Komatsu SK05J-2 Skid Steer Loader Operation and Maintenance Manual (WEAM001801)

Komatsu SK05J-2 Skid Steer Loader Operation and Maintenance Manual (WEAM001801)

Komatsu SK05J-2 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
• 1.4 PRODUCT IDENTIFICATION
  • 1.4.1 MACHINE SERIAL NUMBER
  • 1.4.2 MACHINE IDENTIFICATION PLATE
  • 1.4.3 ENGINE SERIAL NUMBER
  • 1.4.4 CAB SERIAL NUMBER
  • 1.4.5 EXCAVATOR IDENTIFICATION PLATE (if installed)
  • 1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS
• 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 OPERATOR’S 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 PREVENTING BURNS
  • 2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
  • 2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT
  • 2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE
  • 2.2.14 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 i…
• 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 MOVING THE MACHINE
  • 2.4.5 WORKING ON SLOPES
  • 2.4.6 PREVENTING ELECTROCUTION
  • 2.4.7 VISIBILITY
  • 2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES
  • 2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.4.10 WORKING ON LOOSE GROUND
  • 2.4.11 PARKING THE MACHINE
• 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
  • 2.5.1 LOADING AND UNLOADING THE MACHINE
  • 2.5.2 THE ROUTE
• 2.6 BATTERY
  • 2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES
  • 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 KEEPING THE MACHINE CLEAN
  • 2.8.7 USE OF THE ENGINE DURING MAINTENANCE
  • 2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
  • 2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
  • 2.8.10 Rules for refuelling and adding oil
  • 2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
  • 2.8.12 USING LAMPS
  • 2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
  • 2.8.14 PRECAUTIONS CONCERNING THE STARTER
  • 2.8.15 PRECAUTIONS CONCERNING high-pressure HOSES
  • 2.8.16 Precautions to be taken when WORKING ON high-pressure SYSTEMS
  • 2.8.17 Precautions for maintenance WORK INVOLVING high temperatures and pressureS
  • 2.8.18 COOLING FAN AND FAN BELT
  • 2.8.19 WASTE MATERIALS
  • 2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES
• 3.1 SAFETY LOCKS
  • 3.1.1 LOADER LOCKS
• 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 AND 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 CAB
    • 3.5.2.1 RAISING THE CAB
  • 3.5.3 STANDARD SEAT
  • 3.5.4 CUSHIONED SEAT
  • 3.5.5 SAFETY BELT
  • 3.5.6 EMERGENCY EXIT
  • 3.5.7 TECHNICAL DOCUMENTATION CASE
  • 3.5.8 FIRE EXTINGUISHER
  • 3.5.9 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
    • 3.6.5.1 STEERING (CHANGING DIRECTION)
    • 3.6.5.2 MOVING ON SLOPES
    • 3.6.5.3 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 OR LEVEL SURFACES
  • 3.13.4 LOADING MATERIAL ON SLOPES
  • 3.13.5 DIGGING METHOD
  • 3.13.6 CHANGING THE BUCKET
    • 3.13.6.1 RELEASING THE BUCKET
    • 3.13.6.2 COUPLING THE BUCKET
• 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
• 3.15 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 DEPLETED
    • 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
• 4.4 DRIVING TORQUES FOR SCREWS AND NUTS
  • 4.4.1 STANDARD DRIVING TORQUES
  • 4.4.2 SPECIFIC DRIVING TORQUES
• 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
  • 4.7.1 WHEN REQUIRED
    • 4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
    • 4.7.1.b TYRE ROTATION
    • 4.7.1.c WASHING THE COOLING CIRCUIT
    • 4.7.1.d CLEANING THE WATER SEPARATOR
    • 4.7.1.e ADJUSTING THE PARKING BRAKE
  • 4.7.2 CHECKS BEFORE STARTING
    • 4.7.2.a VARIOUS CHECKS
    • 4.7.2.b CHECKING THE RADIATOR FLUID LEVEL
    • 4.7.2.c CHECKING THE FUEL LEVEL
    • 4.7.2.d CHECKING THE ENGINE OIL LEVEL
    • 4.7.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT
    • 4.7.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER
  • 4.7.3 MAINTENANCE EVERY 10 HOURS OF OPERATION
    • 4.7.3.a LUBRICATING THE JOINTS
  • 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
  • 4.7.5 MAINTENANCE EVERY 50 HOURS OF OPERATION
    • 4.7.5.a CHECKING THE TYRE PRESSURE
    • 4.7.5.b CHECKING THE ELECTRICAL WIRING
  • 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
  • 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
    • 4.7.7.a ADJUSTING THE FAN BELT TENSION
    • 4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL
    • 4.7.7.c CHECKING THE GEARING CHAIN TENSION
    • 4.7.7.d CLEANING THE OUTSIDE OF THE RADIATORS
    • 4.7.7.e CHECKING THE WHEEL NUT DRIVING TORQUE
    • 4.7.7.f CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS
    • 4.7.7.g CHANGING THE HYDRAULIC OIL DRAIN FILTER
    • 4.7.7.h CHANGING THE ENGINE OIL
  • 4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION
    • 4.7.8.a CHANGING THE ENGINE OIL FILTER
    • 4.7.8.b CHANGING THE FUEL FILTER
    • 4.7.8.c DRAINING THE FUEL TANK
  • 4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION
    • 4.7.9.a CHANGING THE FINAL TRANSMISSION OIL
    • 4.7.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE TANK
    • 4.7.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
  • 4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION
    • 4.7.10.a CHANGING THE COOLANT
    • 4.7.10.b CHECKING THE ALTERNATOR AND THE STARTER
• 5.1 TECHNICAL DATA
  • 5.1.1 STANDARD OVERALL DIMENSIONS
    • OVERALL DIMENSIONS WITH NARROW BUCKET L 1150 AND STANDARD TYRES (27×8.50-15)
    • OVERALL DIMENSIONS WITH STANDARD BUCKET L 1270 AND STANDARD TYRES (27×8.50-15)
    • OVERALL DIMENSIONS WITH 4 in 1 BUCKET L 1360 AND STANDARD TYRES (27×8.50-15)
    • OVERALL DIMENSIONS WITH WIDE BUCKET L 1400 AND STANDARD TYRES (27×8.50-15))
    • OVERALL DIMENSIONS WITH NARROW BUCKET L 1150 AND OPTIONAL TYRES (7.00-12)
  • 5.1.2 TECHNICAL CHARACTERISTICS
    • TOTAL MASS
    • BUCKET CAPACITY
    • ENGINE
    • ELECTRICAL SYSTEM
    • SPEED
    • TYRES
• 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • 6.1.1 PRECAUTIONS REGARDING SAFETY
  • 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
  • 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
• 6.2 CHANGING THE AUTHORIZED EQUIPMENT
  • 6.2.1 CONNECTING THE EXCAVATOR
  • 6.2.2 CONNECTING THE HYDRAULIC CIRCUIT
  • 6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK
  • 6.2.4 PREPARING THE MACHINE TO USE THE EXCAVATOR
  • 6.2.5 USING THE MACHINE WITH THE EXCAVATOR
• 6.3 PALLET FORKS

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