom and arm, the connection lock c between boom and sliding plate, the center pin d that locks the sliding plate on the frame, raise the stabilizer supports completely and engage the relevant safety chains e.

SK1020-5N/SK1020-5NA

OPERATION â&#x20AC;˘

If the machine is equipped with rear stabilizers, raise the supports completely and engage the relevant safety chains f.

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2-5

OPERATION

Cold Planer Lock

When traveling on roads, always position the cold planer following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment controls by shifting the safety device lever to the locked position.

If the machine is equipped with a cold planer, it is also necessary to apply the lock b on the lifting jacks, in such a way as to keep the equipment at a fixed distance from the ground.

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OPERATION

GENERAL VIEWS Front View of Machine

1. 2. 3. 4.

Bucket Bucket Cylinder Wheels Lifting Cylinder

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5. 6. 7.

Frame Loader Arm Cab

2-7

OPERATION

Rear View of Machine

1. 2.

2-8

Rear Panel Engine Hood

Muffler

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OPERATION

Inside View of Cab

1. Safety bars 2. Left PPC control joystick ISO PATTERN SYSTEM - Travel and steering OPTIONAL PATTERN SYSTEM - Left wheel travel and loader arm control 3. Right PPC control joystick ISO PATTERN SYSTEM - Loader arm and bucket control OPTIONAL PATTERN SYSTEM - Right wheel travel and bucket control 4. Auxiliary hydraulic control pedal 5. Foot accelerator 6. Hand accelerator 7. Parking brake 8. Equipment control locking lever (if installed) 9. Dashboard

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2-9

OPERATION 10. Left console switches 11. Right console switches

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OPERATION

INSTRUMENTS AND CONTROLS Instruments

1. 2. 3.

Hour Meter Engine Coolant Temperature Indicator Fuel Level Indicator

Hour Meter This instrument indicates the total number of operating hours on the engine. The count is continuous and the number is increased by one when the engine has run for one hour, independently of its speed. When the engine is running, the LED (A) positioned under the instrument flashes and counts for every second. The hour meter keeps functioning even if the machine is not traveling or working. The reading of the hour meter is to be considered valid for the calculation of the maintenance intervals.

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2-11

OPERATION Engine Coolant Temperature Indicator This instrument indicates the temperature of the engine coolant, which under normal conditions, should be 80-85°C (176-185°F). After starting the engine and before starting work, let it warm up until the temperature indicator reaches the green range.

If the indicator exceeds the limit values while the engine is running and indicates overheating (which is the red range), let the engine idle until the indicator returns to the normal temperature (which is the green range). When the indicator indicates overheating, the audible alarm also sounds. Try to find the cause if this occurs repeatedly. See “TROUBLESHOOTING” on page 2-101.

Fuel Level Indicator This instrument indicates the fuel level in the tank; this information is available only with the starting key in position “I.” See “Starting Switch” on page 2-21. The green range indicates the normal fuel level, while the red range indicates a low fuel level (reserve). If the indicator reaches the reserve (red range) while the machine is working, stop and add fuel to the correct level.

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OPERATION

Indicator Lights

1. 2. 3. 4. 5. 6.

Alternator Warning Light Preheating Indicator Light Engine Oil Pressure Warning Light Air Cleaner Clogging Warning Light Hydraulic Oil Filter Clogging Warning Light Parking Brake Warning Light

7. 8. 9. 10. 11.

Speed Increase Indicator Light Floating Device Indicator Light Direction Indicator Light Working Light Indicator Light Safety Device Functionality Control Unit

Alternator Warning Light This warning light comes on when the starting circuit is energized and goes out when the engine exceeds idle speed; if this warning light remains on even when the engine is running at the normal operating speed, it means that the alternator is not charging and the battery is not charged correctly.

If the warning light remains off when the starting key is turned to position "I" it means that the alternator is faulty or broken.

SK1020-5N/SK1020-5NA

2-13

OPERATION Preheating Warning Light This warning light comes on when the starting key is turned to position to start the engine at low temperatures and goes out automatically after approximately 13 seconds. See â&#x20AC;&#x153;Starting in Cold Weather or in Cold Climatesâ&#x20AC;? on page 2-59.

Engine Oil Pressure Warning Light This warning light comes on and activates the audible alarm with the engine stopped when the starting circuit is energized and goes out as soon as the engine lubrication circuit is pressurized. If this warning light remains on or comes on with the engine running, stop the machine immediately and try to locate the trouble.

Air Cleaner Clogging Warning Light This warning light comes on when the engine air filter needs cleaning.

Hydraulic Oil Filter Clogging Warning Light This warning light comes on when the hydraulic circuit filter needs replacing.

2-14

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OPERATION Parking Brake Warning Light This warning light comes on when the parking brake circuit is not functioning properly. If this light comes on during normal operation, stop the machine and try to locate the trouble.

Speed Increase Indicator Light This light comes on when the high speed button on the left joystick is pressed. See “Speed Increase Control” on page 2-40.

Floating Device Indicator Light This light comes on when the floating device is selected. See “Floating Device Control” on page 2-40.

Direction Indicator Light (If Equipped) This warning light comes on intermittently when the lever on the dashboard is operated (see “Direction Indicator Switch (If Installed)” on page 2-21) or when the emergency switch is operated (see “Emergency (Hazard) Switch (If Installed)” on page 2-20).

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2-15

OPERATION Working Light Indicator Light This light comes on when the working lights are turned on with the switch on the right console. See â&#x20AC;&#x153;Working Light Switchâ&#x20AC;? on page 220.

Safety Device Functionality Control Unit This control unit is positioned on the dashboard and checks the condition of the safety devices installed on the machine. The signals are shown on the display by the coming on and going out of the warning lights. The functions are the following:

A - Red Warning Light LED off - This indicates that all the safety devices are on and therefore all the machine functions are normal (the solenoid valve ensures the lifting of the work equipment and the machine travel). LED on - This indicates that at least one safety function is lacking; in this case the solenoid valve is closed and does not permit the lifting and therefore the use of the work equipment and the machine travel.

B - Green Indicator Light LED on - This indicates that the operator is correctly seated in the driving position and that the operator seat switch sensor is on. LED off - (With the red warning light coming on at the same time) This indicates that the operator is standing or that he is not inside the cab.

2-16

SK1020-5N/SK1020-5NA

OPERATION

The operator seat switch sensor (in the seat) starts the emergency procedure after a delay of 1.5 seconds. All hydraulic functions are locked out and the parking brake is applied. To resume operation, the operator must sit in the driving position, lower the safety bars and press the parking brake push button on the left console. The delay allows the machine to be operated on uneven ground without signaling repeated emergencies. C - Green Indicator Light LED on - This indicates that the safety bars are down and the work equipment and the travel functions can be operated. LED off - (With the red warning light coming on at the same time) This indicates that the safety bars are not completely down and therefore the work equipment and the travel functions cannot be used.

The sounding of the audible alarm (buzzer) signals that the PPC valve coil is not functioning properly. This alarm sounds even with the engine stopped and the starting key removed from the starting switch. Take notice of the following conditions: A) Engine stops and the audible alarm sounds. Safety bars raised and temporary binding of the PPC solenoid valve. Lower the work equipment to the ground (see “Machine Controls” on page 2-25), get off the machine and try to locate the trouble. B) Audible alarm sounds with the engine off. PPC solenoid valve binding. Lower the work equipment to the ground (see “Machine Controls” on page 2-25), get off the machine and try to locate the trouble. When troubleshooting for extended periods of time, disconnect the negative cable (-) at the battery to avoid discharging it completely.

The green LEDs (seat and safety bar) come on only if the operator has engaged all the safety locks and released the parking brake (red LED on). The LEDs go out whenever the safety bar is lifted (servo controls off); to reactivate the servo controls, sit in the driving position, lower the safety bar and press the parking brake push button (green and red LED’s on).

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2-17

OPERATION

Switches and Push Buttons 1. Parking brake push button 2. Rotating beacon light switch (if installed) 3. Left stabilizer button (if installed) 4. Right stabilizer button (if installed)

5. Working light switch 6. Emergency (HAZARD) light switch (if installed) 7. Parking light and low beam switch 8. Direction indicator switch (if installed)

9. Starting switch

10. Horn 11. Super Flow (continuous forward) hydraulic push button for optional attachments (if installed)

2-18

SK1020-5N/SK1020-5NA

OPERATION 12. Super Flow (momentary reverse) hydraulic push button for optional attachments (if installed) 13. Speed increase button

14. Floating device button (if installed) 15. Operates electrohydraulic functions of optional attachments (if installed)

Parking Brake Push Button

The parking brake is automatically engaged whenever the engine stops; this is due to the lack of pressure in the hydraulic circuit. The push button releases the brake only when the engine is running and all the safety devices are engaged (warning lights off).

If pressed, this switch engages the parking brake. If pressed again, it disengages the brake, thus releasing the machine.

Rotating Beacon Light Switch (If Equipped) This switch turns on the rotating beacon and must be operated when necessary to travel on roads.

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2-19

OPERATION Left Stabilizer Button (If Installed) This is a button with three positions: forward, center and back. Press the button forward or backward to lower or raise the stabilizer. The center position turns the left stabilizer off. See “Left Stabilizer Control” on page 2-43 for use.

Right Stabilizer Button (If Installed) This is a button with three positions: forward, center and back. Press the button forward or backward to lower or raise the stabilizer. The center position turns the left stabilizer off. See “Right Stabilizer Control” on page 2-43 for use.

Working Light Switch Turns on the working lights.

Emergency (Hazard) Switch (If Installed) Operates all the direction lights at the same time and must be used whenever the machine is temporarily parked on the roadside or in an abnormal position while traveling on roads.

2-20

SK1020-5N/SK1020-5NA

OPERATION Parking Light and Low Beam Switch (If Installed) This is a two-position switch: The first click turns on the instrument lights and the parking lights. The second click turns on the low beam or working lights, according to the position of the switch.

Direction Indicator Switch (If Installed) This is a lever switch with three positions. The neutral position is in the center. Shift the switch lever to the right or to the left to indicate the turn direction.

Starting Switch This is a rotary key switch with four positions marked by the following symbols “ “ - }(OFF) - I - “ “ (START). See “Starting with a Warm Engine or in Warm Climates” on page 2-58 for further details on the use of this switch.

Horn This push button is located on the left joystick grip and gives an audible warning to persons in the vicinity of the machine when pushed by the operator at the beginning of work and in case of danger.

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2-21

OPERATION Front Equipment Super Flow Hydraulic System Momentary Switch (If Installed) This is a momentary switch and allows increased oil delivery from the hydraulic pump to flow in reverse only when it is pressed. See “Super Flow Hydraulic System Control (Five Lines)” on page 239 for use.

Front Equipment Super Flow Hydraulic System Continuous Switch (If Installed) This is a double-function switch and allows the oil delivery from the hydraulic pump to constantly flow forward. See “Super Flow Hydraulic System Control (Five Lines)” on page 239 for use.

Speed Increase Button This button is positioned on the underside of the left joystick grip and serves to increase the machine speed when pressed. See “Speed Increase Control” on page 2-40 for use.

Floating Device Switch This switch is positioned on the underside of the right joystick grip and, when pressed, enables the electrohydraulic circuit of the floating device. See “Floating Device Control” on page 2-40 for use.

2-22

SK1020-5N/SK1020-5NA

OPERATION Available for Other Functions The operator has the opportunity to use three push-button controls for electrohydraulic equipment with more than one function. For use, see “Optional Electrical Connections” on page 2-43. 1 - Audible alarm

2 - Electric outlet (if installed)

3 - Optional Master Electrical Disconnect Switch (if installed)

Audible Alarm This audible alarm sounds when the circuits are energized with the starting key (rotation to position “I”) and is automatically disengaged when the engine is started. The sounding of the alarm during operation signals: • insufficient engine oil pressure • overheating of the engine cooling circuit • malfunction of the PPC solenoid valve coil

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2-23

OPERATION 12V Electric Outlet An electric outlet is positioned on the right rear of the cab inner wall for the connection of a lighting device for routine and maintenance operations. It is a two-pole outlet and is in compliance with the ISO 4165-1979 standard. The power supply is 12 V.

Battery Disconnect Switch The battery disconnect switch, located next to the battery under the engine hood (see “Engine Hood” on page 2-48), is used for switching on or off power supply from the battery to the electrical systems of the machine. When the power supply to all the electrical systems is disconnected, stored data for clock time settings or radio channel selection may be lost. Keep the battery disconnect switch in the LOCK position except before: • Storing the machine for one or more months; • Repairing electrical systems; • Performing electric welding; • Handling batteries; or • Replacing fuses or fusible links. To disconnect, turn the machine’s starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch key to the UNLOCK (B) position, and take out the battery disconnect switch key. Cover the keyhole with the attached keyswitch cover. Never turn off the switch while the engine is running, otherwise, electrical systems may be damaged. Always rotate the switch off to UNLOCK (B) if it is necessary to work on the battery or the electrical system, or if electric welding must be carried out on the machine. The electrical connection can be restored by rotating the switch on counterclockwise to LOCK position (A).

2-24

SK1020-5N/SK1020-5NA

OPERATION

Machine Controls

1. Safety bars 2. Left PPC control joystick Travel and steering - ISO PATTERN SYSTEM Left wheel travel and loader arm control - OPTIONAL PATTERN SYSTEM 3. Right PPC control joystick Loader arm and bucket control - ISO PATTERN SYSTEM Right wheel travel and bucket control - OPTIONAL PATTERN SYSTEM 4. Auxiliary hydraulic kit control pedal 5. Foot accelerator 6. Hand accelerator 7. Parking brake 8. Equipment control locking lever (if installed) 9. Super Flow hydraulic system control (continuous forward) (if installed) 10. Speed increase control

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2-25

OPERATION 11. Floating device control

12. Pattern shifting control

13. Right stabilizer control (if installed) 14. Left stabilizer control (if installed)

15. Optional Attachment Electrical Connection control 16. Super Flow hydraulic system control (momentary reverse) (if installed)

2-26

SK1020-5N/SK1020-5NA

OPERATION Safety Bars

Before leaving the operatorâ&#x20AC;&#x2122;s seat, lower the equipment to the ground and rotate the safety bars to the vertical (unlocked) position. The safety devices on this machine are composed of electrical components. Before modifying or replacing any wiring or electrical components, which may result in malfunctions of the devices, contact your Komatsu distributor.

The locking of the PPC control safety device is performed by lifting the safety bars b to a vertical position. The safety device can be released by lowering the safety bars to the horizontal position and pressing the parking brake push button (warning light off).

Equipment movement and machine travel cannot be performed with the safety bars b in the locked, or vertical position.

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2-27

OPERATION

ISO Pattern Control System Left PPC Control Joystick (Travel and Steering)

Before carrying out any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened. Before any maneuver the operator must take all the precautions indicated in “Moving the Machine (ISO Pattern Control System)” on page 2-61 and “How to Move the Machine (Optional Pattern Control System)” on page 2-65.” Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged. When traveling on roads, make sure that all the safety devices have been engaged. Failure to comply with these rules may lead to serious accidents.

Always travel at moderate speed to obtain maximum precision and efficiency while working. While working, the movement of the joystick must be proportional to the required effort to obtain constant engine speed. Maneuver the joystick smoothly, without abrupt movements, and avoid counter rotations as much as possible, since these maneuvers result in rapid tire wear. The joystick grip is provided with the horn, which must be used to warn the persons in the vicinity of the machine at the beginning of work and in case of danger. All movement is cancelled by rotating the safety bars to the locked (vertical) position (see “Safety Bars” on page 2-27). The left PPC control joystick (2) controls the forward/reverse movements and the steering of the machine as indicated in the diagram below.

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SK1020-5N/SK1020-5NA

OPERATION N - Neutral A - Forward gear B - Counter rotation to the right C - Reverse gear D - Counter rotation to the left If the joystick is operated in directions that are inclined with respect to the machine axis, simultaneous steering movements proportional to the angle of inclination are obtained, since the two hydraulic pumps corresponding to each single function are engaged at the same time.

N - Neutral A - Forward left steering B - Forward right steering C - Reverse left steering D - Reverse right steering

Right PPC Control Joystick (Loader Arm and Bucket)

Before carrying out any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened and the safety bars in the unlocked (horizontal) position. Before any maneuver perform the operations described in “OPERATING THE WORK EQUIPMENT” on page 2-91.” When traveling on roads, always lock the equipment controls (see “Equipment Control Locking Lever (If Installed)” on page 2-37). Before leaving the operating position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine. Failure to comply with these instructions may lead to serious accidents.

The loader self-leveling system is operated automatically only when the loader arm is lifted with a loaded bucket. When the loader arm is in the lowering phase the system cannot be operated. At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material from falling out of the bucket.

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2-29

OPERATION The right PPC control joystick d controls the loader arm and bucket functions of the machine as indicated in the diagram below.

The bucket should never be rolled back more than 45Â° with the arm in the dump position. The following diagrams show the basic maneuvers and the possible combined maneuvers.

Basic Maneuvers N - Neutral A - Arm lowering B - Bucket dumping C - Arm lifting D - Bucket roll back

If the joystick is operated in directions that are inclined with respect to the machine axes, simultaneous movements proportional to the angle of inclination are obtained, since the two hydraulic distributors corresponding to each single function are engaged at the same time. N - Neutral A - Arm Lower - Bucket Roll Back B - Arm Lower - Bucket Dump C - Arm Raise - Bucket Dump D - Arm Raise - Bucket Roll Back

All movements are cancelled by shifting the safety bars to the locked (vertical) position.

2-30

SK1020-5N/SK1020-5NA

OPERATION

Optional Pattern Control System Left PPC Control Joystick (Left Wheel Travel, Steering, and Loader Arm Control)

Before carrying out any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened and the safety bars in the unlocked (horizontal) position; before any maneuver the operator must take all the precautions indicated, see “Moving the Machine (ISO Pattern Control System)” on page 2-61 or see “How to Move the Machine (Optional Pattern Control System)” on page 2-65 and see “OPERATING THE WORK EQUIPMENT” on page 2-91. Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged. When traveling on roads, always lock the equipment controls (see “Equipment Control Locking Lever (If Installed)” on page 2-37). When traveling on roads, make sure that all the safety devices have been engaged. Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine. Failure to comply with these instructions may lead to serious accidents.

The self-leveling system is operated automatically only when the loader arm is lifted with a loaded bucket. When the loader arm is in the lowering phase the system cannot be operated. At maximum height the self-leveling system keeps the bucket partially rolled back to prevent the material from spilling out of the bucket.

The left PPC control joystick c serves to control the forward and reverse movements, the steering of the machine to the right, and the loader arm raising and lowering functions according to the movements indicated in the diagram below.

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2-31

OPERATION

To move the machine forward or backward, move the control joysticks c and d at the same time and in the same direction.

N - Neutral A - Forward right steering B - Arm lowering C - Reverse right steering D - Arm lifting

Always travel at moderate speed to obtain maximum precision and efficiency while working. While working, the movement of the joystick must be proportional to the required effort to obtain constant engine speed. Maneuver the joystick smoothly, without abrupt movements and avoid counter rotations as much as possible since these maneuvers result in rapid tire wear. The joystick grip is provided with the horn, which must be used to warn persons in the vicinity of the machine at the beginning of work and in case of danger. All movements are cancelled by rotating the safety bars to the locked (vertical) position (see â&#x20AC;&#x153;Safety Barsâ&#x20AC;? on page 2-27).

2-32

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OPERATION Right PPC Control Joystick (Right Wheel Travel, Steering and Bucket Control)

Before carrying out any maneuver with this joystick, the operator must be seated in the work position with the seat belt fastened. Before every maneuver the operator must take all the precautions indicated: see “Moving the Machine (ISO Pattern Control System)” on page 2-61 and see “How to Move the Machine (Optional Pattern Control System)” on page 2-65 and see “OPERATING THE WORK EQUIPMENT” on page 291. Before moving, make sure that the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged. When traveling on roads, always lock the equipment control (see “Equipment Control Locking Lever (If Installed)” on page 2-37). When traveling on roads, make sure that all the safety devices have been engaged. Before leaving the work position, lower the equipment to the ground and lock the safety bars (vertical position), then stop the engine. Failure to comply with these rules may lead to serious accidents.

The right PPC control joystick c serves to control the forward and reverse movements, the steering of the machine to the left, the bucket roll back and dumping function, according to the movements indicated in the diagram below.

To move the machine forward or backward, shift the control joysticks c and d at the same time and in the same direction.

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2-33

OPERATION N - Neutral A - Forward left steering B - Bucket dumping C - Reverse left steering D - Bucket roll back

Always travel at moderate speed, to obtain maximum precision and maximum efficiency during work. During work, the use of the joystick must be proportional to the required effort to obtain constant engine speed. Move the joystick smoothly, without abrupt movements, and avoid counter rotations as much as possible since these maneuvers result in rapid tire wear. All movements are cancelled by rotating the safety bars to the locked (vertical) position (see â&#x20AC;&#x153;Safety Barsâ&#x20AC;? on page 2-27).

2-34

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OPERATION

Auxiliary Hydraulic Kit Control Pedal (If Installed)

Always engage the safety guard c when use of the control is not required, during travel and when parking the machine. When connecting a hydraulic attachment, make sure the control pedal b is always in the neutral or horizontal position and covered with the safety guard. Never set the control pedal to the maximum flow position unless the machine is stopped, the safety bar is in the raised position, and the operator is seated with the seat belt fastened.

The pedal b controls the starting and stopping of the oil flow to the attachment and has three fixed positions (left, neutral, and right).

To apply the pedal b, lift the safety guard c.

1 - Neutral or horizontal position (HYDRAULIC CIRCUIT CLOSED). No flow provided to the attachment.

2 - Depressed position (HYDRAULIC CIRCUIT OPEN). In the depressed position, continuous oil flow is supplied to the attachment (excavator, demolition hammer, asphalt cutter, etc.) and is obtained by pressing the pedal with the left part of the foot and locking in position with lever d. To release pedal b to the neutral, or horizontal position, push locking lever d forward to agree with illustration .

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2-35

OPERATION 3 - Two direction variable flow position. The pedal is also used to control the oil flow to attachments with two hydraulic circuits (multipurpose buckets, drills, asphalt cutters, etc.). Shift locking lever d to the locked (forward) position and press pedal b to position or to control the flow of oil to the attachment. The amount of flow in each direction is proportional to the distance the pedal is moved.

Foot Accelerator The accelerator pedal b is positioned on the operator’s right and serves to control the engine speed and power. Use the accelerator pedal with care, especially when the machine is under load or is working under difficult conditions. Avoid useless acceleration, to reduce fuel consumption and extend the life of both the engine and the machine.

Hand Accelerator

The use of the hand accelerator is allowed only under the indicated conditions; its use in other conditions may lead to accidents. The hand accelerator must be used during the warming up of the engine and successively when operations with the optional equipment are to be carried out; it can also be used for some maintenance operations. •

Idle position : Lever pushed completely forward.

•

Maximum speed position : Lever pulled completely backward.

2-36

SK1020-5N/SK1020-5NA

OPERATION Parking Brake

The parking brake must be applied whenever the operator leaves the driving position, even if for a short time. The machine must be positioned with the wheels resting firmly on the ground. If one of the wheels is unstable or is resting on a small obstacle, the machine may move. Periodically check the functionality of the parking brake. Failure to comply with these instructions may lead to serious accidents or even death. In case of failure of the hydraulic system, before the recovery of the machine, release the applied brake installed on the travel hydraulic motors (see â&#x20AC;&#x153;Releasing the Parking Brakeâ&#x20AC;? on page 3-25). The braking action is obtained by pressing the switch b (LED ON); the release is obtained by pressing the switch again (LED OFF).

The parking brake is automatically engaged whenever the engine stops; this is due to the lack of pressure in the hydraulic system. Every time the engine is started or restarted, it is necessary to release the parking brake before moving the machine.

Equipment Control Locking Lever (If Installed)

When traveling on roads, always lock the equipment controls. When shifted to the lock position, the lever prevents the equipment controls from being used. Before traveling on roads, always lock the equipment controls.

Rotate the lever clockwise to lock the controls and move it counterclockwise to unlock the controls.

SK1020-5N/SK1020-5NA

2-37

OPERATION Standard Flow Hydraulic System Control (Two Lines)

Never connect an attachment to the hydraulic lines before the attachment is mechanically installed and locked to the machine front coupler. Never connect an implement or tool (which is not coupled to the machine, i.e. hand hammer) to the hydraulic lines while the attachment is activated. Connect hydraulic lines only with the engine off and the parking brake engaged. Do not risk serious injury. Always operate the attachment from the operator’s seat. Do not allow other persons close to the machine or attachment. Read and understand the attachment Operator’s Manual regarding attachment control functions and operation. The oil flow, which is bidirectional, to the attachment is controlled by the pedal (see “Auxiliary Hydraulic Kit Control Pedal (If Installed)” on page 2-35) and is proportional to the distance the pedal is moved in either direction. The hydraulic lines are located on the left arm.

2-38

SK1020-5N/SK1020-5NA

OPERATION Super Flow Hydraulic System Control (Five Lines)

If the Super Flow button is in the ON position, the hydraulic flow will operate the attachment if the button is pressed. The Super Flow hydraulic controls can be used when the operator needs increased oil delivery in the attachments hydraulic system. With the “Super Flow” hydraulic system it is possible to use equipment that requires a high-flow hydraulic line (left) and, at the same time, a standard-flow hydraulic line (right) with limited oil flow for secondary functions (auxiliary hydraulic kit control pedal).

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2-39

OPERATION With the Super Flow hydraulic controls, the operator can utilize two independent hydraulic circuits (located on the right and left arms). With the Super Flow system, the standard flow lines are moved to the right arm. The amount of oil flow in the right hydraulic lines and the flow reversal are managed by means of the pedal (See “Auxiliary Hydraulic Kit Control Pedal (If Installed)” on page 2-35). Left side hydraulic lines are used only for the equipment requiring standard flow rates and controlled by push button b and push button c on the left joystick. To increase oil flow to the attachment, press push button c (red LED above the button on); press the button again to completely stop the oil flow (red LED off) through the hydraulic lines. To increase the oil flow and at the same time reverse it, press and hold push button b. Release push button b to restore normal operation.

Speed Increase Control The button b that allows the machine travel speed to be increased is positioned on the underside of the left joystick grip. When the button is pressed, the speed increases; push the button again to return to normal speed.

The speed increase function should be used only for the high speed repositioning of the machine; in any other case, it is advisable to use the normal speed. Do not use the speed increase control when performing steering or counter-rotation maneuvers.

Floating Device Control The right joystick grip is provided with a switch b that, when pressed, (INDICATING LIGHT ON) (see “Floating Device Indicator Light” on page 2-15) frees the loader arm (floating position), that is, allows it to automatically follow the undulations of the ground. Press the switch again to restore the standard operating conditions (INDICATING LIGHT OFF) (see “Floating Device Indicator Light” on page 2-15).

2-40

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OPERATION Pattern Shifting Control

Before using the pattern shifting control, lower the equipment to the ground, engage the safety devices and stop the engine. Failure to comply with these instructions may lead to serious injuries or even death. The pattern shifting control is located in the engine compartment on the rear wall of the cab and can be reached after opening the engine hood (see “Engine Hood” on page 2-48). The lever (1) of the pattern shifting control has two positions: • ISO CONTROL SYSTEM Lever in position A • OPTIONAL CONTROL SYSTEM Lever in position B

SK1020-5N/SK1020-5NA

2-41

OPERATION The control system selection lever b is held in the correct position by means of a safety screw c. When it is necessary to modify the control system, loosen the safety screw c until lever b can be moved. Use a 13 mm wrench or the factory supplied ring. Select the desired control system and lock the lever in place by tightening the safety screw c.

Before moving the machine, the operator must make sure that the selected control system is the one that is required.

The control panels d located on the sides of the central dashboard are lit from behind. The backlighting of the panels is helpful to the operator in identifying the type of control system selected (ISO PATTERN control or OPTION control).

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OPERATION Right Stabilizer Control

Before moving the machine in any way, make sure that the stabilizer feet are completely raised. Before traveling on roads, make sure that the safety locks of the stabilizer feet have been applied. The right stabilizer is operated by means of the button b installed on the left console and according to the indicated positions. 1. Press the button forward to lower the stabilizer foot. 2. Press the button backward to raise the stabilizer foot.

Left Stabilizer Control

Before moving the machine in any way, make sure that the stabilizer feet are completely raised. Before traveling on roads, make sure that the safety locks of the stabilizer feet have been applied. The left stabilizer is operated by means of the button b installed on the left console and according to the indicated positions. 1 - Press the button forward to lower the stabilizer foot. 2 - Press the button backward to raise the stabilizer foot.

Optional Electrical Connections The right three-button joystick is used when the operator needs to connect electro-hydraulic equipment with several functions. Each push button corresponds to an electric line activated by a pulse control: press the push button to activate the electric contact; release the push button to deactivate the contact. This feature is only available with the Super Flow Auxiliary Hydraulics.

SK1020-5N/SK1020-5NA

2-43

OPERATION

Fuses and Relays

When changing a fuse, turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch to the UNLOCK position, and take out the battery disconnect switch key. If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses having the same capacity. If the engine does not turn when the starting switch is turned to START, check the engine start fuse and if necessary change it.

Machine Function Fuses The fuses relevant to the machine functions are grouped on a single base positioned on the dashboard behind the seat.

Standard Version POSITION

COLOR

CAPACITY A

Violet

Left parking lights

Violet

Control panel lights, right parking lights

Light Blue

Horn, low beam, or front working lights

Brown

7.5

Switch lights

Light blue

Rear working lights

Red

Power supply for joystick switches, floating device, pattern shifting

Red

12V electrical outlet, revolving light

Red

Power supply for control panel, safety unit, solenoid valve stop, control bar sensor, seat sensor, brake switch

Brown

7.5

Back-up alarm

Brown

7.5

Fuel pump, safety relay (against repeated starting), alternator

Green

Solenoid pull relay, servo control safety pressure switch

2-44

CIRCUIT

SK1020-5N/SK1020-5NA

OPERATION Version with Optional Connections POSITION

COLOR

CAPACITY A

CIRCUIT

Violet

Left parking light, number plate light

Violet

Control panel lights, right parking lights

Light blue

Horn, low beam, or front working lights

Red

Switch lights, direction indicator lights

Light blue

Rear working lights, stop lights

Red

Power supply for joystick switches, floating device, pattern shifting

Red

12V electrical outlet, revolving light, emergency lights (HAZARD)

Red

Power supply for control panel, safety unit, solenoid valve stop, control bar sensor, seat sensor, brake switch

Brown

7.5

Back-up alarm, power supply for High-flow 3-way equipment hydraulic system, stabilizers, safety valves

Brown

7.5

Fuel pump, safety relay (against repeated starting), alternator

Green

Solenoid pull relay, servo control safety pressure switch

Main Fuse The main fuse b is positioned near the battery and can be reached by tilting the cab (see “Tilting the Cab” on page 2-51).

POSITION

COLOR

CAPACITY A

RED

SK1020-5N/SK1020-5NA

CIRCUIT SYSTEM GENERAL CIRCUIT

2-45

OPERATION Relays The relays are positioned inside the engine compartment and can be reached by tilting the cab. See â&#x20AC;&#x153;Tilting the Cabâ&#x20AC;? on page 2-51. Some relays are grouped inside the box attached to the right side of the machine frame and can be reached by removing the cover (A).

POSITION

DESCRIPTION

Engine stop relay

Safety relay (against repeated starting)

Other relays are contained inside the base installed on panel (B) behind the seat and can be reached by removing panel (B).

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OPERATION POSITION 3

POSITION 4

POSITION

DESCRIPTION Safety Unit

DESCRIPTION Relay board: A - Stop lights B - 1 way C - 3 way D - Momentary high-low E - 2 way F - Blinking G - Detent high-flow

DESCRIPTION

Stoplight relay

Floating device control relay

Parking brake relay

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OPERATION

GUARDS AND OPERATORâ&#x20AC;&#x2122;S SEAT Engine Hood

Do not open the engine hood when the engine is running. Do not use the machine without engine hood and do not start the engine when the hood is open unless this is expressly prescribed for certain maintenance operations. Failure to follow these rules may result in serious accidents.

Make sure that the safety retainer e is engaged every time you open the hood. OPENING THE HOOD After releasing the lock, press the push button b and raise the engine hood c. The maximum opening position is maintained by the lifting piston d, which is locked in position by the safety retainer e. CLOSING THE HOOD Press the safety retainer e of the lifting piston d and at the same time lower the hood. Push it downwards until the lock engages. Lock the hood.

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OPERATION

Rear Panel

Do not open the rear panel when the engine is running. Do not use the machine without the rear panel and do not start the engine with the panel open if this is not expressly prescribed for certain maintenance operations. Failure to follow these rules may lead to serious accidents.

The rear panel can be opened only after opening the engine hood. When inspecting or carrying out a maintenance operation inside the rear panel, always engage the panel in the safety retainer to keep it open. To reach the release lever c for the rear panel b, raise the engine hood (see â&#x20AC;&#x153;Engine Hoodâ&#x20AC;? on page 2-48). To open the rear cover b, lift the lever c positioned on the inner left side of the machine, at the same time rotate the cover to the maximum opening position and hold it open with retainer d, by proceeding as follows: 1. 2.

Lift retainer d and rotate it clockwise until it rests against the rear cover b. Release retainer d and make sure that it has been engaged correctly.

To close the rear cover b, release retainer d, rotate it counterclockwise and make it rest against the rear cover b.

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OPERATION

Cab

The cab is a combined ROPS-FOPS. Do not modify the ROPS-FOPS. See “Precautions for ROPS” on page 1-30. If it is subjected to an impact for any reason, or if the machine overturns, contact your distributor, who will ensure the operator’s safety. For maintenance or routine operations, the cab must be tilted. Carry out this operation according to the procedure described in section “Tilting the Cab” on page 2-51 and adhere to all safety precautions indicated therein. The cab is the semi-closed type. The windows are positioned on the rear and upper part and the rear window can be removed. In a special request version of the machine, the cab can be completely closed through the addition of side windows and front door.

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OPERATION Tilting the Cab

Tilt the cab only with the machine parked on a firm and level surface and with the loader arm lowered to the ground complete with bucket or any other optional equipment. Make sure that the surface on which the machine is parked is not slippery. Before tilting the cab, make sure that the engine hood is open. The cab must be raised or lowered by two people, one per side and it is important to make sure that the handles and hold points are not dirty with oil or grease. After tilting the cab, always engage the safety split pin of the cab overturning protection lock. Do not carry out any operation on the machine if the safety split pin of the cab overturning protection lock is not engaged. Always tighten the cab fastening screws to the torque indicated in “Specific Torques” on page 3-19.

To carry out some maintenance or routine operations, it is necessary to tilt the cab, an operation that must be carried out by two people according to the following procedure: 1. Stop the machine on firm and level ground. 2. Lower the equipment to the ground. 3. Apply the parking brake and lock the controls by rotating the safety bars to the lock (vertical) position. 4. Stop the engine as indicated in “STOPPING THE ENGINE” on page 2-84. 5. Open the engine hood (see “Engine Hood” on page 2-48) and remove the rear screws b that fasten the cab to the frame. Use a 19 mm hexagon wrench. Remark Do not loosen bolt A when tilting cab. 6. With the help of another person, raise the rear part of the cab using the appropriate handles and pull it forward until it stops. Engage the safety split pin c of the cab overturning protection lock d.

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OPERATION

When lowering the cab, be careful of the hold points and carry out the operation with the help of another person.

Remove the safety split pin c of the cab overturning protection lock d and put it in the appropriate seat e.

Lower the rear of the cab until it touches the support surface.

Reassemble the fastening screws b and tighten them to the torque indicated in paragraph “Specific Torques” on page 3-19 and close the engine hood (see “Engine Hood” on page 2-48).

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OPERATION Standard Seat The seat can be adjusted longitudinally and the operator can choose the driving position that is most suitable for his physique.

The longitudinal adjustment of the seat is obtained by operating the lever b and making the seat slide on the guides; once the desired position has been found, release the lever and carry out slight movements, in order to make sure that the lock pin is engaged in its seat.

Suspension Seat This seat is extremely comfortable, offering four adjustment options: 1 - longitudinal adjustment; 2 - back inclination adjustment; 3 - adjustment of the suspension, aimed at dampening the inevitable vibrations and jerks as much as possible; 4 - seat cushion inclination adjustment. The operator can choose the driving position that is most suitable for his physique. The longitudinal adjustment of the seat is obtained by operating the lever b and making the seat slide on the guides; once the desired position has been found, release the lever and carry out slight movements, in order to make sure that the lock pin is engaged in its seat. The back adjustment is achieved by operating the lever c; operate the lever and try to find the position that is most suitable for the operatorâ&#x20AC;&#x2122;s physical structure. Three different degrees of inclination are possible. The adjustment of the suspension is carried out with the lever d, according to the operatorâ&#x20AC;&#x2122;s weight. The suspension can be stiffened or lightened according to the operatorâ&#x20AC;&#x2122;s needs; adjust the seat suspension by positioning the lever d in one of the five seats available for this purpose. Shift the lever to the left to stiffen the suspension or to the right to lighten it. The inclination of the seat cushion is obtained by operating the lever e and positioning the front part of the cushion at the same time; it is possible to select two different positions.

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OPERATION Seat Belt

Before starting the engine, fasten the seat belt. The seat belt must be changed when it is frayed, damaged or worn and in any case every four years. The seat belt b is of the type with two coupling points and adjustable length c; it must be well tightened and hold the operatorâ&#x20AC;&#x2122;s hips, while leaving the upper part of his body completely free.

Emergency Exit The machine is provided with an emergency exit located in the rear window b. In case of emergency, pull the plate c positioned on the upper side of the window and remove the weather strip completely. Push the window toward the outside.

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OPERATION Technical Documentation Case

The Operation and Maintenance Manual and the Parts Book are integral parts of the machine and must accompany it even in case of resale.

The Operation and Maintenance Manual must be handled with care and kept aboard the machine so it can be easily consulted at any time. Put the manual in the technical documentation case located inside the cab on the left side where the ownership documents and the logbook are usually kept.

Fire Extinguisher

The machineâ&#x20AC;&#x2122;s owner must provide for installing and mounting the fire extinguisher where prescribed. Periodically make sure that the fire extinguisher is full. The fire extinguisher b must be installed by the owner of the machine and positioned inside the cab on the left side behind the left console.

First Aid Kit

Periodically make sure that the first aid kit contains the necessary disinfectants, bandages, medicine, etc. and check their condition and expiration dates. Replace as necessary.

The first aid kit must be installed by the owner of the machine and positioned inside the cab on the right side behind the right console.

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OPERATION

OPERATING THE MACHINE Checks Before Starting the Engine Visual Checks

Dirt, oil, and fuel in the engine compartment near its hot parts may damage the machine and even cause fires. Check frequently and eliminate any leakage; if leakages occur repeatedly, contact your distributor.

Before starting the engine, check around and under the machine to verify: 1. If there are loose screws or nuts 2. If there are oil, fuel, or coolant leaks 3. The wear of the work equipment 4. The fastening of the electrical connections 5. The fastening of the engine exhaust pipe and manifold 6. The conditions of the rims and the wear of the tires 7. If the safety and warning plates are sufficiently clean 8. If the ladders and the handles for access to the operatorâ&#x20AC;&#x2122;s seat are clean Any leak or abnormality must immediately be repaired and any trace of oil or grease must be removed. Further visual checks concern: 9. The condition of the seat belt 10. The efficiency of the instruments and of the dashboard 11. The condition of the cab windows and the efficiency of the lights, working lights and direction indicators

Daily Checks

To prevent fires, do not smoke during fuel and oil filling and do not use open flames or non-approved lighting to check the fuel and oil levels. If fuel, oil, or lubricants are spilled while filling the tanks, clean the spills immediately.

Before starting any operation, check the engine coolant, engine oil, and hydraulic circuit oil levels. At the end of work, refuel to avoid the formation of condensation, always checking the fuel level on the indicator provided on the dashboard.

Avoid filling the fuel tank completely to leave room for the fuel to expand. After filling the tank, put back the filler cap making sure that the bleed hole is completely open. Check the engine oil level with the machine level and the hydraulic circuit oil level with the front bucket resting on the ground.

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OPERATION Operational Checks

All the checks must be carried out by the operator while seated, with the seat belt fastened. When the machine is at rest after use or maintenance, some safety locks may not be engaged; when the operator gets into the cab, he must make sure that all the mechanical safety locks are engaged and that the equipment cannot move suddenly and create dangerous situations. The checks concern: 1. The locking of the safety bars 2. The hand accelerator idle position 3. The neutral position of the controls 4. The application of the parking brake The following check is carried out by turning the starting key to position â&#x20AC;&#x153;Iâ&#x20AC;? to apply voltage to the control panel and check the functionality of the audible alarm, of the fuel level indicator, and of the engine oil pressure, alternator, and preheating, warning lights.

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OPERATION

Starting the Engine

Before starting the engine, carefully read the instructions and information regarding safety given in this manual and make sure that you know the controls. From the moment in which the engine is started, the operator is directly responsible for any damage that may be caused by wrong maneuvers and non-compliance with the safety regulations and the rules of the road. Before starting the engine, make sure that there is no one within the operating radius of the machine and sound the horn.

Starting with a Warm Engine or in Warm Climates 1.

Turn the starting key directly to position “ “ (START).

As soon as the engine starts, release the starting key, which will automatically return to position “I.”

If the engine does not start within 15 seconds, release the key, which will automatically return to position “I” and wait 30 seconds before trying again.

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OPERATION Starting in Cold Weather or in Cold Climates

Do not use any starting fluids or ether to assist in starting an an engine in cold weather. These products may cause an explosion, damaging the engine or causing injury. 1.

2. 3.

Pull the accelerator lever until reaching half of its stroke and turn the starting key to the preheating position “ “ for a maximum of 13 seconds in the coldest weather. Preheating is indicated by the warning light located on the dashboard. Turn the starting key to position “ “ (START) until the engine starts or for a maximum of 15 seconds. As soon as the engine starts, release the starting key, which will automatically return to position “I” and reduce the engine speed to idle.

If the engine does not start on the first attempt, repeat steps 1 and 2 after waiting for at least one minute, to not overload the battery.

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OPERATION

Warming the Engine 1. 2.

After starting the engine, let it warm up before starting work. The ideal warming up of the engine is achieved with a constant speed obtained with the hand accelerator.

Do not use full throttle or accelerate abruptly until the coolant temperature has reached at least 60°C (140° F). 3. 4.

To reduce the time necessary to warm up the engine, move the hand accelerator lever now and then to the midpoint of its travel. During the warming up of the engine, check the color of the exhaust gases and verify if abnormal noises or vibrations can be noticed; any problem must be verified and its cause must be eliminated.

Heating the Hydraulic Oil When warming up the engine, especially in cold weather, it is advisable to also heat the hydraulic system oil. For this reason, when the coolant temperature has reached approximately 60°C (140°F), proceed as follows: 1. Release the safety device of the controls by rotating the safety bars and releasing the park brake. See “Safety Bars” on page 2-27. 2. Slowly extend and retract the lift and bucket cylinders completely several times. 3. Lower the bucket to the ground and lock the safety device again by rotating the safety bars (see “Safety Bars” on page 227).

Hydraulic Oil Travel Circuit Warm-up

Always warm-up the travel circuit oil when the machine has been parked, stored or idled at 0°C (32°F) or below. Do not operate the machine while the travel circuit oil is being warmed up. Do not risk serious injury or property damage. When the machine has been parked or stored at 0°C (32°F) or below since the date of last use or idled for a prolonged period of time at or below such temperatures, always follow the instructions below to ensure proper warming of the oil in the hydrostatic travel circuit. 1. Start engine and warm-up engine and the hydraulic oil as per the Operation and Maintenance Manual. Remark The filter bypass warning light should be off before continuing. 2. Place travel control in High Gear or Rabbit Speed.

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OPERATION 3. 4. 5.

Release and then reapply the park brake switch one time. This will activate the travel circuit allowing oil to circulate. With the parking brake applied, hold the drive PPC control in the full forward position (over relief) for four to six minutes. In a clear and open area, drive the machine in a normal manner Forward and Reverse for 6 to 8 m (20 to 25 ft) for a minimum of two minutes or until braking controls operate normally. Reminder: Repeat the warm-up procedure if the machine has been parked or stored since its last use at or below 0Â°C (32Â°F).

Moving the Machine (ISO Pattern Control System)

Before moving the machine, make sure that you are completely familiar with all control functions and all relevant safety regulations. The operator must be seated in the driving position with seat belt fastened. Before moving the machine, check the position of the rearview mirrors and make sure that there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area. Be extremely careful when engaging reverse and make sure there are no people, work equipment or obstacles in the way. Avoid maneuvers or changes of direction when traveling at full speed, since the maneuvers carried out under these conditions cause abrupt machine movements. Do not use the speed increase function when changing direction or carrying out a counter-rotation. The use of the speed increase function is allowed only for fast transfers of the machine. Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety device of the controls is released (safety bars down) and the bucket is rolled back; the equipment control joystick must be in neutral position. Release the parking brake.

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OPERATION 1.

Pull the hand accelerator lever and set the engine to the desired travel speed.

Operate the joystick b, shifting it forward to make the machine advance or backward to make it move in reverse.

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OPERATION Steering (Changing Direction)

If possible, avoid any abrupt change of direction. Counter-rotations should be carried out with the machine running at moderate speed. When traveling on roads, avoid carrying out counter-rotations, since they may create dangerous situations; carry out counter-rotations only during work cycles.

CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING To turn to the LEFT, operate the travel joystick as indicated in the diagram. To move FORWARD, push the joystick to the left with 45째 inclination. To move BACKWARD, pull the joystick to the right with 45째 inclination.

To turn to the RIGHT, operate the travel joystick as indicated in the diagram. To move FORWARD, push the joystick to the right with 45째 inclination. To move BACKWARD, pull the joystick to the left with 45째 inclination.

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OPERATION CHANGING DIRECTION WHEN THE MACHINE IS MOVING To turn to the LEFT, rotate the travel joystick counterclockwise by approximately 45째.

To turn to the RIGHT, rotate the travel joystick clockwise by approximately 45째.

HOW TO CARRY OUT A COUNTER ROTATION (with the machine not moving) To turn to the LEFT, shift the travel joystick to the left with an angle of 90째 with respect to the longitudinal axis.

To turn to the RIGHT, shift the travel joystick to the right with an angle of 90째 with respect to the longitudinal axis.

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OPERATION

How to Move the Machine (Optional Pattern Control System)

Before moving the machine, make sure that you know the control functions and all the relevant safety regulations perfectly. The operator must be seated in the driving position with seat belt fastened and the safety bars lowered. Before moving the machine, check the position of the rearview mirrors and make sure that there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area. Be extremely careful when engaging reverse and make sure that there are no people, work equipment or obstacles in the way. Avoid maneuvers or changes of direction when traveling at full speed, since the maneuvers carried out under these conditions cause abrupt machine movements. Do not use the speed increase function when changing direction or carrying out a counter-rotation. The use of the speed increase function is allowed only for fast transfers of the machine.

Before moving the machine, check the instruments, warm up the engine and the hydraulic system oil, make sure that the safety device of the controls is released (safety bars down) and the bucket is rolled back; the equipment control joysticks must be in neutral position. Release the parking brake. 1.

Pull the hand accelerator lever and set the engine at the desired travel speed.

Operate the joysticks b and c at the same time, shifting them forward or backward to move the machine.

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OPERATION Steering (Changing Direction)

If possible, avoid any abrupt change of direction. Counter rotations should be carried out with the machine running at moderate speed. When traveling on roads, avoid carrying out counter rotations, since they may create dangerous situations; carry out counter rotations only during work cycles.

CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING To turn to the LEFT, operate the right joystick by proceeding as follows: to move FORWARD, push the joystick; to move BACKWARD, pull the joystick.

To turn to the RIGHT, operate the left joystick by proceeding as follows: to move FORWARD, push the joystick; to move BACKWARD, pull the joystick.

CHANGING DIRECTION WHEN THE MACHINE IS MOVING (THE TWO JOYSTICKS ARE IN THE SAME POSITION) To turn to the LEFT, shift the left joystick to the NEUTRAL position (N): the machine will turn to the LEFT.

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OPERATION To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N): the machine will turn to the RIGHT.

HOW TO CARRY OUT A COUNTER-ROTATION (WITH THE MACHINE NOT MOVING) To turn to the LEFT, pull the left joystick backward and push the right joystick forward.

To turn to the RIGHT, pull the right joystick backward and push the left joystick forward.

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OPERATION

Hand and Foot Control System Machine Controls

The controls represented in the figures and not described in this section remain unchanged and are the same present on the standard version. For details on how to use them, see “Machine Controls” on page 225.

Left PPC control joystick HAND & FOOT CONTROL SYSTEM (Left wheel travel) Right PPC control joystick HAND & FOOT CONTROL SYSTEM (Right wheel travel and auxiliary hydraulic control) Left foot operated hydraulic control HAND & FOOT CONTROL SYSTEM (Loader arm raising and lowering control) Right foot operated hydraulic control HAND & FOOT CONTROL SYSTEM (Bucket dumping and roll back control)

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OPERATION

Travel and Steering Control Joysticks

Before carrying out any machine movements with these joysticks, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any machine movement the operator must take all the precautions (see “How to Move the Machine (Hand and Foot Control System)” on page 2-77). Before moving, make sure the safety bars are in the horizontal (unlocked) position and the parking brake is disengaged. When traveling on roads, always lock the equipment controls (“Equipment Control Locking Lever (If Installed)” on page 2-37). When traveling on roads, always make sure all safety devices have been engaged. Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the locked (vertical) position, then stop the engine. Failure to follow these rules may lead to serious accidents.

The travel control joysticks b and c are positioned on the operator's left and right side, respectively, and control the forward and reverse travel of the machine according to the movements shown in the diagram.

To move the machine forward or in reverse, shift the joysticks b and c at the same time and in the same direction. For further details on the use of the joysticks see “How to Move the Machine (Hand and Foot Control System)” on page 2-77.

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OPERATION N - Neutral A - Forward B - Reverse

The right PPC control joystick c is used to control the right wheels and also to control the auxiliary hydraulic circuit according to the movements indicated in the following diagram: N -Neutral A -Right wheel forward travel B -Right wheel reverse travel C -Oil delivery from the male coupling of the auxiliary hydraulic circuit D -Oil delivery from the female coupling of the auxiliary hydraulic circuit For details on the use of the auxiliary hydraulic control, see “Auxiliary Hydraulic Control Joystick” on page 2-74.

Always travel with the engine running at moderate speed to obtain maximum precision and productivity while working. While working, use of the joysticks must be proportional to the effort required to maintain a constant engine speed. Operate the joysticks smoothly, without abrupt movements and avoid counter-rotations as much as possible, since this type of machine movement causes rapid tire wear. Remark The horn d is positioned on the grip of the left joystick b and must be used to warn all the people in the vicinity before starting work and in case of danger. All movements can be stopped by rotating the safety bars to the vertical (locked) position. See “Safety Bars” on page 2-27.

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OPERATION Work Equipment Control Pedals (Loader Arm and Bucket)

Before carrying out any machine movement with these pedals, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position; before any machine movement the operator must take all the precautions (see “How to Move the Machine (Hand and Foot Control System)” on page 2-77. When traveling on roads, always lock the equipment controls (see “Equipment Control Locking Lever (If Installed)” on page 2-37). Before leaving the work position, lower the equipment to the ground and rotate the safety bars to the lock (vertical) position, then stop the engine. Failure to follow these rules may lead to serious accidents.

The self-leveling system is automatically operated only when the loader arm is lifted with a full bucket. When the arm is being lowered, the self-leveling system does not engage. At maximum height, the self-leveling system keeps the bucket partially rolled back to prevent material from being spilled.

The control pedals b and c are positioned on the floorboard in front of the operator seat and control the movements of the loader arm and the bucket.

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OPERATION The pedal b, positioned on the operator's left, controls the raising and lowering of the loader arm, as indicated in the following diagram:

N - Neutral A - Loader arm raise B - Loader arm lower

On machines provided with a floating device, press the pedal to position B (lower loader arm) and press the switch positioned under the right joystick. See â&#x20AC;&#x153;Machine Controlsâ&#x20AC;? on page 2-68.

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OPERATION The pedal c, positioned on the operator's right, controls the roll back and dumping of the bucket, as indicated in the following diagram:

N - Neutral A - Bucket roll back B - Bucket dumping

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OPERATION Auxiliary Hydraulic Control Joystick

Before carrying out any machine movements with this joystick, the operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position. The control joystick b is positioned on the operator's right and controls the movement of the right wheels and the auxiliary hydraulic circuit, according to the movements indicated on the plate c and in the following diagram:

N - Neutral A - Right wheel forward travel B - Right wheel reverse travel C - Oil delivery from the male coupling d of the auxiliary hydraulic circuit D - Oil delivery from the female coupling e of the auxiliary hydraulic circuit

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OPERATION The auxiliary hydraulic control starts and stops the oil flow to any optional equipment and has four positions (neutral, left, right and detent position). 1.

Neutral position (N) (CLOSED HYDRAULIC CIRCUIT) No oil flow to the optional equipment.

Positions (C) and (D) (OPEN HYDRAULIC CIRCUIT) These positions are used to control optional equipment with bidirectional oil flow (multi-purpose bucket, drill, asphalt cutter, etc.). Move the joystick b to position (C) to deliver oil from the male coupling d positioned on the left side of the loader arm, or to position (D) to deliver oil from the female coupling e.

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OPERATION 3.

Detent position (E) (OPEN HYDRAULIC CIRCUIT) This position is used to obtain a continuous unidirectional oil flow for the operation of equipment such as excavator, demolition hammer, sweeper, etc. To hold the joystick b in the detent position (E), move the joystick further to the left.

The joystick b remains in detent position (E) only with a pressurized hydraulic system. When the joystick b is in position (E), pressurized oil is delivered from the male coupling d, with return through the female coupling e.

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OPERATION How to Move the Machine (Hand and Foot Control System)

Before moving the machine, make sure that you are completely familiar with the control functions and all relevant safety regulations. The operator must be seated in the work position with seat belt fastened and the safety bars in the unlocked (horizontal) position. Before moving the machine, check the position of the rearview mirrors (if installed) and make sure there is no one within the operating radius of the machine and that there are no obstacles in the surrounding area. Be extremely careful when shifting into reverse and make sure that there are no people, work equipment or obstacles in the way. Avoid any travel maneuver or change of direction with the accelerator at maximum speed, since maneuvers carried out under these conditions may cause dangerous machine movements. Do not use the speed increase function when changing direction or carrying out a counter-rotation. The speed increase function must be used only for traveling at high speed. Check the instruments and warm up the engine and the hydraulic system oil before moving the machine. Make sure that the safety bars are lowered to the horizontal (unlocked) position and that the bucket is rolled back; the equipment control pedals must be in neutral position. At this point, release the parking brake. 1.

Set the manual accelerator lever to the desired travel speed.

Move the joysticks b and c forward or backward at the same time to move the machine.

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OPERATION Steering (Changing Direction)

Avoid abrupt changes of direction as much as possible. Carry out counter-rotations at moderate speed. Avoid carrying out counter-rotations when traveling on roads, since these maneuvers may cause dangerous situations; make counter-rotations only during work. Do not use the speed increase function when changing direction or carrying out a counter-rotation.

Changing Direction with Machine at Rest To turn to the LEFT, use the right joystick as follows: To move FORWARD, push the joystick. To move BACKWARD, pull the joystick.

To turn to the RIGHT, use the left joystick as follows: To move FORWARD, push the joystick. To move BACKWARD, pull the joystick.

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OPERATION Changing Direction with Machine in Motion (the two joysticks are shifted to the same position) To turn to the LEFT, shift the left joystick to the NEUTRAL position (N) and the machine will turn to the LEFT.

To turn to the RIGHT, shift the right joystick to the NEUTRAL position (N) and the machine will turn to the RIGHT.

How to Perform a Counter-rotation with Machine at Rest To perform a counter-rotation to the LEFT, pull the left joystick backward and push the right joystick forward.

To perform a counter-rotation to the RIGHT, pull the right joystick backward and push the left joystick forward.

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OPERATION Moving on Slopes

Before working on slopes, always check the functionality of the parking brake. Always go up or down slopes at moderate speed and with the heavier end of the loader always directed towards the top of the slope. When going up or down slopes, keep the equipment lowered; movements with the arm raised may cause the machine to overturn. Do not use the speed increase function when the machine travels on slopes. When working on slopes the following precautions should be taken to avoid risks for the operator and anyone in the vicinity; the checks and operations to be carried out are the following: 1. Always check the work area for snow, landslides, gravel, loose ground and anything that may suddenly modify the work conditions and the stability of the machine. 2. When it is necessary to travel downhill, the front bucket must always be directed downward, in transport position. 3. When loading or traveling uphill, the front bucket must always be directed upward. 4. When moving the machine during work cycles, always lower the bucket. 5. Carry out any lateral movement on a flat surface at the beginning or at the end of the slope; if this is not possible, move at an angle, keeping the machine axis as parallel to the slope direction as possible. Do not move at too great an angle or, even worse, with the machine axis rotated by 90Â° with respect to the slope direction.

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OPERATION Maximum Immersion Depth

If it is necessary to work with the machine immersed in water on river banks or sea shores, always check the water depth and the current flow. Make sure that the surface on which you are working is sufficiently firm.

If it is necessary to work with the machine immersed in water, make sure that the maximum depth does not exceed 24 cm and in any case that the engine cooling fan does not touch the water, since it may get damaged or even break.

When working in water or on muddy ground, lubricate the articulated joints more frequently than usual. After work, remove any dirt or mud and lubricate the articulated joints.

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2-81

OPERATION

PARKING THE MACHINE Parking on Level Ground

Park the machine on firm and flat ground, in a sufficiently wide space, so that the checks, daily lubrication and refueling can be carried out without problems. Lower the work equipment to the ground. Engage all safety locks and apply parking brake. Keep to all the safety rules to avoid any movement of the machine when the operator is absent. When leaving the machine, remove the starting key. 1. 2. 3.

4. 5. 6. 7. 8. 9.

Park the machine on firm and flat ground in a sufficiently wide space. Lower the bucket to the ground. Lock the equipment and travel hydraulic control by shifting the safety bars to the lock position (vertical) (see “Safety Bars” on page 2-27). Engage the safety guard to lock the optional equipment control pedal. Apply the parking brake. Stop the engine following the procedure indicated in paragraph (see “STOPPING THE ENGINE” on page 2-84). Remove the starting key. Leave the cab using the handles and the footboards. Refuel taking the necessary precautions.

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OPERATION

Parking on Slopes

The movement of the machine when the operator is not on board may cause serious accidents or even death; to prevent this, carry out the operations described below. Park on slopes only when it is absolutely unavoidable. Park only with the front bucket directed downwards. 1.

3. 4. 5. 6. 7. 8. 9.

Park the machine with the bucket directed downwards and resting against an obstacle. If this is not possible due to the absence of natural obstacles, rotate the bucket to the dump position and thrust the teeth into the ground. Lock the equipment and travel hydraulic controls by rotating the safety bars to the lock (vertical) position (see “Safety Bars” on page 2-27). Engage the safety guard to lock the optional equipment control pedal. Apply the parking brake. Stop the engine following the procedure indicated, see “STOPPING THE ENGINE” on page 2-84. Remove the starting key. Leave the cab using the handles and footboards. Put wedges under the wheels. Refuel taking the necessary precautions.

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2-83

OPERATION

STOPPING THE ENGINE

The sudden stop of the engine while it is running shortens its life. Do not stop it suddenly except in case of an emergency. It is also recommended not to stop the engine suddenly if it has been running for a long period and is still hot. In this case, let the engine idle at a minimum speed of 1200 rpm for about five minutes to allow it to cool down gradually before stopping. Before stopping the engine, proceed as follows: 1. Rest the work equipment on the ground. 2. Shift the joysticks to the neutral position and engage the safety devices. 3. Move the hand accelerator lever to the idle position. Stop the engine by turning the starting key to position â&#x20AC;&#x153;Oâ&#x20AC;? (OFF).

2-84

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OPERATION

TRANSPORTING THE MACHINE Loading and Unloading

The loading and unloading of the machine must be carried out on a flat surface and at a safe distance from the edges of ditches or from the road side. Block the transport vehicle by positioning wedges in front of and behind each wheel. Make sure that the ramps are sufficiently strong; if necessary, reinforce them with blocks to prevent any dangerous bending. Make sure the ramps are the same length, firmly anchored to the motor vehicle, parallel to each other and perpendicular to the loading board; the distance between the ramps must be suitable for the machine gauge. Position the ramps with a maximum inclination of 15Â°. Remove any trace of oil, grease or ice from the ramps and the loading board. Do not change direction when the machine is already on the ramps; if necessary, go down and find the correct direction. 1.

2. 3. 4. 5. 6. 7.

The machine, with empty bucket or without optional accessories, must move on the ramps with the bucket b at the back and raised above the ground. Once the machine has been loaded, lower the work equipment to the bed and rotate the safety bars to the lock (vertical) position. Apply the parking brake. Stop the engine and remove the starting key. Keep the machine in position also by putting wedges c in front of and behind each wheel. Attach the machine with tie downs or chains d in the tie down hooks f and g. Cover the end of the exhaust pipe e.

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2-85

OPERATION

Transport 1. 2.

Check the overall dimensions; the height, width and weight of the means of transport - machine included. It must be compatible with the road and any tunnel, subway, bridge, electric or telephone line that may be found on the way. Observe all regulations regarding signals, speed limits, road traffic, permits, etc.

HOW TO LIFT THE MACHINE

Use cables of adequate strength to lift the machine. Do not use worn cables or cables with broken strands. Do not lift the machine with the operator on board and make sure that no one is approaching the machine before lifting it. Before lifting the machine, make sure the eye bolts are correctly attached to the cab roof.

The owner of the machine is responsible for installing the eyebolts correctly on the cab roof. Use only eyebolts approved by Komatsu for this specific type of machine. Torque to 80 N•m (59 lbf ft). Approved eyebolts must be requested from your Komatsu distributor, specifying the machine model and serial number. Lifting of skid steer machines must be done in accordance shown. An improper lifting rig will cause damage to the ROPS structure. To lift the machine, proceed as follows: 1. Park the machine on a flat level surface and lower the loader arm to the ground. Shut off the engine and cycle the controls to remove any residual hydraulic pressure from the work equipment circuits. 2. Turn the parking brake switch on and the block the wheels. 3. Remove the key from the starting switch until the repairs are complete. Place a tag on the steering controls advising “Do Not Operate” indicating that this machine is being repaired. It should not be started or moved for any reason until the tag is removed by the person doing the repairs.

Observe all safety and precautionary standards as dictated by the work conditions under which the equipment will be inspected, reworked and repaired. Consult the Shop Manual and your Komatsu distributor with any and all questions regarding safety.

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OPERATION Remark Have only an experienced welder carry out the welding. The drawing shows the welding groove size and fillet welding leg length by the carbon dioxide gas arc welding. After finishing the welding, apply caulking on the modified section to prevent rust in the area.

Front Lifting Eye 1.

Position the front lift eyes e and rotate inboard 37Â°.

Secure with the mounting hardware f and g keeping the lifting eyes around 37Â°. (New decal c position, if not already present.)

Install the stoppers d to the rear. (Old decal should be removed if still present.)

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2-87

OPERATION

Rear Lifting Eye

1. 1.

Position the rear lift eye b to dimensions shown, clamp and weld in place. (Position the new kit decal c here if not already present.)

Lifting the Machine 1. 2.

Insert chains or nylon ropes in the two front eye bolts on the cab roof and attach with the appropriate retainers or safety pins. Assemble the chains or nylon ropes in the two couplings on the rear shoulders of the frame.

Always use the four attaching points provided for the lifting of the machine. 3.

Lift slowly until the chains or ropes are tensioned and make sure that the machine is hooked correctly before lifting it off the ground. Avoid jerks and abrupt directional changes during the lift.

When lifting the machine, make sure that it is correctly balanced and that it can be lifted level. Do not lift the machine with optional equipment installed on it.

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OPERATION

COLD WEATHER PRECAUTIONS During cold weather or in areas where the temperature is particularly low, especially during the night, it is necessary to take some countermeasures meant to limit the damage resulting from low temperatures.

Fuel and Lubricants 1. 2.

Change the fuel and use winter fuel ASTM D975N.1 when the ambient temperature is below -10°C (14°F). Change the engine oil for an oil of suitable viscosity. For the relevant specifications, see “FUEL, COOLANT AND LUBRICANTS” on page 3-6.

Coolant

The coolant containing antifreeze is flammable; do not smoke and do not use open flames when checking and preparing the mixture. Do not use methanol-, ethanol- or propanol-based antifreezes. 1. 2. 3. 4. 5. 6.

Use only permanent, ethylene glycol-based antifreeze, with corrosion inhibitors and antifoam products. The antifreeze to water ratio must be 1:1 (50% antifreeze and 50% water). Do not use plugging additives, either alone or added to the antifreeze, to eliminate leakage. Do not mix antifreezes of different brands. The use of permanent antifreeze requires only the checking of the level and the periodic changing of the fluid. It is not necessary to wash the coolant system. The required standards for the permanent antifreeze are SAE-J1034 and FEDERAL STANDARD O-A-548D. In case of doubt regarding the compliance of the antifreeze used with the standards, contact the manufacturer and ask for precise information.

Hydraulic Oil Travel Circuit Warm-up

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OPERATION 3. 4. 5.

Battery

Keep sparks and open flames away from the battery to avoid explosions due to the presence of gas. The battery electrolyte is dangerous. If it comes in contact with the eyes or skin, immediately rinse with plenty of water and consult a doctor without delay. 1.

When the ambient temperature decreases, the battery capacity decreases accordingly and, if the battery charge is low, the electrolyte may freeze. Keep the battery completely charged and insulate it to protect it from low temperatures, so the machine can be started without problems the following day. Measure the specific gravity of the fluid and check the battery charge percentage in comparison to the following table: FLUID TEMPERATURE

CHARGE% 20°C (68°F) 0°C(32°F) -10°C(14°F) -20°C(-4°F)

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

To prevent the fluid from freezing, add distilled water in the morning, before starting work.

Other Precautions 1.

Before using the machine in normal operating conditions, carry out some slow movements either forward or in reverse, and operate all the work equipment cylinders slowly more than once. These operations serve to warm up and decrease the viscosity of the oil in the hydraulic circuit and the transmission.

Precautions at the End of Work 1. 2. 3. 4.

Completely remove mud and water from the machine body. Park the machine on firm ground; if the machine must be parked near banks or ditches, park it on wooden boards to distribute the weight of the machine over a larger area. Be careful of water drops forming on the hydraulic cylinder rods. These drops must be completely removed, since if they freeze the cylinder seals may be damaged. After removing the water drops, protect the rods with oil. Drain any condensation that may have formed in the fuel tank to prevent the water from freezing overnight. Since the battery capacity may decrease considerably at low temperatures, after work cover the battery or remove it and store it at a suitable temperature.

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OPERATION

WARM WEATHER PRECAUTIONS 1.

At the end of the cold weather, change the lubricants, the coolant and the fuel.

The engine coolant must be changed only if it is not permanent. See “FUEL, COOLANT AND LUBRICANTS” on page 3-6. 2. 3. 4.

Make sure the cooling fan belt is in good condition. Make sure that the fins of the radiator and of the heat exchanger are clean. Check the radiator cap gasket and spring; in case of doubt regarding tightness and setting, change the cap.

OPERATING THE WORK EQUIPMENT

Always fasten the seat belt. Before moving the equipment, make sure that there is no one standing in the work area. Carry out all the possible movements and make sure that the control joysticks operate correctly. If visibility is insufficient, proceed at low speed and ask the assistance of another person. Always warn the persons present in the work site, even if they are authorized, by means of the horn. The basic illustrations shown are those necessary for the proper use and utilization of the machine. The operator must get to know the controls, the prescribed operating method, and learn how to organize work in an open area, while seated in the driving position.

Lowering the Equipment in Case of Machine Failure

Carry out the operations while seated in the work position with the seat belt fastened. After lowering the equipment to the ground, move the control joysticks more than once to release any residual pressure. If the machine should suddenly stop with the work equipment raised due to a mechanical or hydraulic failure, the operator must lower the equipment to the ground before leaving the machine to locate the trouble. Make sure that the safety bars are lowered (open hydraulic circuit), turn the starting key to position “I” and lower the bucket to the ground by shifting the equipment control joystick; only limited movements are possible.

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OPERATION

Organizing the Work Area If, after a first inspection, the area appears to be uneven, encumbered with big obstacles or characterized by considerable height differences, it is advisable to level the ground as much as possible, before starting work, for the benefit of the loader and the vehicles to be loaded. This preliminary operation will make work quicker, ensure better results, and at the same time reduce the operatorâ&#x20AC;&#x2122;s stress and the straining of the machine components; furthermore, this will considerably reduce the time necessary to load the trucks destined for the transport of the material. To obtain the best performance from the machine it is necessary to synchronize the movements of the equipment with the traveling movements, by operating the joysticks smoothly and without jerks. The changes of direction must be carried out correctly with ample steering radii. Short steering radii or counter rotations involve useless efforts of the machine and rapid tire wear.

Loading Heaped and Level Material The efficiency of the bucket depends on how the operator starts loading; proceed as follows: 1. Start moving with the arm completely lowered and direct the bucket towards the base of the pile. 2. While the upper material falls down filling the bucket, raise the arms gradually and at the same time roll the bucket to the end of its stroke.

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OPERATION 3.

Reverse the motion of the machine and dump the bucket into the truck.

Start loading the truck from the cab side and, if the material is sufficiently mixed, dump from the maximum height to increase the compaction of the material and its distribution on the loading platform. 4.

After removing the pile completely, incline the bucket forward, lower the arm until the front wheels are slightly raised and, moving in reverse, level the ground distributing the material uniformly. Repeat the operation reducing the inclination of the bucket for the finishing work.

Loading Operations on Slopes

Travel uphill with the bucket directed forward; the same rule must be followed when loading. Travel downhill in reverse with the loader directed forward and bucket lowered. Move, changing direction very slowly, with the bucket as low as possible. Avoid any transverse position with respect to the slope direction. Sudden movements of the bucket and dangerous positions may cause the machine to overturn and lead to serious accidents or even death.

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OPERATION

Digging Method 1. 2.

At the beginning of work, keep the bucket at the correct penetration angle. Once the desired digging depth has been reached, position the bucket with its back parallel to bottom of the excavation and then start filling. During the collection phase, move the bucket and arm simultaneously. Combined movements facilitate the filling of the bucket and therefore increase productivity. The removal depth must be correct and suitable for the type of ground; an excessive digging depth may cause the locking of the movements due to the overloading of the engine and pump, and therefore slow down the digging operations. To dump material from piles, unload the bucket as soon as it gets near the dumping area; the inertia resulting from the movement will ensure the compaction of the material with no need to use the bucket for this purpose, which avoids impacts and vibrations that facilitate the wear of pins and bushings. The correct method is illustrated in pictures b, c, and d.

CORRECT The bucket starts digging with a slight penetration angle.

INCORRECT If the penetration angle is too wide, the bucket is thrust downwards, slowing the digging work.

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OPERATION

Changing the Bucket or Attachment with Standard Quick Coupler

• Stop the machine on a firm and level surface and lower the bucket or attachment to the ground. • Before leaving the machine, stop the engine, release the residual hydraulic pressures by operating the equipment control joystick more than once in all directions and raise the safety bars to the locked position. • Clean the upper and lower mounting areas of the bucket or attachment of all dirt and debris before mounting or releasing it to or from the quick coupler. • Before starting work, make sure the quick coupler locking pins are completely engaged in, and protruding from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are pushed down to a horizontal (locking) position. • After locking the equipment and before starting work, make sure that the locking pins are correctly engaged and the length of the protruding portion of the pins is in compliance with the prescribed safety values, see “Checking the Position of the Locking Pins” on page 2-98. Keep the levers lubricated and free of dirt and debris. Lubricate the coupling pins and keep the area around the pins free of dirt and debris.

Do not use your fingers to align the holes, since your fingers may be injured or cut in the event of the loader bucket or attachment suddenly moving. The loader is designed in such a way as to permit the installation of various types of buckets or attachments. To ensure their quick and comfortable change, a special universal coupler is provided with the machine which permits the release or installation of the bucket or attachment via a spring loaded over-center lever and pin latching system that secures the machine coupler to an attachment or bucket. Locking the Bucket or Attachment Rotate the levers b down to a horizontal position facing the center of the bucket or attachment c. Unlocking the Bucket or Attachment Rotate the levers b completely upward to a vertical position.

For Non-Komatsu attachments, read the manufacturer’s instruction manual before installing any attachment. Refer to the Komatsu Skid Steer Attachment Directory for a single source of work site application choices of attachments.

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2-95

OPERATION Removing the Bucket or Attachment

AVOID INJURY Perform all operations with the bucket or attachment at ground level. 1. 2. 3. 4. 5.

Lower the arm completely and rest the bucket on the ground in a horizontal position. Stop the engine, release any residual hydraulic pressures, raise the safety bars to the locked position and leave the operatorâ&#x20AC;&#x2122;s seat. Pull both lock levers b completely upward to a vertical position to disengage coupling pins c. Return to the operatorâ&#x20AC;&#x2122;s seat, fasten the seat belt, lower the safety bar, start the engine and release the brake. Rotate the coupler d forward allowing the bucket or attachment retaining lip e to slide off the top edge of the coupler.

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OPERATION Installing the Bucket or Attachment

Do not use your fingers to align the holes, since they may become stuck or even cut in case of sudden or uncontrolled movements. 1.

Make sure that levers b are in a vertical position and that coupling pins c are completely retracted.

Incline the top of coupler d forward and slowly approach the bucket e or attachment until the top edge of the coupler is completely under the top flange of the bucket e or attachment. Make sure you center the coupler with the bucket or attachment. Tilt the coupler backward until the cutting edge of the bucket or attachment is slightly off the ground.

4. 5. 6.

Roll back the bucket or attachment completely. Stop the engine, release the residual hydraulic pressures, raise the safety bars to the locked position and leave the operatorâ&#x20AC;&#x2122;s seat. Lock the bucket or attachment to the coupler by rotating levers b toward the center of the bucket or attachment to a horizontal position.

Before moving the machine, make sure that the locking pins c are completely engaged in the tabs provided on the bucket or attachment. To confirm engagement, tilt the bucket or attachment down and apply downward pressure. Back up the machine to make sure there is no movement between the bucket or attachment and the coupler.

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2-97

OPERATION Checking the Position of the Locking Pins The position of the coupler locking pins b must be checked with the levers in the locked or horizontal position. The length of the protruding part of the pins must be in compliance with the specified values, as indicated in the figure. To check the locking pin protrusion: 1. Slowly raise the arm. 2. Roll the bucket or attachment forward until the pin protrusion can be seen from the operator’s seat.

If the length b does not appear within the specified range, adjust it by proceeding as indicated in “Adjusting the Locking Pins” on page 2-99.

Coupler locking pins must extend through the holes in the bucket or attachment. Levers must be fully down and locked. Failure to secure the locking pins can allow the bucket or attachment to come off and may cause serious injury or death.

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SK1020-5N/SK1020-5NA

OPERATION Adjusting the Locking Pins The pin adjustment must be carried out with the bucket flat on the ground and the levers b of the quick coupler in a horizontal or locked position and proceeding as indicated below: 1. Check the protrusion of the locking pins per â&#x20AC;&#x153;Checking the Position of the Locking Pinsâ&#x20AC;? on page 2-98. 2. Loosen lock nut d. 3. Adjust nut c until the specified dimension is reached. 4. Tighten lock nut d against adjusting nut c to maintain the specified dimension.

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2-99

OPERATION

Long Periods of Inactivity Before the Period of Inactivity

When draining the fuel, do not smoke or bring exposed flames near the machine. Place a container under the machine to gather the fuel and prevent it from spreading around. If some fuel is spilled, clean the dirty surface immediately. To protect the cylinder rods when the machine is not used, position the work equipment as shown. This serves to prevent the cylinder rods from rusting.

If the machine must be stored for a long period of inactivity, it is advisable to put it in a sheltered place and to take the following precautions, to keep all its components sound and efficient: 1. Clean the machine thoroughly, repainting it where necessary to prevent oxidation. 2. Drain and replace all the hydraulic circuit fluids and the lubricants, axles, reduction gears, converter and engine, keeping to the rules indicated in the section regarding maintenance. 3. Change all the filtering elements, air cleaner, engine oil filter, hydraulic circuit filters, diesel oil filter. 4. Change the coolant to permanent type coolant. 5. Drain the normal fuel and fill the tank with at least 5 l of special washing and protecting fuel. 6. Let the engine run for about ten minutes, in such a way as to eliminate the remaining normal fuel from the filters, the injection pump and the entire fuel supply system. This operation avoids the locking of the injection pump and the injectors. Stop the engine and refuel with normal diesel oil. 7. Turn the starting switch to the OFF position. Wait over one minute. Then turn the battery disconnect switch to the UNLOCK position, take out the battery disconnect switch key and cover the keyswitch with the protective cap. Remove the battery, check the electrolyte level and make sure that the battery charge is sufficient. Store the battery in a room with suitable temperature and periodically recharge it. 8. Grease the hydraulic cylinder rods and the equipment joints. 9. Seal the end of the exhaust pipe. 10. Move the machine controls to the neutral position and engage all the safety locks. 11. Hang a warning notice on the controls to indicate the condition of the machine. 12. Lock the engine hood. Remark When the battery gets switched off, power supply to all the electrical systems is disconnected and stored data for clock time settings or radio channel selection will be lost.

During the Period of Inactivity

If it is necessary to carry out a rust prevention treatment while the machine is kept indoors, open doors and windows to increase ventilation and avoid poisoning by gas.

Start the engine and move the machine for a short distance once a month, so a new oil film covers all the moving parts and the surfaces of the components. Provide also for charging the battery.

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OPERATION After the Period of Inactivity

If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your distributor.

When using the machine after a long period of inactivity, proceed as follows: 1. Remove the seals from the exhaust pipe and the fuel tank. 2. Check all the fluid levels: engine oil, coolant, fuel, hydraulic circuit oil. 3. Make sure that the battery charge is sufficient and install the battery and turn the battery disconnect switch to the LOCK position. 4. Disconnect the engine stop solenoid. 5. Turn the starting key directly to the start position and keep it there until the engine oil pressure warning light goes out. This operation serves to start the circulation of the lubricating oil and to carry out a first lubrication cycle. 6. Reconnect the stop solenoid valve and start the engine. 7. Run the engine at idle for about 20 minutes. 8. While the engine is warming up, remove the protection grease from the hydraulic cylinder rods. 9. Before moving the machine, make sure that the instruments, the warning lights, working lights work properly. 10. Warm up the hydraulic cylinders, by slowly moving all the work equipment as soon as possible.

TROUBLESHOOTING How to Move the Machine

When moving the machine, use a wire rope suitable for the weight of the machine to be removed. If the machine gets stuck in mud and cannot get out using only its motive power, or in case of breakdown, use a wire rope as shown in the figure at right.

In case of failure of the hydraulic circuit, before moving the machine release the applied parking brake installed on the rear axle, see “Releasing the Parking Brake” on page 3-25.

Fuel is Completely Depleted Before starting the engine, when the fuel has run out and therefore air has entered the fuel supply circuit, it is necessary to bleed the fuel supply circuit. For the necessary operations, see “Maintenance Every 500 Hours of Operation” on page 3-41.

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OPERATION

Discharged Battery

When checking or carrying out any operation on the battery, stop the engine and make sure that the starting switch is in OFF position, wait one minute, then turn the battery disconnect switch to the UNLOCK position and take out the battery disconnect switch key and cover with protective cap. When working on the battery, always wear safety glasses and rubber gloves. It is dangerous to charge a battery when mounted on a machine. Remove the battery before charging. Disconnect the ground cable (-) first when removing the battery. When installing the battery, connect the positive cable (+) first. The battery produces hydrogen, which may explode. Do not use open flames and do not smoke near the battery, and avoid producing sparks. The battery electrolyte is made of diluted sulfuric acid that may corrode clothes and even skin. In case of contact with this fluid, immediately rinse the involved area with plenty of water. If the acid gets into the eyes, immediately rinse with plenty of water and consult a doctor without delay. If a tool comes into contact with the positive terminal and the machine structure at the same time, this may generate sparks with consequent risk of explosion. If the terminals are loose, there is a danger that the defective contact could generate sparks that may cause an explosion. Lock levers and parking brakes are to be in the LOCK position. Check that control levers and transmission are in the NEUTRAL position.

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OPERATION Charging the Battery If the battery is not handled correctly when charging, there is a danger that the battery may explode. Always follow the warnings and instructions provided here and see “BATTERY” on page 1-43 in addition to the instruction manual accompanying the charger. It is dangerous to charge a battery when mounted on a machine. Remove the battery before charging. When working with the battery, first turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch to the UNLOCK position, and take out the battery disconnect switch key. Cover the switch keyhole with the attached protective cap. • • • • • •

Do not use or charge the battery if the battery electrolyte level is below the MIN level line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the MAX level line. Set the voltage of the charger to match the voltage of the battery to be charged. If the correct voltage is not selected, the charger may overheat and cause an explosion. Connect the positive (+) charger clip to the positive (+) terminal of the battery, then connect the negative (-) charger clip to the negative (-) terminal of the battery. Be sure to attach the clips securely. Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set it to less than the rated battery capacity. If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and explode. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a danger that this will ignite the battery electrolyte and cause the battery to explode.

Starting the Engine with Jumper Cables

• Do not allow contact between the positive (+) and negative (-) terminals when connecting the cables. • Wear safety glasses and rubber gloves when working with the battery. • Do not allow contact between the working machine and the problem machine. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen gas explodes, it could cause serious damage and injury. • Be careful not to make a mistake when connecting a jumper cable. In the last connection (to the upper structure frame), a spark could result; connect the cable to a spot far away from the battery. (Avoid the work equipment, however, because it is not a good conductor.) • When removing the jumper cable, exercise good care so that the jumper cable clips do not contact each other or the chassis. • • • • •

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a danger that this will ignite the battery electrolyte and cause the battery to explode. Do not use or jump the battery if the battery electrolyte level is below the MIN level line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the MAX level line. Connecting the jumper cables incorrectly may cause the battery to explode. Follow the warnings and directions carefully. When starting the engine with the aid of another machine, connect the batteries in parallel. When connecting the cables, avoid any contact between the positive cable (+) and the negative cable (-). The machine with the good battery must have the same battery voltage of the machine with the bad battery. The cables and clips must be suitable for the current load that must be transferred and are not damaged or corroded. Make sure the clips hold the terminals securely.

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OPERATION Connecting the Cables and Starting the Engine L

Set lock lever to LOCK position regardless of whether the machine is working normally or has failed. Check that all the control levers and transmission are in the neutral position. 1.

2. 3. 4. 5. 6.

In the machine with the bad battery, turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch to the UNLOCK position and remove the battery disconnect switch key and cover keyswitch with protective cap. Connect the positive poles (+) of the two batteries with each other A. Connect the cable of the negative terminal (-) of the charged battery to the frame of the machine to be started B. Start the engine of the machine with the good battery and increase its speed. Turn the battery disconnect switch of the bad battery to the LOCK position. Start the engine of the machine with the bad battery, see â&#x20AC;&#x153;Starting with a Warm Engine or in Warm Climatesâ&#x20AC;? on page 2-58.

Removing the Cables When the engine has started, remove the cables in reverse order of the connection process. 1. Disconnect the negative cable (-) from the frame of the problem machine that has been started and then from the battery B. 2. Disconnect the positive cable (+) first from the good battery used for the starting and then from the bad battery A.

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OPERATION

Other Troubles ✩ Always contact your distributor when you have to carry out this operation. ★ If the anomaly or its cause are not included in the failures indicated below, contact your distributor for the necessary repair.

Electrical Circuit TROUBLE

CAUSE

REMEDY ★ Check and repair any loose termi-

Lights do not work satisfactorily even with engine running at high speed

• Faulty cables

Lights come on intermittently with engine running

• Faulty fan belt tension

✩ Adjust fan tension, see EVERY 250 HOURS

Alternator charge warning light does not go out with engine running and increasing speed

• Faulty alternator • Faulty cables

★ Change ★ Check and repair

Alternator emits an abnormal noise

• Faulty alternator

★ Change

Starter does not turn with key in START position

• • • •

★ Check and repair

Starter pinion engages and then disengages

• Battery charge insufficient

✩ Charge or replace battery

Starter makes engine turn slowly

• Battery charge insufficient • Faulty starter

★ Change

nal and connection

Faulty cables Battery charge insufficient Faulty main fuse Battery disconnect switch is in the UNLOCK position

✩ Charge or replace battery ✩ Change ✩ Turn the switch to the LOCK position

✩ Charge or replace battery

Starter disengages before engine has started

• Faulty cables • Battery charge insufficient

★ Check and repair

Engine oil pressure warning light does not come on when engine is stopped, starting key in “I” position

• Faulty bulb • Faulty pressure sensor

★ Change ★ Change

Alternator charge warning light does not come on when engine is stopped, starting key in “I” position

• Faulty bulb • Faulty cables

★ Change ★ Check and repair

SK1020-5N/SK1020-5NA

✩ Charge or replace battery

2-105

OPERATION Hydraulic System TROUBLE

CAUSE

REMEDY

Pump emits an abnormal noise

• No oil in the tank • Faulty pump • Hydraulic oil unsuitable for the temperature

✩ Top off ★ Repair or change ✩ Change oil

Equipment moves only at low speed

• Faulty pump • Max. pressure valves out of rating or not closed due to impurities • Dirty drain filter

★ Repair or change ★ Calibrate or change

2-106

✩ Change

SK1020-5N/SK1020-5NA

OPERATION Engine TROUBLE

CAUSE

REMEDY

Oil pressure warning light remains on even with engine at high speed

• Oil level in oil pan too low • Oil filter clogged • Oil unsuitable for the season

✩ Top off ✩ Change filter ✩ Change

Steam comes out of radiator breather pipe

• Fluid level low, fluid leakage • Fan belt slackened • Mud or limestone accumulated in cooling system • Radiator fins damaged or closed • Faulty thermostat • Radiator cap loose or broken (Working at considerable altitude)

✩ Top off, repair ✩ Check and adjust belt tension ✩ Change fluid and clean cooling system ✩ Repair or clean ★ Change ✩ Tighten cap or change unit

Temperature indicator always on the right end of the scale

• Faulty temperature indicator

★ Change

Temperature indicator pointer always on the left end of the scale

• Faulty thermostat • Faulty indicator

★ Change ★ Change

Engine does not start with starter running

• No fuel • Air in fuel system • Compression defect, valves with wrong clearance

✩ Refuel ✩ Bleed system ★ Adjust valve clearance

Exhaust gases white or light blue

• Too much oil in oil pan • Unsuitable fuel

✩ Correct oil level ✩ Change with suitable fuel

Exhaust gases occasionally tend to be black

• Air cleaner clogged • Faulty injectors • Faulty compression

★ Change ★ Adjust valve clearance

Combustion noise occasionally makes a breathing sound

• Faulty injectors

★ Change

Abnormal noises, during combustion or in mechanical parts

• Fuel with low cetane rating

✩ Change to fuel compliant with standards ✩ See defects of temperature indicator ★ Change ★ Adjust valve clearance

Engine coolant temperature indicator reaches overheating (red) range

• Overheating • Muffler insides damaged • Excessive valve clearance

SK1020-5N/SK1020-5NA

✩ Clean or change

2-107

OPERATION Hydrostatic Transmission

TROUBLE

CAUSE

REMEDY

Machine moves neither forward, nor backward

• • • • • •

Oil level insufficient Suction filter clogged Faulty flexible coupling Max. pressure valves faulty or dirty Positioning hydraulic connection interrupted Travel motor faulty

✩ Top off ✩ Change ★ Change coupling ★ Clean or change valves ★ Restore connection ★ Repair or change

Machine moves with delay Abnormal noise

• • • • • •

Oil level too low Presence of foam Suction pipe tightness Suction filter clogged Fuel supply max. pressure valve faulty Travel motor faulty

✩ Top off ✩ Use the recommended oil ★ Check and eliminate leakage ✩ Change ★ Disassemble clean or change ★ Repair or change

Traction force in the two travel directions is insufficient

• Engine does not reach max. speed

★ Change diesel oil filter and

• Auxiliary fuel pump (gear pump) faulty • Max. pressure valve setting incorrect • Connection to servo control faulty lever angle incorrect • Pressure relief valve setting incorrect • Excessive oil temperature

★ Repair or change ★ Set ★ Restore connection shift lever

check injection pump

• Travel motor faulty

to correct position

★ Set ✩ Check oil level and clean exchanger ★ Repair or change

Traction force is insufficient in one direction only

• Engine strongly overloaded • Incorrect setting of the max. pressure valve relevant to that direction

✩ Reduce loads due to lifting ★ Set valve

Oil overheating

• Oil level too low • Exchanger clogged or dirty

✩ Top off ★ Check and change if necessary ★ Use the recommended oil ★ Check and eliminate leakage ★ Check setting - repair or change ★ Repair or change ★ Set valve ★ Repair or change

• Unsuitable oil • Suction pipe tightness • Setting and operation of the max. pressure valves • Travel pump faulty • Pressure relief valve with high setting • Travel motor faulty

2-108

SK1020-5N/SK1020-5NA

OPERATION

TROUBLE

CAUSE Suction filter clogged Engine does not reach max. speed Auxiliary pump (gear pump) faulty Pilot pressure insufficient Pressure relief valve setting incorrect

REMEDY ✩ Change ★ Change diesel oil filter and check injection pump ★ Check delivery, repair or change ★ Set ★ Set to rated value

Machine does not reach max. speed selected

• • • • •

Machine decelerates intermittently

• Mechanical connection with servo control lever too hard

★ Check if rotation is smooth

Machine accelerates slowly

• Engine power drop

★ Check clogging of diesel oil filter,

• Pressure relief valve setting incorrect

★ Set to rated value

• Sealing rings faulty • Counterpressure in pump casing • By-pass valve setting too high

★ Change ★ Drain pipes clogged or damaged ★ Check and restore

injection pump and valves

Oil leakage from engine propeller shaft and/or pump

SK1020-5N/SK1020-5NA

2-109

OPERATION

MEMORANDUM

2-110

SK1020-5N/SK1020-5NA

3MAINTENANCE

SK1020-5N/SK1020-5NA

3-1

MAINTENANCE

GUIDE TO MAINTENANCE • • • • •

•

• •

•

Before opening the engine hood, engage safety locks and stop the engine. If it is necessary to check the hydraulic oil level in the reservoir, lower the arm and rest the bucket on the ground. See “SAFETY LOCKS” on page 2-2. Carry out any operation on firm and level ground after applying the parking brake. Raise the cab taking all the precautions indicated in “Tilting the Cab” on page 2-51. Use genuine Komatsu oils and greases suitable for the ambient temperature. Use clean oils and greases and keep the oil and grease containers clean. Keep any foreign matter away from oils and greases. Always keep the machine clean. This makes it easier to locate any parts causing problems. Keep the grease fittings, the breathers, and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into or on them. Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least 40 to 50°C (104-122°F) before draining hot liquids. After changing the oil or the filters, check if metal particles are present. If you find large quantities of metal particles, contact your distributor. Check and change the oil in clean locations and prevent any impurities from getting into the tank and/or container. Before carrying out any maintenance operation, hang the warning plates on the starting switch and control levers to prevent anyone from starting the engine by mistake. When performing maintenance operations, always take the precautions indicated on safety decals applied to the machine. Instructions for arc welding: 1. Turn starting key to the OFF position. Wait one minute or more, then turn the battery disconnect switch to the UNLOCK position, remove the battery disconnect switch key and cover the keyswitch with the protective cap. 2. Disconnect the battery; first, negative (-) pole and then positive (+) pole. Disconnect the alternator. 3. Do not apply more than 200V continuously. 4. Connect the ground cable within 1 m from the point on which welding will take place. 5. Avoid placing gaskets and bearings between the welding area and ground cable. Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids. When O-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all O-rings and gaskets with new ones. Fit the O-rings and gaskets correctly when reassembling. Avoid keeping loose objects or tools in your pockets. They may fall out and drop into the machine, especially when you open covers and work on the machine while bending over it. When washing the machine, do not direct high-pressure water jet onto the radiator and heat exchanger. When washing the machine, protect electric system connectors and avoid getting the starting switch wet. Before starting work in mud, in rain, on seashores, or river banks perform general lubrication. Wash the machine immediately after work to protect components from rust. Lubricate equipment joints more frequently than usual. When working at dusty work sites, proceed as follows: 1. Check the air cleaner for any clogging and clean it more frequently than usual. 2. Clean the radiator and the heat exchanger frequently to avoid any clogging of the fins. 3. Change the diesel oil filter more frequently than usual. 4. Clean the electrical components, especially the starter and alternator, to avoid any accumulation of dust. Never mix oils of different brands. Do not top off with any oil different from oil used in the machine. If necessary, drain all the oil and fill tank with new, different brand oil.

Oils, filters, coolant, and the batteries are considered special waste and must be collected and disposed of according to the regulations in force. Combustible material of some components may become extremely dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale fumes.

3-2

SK1020-5N/SK1020-5NA

MAINTENANCE

MAINTENANCE NOTES ★ Use only genuine Komatsu replacement parts. Do not mix different types of oil. Unless specified otherwise, oils and coolant used by Komatsu before delivery of the machine are as follows: ITEM

SPECIFICATIONS

• Engine oil

SAE 10W-30 API classification DH

• Hydraulic system oil and hydrostatic transmission oil

SAE 10W API classification DH

• Biodegradable hydraulic system oil (only for machines in which the synthetic biodegradable oil type HEES is used not of plant origin).

SHELL NATURELLE HFX-32

• Final transmission oil

SAE 10W-30 API classification DH Ambient temperature above -10° C (14°F): ASTM D975 no. 2 diesel oil

• Fuel Ambient temperature below -10° C (14°F): ASTM D975 no. 1 diesel oil • Radiator coolant

Permanent, ethylene glycol-based antifreeze, with corrosion inhibitor for protection up to -36°C (-33°F)

Notes Regarding the Engine Engine Oil ★ Engine oil must be selected very carefully since it lubricates the engine, which is the machine’s heart; the main maintenance operations required for engine oil are as follows: 1. Daily check of the oil level. 2. Check condition of the oil with periodic analysis. 3. Periodic oil changes.

SK1020-5N/SK1020-5NA

3-3

MAINTENANCE Coolant •

•

• • • •

Engine coolant serves to keep the engine at the correct temperature ensuring optimal operating conditions. Check coolant level in the expansion tank daily and top off if necessary. The quantity of antifreeze to be added to the coolant depends on the minimum temperature in the place where the machine is working. Use only permanent ethylene glycol-based antifreeze with the addition of anticorrosion and anti-foam products. The antifreeze to water ratio must be 50% (50% antifreeze and 50% water). The antifreeze-water coolant is flammable; do not use exposed flames near the coolant and do not smoke while topping off. The use of permanent antifreeze requires only the routine change. It is not necessary to wash the cooling circuit. Use drinkable water or soft water. Do not use corrosion inhibitors containing soluble oil because they damage the rubber couplings. The required standards for permanent antifreeze are the following: SAE-J1034 and FEDERAL STANDARD O-A-548D. If in doubt regarding the compliance of the antifreeze used with the standards, contact your Komatsu distributor and ask for precise information.

Fuel • • • •

Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its power. Always refuel at the end of the work day. When refueling, make sure that there is no water on the fuel drum cover and take care not to draw condensation from the drum bottom. If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.

Notes Regarding the Hydraulic System • •

• •

Be extremely careful when performing maintenance on the hydraulic system since the oil is very hot immediately after operation. The system is pressurized not only during work, but also at the end of work. The maintenance operations required for the hydraulic system are the following: 1. Check the oil level in the tank daily. 2. Periodically change the oil filter. 3. Periodically change the oil and clean the suction filter. Always bleed the system after changing the oil filter or the oil. When a component is removed from the circuit, check the gaskets and O-rings and change them if they are damaged. When a cylinder or a component of the hydraulic system is removed, after reassembly bleed the system by proceeding as follows: 1. Start the engine and let it idle. 2. Make all the cylinders perform four to five movements, stopping them at about 100 mm from the end of their stroke. 3. Slowly make all the cylinders reach the end of their stroke three to four times.

Notes Regarding the Electrical System •

If the cables are wet or their insulating material is damaged, the electrical system may short, and may result in machine malfunctions. The maintenance operations required for the electrical system are the following: 1. Check the alternator belt tension. 2. Check the alternator belt for damage or breakage. 3. Check the battery electrolyte level.

•

Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component with characteristics different from those specified and approved by Komatsu. Be careful to keep the electric system dry. When working on seashores, rivers or lake banks, protect the jack plugs from corrosion. Do not connect any optional device to the fuses, starting switch, battery, relays, etc. For the installation of any optional equipment, contact your distributor. If any electric welding needs to be done, turn the battery disconnect switch to the UNLOCK position, disconnect the battery and the alternator.

•

3-4

SK1020-5N/SK1020-5NA

MAINTENANCE

Notes Regarding Lubrication • •

•

Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and the noise that may be produced if the articulated joints are dry. Lubrication is to be carried out with grease or oil. The maintenance operations required for the components that need lubricating are the following: 1. Check the fluid and lubricant levels. 2. Change oil at recommended intervals. 3. Inject grease through the grease fittings. Use only the specified lubricants, according to the ambient temperature. Always clean the grease fittings before injecting grease and remove any excess grease after lubrication. This cleaning operation must be performed with extreme care on the revolving parts. Keep the lubricants at the correct levels; excessive or insufficient quantities are to be avoided.

Wear Parts List •

The parts subject to wear such as filters, bucket teeth, etc., must be replaced according to the periodic maintenance intervals prescribed or when they reach their wear limit. The timely change of these parts ensures economical use of the machine. Use only genuine Komatsu parts, which alone can guarantee excellent quality and interchangeability. ITEM

DESCRIPTION

QTY

CHANGE INTERVAL

Hydraulic oil filter

Cartridge (drain)

Every 500 hours

Engine oil filter

Cartridge

Every 250 hours

Fuel filter

Cartridge

Every 500 hours

Air cleaner

Main cartridge Safety cartridge

1 1

When required When required

Front bucket

Teeth Screw Nut

6 12 12

– – –

SK1020-5N/SK1020-5NA

3-5

MAINTENANCE

FUEL, COOLANT AND LUBRICANTS Selection According to the Ambient Temperature

Ambient Temperature Reservoir

Kind of fluid

-30 -22

-20 -4

-10 14

0 32

10 50

Capacity

20 68

30 86

40 104

50°C1 22°F

Specified

Refill

10 l (2.64 gal)

10 l (2.64 ga)

50 l (13.2 gal)

32 l (8.4 gal)

50 l (13.2 gal)

32 l (8.4 gal)

13.5 l (3.5 gal)

72l (19.0 gal)

15 l (3.9 gal)

SAE 5W-30 SAE 10W Engine oil pan

API DH

SAE 30 SAE 40 SAE 10W-30

Hydraulic system

Oil API DH

Hydraulic system with biodegradable oil

See page 3-12

Chain case (ea.)

Oil API DH

Fuel tank

Diesel fuel

SAE 5W-30 SAE 10W

SAE 10W-30 ASTM D975 No. 1 ASTM D975 No. 2

Engine cooling system

Permanent Coolant

Ethylene Glycol Base

Grease

LUBRICATION POINTS Articulated joint, grease fittings

CONSISTENCY

TYPE

NLGI 2

(See note 1)

Note 1: The recommended lubricating grease is No.2 multi-purpose lithium grease with 3% molybdenum disulfide (Lithio EP + MoS2).

3-6

SK1020-5N/SK1020-5NA

MAINTENANCE Remark When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

•

When starting the engine in an atmospheric temperature of lower than 0°C (32°F), use engine oil SAE10W, SAE5W-30 and SAE10W-30, even though an atmospheric temperature goes up 10°C (18°F) more during the daytime. • Use engine oil with DH classifications; if oil with F classification is used, reduce the engine oil change interval by one half. • Use genuine Komatsu products which has been specifically formulated and approved for use in the engine, hydraulic work equipment, in the reduction gears, and in the transmission. First filling quantity: total quantity of oil, including the oil for the components and pipes. Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute NLGI: National Lubricant Grease Institute

SK1020-5N/SK1020-5NA

3-7

MAINTENANCE

No. 1

Supplier KOMATSU

Engine Oil API DH

Transmission Oil GM Dexron® II C4 Allison C4

Grease LI, EP, MoS2

Premium multi-grade Engine Oils PM701 SAE 10W/30 SAE 15W/40

Komatsu PM704 (1902) Dexron® III

Komatsu Super Grease NLGI 2 PM706 ASTM D128

Antifreeze Coolant [Ethylene Glycol Base] Permanent Type –

AMOCO

Amoco 300 SAE 15W/40

Dexron II ATF

Molylith grease 2

Ready Antifreeze

ARCO

Arcofleet S3 plus SAE 15W/40 Hy-Vis HD extra S3 plus SAE 15W/40

ATF Dexron II

Litholine HEP 2 Arco EP moly D

Sincol-Blu (-40°C)

Vanellus C3 SAE 15W/40 Vanellus C3 Extra SAE 15W/40

Autran MBX

Grease LTX2-M

Sigil Fluid (-40°C)

CALTEX

RPM Delo 500 RPM Delo 600 RPM Delo SPH

ATF-HD

Molytex EP2

AF engine coolant CX engine coolant

CASTROL

Turbomax RX super

TQ - Dexron II

Spheerol LMM

Antifreeze (pure)

CHEVRON

Delo 400 Delo 500

Supreme Automatic Transmission Fluid

Moly grease

Flurant

CITGO

CONOCO

*Fleet motor oil SAE 15W/40

EXXON (ESSO)

Essolube TD ATF Dexron II D SAE 15W/40 D-21849 (East Canada) Heavy Truck Diesel D-21848 (West Canada) Motor Oil SAE 15W/40

MP Grease Moly

All-season coolant

GULF

Super duty SAE 15W/40 Super duty plus SAE 15W/40

Gulfcrown EP2 Gulfcrown EP special

Antifeeze and coolant

–

MOBIL

D-21571

–

D21718 D21570

–

– ATF 220

– Fleet Heavy Duty

Mobilgrease

Delvac 1300 Super SAE 15W/40 Delvac 1200 Super SAE 15W/40 Delvac 1300 Super SAE 10W/30 13

PENNZOIL

–

Supreme duty fleet Pennzoil ATF SAE 14W/40

SHELL

SUN

TEXACO

3-8

UNION

Rimula Super SAE 15W/40 Myrina X SAE 15W/40 Rotella T SAE 10W/30

Donag TG (Dexron II)

Multi-purpose white grease 705 707L White-bearing grease

Antifreeze and summer coolant

Alvania EP grease MP MOS (Can.) Retinax AM (Corea)

Shellzone all-season antifreeze

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

Molytex EP2

Ursa Super TD SAE 15W/40 Ursa Super LA SAE 15W/40

Havoline ATF Dexron II Texamatic 7045 (9226)

Guardol

D21460

–

Unoba EP

–

SK1020-5N/SK1020-5NA

MAINTENANCE

APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indicated in the following table is authorized and recommended: SUPPLIER KOMATSU

HEES SYNTHETIC BIODEGRADABLE OIL BO 46 G4 (KES 07.872)

AGIP

–

ARAL

–

AVIA

–

CONDAT

CONDAT D 46 K

ELF

–

ESSO

–

FINA

BIOHYDRAN SE 46

FUCHS

–

KENDALL

–

KUWAIT PETROLEUM K8

–

MOBIL

EAL SYNDRAULIC

MOBIL (USA)

–

PAKELO

–

PANOLIN

HLP SYNTH 46

SHELL

NATURELLE HFX-32

TAMOIL

–

TEXACO

–

TOTAL VAVOLINE

SK1020-5N/SK1020-5NA

HYDROBIO 46 –

3-9

MAINTENANCE

It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the engine, the transmission, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Fill with HEES oil. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at least 40°C (104°F), then start moving the equipment, so that all the parts of the system are filled with oil. Stop the engine and check the oil level, (see “Hydraulic System Oil Level” on page 3-30). For the lubrication procedures for the single points, see “MAINTENANCE PLAN” on page 3-20. The type of lubricant to be used is indicated in the lubricant table. See “FUEL, COOLANT AND LUBRICANTS” on page 36.

3-10

SK1020-5N/SK1020-5NA

MAINTENANCE

LUBRICATION DIAGRAMS General

SK1020-5N/SK1020-5NA

3-11

MAINTENANCE

PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY To ensure safety every moment while driving and using the machine, the operator must carry out all periodic maintenance operations prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the following pages, which are especially related to safety and fire prevention rules. These components are subject to wear and since it is particularly difficult to evaluate their conditions through simple periodic maintenance, after a certain period it is advisable to change them regardless of their state to keep them efficient. Repair or replace these components immediately in case of failures or abnormalities, even if the time interval prescribed for their change has not elapsed yet. If the hose clamps show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses. In addition to periodic replacement of the components listed on the following pages, the inspections described below are to be performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute any other required measure. TYPE OF CHECK

CHECK ITEM

Check before starting

Leakage from joints, grease fittings, hydraulic hoses, or fuel lines

Periodic check (monthly check)

Leakage from joints, fittings, hydraulic hoses, or fuel lines Damaged hydraulic or fuel lines, cracks, wear and tear

Periodic check (annual check)

Leakage from joints, fittings, hydraulic hoses fuel lines Deteriorated, twisted, damaged hydraulic hoses fuel lines, cracks, wear and tear, or in contact with other parts of the machine

3-12

SK1020-5N/SK1020-5NA

MAINTENANCE

Critical Parts for Safety Fuel Supply System NO

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

Fuel line (Fuel tank - precleaner)

Fuel line (Precleaner - fuel pump)

Fuel line (Fuel pump - fuel filter)

Fuel line (Fuel filter - injection pump)

Fuel line (Fuel filter - fuel tank)

Fuel recovery line (Injection pump - fuel filter)

Fuel recovery line (Between the injectors - injection pump)

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

â&#x2DC;&#x2026; For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced. When replacing hoses, always change O-rings, gaskets, and associated components.

SK1020-5N/SK1020-5NA

3-13

MAINTENANCE Standard Flow Hydraulic System NO

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

REPLACEMENT INTERVAL Every 2 years or 4000 hours, whichever occurs first

Hydraulic hose (Travel pump supply)

Hydraulic hose (Machine function pump supply)

3-14

SK1020-5N/SK1020-5NA

MAINTENANCE

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

Hydraulic hoses (Lift cylinders)

Hydraulic hoses (Bucket cylinders)

Hydraulic hoses (Auxiliary hydraulic kit - 2 line)

SK1020-5N/SK1020-5NA

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

3-15

MAINTENANCE Super Flow Hydraulic System NO

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

Hydraulic hose (Travel pump supply)

Hydraulic hose (Machine function pump supply)

Hydraulic hose (Flow rate increase pump supply)

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

3-16

SK1020-5N/SK1020-5NA

MAINTENANCE

COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING

QTY

Hydraulic hoses (Lift cylinder)

Hydraulic hose (Bucket cylinder)

Hydraulic hose (Auxiliary hydraulic kit - 3 line)

SK1020-5N/SK1020-5NA

REPLACEMENT INTERVAL

Every 2 years or 4000 hours, whichever occurs first

3-17

MAINTENANCE Operator’s Safety No

Components needing replacement

Qty

Interval

Seat belt (see “Seat Belt Inspection” on page 1-35 in the Safety Section for details)

Every 3 years after the start of usage or 5 years after the date of manufacture or at first sign of wear or damage

3-18

SK1020-5N/SK1020-5NA

MAINTENANCE

TIGHTENING TORQUE Standard Torque for Bolts and Nuts

Thread diameter (mm)

Pitch (mm)

6 8 10 12 14

1 1.25 1.5 1.75 2

16 18 20 22 24 27 30

Property class designation

Wrench size (mm)

8.8

10.9

N•m

10 13 17 19 22

9.5 ± 1 23 ± 2 45 ± 4.9 77 ± 8 122 ± 13

13.5 ± 1.5 32.2 ± 3.5 63 ± 6.5 108 ± 11 172 ± 18

2 2.5 2.5 2.5 3

24 27 30 32 36

191 ± 21 262 ± 28 372 ± 40 511 ± 57 644 ± 70

268 ± 29 366 ± 36 524 ± 57 719 ± 80 905 ± 98

3 3.5

41 46

945 ± 100 1287 ± 140

1329 ± 140 1810 ± 190

Specific Torques

This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.

Item

Description

N•m

Cab

Rear fastening bolts

98 ± 7.3

Wheels

Front Rear

186 ± 9.8 186 ± 9.8

Engine

Front support central bolt Rear support central bolt

66 ± 7.3 66 ± 7.3

Chassis

Front drainage plug Side access cover plug

SK1020-5N/SK1020-5NA

50 ± 5 50 ± 5

3-19

MAINTENANCE

MAINTENANCE PLAN

SERVICE ITEM

PAGE

WHEN REQUIRED 1. Air cleaner cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 2. Tire rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 3. Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 4. Releasing the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 5. Check battery charge level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 CHECK BEFORE STARTING 1. Various checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 2. Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 3. Check fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 4. Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 5. Check hydraulic oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 6. Drain water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 7. Check wiring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 INITIAL 50 HOURS SERVICE 1. Every 50 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 2. Check drive chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 3. Check wheel nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 4. Hydraulic oil drain filter (for machines filled with biodegradable oil only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 EVERY 50 HOURS SERVICE 1. Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 2. Check coolant level in radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 INITIAL 250 HOURS SERVICE 1. Every 250 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 2. Hydraulic oil drain filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-20

SK1020-5N/SK1020-5NA

MAINTENANCE

EVERY 250 HOURS SERVICE 1. Previous maintenance - 50 hours service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 2. Fan belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 3. Check drive chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 4. Adjust chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 5. Clean outside of the radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 6. Check wheel lug nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 7. Check oil level in chain cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 8. Lubricate joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 9. Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 10. Change engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

INITIAL 500 HOURS SERVICE (for Machines with HEES Oil Only) 1. Every 500 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 2. Change hydraulic oil and clean suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 EVERY 500 HOURS SERVICE 1. Previous maintenance - 50 and 250 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 2. Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3. Change hydraulic oil drain filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 4. Clean water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 5. Drain condensation from hydraulic oil tank (for machines with HEES oil only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 EVERY 1000 HOURS SERVICE 1. Previous maintenance - 50, 250 and 500 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 2. Change oil in chain case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3. Change hydraulic system oil and clean suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 4. Check and adjust engine valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

EVERY 2000 HOURS SERVICE 1. Previous maintenance - 50, 250, 500 and 1000 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 2. Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 3. Change suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 4. Check alternator and starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

SK1020-5N/SK1020-5NA

3-21

MAINTENANCE

When Required Air Cleaner Cartridge

Remove the air cleaner only after stopping engine, and do not start engine after the air cleaner is removed. Always wear safety glasses during cleaning operations. â&#x2DC;&#x2026; The air filter system consists of a primary filter element with considerable capacity and of a secondary cartridge that ensures additional safety protection. The primary element can be cleaned with compressed air, while the cartridge must be replaced. The filter must be cleaned when the clogging warning light A positioned on the instrument panel comes on or flashes. The air cleaner can be reached after raising the engine hood and opening the rear panel. To clean the primary element, proceed as follows: 1. Release safety locks b, moving them toward the outside and remove the filter cover c.

2. 3.

Remove the main filtering element d. Lightly tap the filter element d on the palm of your hand, in a manner to remove the dust, and blow compressed air on the inner surface, keeping the air jet at a distance of approximately 15 cm (5.9 in.) and taking care to prevent pressure from exceeding 4 to 5 kg/cmÂ˛ (58-73 psi).

Carefully clean the inside of the filter case e, taking care to prevent foreign debris from getting into the suction duct and reassemble the unit making sure that the ejector is positioned vertically and at the bottom.

If the clogging warning light comes on after starting the engine, it is necessary to replace the primary filter element and safety cartridge. Replace the primary filter element after five cleaning operations or after one year. Every time the primary filter element is replaced, the safety cartridge must also be replaced.

3-22

SK1020-5N/SK1020-5NA

MAINTENANCE To change the safety cartridge, after removing the primary element, then proceed as follows: 5. Remove the safety cartridge f and replace it with a new one. 6. Once the safety cartridge f has been installed inside the filter case e, make sure that it is perfectly seated in its housing. 7. Reassemble the unit as described above, making sure that all filter components are perfectly locked. 8. Push the safety locks b toward the housing.

Tire Rotation

The tires must not be inflated exceeding the recommended pressure (see â&#x20AC;&#x153;Technical Specificationsâ&#x20AC;? on page 4-6). Inflate all the tires to the same pressure. To avoid losing stability and maneuverability, always use the machine with properly inflated tires and avoid incorrect maneuvers that may shorten their life. The maneuvers to be avoided are the following: 1 - Excessive skidding when loading material 2 - Abrupt steering, starting and stopping maneuvers 3 - Excessive use of counter rotations If excessive tire wear is observed, it is advisable to exchange the front wheels with the rear wheels immediately so that the wear gets uniform on the four wheels over time. If two tires are worn more than the others, change their position keeping them on the same side so that the rolling diameter is the same on connected wheels. When it is necessary to change two tires, adopt the same procedure and eliminate the most worn ones, installing the new ones on the same side.

Use only tires recommended by the manufacturer.

SK1020-5N/SK1020-5NA

3-23

MAINTENANCE Draining the Fuel Tank

When draining the fuel tank, avoid spilling fuel, since this may cause fires. If some fuel is accidentally spilled, clean the dirty area immediately, to prevent it from getting slippery and to avoid fires. This operation serves to let all the impurities and the condensation flow out of the tank. Proceed as follows: 1. Raise the engine hood (see “Engine Hood” on page 2-48). 2. Open the valve b, using the lever c supplied with the machine. 3. Turn the extension c counterclockwise until clean fuel flows out.

4. 5.

Turn the extension c clockwise to stop the fuel flow. Close the engine hood (see “Engine Hood” on page 2-48) and put the extension c in the technical documentation case (see “Technical Documentation Case” on page 2-55).

The tank must be drained before starting the engine with temperatures exceeding 0ºC (32°F); when the temperature is below 0ºC (32°F), the tank must be drained at the end of work with the machine at operating temperature to prevent the condensation from freezing. The condensation and the impurities that may have accumulated inside the tank must be drained before refueling.

3-24

SK1020-5N/SK1020-5NA

MAINTENANCE Releasing the Parking Brake

In case of failure of the hydraulic system and before moving the machine, release the parking brake installed on the travel motors. The release of the parking brake is obtained by acting on the applied brake installed on the travel motors, according to the following procedure. 1. Raise the cab (see “Tilting the Cab” on page 2-51). 2.

Disconnect the pipe b that supplies pressure to the travel motors.

3. 4.

Connect a grease nipple d to the union c. Using a grease pump, inject grease until the minimum pressure required to release the brake is reached. After releasing the brake, carry out the necessary maintenance operations. To restore the braking circuit to the standard configuration, remove the grease nipple d from the coupling c and put back the pipe b. Lower the cab (see “Tilting the Cab” on page 2-51).

5. 6.

After restoring the circuit to the standard configuration, it is not necessary to make any adjustments.

SK1020-5N/SK1020-5NA

3-25

MAINTENANCE Checking the Battery Charge Level

Check the battery charge level only with the engine stopped. To prevent gas explosions, do not use open flames, do not smoke, or wipe the battery with a dry cloth. Avoid producing sparks due to short circuits. The battery electrolyte is dangerous. In case of contact with the eyes or the skin, wash with plenty of running water and consult a doctor.

Make sure that the connection terminals are not oxidized. If necessary, clean them and cover them with anti-oxidation grease. The battery b can be reached after opening the engine hood (see “Engine Hood” on page 2-48) )

The change of color of the indicator shows the battery charge level, according to the table positioned beside the indicator itself: - Green: the charge is correct - Grey: the battery needs recharging - White: the battery must be replaced See “Discharged Battery” on page 2-102 for instructions to charge and jump the battery. For information to replace the battery, see the Shop Manual Disassembly and Assembly Section.

If a dry battery is installed, check the electrolyte level, which must be approximately 6 mm above the edge of the plate; if necessary, top off using distilled water only. If, on the contrary, the level is low because some electrolyte has spilled, add sulfuric acid, dilute as much as necessary to reach the concentration suitable for the ambient temperature (see “Battery” on page 2-90). It is advisable to add distilled water before starting work, to prevent it from freezing. Before putting back the cell plugs, make sure that the breather holes are not clogged.

3-26

SK1020-5N/SK1020-5NA

MAINTENANCE

Checks Before Starting Various Checks

Dirt, oil, and fuel spread in the engine compartment near hot areas may cause fires and damage the machine. Check to see if there are frequent leaks, and perform any necessary repairs immediately. If this occurs repeatedly, contact your distributor. Before starting the engine, check the following: 1. Check for loose screws or nuts. 2. Check for oil, fuel or coolant leakage. 3. Check for worn equipment. 4. Check condition of wheel rims, and condition and wear of the tires. 5. Check condition and efficiency of instruments and warning lights on the dashboard, working lights and direction indicators. The other general checks concern safety, and functionality: 1. Integrity of the seat belt system. See “Seat Belt Inspection” on page 1-35. 2. Clearness and legibility of the warning decals. 3. Cleanliness of the ladders and handrails used to reach the drivers seat, cleanliness inside the operator’s compartment.

Checking the Coolant Level

Carry out this check with the machine parked on a level surface and the equipment resting on the ground. Do not remove the radiator cap. The coolant level must be checked with cold engine and the coolant reservoir. The coolant reservoir b can be reached by raising the engine hood (see “Engine Hood” on page 2-48) and opening the rear panel (see “Rear Panel” on page 2-49). The coolant level must fall between the MIN and MAX marks. If necessary, add coolant and, if a constant and considerable decrease in the fluid level is noticed, check the tightness of the radiator-engine unit and of the radiator.

SK1020-5N/SK1020-5NA

3-27

MAINTENANCE Checking the Fuel Level

When refueling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately. Fuel is flammable. Don’t smoke while refueling and keep open flames away. Place the fuel nozzle into the filler neck when refueling. To check the fuel level, use the indicator b positioned on the dashboard, after turning the ignition key to position “I.”

To refuel, if necessary, open the engine hood (see “Engine Hood” on page 2-48). Do not fill the tank completely in order to leave room for the fuel to expand.

It is advisable to refuel after work in order to avoid the formation of water condensation. After refueling, tighten the filler cap c thoroughly, lower the engine hood and lock it.

3-28

SK1020-5N/SK1020-5NA

MAINTENANCE Engine Oil Level

After the machine is stopped, the engine and fluids are very hot. Let the engine cool down before performing any check. Hot engines may cause burns. If it is necessary to check the oil level during or soon after work, stop the engine and wait for 15 minutes before checking. The dipstick b can be reached after opening the engine hood. The check must be performed with a cold engine and the machine located on level ground. The oil level can be checked on the graduated dipstick b and must be between MIN and MAX marks. If the level is near the MIN mark, top off with oil, through filler tube c, of the same brand, suitable for the ambient temperature, as prescribed in the lubricant chart (see â&#x20AC;&#x153;FUEL, COOLANT AND LUBRICANTSâ&#x20AC;? on page 3-6).

SK1020-5N/SK1020-5NA

3-29

MAINTENANCE Hydraulic System Oil Level

The oil level in the hydraulic system must be checked with cold oil and the machine positioned on a level surface and the bucket resting on the ground. If it is necessary to top off, stop the engine and then eliminate the residual pressures present in the work equipment, move the controls more than once and in the tank by slowly loosening filler cap. When adding oil, do not exceed the MAX level. This would damage the hydraulic system and cause oil to overflow. If a constant or abnormal decrease of the oil level is observed, thoroughly check the hydraulic system, the pistons and pump for leaks. After topping off, tighten the hydraulic tank cap completely.

To check the oil level in the hydraulic circuit, open the rear panel (see “Rear Panel” on page 2-49). The oil level must be visible through the gauge b positioned on the tank and must be between the MIN and MAX marks. If the level is near the MIN mark, top off through the filling opening c with suitable hydraulic oil (see “FUEL, COOLANT AND LUBRICANTS” on page 3-6), after removing the cap. Reinstall and tighten the cap after topping off.

3-30

SK1020-5N/SK1020-5NA

MAINTENANCE Draining Water Separator

Fuel is flammable; do not use open flames and do not smoke while draining the water separator. If some fuel is spilled, wipe it up immediately. The water separator can be reached after opening the engine hood (see “Engine Hood” on page 2-48). The check must be carried out by means of the red ring b installed in the filter. When the red ring floats on the surface of the water contained in the water separator, it is necessary to drain it. Provide a suitable container to catch the drained liquid. Proceed as follows: 1. Turn the valve c to close the fuel flow. 2. Loosen the wing cap d and drain the condensate until clear diesel fuel flows out. Close the wing cap d. 3. Open the valve c. 4. Drain the fuel tank as described in paragraph “Draining the Fuel Tank” on page 3-24. 5. Bleed the fuel supply circuit as described in paragraph “Changing the Fuel Filter” on page 3-41. 6. Properly dispose of the drained liquid.

If the filtering element is considerably clogged or damaged, change it.

Checking the Wiring System

Before replacing a fuse, first turn the starting switch to the OFF position, wait over one minute, then turn the battery disconnect switch to the UNLOCK position and remove the battery disconnect key. If the fuses are corroded, oxidized or they are not perfectly held in their seat, replace them only with fuses having the same capacity. If there are signs of short circuit on the cables, find out the cause and repair them; always contact your Komatsu distributor for troubleshooting. Before checking the wiring, take all the necessary precautions to ensure safety. Make sure that there are no disconnected cables or signs of short circuits in the electrical system. Make sure that all the cables are well tightened in the corresponding terminals; tighten any loose cables.

SK1020-5N/SK1020-5NA

3-31

MAINTENANCE

Maintenance After the First 50 Hours of Operation These maintenance operations must be carried out after the first 50 hours of operation, together with those to be carried out “EVERY 50 HOURS.” ★ CHECK THE DRIVE CHAIN TENSION ★ CHECK THE WHEEL NUT TORQUE ★ HYDRAULIC OIL DRAIN FILTER (only for machines filled with biodegradable oil) For details on the various maintenance operations, see sections “Maintenance Every 250 Hours of Operation” on page 3-33 and “Maintenance Every 500 Hours of Operation” on page 3-41.

Maintenance Every 50 Hours of Operation Checking Tire Pressure

Inflate the tires standing beside the outer belt. Do not exceed the pressures recommended in the see “Technical Specifications” on page 4-6. The pressure must be as indicated in the specifications (see “Technical Specifications” on page 4-6). While checking the tire pressure, also check the condition of the tread and sidewalls.

Checking the Coolant Level in the Radiator

Carry out this check with the machine parked on a level surface and the equipment resting on the ground. Do not remove the radiator cap when the fluid is hot, since it may spray out and cause burns. Loosen the cap slowly in order to release the pressure before removing it. The radiator cap can be reached after raising the engine hood (see “Engine Hood” on page 2-48). Remove the cap (1) and make sure that the fluid level reaches the filling hole.

If the fluid level in the radiator is low and the expansion tank is full of coolant, check the tightness of the radiator cap and make sure that there is no air leakage from the radiator to expansion tank coupling. If this occurs repeatedly, contact your distributor.

3-32

SK1020-5N/SK1020-5NA

MAINTENANCE

Maintenance After the First 250 Hours of Operation Perform the following maintenance after the first 250 hours, together with those to be initiated EVERY 250 HOURS. ★ HYDRAULIC OIL DRAIN FILTER For details on the various maintenance operations, see “Maintenance Every 500 Hours of Operation” on page 3-41.

Maintenance Every 250 Hours of Operation These operations must be carried out together with those to be carried out with “Maintenance Every 50 Hours of Operation” on page 3-32.

Fan Belt Tension The fan belt can be reached after opening the engine hood; see “Engine Hood” on page 2-48. The test is manual: press the belt b with your thumb on the indicated point with a force equal to about 10 kg (22 lb.) N; the resulting deflection must be about 10 to 15 mm (0.4-0.6 in). If the deflection exceeds this value, loosen the bolt c that fastens the alternator d and, with a lever inserted between the engine block and casing, move the alternator. Lock the bolt and check again. Use a 12 mm wrench. A Fan pulley B

Driving shaft puller

Alternator pulley

If the belt is worn, replace it and check the tension again after a few hours of operation.

SK1020-5N/SK1020-5NA

3-33

MAINTENANCE Checking the Drive Chain Tension

Stop the machine on firm and level ground, raise the front and rear wheels until they are not in contact with the ground any longer and engage all the safety locks before stopping the engine. Secure the machine in this position by applying bearing blocks under the front part of the frame.

FRONT CHAINS After raising the front part of the machine and securing it in this position with safety blocks, mark a point on the outer perimeter of the front rim and, moving the wheel, make sure that the point moves a distance between 2 and 6 mm. This range determines the correct tension of the chain. Repeat this operation for the opposite wheel. REAR CHAINS After raising the rear part of the machine and securing it in this position with safety blocks, mark a point on the outer perimeter of the rear rim and, moving the wheel, make sure that the point moves a distance between 2 and 6 mm. This range determines the correct tension of the chain. Repeat this operation for the opposite wheel.

Check the tension on the front and rear wheels and if the slack exceeds 6 mm, contact your distributor.

3-34

SK1020-5N/SK1020-5NA

MAINTENANCE Adjusting the Chains

The adjustment must be carried out with the machine parked on a firm, level and non slippery surface. Before carrying out the adjustment, take all the necessary safety precautions. Provide a suitable container to hold any oil leakage from the hub area.

When adjusting the hub-holding plate, do not loosen the fastening nuts by giving them more than two turns to prevent any oil leakage. If the wheel slack exceeds 6 mm, carry out the following operations: 1. Remove the wheel nuts using a 24 mm hexagon wrench. 2. Position the adjusting screw d, included with the machine, in the appropriate adjusting tab and tighten it to touch the hub-holding plate b. Use a 17 mm hexagon wrench. 3. Loosen the nuts c of the hub-holding plate b, giving them a maximum of two full turns. Use a 22 mm hexagon wrench.

Tighten the screw d, to push the hub-holding plate 1 or 2 mm. Tighten at least three nuts c, opposite of each other, on the hubholding plate. 6. Install the wheel and check the wheel slack. If the wheel slack value is not within the prescribed value range, repeat the operation described above. If the wheel slack value is within the range, proceed as follows: 7. Remove the wheel again. 8. Tighten all the nuts c of the hub-holding plate b to the specified torque (see “Standard Torque for Bolts and Nuts” on page 3-19). 9. Remove the adjusting screw d. 10. Reassemble the wheel, tightening the nuts to the specified torque (see “Specific Torques” on page 3-19). Repeat this procedure for the other wheels. Check the oil level in the chain case after the machine is back on the ground. 4. 5.

It is important to remember that each side of the final transmission (right and left) contains two chains (front and rear) that transmit motion to the corresponding wheels. Each chain can be adjusted independently of the others.

SK1020-5N/SK1020-5NA

3-35

MAINTENANCE Cleaning the Outside of the Radiator

If compressed air, steam or water are directed against a person, they may cause injuries. Always wear eye protection and safety shoes. The radiator/hydraulic oil cooler can be cleaned after opening the rear panel (see “Rear Panel” on page 2-49), using a compressed air jet and, if necessary, carrying out a washing cycle with low-pressure water or steam. The specific detergents available on the market can be used, provided that the instructions given on the package are followed and that at the end of the operations the washed parts are rinsed and dried.

Do not use products containing petroleum products, even if in small quantities, since these promote the sticking of dust, which reduces the heat exchange process. Clean the outside of the radiator whenever the radiator and the hydraulic oil cooler are dirty with oil, diesel oil, greasy or oily substances. If the machine is used in dusty places, clean the radiator/hydraulic oil cooler more frequently, to avoid the clogging of the fins.

Checking the Wheel Nut Torque

On new machines, check the wheel nut torque after the first 50 hours of operation and successively every 250 hours. This check serves to restore the correct torque to the wheels on the hubs. The torque must be checked with a torque wrench b containing the values indicated in paragraph “Specific Torques” on page 3-19. Use a 24 mm wrench.

Do not increase the specified torque and keep it within the prescribed values. When checking the torque, do not lubricate the stud threads or the nut.

3-36

SK1020-5N/SK1020-5NA

MAINTENANCE Checking the Oil Level in the Chain Cases This check must be carried out on each case with the machine at rest on level ground. The check is visual and serves to verify that the lubricant reaches the height of the hole b; if this is not the case, top off using the recommended type of oil. (See “FUEL, COOLANT AND LUBRICANTS” on page 3-6). Use a 19 mm hexagon wrench.

SK1020-5N/SK1020-5NA

3-37

MAINTENANCE Lubricating the Joints

Clean the grease nipples before applying the grease pump. After lubrication, remove any excess grease. If the machine is used in difficult conditions, perform these maintenance operations more frequently. These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground. For the lubrication, use a grease pump and the recommended grease. (See â&#x20AC;&#x153;FUEL, COOLANT AND LUBRICANTSâ&#x20AC;? on page 36).

As a general rule, consider that each cylinder is provided with two grease nipples positioned on the couplings and that each pin serving as fulcrum for a movement is provided with at least one grease nipple. EQUIPMENT LUBRICATION POINTS

3-38

1 - Bucket coupling pin

(2 points)

2 - Tool-holder plate fulcrum pin

(2 points)

3 - Bucket cylinder head pin

(2 points)

4 - Bucket cylinder base pin

(2 points)

5 - Lifting cylinder head pin

(2 points)

6 - Arm fulcrum pin

(2 points)

7 - Lifting cylinder base pin

(2 points)

SK1020-5N/SK1020-5NA

MAINTENANCE Changing the Engine Oil

Immediately after the engine has been shut off the engine oil is very hot and may cause burns. Let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil. The oil that may be spilled during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove any trace of oil from the floor. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

Drain the oil after positioning the drain hose outside the engine compartment. Change the engine oil at the same time as the engine oil filter (see “Changing the Engine Oil Filter” on page 3-40). This operation must be carried out with the machine parked on firm and level ground and the step succession is the following: 1. Detach the lower cover b after removing the fastening screws c. Use a 17 mm spanner. 2. Extract the oil drain flexible pipe d from the lower opening. 3. Raise the engine hood (see “Engine Hood” on page 2-48). 4. Remove the drain plug e of the drain hose d, gathering the used oil that flows out into a container with suitable capacity. Use a 27 mm wrench. While the oil flows out, remove the filler cap f, so that the oil can flow freely. 5. After the oil has completely drained from the pan, screw the drain plug e back into the drain hose and pour the specified quantity of new oil into the pan, using the dipstick g to make sure that the oil reaches the MAX level. 6. Replace the filler cap f, start the engine, let it run for five minutes and then stop it. Check the level again and top off, if necessary. 7. Close the lower cover b. 8. Close the engine hood. Use oil suitable for the ambient temperature (see “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

After the oil change and after removing any trace of oil, put the drain hose back inside the engine compartment.

SK1020-5N/SK1020-5NA

3-39

MAINTENANCE Changing the Engine Oil Filter

Immediately after the engine has stopped, the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil. The oil that may spill during the change makes the ground slippery, therefore, use anti-slip shoes and immediately remove any trace of oil from the floor. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. This operation must be carried out during every oil change. Proceed as follows: 1. Raise the engine hood (see “Engine Hood” on page 2-48). 2. Drain the engine oil (see “Changing the Engine Oil” on page 339) into a suitable container. 3. Position a container below the filter to catch any oil. Unscrew the used filter b with the special wrench provided and dispose of it properly. 4. Clean the contact surface between the seal and the filter base c. 5. Lubricate the seal of the new filter and screw on until the filter contacts the base. 6. Give the filter a further half turn by hand. 7. Fill the engine with new oil and complete the operations as described in see “Changing the Engine Oil” on page 3-39. Start the engine, make sure that there is no leakage and that the oil pressure warning light goes out. Close the engine hood.

Do not use the wrench to tighten the filter, since this may cause damage and result in oil leaks.

Maintenance After the First 500 Hours of Operation ★ (Only for machines filled with synthetic biodegradable oil type HEES) ★ The following maintenance operation must be carried out after the first 500 hours of operation, together with those to be carried out EVERY 500 HOURS. • HYDRAULIC OIL CHANGE AND CLEANING OF THE SUCTION FILTER For details on the various maintenance operations, see “When Required” on page 3-22.

3-40

SK1020-5N/SK1020-5NA

MAINTENANCE

Maintenance Every 500 Hours of Operation These operations must be carried out together with those to be carried out EVERY 50 and 250 HOURS.

Changing the Fuel Filter

Change the filter element after work and after the engine has cooled down to 40-45°C (104-113°F). When this operation is performed, fuel may spill; clean the spill immediately, to prevent any risk of slipping or fire. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. The fuel filter and the fuel pump can be reached by opening the engine hood (see “Engine Hood” on page 2-48). FUEL FILTER 1.

2. 3.

4. 5.

Clean the outside of the filter and then unscrew the used filter b with the special wrench provided and dispose of the filter properly. Clean the inside of the head c. Lubricate the new filter seal and screw on until the seal contacts the base.

Give the filter a further half turn by hand. Bleed the fuel supply circuit.

BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to position “I” and wait for approximately 15-20 seconds, to bleed the fuel supply circuit.

After bleeding the circuit, turn the ignition key to position “ “ for a few seconds and wait at least two minutes before starting the engine. If the engine starts without problems and then stops or works irregularly, check if there is air in the circuit; if so, check the tightness of the fuel filter and of the fuel pump prefilter. After the fuel has run out, bleed the circuit by proceeding as described above and repeat the operation at least two or three times.

SK1020-5N/SK1020-5NA

3-41

MAINTENANCE Changing the Hydraulic Oil Drain Filter

Immediately after the engine has stopped the hydraulic oil is very hot; let it cool down until it reaches a temperature of 4045°C (104-113°F) before changing the filter. The hydraulic system is pressurized; loosen the filling cap slowly to release the residual pressure. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force.

On new machines, change the hydraulic oil filter cartridge after the first 250 hours of operation and successively every 500 hours. On machines filled with synthetic biodegradable oil type HEES, the first change must be carried out after the first 50 hours of operation and the successive changes every 500 hours. The filter is positioned on the hydraulic system drain outlet and blocks the metal particles that come off the various components due to their wear. The filter can be reached after opening the rear panel (see “Rear Panel” on page 2-49). To change it, proceed as follows: 1. Slowly loosen the filler cap b to release the residual pressure from the tank and then remove the cap. 2. Unscrew the used filter c and discard it. 3. Clean the contact surface between the seal and the filter base d, lubricate the seal of the new filter and screw on until the seal contacts the base. 4. Give the filter a further half turn by hand. 5. Close the rear panel. 6. Check for oil leaks after running the engine.

Do not use the wrench to tighten the filter, since this may cause damage and result in oil leakage. If the machine contains synthetic biodegradable oil type HEES, the filter must be changed after the first 50 hours of operation.

3-42

SK1020-5N/SK1020-5NA

MAINTENANCE Cleaning the Water Separator

Change the precleaner at the end of work and after the engine has cooled down to 40-45°C (104-113°F). When these operations are performed, fuel may spill; clean the dirty areas immediately to prevent any risk of slipping or fire. The water separator can be reached after opening the engine hood (see “Engine Hood” on page 2-48). 1. Close the valve b. 2. Loosen the metal ring c and remove the cup d and the filtering element, collect the fluid in a container of suitable capacity. 3. Clean the inside of the cup and the filter with diesel oil or oil. 4. Replace the filter and the cup d, tighten the metal ring c and open the valve b.

When disassembling the water separator, be careful not to lose the red ring contained in the cup. If the filtering element is clogged or damaged, change it.

BLEEDING THE CIRCUIT After filling the tank, turn the ignition key to position “I” and wait for approximately 15-20 seconds to bleed the fuel supply circuit.

After bleeding the circuit, turn the ignition key to position “ ” for a few seconds and wait at least two minutes before starting the engine. If the engine starts without problems and then stops or works irregularly, check if there is air in the circuit; if so, check the tightness of the fuel filter and of the fuel pump prefilter. After the fuel has run out, bleed the circuit by proceeding as described above and repeat the operation at least two or three times.

SK1020-5N/SK1020-5NA

3-43

MAINTENANCE Draining Condensation from the Hydraulic Oil Tank (Only for machines filled with synthetic biodegradable oil type HEES)

Lower the loader arm completely, rest the bucket on the ground and, after stopping the engine, eliminate the residual pressures that may be present in the equipment (by operating the controls more than once) and lock the safety bars (see “Safety Bars” on page 2-27). Let the oil cool down until it reaches 40-45°C (104-113°F) before performing any maintenance operation. Immediately clean any area dirty with oil. Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures that may be present in the equipment by operating the controls more than once. Raise the engine hood (see “Engine Hood” on page 2-48) and open the rear panel (see “Rear Panel” on page 2-49). 1. Slowly loosen the filler cap b to release the residual pressure from the tank and remove the cap. 2. Position a container of suitable capacity under the drain plug.

3-44

SK1020-5N/SK1020-5NA

MAINTENANCE 3. 4.

Loosen the lower plug c until the condensation has completely drained. Use a 12 mm hexagon wrench. Retighten the lower plug c, check the oil level and top off if necessary. Install the filler cap b and close the rear panel and the engine hood.

Be careful to only loosen the lower plug enough to allow the condensation to drain and not lose too much hydraulic oil.

The draining of the tank must be carried out at temperatures exceeding 0째C (32째F), before starting the engine. When the temperature is below 0째C (32째F), the hydraulic oil tank must be drained at the end of work, or when the temperature of the machine is high enough to prevent the condensation from freezing and to allow it to flow out of the tank without problems.

SK1020-5N/SK1020-5NA

3-45

MAINTENANCE

Maintenance Every 1000 Hours of Operation These operations must be carried out together with those to be carried out EVERY 50, 250, 500 HOURS.

Changing the Oil in the Chain Case

Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. This operation must be carried out on each case with the machine parked on level ground and at operating temperature, so the oil flows freely and can be drained easily together with the solid particles suspended in it. 1. Remove the drain plug b and let the used oil drain completely. Use a 19 mm hexagon wrench. 2. While the oil flows out, remove the fill plug c. Use a 19 mm hexagon wrench. 3. After draining the used oil, replace the plug b and fill with the recommended oil through the fill hole c until the oil reaches the lower edge of the hole. 4. Reinstall the plug c. Move the machine back and forth and check the level again with the machine at rest. Use only the recommended type of oil (see â&#x20AC;&#x153;FUEL, COOLANT AND LUBRICANTSâ&#x20AC;? on page 3-6).

3-46

SK1020-5N/SK1020-5NA

MAINTENANCE Changing the Hydraulic System Oil and Cleaning the Suction Filter

On machines filled with synthetic biodegradable hydraulic oil type HEES the oil must be changed after the first 500 hours of operation and successively every 1000 hours, and in any case at least once a year.

Lower the loader arm completely, lower the bucket to the ground, stop the engine, release the residual pressures from the work equipment circuits (by operating the controls more than once) and lock the safety bars (see “Safety Bars” on page 2-27). Let the oil cool down until it reaches 40-45°C (104-113°F) before carrying out any maintenance operation. Immediately clean any area dirty with oil. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures from the work equipment circuits by operating the controls more than once. Raise the engine hood (see “Engine Hood” on page 2-48) and open the rear panel (see “Rear Panel” on page 2-49). 1. Slowly loosen the filler cap b to release the residual pressure from the tank and then remove the cap.

SK1020-5N/SK1020-5NA

3-47

MAINTENANCE 2.

4. 5.

Remove the lower plug c and let the used oil flow out completely, gathering it in a container with suitable capacity. Use a 12 mm hexagon spanner. Once the oil has been drained, disconnect the suction pipe d and remove the flange e after removing the screws f. Use a 17 mm hexagon spanner. Clean the filtering element g. Put back the flange e, the filter g, the gasket h and the lower plug c.

3-48

SK1020-5N/SK1020-5NA

MAINTENANCE 6.

Fill the tank with the specified oil until reaching the correct level i. Use only the prescribed type of oil (see “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

Raise the cab (see “Tilting the Cab” on page 2-51) and make sure that the oil in the hydraulic pump reaches the maximum level. To do this, remove the upper plug j and make sure that the hole is completely filled with oil. Use a 1/2” square drive wrench. 8. If the oil does not reach the maximum level, top off with the specified oil (see “FUEL, COOLANT AND LUBRICANTS” on page 3-6). 9. After the check, lower the cab, install the filler cap b, close the rear panel and the engine hood and bleed the system. 10. Make sure that all the control levers are in neutral position and let the engine idle for two or three minutes before operating the work equipment. Move each piston more than once to bleed the system; check level again and top off if necessary.

Never start the engine with an empty tank, since this would certainly damage the pump.

Checking and Adjusting the Engine Valve Clearance Since the check and adjustment of the engine valve clearance require the use of special tools, have these operations carried out by your distributor.

SK1020-5N/SK1020-5NA

3-49

MAINTENANCE

Maintenance Every 2000 Hours of Operation Carry out these operations together with those to be performed EVERY 50, 250, 500 and 1000 HOURS.

Changing the Coolant

Immediately after the engine has stopped the coolant is very hot and under pressure and may cause serious burns. Let the engine cool down until it reaches approximately 40-45°C (104-113°F) before changing the coolant. Slowly loosen the radiator cap, to release the residual pressure. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. Changing permanent-type coolant does not require descaling the system. 1. 2. 3.

6. 7.

Raise the engine hood (see “Engine Hood” on page 2-48) and open the rear panel (see “Rear Panel” on page 2-49). Loosen and remove the filler cap b of the radiator. Open the drain cock c of the radiator, remove the drain plug d positioned on the engine block and let the fluid flow into a suitable size container. Use a 17 mm hexagon wrench. While the fluid flows out, drain the coolant tank e. Close the drain cock c and install the plug d on the engine block. Fill the radiator with new coolant (see “FUEL, COOLANT AND LUBRICANTS” on page 3-6).

Start the engine and let it idle for a few minutes; check the level again and if necessary top off before putting back the radiator cap b. Fill the tank e until reaching the maximum level. Close the rear panel and the engine hood.

3-50

SK1020-5N/SK1020-5NA

MAINTENANCE Changing the Suction Filter

Lower the loader arm completely, rest the bucket on to the ground, stop the engine, eliminate the residual pressures that may be present in the equipment (by operating the controls more than once) and lock the safety bars (see “Safety Bars” on page 2-27). Before carrying out any maintenance operation, let the oil cool down until it reaches 40-45°C (104-113°F). Immediately clean any area dirty with oil. Oils, filters, coolants and batteries are considered special waste and must be collected and disposed of according to the anti-pollution regulations in force. Stop the machine on a firm and level surface, lower the equipment to the ground, stop the engine and release the residual pressures from the equipment by operating the controls more than once. Raise the engine hood (see “Engine Hood” on page 2-48) and open the rear panel (see “Rear Panel” on page 2-49). The suction filter must be changed every two hydraulic oil changes. 1. Slowly loosen the filler cap b in order to release the residual pressure from the tank and then remove it.

SK1020-5N/SK1020-5NA

3-51

MAINTENANCE 2. 3.

4. 5. 6.

Drain the hydraulic oil (“Changing the Hydraulic System Oil and Cleaning the Suction Filter” on page 3-47). Once the oil has been drained, disconnect the suction pipe d and remove the flange e after removing the screws f. Use a 17 mm hexagon spanner. Change the filtering element g. Put back the flange e, the filter g, the gasket h and the lower plug c. Complete the tank filling operations by proceeding as described in “Changing the Hydraulic System Oil and Cleaning the Suction Filter” on page 3-47.

Never start the engine with an empty tank since this would certainly damage the pump.

Checking the Alternator and the Starter For any inspection and/or repair, contact your distributor. If the engine is started frequently, the alternator and the starter should be inspected every 1000 hours of operation.

3-52

SK1020-5N/SK1020-5NA

4SPECIFICATIONS

SK1020-5N/SK1020-5NA

4-1

SPECIFICATIONS

SPECIFICATIONS Standard Machine Overall Dimensions

The weight of the machine increases by 200 kg (441 lb) when it is equipped with solid tires. If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in). OVERALL DIMENSIONS WITH STANDARD BUCKET L 1880 (6’2”) AND TIRES (12-16.5)

Unit: mm

4-2

SK1020-5N/SK1020-5NA

SPECIFICATIONS

OVERALL DIMENSIONS WITH NARROW BUCKET L 1730 (5’8”) AND TIRES (12-16.5)

SK1020-5N/SK1020-5NA

4-3

SPECIFICATIONS

Machine Overall Dimensions with Optional Equipment

The weight of the machine increases by 200 kg (441 lb) when it is equipped with solid tires. MACHINE OVERALL DIMENSIONS WITH EXCAVATOR

4-4

SK1020-5N/SK1020-5NA

SPECIFICATIONS MACHINE OVERALL DIMENSIONS WITH ASPHALT CUTTER

SK1020-5N/SK1020-5NA

4-5

SPECIFICATIONS

Technical Specifications TOTAL WEIGHT Standard machine maximum

3350 kg (7385 lb)

Maximum with bucket L 1730

3330 kg (7341 lb)

Maximum with bucket L 1880

3350 kg (7385 lb)

Maximum total mass with excavator E35-2

4200 kg (9259 lb)

Maximum total mass with asphalt cutter

4250 kg (9370 lb)

BUCKET CAPACITY Standard bucket L 1880 (SAE)

0.42 cu.m. (0.55 cu.yd.)

Narrow bucket L 1730 (SAE)

0.40 cu.m. (0.52 cu.yd.)

Wide bucket L2030 (SAE)

0.45 cu.m. (0.59 cu.yd.)

ENGINE Komatsu diesel engine model

S4D98E-2NFE

Rated power (2500 rpm EEC 80/1269)

64 kW (85.8 HP)

Maximum torque (1600 rpm EEC 80/1269)

286 Nâ&#x20AC;¢m (211 lbf ft)

ELECTRICAL SYSTEM Alternator

12 V

Electrical output

40 A

Ground

Negative

Battery

100 Ah-12 V

Starter

3.0 kW (4.02 HP)

SPEED FORWARD

REVERSE

GEARS

km/h

15.5

MPH

6.2

9.6

6.2

9.6

TIRES SIZE

MAKE

INFLATION PRESSURE

12x16.5 PR10

OMEGA

4 kg/cm2 (58 psi)

12x16.5 PR10

HAULER

4 kg/cm2 (58 psi)

12x16.5 PR10

GOOD-YEAR

4 kg/cm2 (58 psi)

2x16.5 PR10

AIR BOSS

4-6

SK1020-5N/SK1020-5NA

5OPTIONAL ATTACHMENTS

SK1020-5N/1020-5NA

5-1

OPTIONAL ATTACHMENTS

OPTIONAL EQUIPMENT Komatsu machines can be supplied with optional equipment in addition to the standard equipment. If optional equipment is installed and used on your machine, read and study all operations and safety information instructions relating to the optional equipment you will be using. Failure to do so may result in damage to the equipment or injury to the operator. Komatsu cannot be held liable for damage, accident or reduction of machinery performance due to the application and use of unauthorized equipment. Always use authorized equipment on your machine.

Basic Precautions The installation of optional accessories or equipment other than those authorized by Komatsu shortens the life of the machine and may also cause problems concerning safety. It is advisable to contact a Komatsu distributor before installing any accessory not indicated in this operation and maintenance manual. In case of failure to comply with this recommendation, Komatsu declines any responsibility for accidents or damage.

Install or remove optional equipment on a firm level surface. Be sure the equipment you are installing is in good operating condition. When operations are performed using two or more people, agree to communication signals in advance and stick to them. Always use an overhead crane when lifting equipment weighing more than 25 kg (55 lb). Always support any heavy part before removing it. When heavy parts are lifted, be mindful of the objectâ&#x20AC;&#x2122;s position of the center of gravity. It is very dangerous to carry out any operation with a suspended load; therefore, always position the load on a support and make sure that it is in a safe position. When installing or removing any equipment, make sure that it is stable and cannot fall down. Never stand under loads being lifted by a crane. Take care to choose a safe position, where you do not run any risk in case the load should fall down.

Cranes must be operated by specialized personnel. Do not allow non-specialized personnel to use cranes.

For further details regarding installation and removal operations, contact your distributor.

5-2

SK1020-5N/1020-5NA

OPTIONAL ATTACHMENTS

Precautions Regarding the Installation of Equipment

The use of lengthened work equipment reduces the stability of the machine. If it is necessary to go up or down a slope, be particularly careful, since the machine may lose its balance and overturn. When installing work equipment with dimensions exceeding those of the standard equipment, be aware of the space necessary for the movements of the equipment and of the machine.

Optional Equipment Measurements ★ Specific weight of the handled material = 1.8 tons/m³

Max. Dimensions

Equipment

Max. Weight kg (lb)

Width mm (inch)

Height mm (inch)

Max. SAE Capacity m³ (cu. yd.)

Max. Operating Pressure kg/cm² (psi)

Max. Flow l/min (gpm)

Front bucket

197 (434)

1880 (74.0)

520 (20.5)

0.42 (0.55)

–

Multipurpose front bucket

–

1880 (74.0)

550 (21.6)

–

206 (2988)

80 (21.1)

Excavator

1100 (2425)

● –

❑3200 (126.0)

Excavator

206 (2988)

80 (21.1)

Excavator bucket

73 (161)

800 (31.5)

–

Hydraulic hammer

150 (331)

–

206 (2988)

80 (21.1)

Drill

190 (419)

❊600 (23.6)

–

206 (2988)

80 (21.1)

Pallet fork

160 (353)

1500 (59.0)

710 (27.9)

▲1000 (39.3 in.)

206 (2988)

–

Manure fork

120 (365)

1800 (70.8)

–

206 (2988)

–

Grapple fork

190 (419)

1800 (70.8)

–

206 (2988)

80 (21.1)

● - Maximum outreach ❑ - Maximum digging depth ❊ - Measurement referenced to the tool diameter ▲ - Maximum tooth length

SK1020-5N/1020-5NA

5-3

OPTIONAL ATTACHMENTS

Optional Equipment Measurements with the Super-flow Hydraulic System Specific weight of the handled material = 1.8 tons/m³ Max. Dimensions Height mm (inch)

Max. SAE Capacity m³ (cu. yd.)

Max. Operating Pressure kg/cm² (psi)

Max. Flow l/min (gpm)

1880 (74.0)

520 (20.5)

0.42 (0.55)

–

1880 (74.0)

550 (21.6)

–

206 (2988)

80 (21.1)

Asphalt cutter

900 (1984)

1000 (39.3)

❑

–

206 (2988)

130 (34.3)

Excavator

1100 (2425)

● –

▲3200 (126.0)

Excavator

206 (2988)

80 (21.1)

Excavator bucket

73 (161)

800 (31.5)

–

Hydraulic hammer

150 (331)

–

206 (2988)

80 (21.1)

Drill

190 (419)

❊600 (23.6)

–

206 (2988)

80 (21.1)

Pallet fork

160 (353)

1500 (59.0)

710 (27.9)

◆1000 (39.3 in.)

206 (2988)

–

Manure fork

120 (365)

1800 (70.8)

–

206 (2988)

–

Grapple fork

190 (419)

1800 (70.8)

–

206 (2988)

80 (21.1)

Equipment

Max. Weight kg (lb)

Width mm (inch)

Front bucket

197 (434)

Multipurpose front bucket

● - Maximum outreach ▲ - Maximum digging depth ❊ - Measurement referenced to the tool diameter ◆ - Maximum tooth length ❑ - Cutting depth

5-4

SK1020-5N/1020-5NA

OPTIONAL ATTACHMENTS

Changing the Equipment

Stop the machine on a firm and level surface and lower the equipment to the ground. Before getting off the machine, stop the engine, release the residual pressures by moving the equipment control levers more than once in all directions and lock the safety bars (see “Safety Bars” on page 2-27). Before starting work, make sure the quick coupler locking pins are completely engaged in, and protruding from, the retaining tabs (slots) provided on the bucket or attachment and that the coupler levers are pushed down to a horizontal (locking) position. Do not use your fingers to center the pins, since they may be injured or even cut due to sudden or uncontrolled movements. to

The machine is provided with a special tool-holder, called a universal quick coupler, which is used for the installation of buckets or optional equipment. Change the optional equipment using the same procedure adopted to change the bucket, see “Changing the Bucket or Attachment with Standard Quick Coupler” on page 2-95. Besides the assembly on the tool-holder, the hydraulic excavator also requires fastening to the machine by means of two connecting tie-rods and the hydraulic connection for the independent control of the equipment. When changing equipment with independent hydraulic circuits, stop the oil flow to the equipment with the auxiliary kit pedal and disconnect the quick disconnects before releasing the equipment from the tool-holder. See “Connecting the Hydraulic Circuit” on page 5-6.

Connecting the Excavator Couple the excavator to the quick coupler with the same procedure as the standard equipment and connect the tie rods. 1. Attach the tie-rods (1) to the excavator and secure them with the hitch pins (2). 2. Engage the tie-rods with the couplings (3) and connect the hydraulic circuit. See “Connecting the Hydraulic Circuit” on page 5-6. To disconnect the excavator from the quick coupler, proceed as follows: 3. Release the tie rods (1) from the plates (3) and disconnect the hydraulic circuit of the excavator. 4. Raise the tie rods (1) and lock them with the safety locks (4).

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OPTIONAL ATTACHMENTS

Connecting the Hydraulic Circuit

Before performing any operation on the hydraulic circuit, stop the engine and eliminate the residual pressures from the equipment circuits by operating the controls more than once, then lock the safety bars (see â&#x20AC;&#x153;Safety Barsâ&#x20AC;? on page 227). Immediately clean any area dirty with oil. After the mechanical connection of equipment with the independent hydraulic circuit, make sure that the auxiliary control pedal is in position - flow interrupted - and connect the hoses of the equipment connection to the quick disconnects (1) and (2). The quick disconnects must be in compliance with the ISO 8434-3 standard.

In case of doubt regarding the connection of the hydraulic circuit to the equipment, contact your distributor.

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OPTIONAL ATTACHMENTS

SK1020-5N/1020-5NA

5-7

OPTIONAL ATTACHMENTS

Connecting the Return Circuit with Direct Drainage into the Tank

Before performing any operation on the hydraulic circuit, stop the engine and eliminate the residual hydraulic pressures from the equipment circuits by operating the controls more than once, then lock the safety bars (see “Safety Bars” on page 2-27). Immediately clean any area dirty with oil. The machine may be fitted for the attachment of equipment with a separate return circuit directly into the tank. The return system is positioned on the left side of the loader arm and the equipment drain pipe must be connected to the union (1).

In case of doubt regarding the connection of the hydraulic circuit to the equipment, contact your distributor.

Preparing the Machine for the Use of the Excavator After the installation of the excavator, make sure that the mechanical and hydraulic connections have been done correctly and proceed as follows. 1. Press the auxiliary control pedal with your toe until engaging it in position (B); this position ensures the flow of oil to the equipment. 2. Lower the excavator stabilizers and raise the front wheels. For the use of the excavator, see the specific manufacturer’s instruction manual. 3. If the machine is equipped with rear stabilizers, lower them until the rear wheels are partially raised; this maneuver stabilizes the machine and avoids any tire overload. See “Right Stabilizer Control” on page 2-43 and see “Left Stabilizer Control” on page 2-43.

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OPTIONAL ATTACHMENTS

Using the Machine with the Excavator

Before using the excavator, read the relevant operation and maintenance manual carefully and follow the instructions. If the machine is equipped with rear stabilizers, always lower them before using the excavator. After the digging operation and before moving the machine, bring the stabilizers back to their original position. If it is necessary to travel on roads, engage all the safety locks provided. See “SAFETY LOCKS” on page 22.

Pallet Forks

Before using the forks for any operation, the operator must get acquainted with the increased dimensions of the machine and must also practice the use of the swinging movements. After grasping the material with the forks and before lifting the load, swing the equipment in such a way as to lift the tips of the forks and prevent the load from slipping. Use the lifting, swing and travel controls slowly and smoothly, to avoid jerks that may cause the load to move. Use the maximum fork width possible. The forks must always be resting on the plate and be secured in their position with the safety pins.

The pallet forks make it possible to use the machine like a normal lift truck and the controls for lifting and swinging the loads are the same used to control the standard bucket, see “Machine Controls” on page 2-25. The pallet forks may require being set to different widths (distance from each other) according to the load to be handled: adjustment is made by sliding them on the upper coupling bar; once the desired position has been found, carry out slight movements to make sure that the upper lock pin is engaged in its seat.

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5-9

OPTIONAL ATTACHMENTS

MEMORANDUM

5-10

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