Komatsu CK20-1 Crawler Skid Steer Loader Operation and Maintenance Manual (WEAM011000)

Komatsu CK20-1 Crawler Skid Steer Loader Operation and Maintenance Manual (WEAM011000)

Komatsu CK20-1 Crawler Skid Steer Loader Index:

• 1.1 FOREWORD
• 1.2 INFORMATION ON SAFETY
• 1.3 INTRODUCTION
  • 1.3.1 INTENDED USES
  • 1.3.2 IMPROPER OR UNAUTHORIZED USES
  • 1.3.3 MAIN CHARACTERISTICS
  • 1.3.4 RUNNING-IN
  • 1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
• 1.4 PRODUCT IDENTIFICATION
  • 1.4.1 MACHINE SERIAL NUMBER
  • 1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
    • 1.4.2.1 MACHINE SERIAL NUMBER PLATE
    • 1.4.2.2 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
  • 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
  • 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
  • 1.4.5 CAB SERIAL NUMBER
  • 1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)
  • 1.4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
  • 1.4.8 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)
• 1.5 KOMTRAX SYSTEM
  • 1.5.1 GENERAL PRECAUTIONS
• TABLE OF CONTENTS
• 2.1 SAFETY, NOISE AND VIBRATION PLATES
  • 2.1.1 POSITION OF THE SAFETY PLATES
    • 2.1.1.1 SAFETY PLATES
    • 2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR
  • 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
  • 2.1.3 POSITION OF THE NOISE PLATES
  • 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• 2.2 GENERAL PRECAUTIONS
  • 2.2.1 GENERAL SAFETY RULES
  • 2.2.2 SAFETY DEVICES AND GUARDS
  • 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
  • 2.2.4 UNAUTHORIZED MODIFICATIONS
  • 2.2.5 LEAVING THE OPERATORS SEAT
  • 2.2.6 GETTING ON AND OFF THE MACHINE
  • 2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)
  • 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL
  • 2.2.9 LIFTING OF PERSONNEL PROHIBITED
  • 2.2.10 PREVENTING BURNS
  • 2.2.11 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
  • 2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.2.13 DETERGENT FOR THE WINDOWS (only for cab with front door)
  • 2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT
  • 2.2.15 PRECAUTIONS CONCERNING THE CAB STRUCTURE
  • 2.2.16 PRECAUTIONS CONCERNING THE EQUIPMENT
• 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
  • 2.3.1 SAFETY ON THE WORK SITE
  • 2.3.2 FIRE PREVENTION
  • 2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB
  • 2.3.4 ROOM VENTILATION
  • 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)
  • 2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS – CHECKING THE WINDSHIELD WIPER BLADES (if installed)
• 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
  • 2.4.1 STARTING THE ENGINE
  • 2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS
  • 2.4.3 CHECKS FOR TRAVELLING IN REVERSE
  • 2.4.4 HAND SIGNALS
  • 2.4.5 MOVING THE MACHINE
  • 2.4.6 WORKING ON SLOPES
  • 2.4.7 PROHIBITED OPERATIONS
  • 2.4.8 PREVENTING ELECTROCUTION
  • 2.4.9 VISIBILITY
  • 2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
  • 2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.4.12 WORKING ON LOOSE GROUND
  • 2.4.13 PARKING THE MACHINE
• 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
  • 2.5.1 LOADING AND UNLOADING THE MACHINE
  • 2.5.2 TRANSPORT
• 2.6 BATTERY
  • 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
  • 2.6.2 STARTING WITH BOOSTER CABLES
• 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
• 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
  • 2.8.1 WARNING PLATES
  • 2.8.2 TOOLS
  • 2.8.3 PERSONNEL
  • 2.8.4 EQUIPMENT
  • 2.8.5 WORKING UNDER THE MACHINE
  • 2.8.6 STABILITY
  • 2.8.7 REPAIR WELDS
  • 2.8.8 KEEPING THE MACHINE CLEAN
  • 2.8.9 USE OF THE ENGINE DURING MAINTENANCE
  • 2.8.10 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
  • 2.8.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
  • 2.8.12 BATTERY MAIN SWITCH PRECAUTIONS
  • 2.8.13 RULES FOR REFUELLING AND ADDING OIL
  • 2.8.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR
  • 2.8.15 USING LAMPS
  • 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
  • 2.8.17 PRECAUTIONS CONCERNING THE STARTER
  • 2.8.18 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES
  • 2.8.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS
  • 2.8.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
  • 2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE RUBBER TRACK TENSION
  • 2.8.22 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
  • 2.8.23 HYDRAULIC ACCUMULATOR
  • 2.8.24 COOLING FAN AND FAN BELT
  • 2.8.25 CHEMICAL HAZARD
  • 2.8.26 WASTE MATERIALS
  • 2.8.27 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
  • 2.8.28 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»
  • 2.8.29 FINAL DISPOSAL OF THE MACHINE
• 3.1 SAFETY LOCKS
  • 3.1.1 LOADER LOCKS
  • 3.1.2 EXCAVATOR LOCKS (if installed)
  • 3.1.3 ASPHALT CUTTER LOCKS (if installed)
• 3.2 GENERAL VIEWS
  • 3.2.1 FRONT GENERAL VIEW
  • 3.2.2 REAR GENERAL VIEW
  • 3.2.3 CAB INSIDE GENERAL VIEW
• 3.3 INSTRUMENTS AND CONTROLS
  • 3.3.1 INSTRUMENTS
  • 3.3.2 WARNING LIGHTS
  • 3.3.3 SWITCHES UND PUSH BUTTONS
  • 3.3.4 ELECTRICAL ACCESSORIES
  • 3.3.5 MACHINE CONTROLS
• 3.4 FUSES AND RELAYS
  • 3.4.1 MACHINE FUNCTION FUSES
  • 3.4.2 MAIN FUSE
  • 3.4.3 RELAYS
• 3.5 GUARDS AND DRIVER’S SEAT
  • 3.5.1 ENGINE HOOD
  • 3.5.2 REAR PANEL
  • 3.5.3 CAB
    • 3.5.3.1 RAISING THE CAB
  • 3.5.4 STANDARD SEAT
  • 3.5.5 CUSHIONED SEAT
  • 3.5.6 SAFETY BELT
  • 3.5.7 EMERGENCY EXIT
  • 3.5.8 TECHNICAL DOCUMENTATION CASE
  • 3.5.9 FIRE EXTINGUISHER
  • 3.5.10 FIRST AID KIT
• 3.6 USE OF THE MACHINE
  • 3.6.1 CHECKS BEFORE STARTING THE ENGINE
    • 3.6.1.1 VISUAL CHECKS
    • 3.6.1.2 DAILY CHECKS
    • 3.6.1.3 OPERATIONAL CHECKS
  • 3.6.2 STARTING THE ENGINE
    • 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
    • 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
  • 3.6.3 WARMING THE ENGINE
  • 3.6.4 HEATING THE HYDRAULIC OIL
  • 3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)
    • 3.6.5.1 STEERING (CHANGING DIRECTION)
  • 3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)
    • 3.6.6.1 STEERING (CHANGING DIRECTION)
  • 3.6.7 MOVING ON SLOPES
  • 3.6.8 MAXIMUM IMMERSION DEPTH
• 3.7 PARKING THE MACHINE
  • 3.7.1 PARKING ON LEVEL GROUND
  • 3.7.2 PARKING ON SLOPES
• 3.8 STOPPING THE ENGINE
• 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
  • 3.9.1 LOADING AND UNLOADING THE MACHINE
  • 3.9.2 TRANSPORT
• 3.10 HOW TO LIFT THE MACHINE
• 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
  • 3.11.1 FUEL AND LUBRICANTS
  • 3.11.2 COOLANT
  • 3.11.3 BATTERY
  • 3.11.4 OTHER PRECAUTIONS
  • 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
• 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
• 3.13 USING THE WORK EQUIPMENT
  • 3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE
  • 3.13.2 ORGANIZING THE WORK AREA
  • 3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES
  • 3.13.4 LOADING MATERIAL ON SLOPES
  • 3.13.5 DIGGING METHOD
  • 3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING
    • 3.13.6.1 RELEASING THE BUCKET
    • 3.13.6.2 COUPLING THE BUCKET
  • 3.13.7 CHANGING THE BUCKET OR THE EQUIPMENT WITH OPTIONAL RAPID COUPLING
    • 3.13.7.1 REMOVING THE BUCKET OR THE EQUIPMENT
    • 3.13.7.2 CONNECTING THE BUCKET
    • 3.13.7.3 CHECKING THE POSITION OF THE LOCKING PINS
    • 3.13.7.4 ADJUSTING THE LOCKING PINS
  • 3.13.8 USING THE RUBBER TRACKS
    • 3.13.8.1 OPTIMAL USE OF THE RUBBER TRACKS
    • 3.13.8.2 RUBBER TRACK WARRANTY
    • 3.13.8.3 PRECAUTIONS TO BE TAKEN WHEN USING THE RUBBER TRACKS
    • 3.13.8.4 PRECAUTIONS FOR USE
• 3.14 LONG PERIODS OF INACTIVITY
  • 3.14.1 BEFORE THE PERIOD OF INACTIVITY
  • 3.14.2 DURING THE PERIOD OF INACTIVITY
  • 3.14.3 AFTER THE PERIOD OF INACTIVITY
  • 3.14.4 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE
• 3.15 TROUBLESHOOTING
  • 3.15.1 HOW TO REMOVE THE MACHINE
  • 3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED
  • 3.15.3 IF THE BATTERY IS DOWN
    • 3.15.3.1 STARTING WITH BOOSTER CABLES
  • 3.15.4 OTHER TROUBLES
    • 3.15.4.1 ELECTRICAL CIRCUIT
    • 3.15.4.2 HYDRAULIC SYSTEM
    • 3.15.4.3 ENGINE
    • 3.15.4.4 HYDROSTATIC TRANSMISSION
• 4.1 GUIDE TO MAINTENANCE
• 4.2 MAINTENANCE NOTES
  • 4.2.1 NOTES REGARDING THE ENGINE
    • 4.2.1.1 ENGINE OIL
    • 4.2.1.2 COOLANT
    • 4.2.1.3 FUEL
  • 4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
  • 4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM
  • 4.2.4 NOTES REGARDING LUBRICATION
  • 4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
• 4.3 FUEL, COOLANT AND LUBRICANTS
  • 4.3.1 COOLANT
  • 4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES
• 4.4 DRIVING TORQUES
  • 4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS
  • 4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS
  • 4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS
• 4.5 LUBRICATION
  • 4.5.1 LUBRICATION DIAGRAM
• 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY
  • 4.6.1 CRITICAL PARTS FOR SAFETY
• 4.7 MAINTENANCE PLAN
• 4.8 MAINTENANCE PROCEDURE
  • 4.8.1 WHEN REQUIRED
    • 4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
    • 4.8.1.b DRAINING THE FUEL TANK
    • 4.8.1.c RELEASING THE PARKING BRAKE (Only in case of failure and if it is impossible to start the engine)
    • 4.8.1.d CHECKING THE BATTERY CHARGE LEVEL
    • 4.8.1.e CHECKING THE RUBBER TRACKS
    • 4.8.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION
    • 4.8.1.g CHANGING THE RUBBER TRACKS
  • 4.8.2 CHECKS BEFORE STARTING
    • 4.8.2.a VARIOUS CHECKS
    • 4.8.2.b CHECKING THE COOLANT LEVEL
    • 4.8.2.c CHECKING THE FUEL LEVEL
    • 4.8.2.d CHECKING THE ENGINE OIL LEVEL
    • 4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT
    • 4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER
    • 4.8.2.g CHECKING THE WIRING SYSTEM
  • 4.8.3 MAINTENANCE AFTER THE FIRST 10 HOURS OF OPERATION
  • 4.8.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
  • 4.8.5 MAINTENANCE EVERY 50 HOURS OF OPERATION
    • 4.8.5.a CHECKING THE RUBBER TRACK TENSION
    • 4.8.5.b CHECKING THE COOLANT LEVEL IN THE RADIATOR
    • 4.8.5.c CHECKING THE OIL LEVEL IN THE REDUCTION GEARS
  • 4.8.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
  • 4.8.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
    • 4.8.7.a ADJUSTING THE FAN BELT TENSION
    • 4.8.7.b CLEANING THE OUTSIDE OF THE RADIATORS
    • 4.8.7.c LUBRICATING THE JOINTS
    • 4.8.7.d CHANGING THE ENGINE OIL
    • 4.8.7.e CHANGING THE ENGINE OIL FILTER
    • 4.8.7.f CHECKING THE DRIVING TORQUE OF THE SCREWS AND NUTS THAT FASTEN THE CARRIAGES TO THE MACHINE FRAME
  • 4.8.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES)
  • 4.8.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
    • 4.8.9.a CHANGING THE FUEL FILTER
    • 4.8.9.b CHANGE THE HYDRAULIC OIL DRAIN FILTER
    • 4.8.9.c CHANGE THE OIL IN THE TRAVEL REDUCTION GEARS
    • 4.8.9.d CLEANING THE WATER SEPARATOR
    • 4.8.9.e DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)
    • 4.8.9.f REVERSING THE SPROCKETS AND THE RUBBER TRACKS
  • 4.8.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
    • 4.8.10.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER
    • 4.8.10.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
  • 4.8.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
    • 4.8.11.a CHANGING THE COOLANT
    • 4.8.11.b CHANGING THE SUCTION FILTER
    • 4.8.11.c CHECKING THE ALTERNATOR AND THE STARTER
• 4.9 END OF SERVICE LIFE
• 5.1 TECHNICAL SPECIFICATIONS
  • 5.1.1 STANDARD MACHINE OVERALL DIMENSIONS
    • 5.1.1.1 OVERALL DIMENSIONS WITH STANDARD BUCKET L 1730
    • 5.1.1.2 OVERALL DIMENSIONS WITH BUCKET L 1550
    • 5.1.1.3 OVERALL DIMENSIONS WITH BUCKET L 1800
  • 5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT
    • 5.1.2.1 MACHINE OVERALL DIMENSIONS WITH EXCAVATOR (E30)
    • 5.1.2.2 MACHINE OVERALL DIMENSIONS WITH ASPHALT CUTTER
    • 5.1.2.3 OVERALL DIMENSIONS WITH MIXING BUCKET
    • 5.1.2.4 OVERALL DIMENSIONS WITH SWEEPER
  • 5.1.3 TECHNICAL CHARACTERISTICS
• 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • 6.1.1 PRECAUTIONS REGARDING SAFETY
  • 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
• 6.2 SPECIFICATIONS
  • 6.2.1 ARM-PIN INFORMATION
• 6.3 ATTACHMENT GUIDE
  • 6.3.1 COMBINATIONS OF WORK EQUIPMENT
  • 6.3.2 ATTACHMENT CONFIGURATION
• 6.4 CHANGING THE AUTHORIZED EQUIPMENT
  • 6.4.1 CONNECTING THE EXCAVATOR
  • 6.4.2 CONNECTING THE HYDRAULIC CIRCUIT
  • 6.4.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK
  • 6.4.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR
  • 6.4.5 USING THE MACHINE WITH THE EXCAVATOR
• 6.5 PALLET FORKS
• 6.6 CHANGING THE OPERATING PATTERN
  • 6.6.1 HOW TO CHANGE THE OPERATING PATTERN
• 6.7 HAND & FOOT CONTROL SYSTEM
  • 6.7.1 MACHINE CONTROLS
    • 6.7.1.1 TRAVEL AND STEERING CONTROL LEVERS
    • 6.7.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)
    • 6.7.1.3 AUXILIARY HYDRAULIC KIT CONTROL
  • 6.7.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)
    • 6.7.2.1 STEERING (CHANGING DIRECTION)

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