Komatsu Utility Avance WB91R-2, Operation & Maintenance Manual

Page 1: ...4 and up Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintain ing this machine This manual should be kept inside the cab for refer ence and periodically reviewed by all personnel who will come into contact with the machine WARNING ...

Page 2: ......

Page 3: ...tations regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval Therefore it is advisable to consult the hour meter and the maintenance plan frequently Over the years Komatsu Utility Dealers have gathered considerable experience in custo...

Page 4: ...njuries The message can be used even to indicate the risk of damage to the machine only This word is used when precautions are indicated which must be taken to avoid actions that may shorten the life of the machine Komatsu Utility cannot reasonably predict every circumstance that might involve a potential hazard during the op eration or maintenance of the machine for this reason the safety message...

Page 5: ...ic system DANGER Before carrying out any electrical welding disconnect the battery and the alternator See 2 8 13 PRE CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR DANGER Install only authorized additional equipment See 6 1 AUTHORIZED OPTIONAL EQUIPMENT DANGER The machine can travel on roads only if provided with homologated equipment before travelling on roads make sure that the equipment wit...

Page 6: ...manuals if the equipment is supplied by Komatsu Utility these publications are enclosed to this manual The instructions regarding the assembly of the authorized equipment the controls requiring special ar rangement on the machine and the hydraulic couplings necessary for the operation of the equipment are grouped in the final section of this manual Komatsu Utility backhoe loaders are constructed e...

Page 7: ... paying special attention to the following indications After the start let the engine idle for 5 minutes in such a way as to warm it up gradually before actual opera tion Avoid operating the machine with the limit loads allowed or at high speed Avoid abrupt starts or accelerations useless sudden decelerations and abrupt reversals After the first 250 hours carry out the following operations in addi...

Page 8: ...ompliance with the CE harmonized standards The plate with the mark is applied inside the operator s cab on the left vertical wall of the frame in correspondence with the brake pedals MODEL SERIAL N YEAR TOTAL MAX WEIGHT ENGINE POWER MAX WEIGHT FRONT AXLE MAX WEIGHT REAR AXLE kg kw kg kg MODELLO MODEL TYP MODELE MATRICOLA N SERIAL N FABR NR SERIE NR ANNO YEAR BAUJAHR ANNEE MASSA TOTALE MAX TOTAL MA...

Page 9: ...te positioned on the rear side of the tappet cover The plate regarding the exhaust emission regulations is applied to the front side of the tappet cover RWAB0620 RWA02450 The serial number of the front axle is stamped on the plate posi tioned on the right side of the axle body RWA02460 The serial number of the rear axle is stamped on the plate posi tioned on the right side of the axle body ...

Page 10: ...WA02540 The transmission serial number is stamped on the plate pos tioned on the right side of the transmission case RWA02500 The cab serial number is stamped on the plate positioned on the right center pillar RWA18190 The serial number is stamped on the plate positioned inside the canopy on the front right part ...

Page 11: ...INTRODUCTION 9 1 4 9 SERIAL NUMBERS AND DEALER S ADDRESS Machine n Model Engine n Front axle n Rear axle n Transmission n Dealer Address Tel Person to contact NOTES Canopy n Cab n ...

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Page 13: ...OF THE NOISE PLATES ON MACHINES WITH CAB model WB93R 2 27 2 1 5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 28 2 2 GENERAL PRECAUTIONS 29 2 2 1 GENERAL SAFETY RULES 29 2 2 2 SAFETY DEVICES AND GUARDS 29 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS 29 2 2 4 UNAUTHORIZED MODIFICATIONS 30 2 2 5 LEAVING THE OPERATOR S SEAT 30 2 2 6 GETTING ON AND OFF THE MACHINE 31 2 2 7 CHECKING THE REAR VIEW MIRRO...

Page 14: ...4 EQUIPMENT 46 2 8 5 WORKING UNDER THE MACHINE 46 2 8 6 CLEANING THE MACHINE 46 2 8 7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS 47 2 8 8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 47 2 8 9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 48 2 8 10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP 49 2 8 11 CHECKING THE COOLANT LEVEL IN THE RADIATO...

Page 15: ...1 MACHINE CONTROLS Standard version 77 3 3 6 2 MACHINE CONTROLS Version with servo controls available upon request 78 3 4 FUSES AND RELAYS 106 3 4 1 EQUIPMENT FUSES AND RELAYS 106 3 4 1 1 FUSES 107 3 4 1 2 RELAYS 108 3 4 2 ENGINE FUSES AND RELAYS 108 3 4 2 1 FUSES 109 3 4 2 2 RELAYS 109 3 4 3 SIDE DASHBOARD RELAYS 110 3 4 4 SIDE DASHBOARD RELAYS AND FUSES Only with servo controls 110 3 4 2 1 FUSES...

Page 16: ...TO BE TAKEN IN THE WARM SEASON 139 3 12 USING THE MACHINE AS A LOADER 140 3 12 1 BUCKET POSITION INDICATOR 140 3 12 2 ORGANIZING THE WORK AREA 140 3 12 2 1 LOADING HEAPED AND LEVEL MATERIAL 141 3 12 2 2 LOADING OPERATIONS ON SLOPES 142 3 12 3 CHANGING THE STANDARD FRONT BUCKET 142 3 13 USING THE MACHINE AS AN EXCAVATOR 143 3 13 1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OU...

Page 17: ...WHEN REQUIRED 182 4 7 1 a CHECKING CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE 182 4 7 1 b CHECKING AND CLEANING THE CAB AIR FILTER 183 4 7 1 c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER only for machines with air conditioner 184 4 7 1 d BLEEDING THE BRAKING CIRCUIT 185 4 7 1 e CLEANING THE WATER SEPARATOR 186 4 7 1 f CHECKING AND ADJUSTING THE FRONT WHEEL TOE IN 186 4 7 1 g CHECKING AN...

Page 18: ... 10 a CHANGING THE ENGINE OIL 207 4 7 10 b CHANGING THE ENGINE OIL FILTER 208 4 7 10 c CHANGING THE HYDRAULIC SYSTEM OIL FILTER 209 4 7 10 d CHANGING THE FUEL FILTER 210 4 7 10 e DRAINING THE FUEL TANK 211 4 7 10 f DRAINING THE HYDRAULIC OIL TANK Only for machines in which the synthetic biodegradable oil type HEES is used 212 4 7 10 g CLEANING THE OUTSIDE OF THE RADIATORS 213 4 7 10 h CLEANING THE...

Page 19: ...STICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB91R 2 239 6 1 2 2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB93R 2 240 6 2 FRONT EQUIPMENT QUICK COUPLING DEVICES 241 6 2 1 MANUAL CONTROL QUICK COUPLING 241 6 2 2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET 242 6 2 3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW 242 6 3 4in1 BUCK...

Page 20: ...TH UNIDIRECTIONAL OIL FLOW 264 6 8 1 DESCRIPTION AND CONTROL 264 6 8 1 1 VERSION WITH STANDARD CONTROLS 264 6 8 1 2 VERSION WITH SERVO CONTROLS if installed 264 6 8 2 INSTALLING AND CONNECTING THE EQUIPMENT 265 6 8 3 MAINTENANCE 265 6 9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET 266 6 9 1 DESCRIPTION AND CONTROL 266 6 9 1 1 VERSION WITH STANDARD CONTROLS 266 6 9 1 2 VERSION WITH SERV...

Page 21: ...SAFETY AND ACCIDENT PREVENTION ...

Page 22: ...n made of water and detergent Do not use fuel petrol or solvents If the plates are damaged ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer In case of replacement of a component provided with a safety plate make sure that this plate is applied also on the new piece The machine can be provided with other plates in addition to those indicated below keep also to the instruc tions...

Page 23: ...SAFETY NOISE AND VIBRATION PLATES 21 RWA30460 RWA00020 RWA00020 RWA00190 RWA00030 RWA37700 RWA00160 RWA00150 ...

Page 24: ...ust know the symbols contained in the pictograms perfectly the following description illustrates what they look like and their respective meanings RWA00020 Do not approach or stand in the equipment operating radius when the boom and the bucket are raised RWA00010 Do not open or remove the hood when the engine is running RWA34380 BIO OIL Only for machines in which the synthetic biodegradable oil ty...

Page 25: ...AULIC OIL TOPPING UP REFUELLING ENGINE LUBRICATING OIL FILTER FUEL FILTER ENGINE AIR SUCTION FILTER RWA00030 Carefully read the contents of the manual before using the ma chine or performing maintenance operations RWA00050 D RWA00040 RWA00080 D RWA00060 RWA00090 ...

Page 26: ...LATES 24 ENGINE COOLANT ENGINE COOLANT PRESSURE HYDRAULIC OIL LEVEL HYDRAULIC OIL FILTER ELECTRIC OUTLET TRANSMISSION OIL LEVEL HYDRAULIC TRANSMISSION OIL FILTER RWA00130 RWA00110 RWA00100 RWA00070 12 V RWA00120 RWA00180 RWA00170 ...

Page 27: ...SAFETY NOISE AND VIBRATION PLATES 25 ANCHORAGE POINT EMERGENCY EXIT BOOM LOCK SWING LOCK BRAKE OIL DO NOT LIFT MORE THAN 1000 kg RWA00200 RWA00190 RWA00160 RWA00150 RWA00140 1000 Kg RWA00210 ...

Page 28: ...etrol or solvents If the plates are damaged ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer In case of replacement of a component provided with a noise plate make sure that this plate is applied also on the new piece RWA37710 ISO 6396 2000 14 EC 2000 14 EC RWA37720 This value indicates the noise level outside the machine and refers to the noise perceived by persons in the vic...

Page 29: ...tergent Do not use fuel petrol or solvents If the plates are damaged ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer In case of replacement of a component provided with a noise plate make sure that this plate is applied also on the new piece RWA37710 ISO 6396 2000 14 EC 2000 14 EC RWA37720 This value indicates the noise level outside the machine and refers to the noise percei...

Page 30: ...SUBJECTED According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine the upper limbs are subjected to vibrations lower than 2 5 m sq sec while the seated part of the body is subject to vibrations lower than 0 5 m sq sec ...

Page 31: ...y belt see 3 5 7 SAFETY BELT Do not remove the safety devices and always keep them in good operating conditions Any improper use of the safety devices may result in serious injuries or even death RWA00960 Do not wear large or loose clothes rings and watches and do not approach the machine with loose long hair since they can get entagled in the moving parts of the machine and cause se rious injurie...

Page 32: ...osition See 2 4 11 PARK ING THE MACHINE Before leaving the operator s seat carry out the following oper ations in the sequence indicated below 1 Rest the equipment onto the ground 2 Connect the safety devices of the controls 3 Apply the parking brake 4 Shift the reversing gear lever to the neutral position 5 Stop the engine IMPORTANT If the machine is equipped with backhoe servo controls before le...

Page 33: ...se mud or rubble Safety canopy RWA04790 RWA00340 Make sure that the rear view mirrors are clean and correcly positioned they must allow the operator to see the rear of the machine with no need to move the chest with respect to the normal work position If the rear view mirrors should move or break during work stop the machine immediately and fasten or change them Working without checking the back o...

Page 34: ...idual pres sure before removing it The hot fluid that spurts out may cause serious burns Before checking the engine oil and hydraulic circuit oil level stop the engine and let the oil cool down The hot oil that can be sprayed out of the tank may cause serious burns RWA01000 RWA01010 Asbestos powder can be hazardous to your health if it is in haled If you handle materials containing asbestos fibers...

Page 35: ...sinfectants bandages medicins etc It is necessary to know what to do in case of fire Make sure that you have the phone numbers of the persons or structures you may need to contact in case of an emergency at hand either at the work site and where maintenance opera tions are performed If the cab is inadvertently hit or the machine overturns during work the cab may be damaged with consequent reductio...

Page 36: ...hem inneffective 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 RWA01040 Completely remove all wood chips rubbish paper and other flammable materials that may have accumulated inside the en gine compartment since they can cause fires Check the fuel and hydraulic system pipes for leak...

Page 37: ...n order to ensure perfect visibility Adjust the rear view mirrors if they have moved so that the operator sitting in the driving position can clearly see the back of the machine If any window light or mirror is damaged change it Make sure that the road lights stoplights direction indicators and working lights are properly working If neces sary change the faulty bulbs with new ones making sure that...

Page 38: ...engaging the safety coupling The arm and bucket must in any case be com pletely folded 5 The backhoe must be rotated and resting on the structure This is the only position homologated for road travel in Italy 6 For travelling with folded backhoe the unit must be moved on its guide in such a way as to be positioned to wards the road center against the lock and with the bucket facing the road side 7...

Page 39: ...the machine is equipped with this acoustic alarm 1 before any reversal make sure that it functions correctly See 3 3 6 pos 1 REVERSING GEAR LEVER to check the functionality of the alarm RWAB0630 1 30 40 cm RWA00350 When moving the machine position the front bucket at about 30 40 cm from the ground this position makes it possible to evaluate the space required for the movements more precisely and a...

Page 40: ...n these conditions it may slipi Before working on a slope always check the efficiency of the brakes engage a low gear and the four wheel drive Do not travel down slopes in neutral you may lose control of the machine and cause serious injuries and even death Avoid disengaging the gearshift with the push button posi tioned on the loader control lever When travelling down a slope engage a low gear so...

Page 41: ...to be done first in case of electrocution 5 Keep the phone number of the electricity company and of the nearest first aid station at hand If the work equipment gets accidentally entangled in the ca bles the operator must not leave the cab until the electricity company has insulated the line When carrying out this kind of operations warn everyone standing in the work area to keep at the minimum dis...

Page 42: ... acceleration and abrupt steering with reduced steering radius If the machine is used to clear snow or as snowplough on roads installing the specific optional equipment and even chains if necessary be careful to the road shoulders and to any object obstacle buried in the snow way side posts milestones signs just above the asphalt etc When working in tunnels galleries under electric cables or other...

Page 43: ...ocks under the front and rear wheels Always rest the work equipment on the ground if it is neces sary to park with raised arms make sure that the safety locks are engaged Always engage the control lever safety locks IMPORTANT If the machine is equipped with backhoe servo controls always engage the control locking safety device by press ing the relevant switch see 3 3 6 2 MACHINE CONTROLS Version w...

Page 44: ... have the same length Position the ramps with a maximum inclination of 15 Make sure that the ramp surface is clean and there is no trace of grease oil soil and ice remove dirt from the wheels before starting to load the machine on the vehicle The machine must be loaded on the vehicle with the bucket di rected forwards that is in the direction of advancement of the vehicle Do not correct the trajec...

Page 45: ...l sparks or naked flames Before working with batteries stop the engine and remove the ignition key Avoid short circuiting the battery terminals through accidental contact with metal objects or tools or through the inversion of the terminals Tighten the battery terminals securely Loose terminals may generate sparks and even cause the explosion of the battery RWA01190 When starting the machine with ...

Page 46: ...ds A twisted cables B deformed cables C During the removal no one can be allowed to get near the ma chines or the cable Do not get astride the cable Remove the machine only as much as necessary to permit the required repairs Do not remove the machine in any way other than that indicat ed in paragraph 3 15 1 HOW TO REMOVE THE MACHINE CAUTION The maximum applicable force for each draw hook is F 6200...

Page 47: ... performed Do not use worn damaged low quality tools or tools that are not suitable for the tasks to be performed in order to avoid any personal injuryti After use always clean the tools carefully and put them in the appropriate compartment positioned inside the seat support After use carefully clean the tools and put them in the com partment obtained inside the seat support If the operator plans ...

Page 48: ...ools or broken pieces are dan gerous because they may cause someone to slip or trip Al ways keep the machine and the work site clean and tidy To clean the machine use a pressurized jet of warm water or steam and the appropriate detergents available on the market Do not use gas oil oil or solvents since the former leave an oily coat that favours the sticking of dust while the latter even if weak da...

Page 49: ...rvo controls always engage the control locking safety de vice by pressing the relevant switch see 3 3 6 2 MACHINE CONTROLS Version with servo controls pos 27 When carrying out maintenance operations do not touch the moving parts of the machine and avoid wearing large and loose clothes Periodically change the following components which are important for safety and fire prevention Fuel supply system...

Page 50: ...trol le vers apply the parking brake and carry out any maintenance operation with the help of another person an operator must re main on board and the words to be used during the operation must be agreed upon IMPORTANT If the machine is equipped with backhoe servo controls always engage the control locking safety device by press ing the relevant switch see 3 3 6 2 MACHINE CONTROLS Version with ser...

Page 51: ...and avoid smoking When refuelling hold the fuel gun firmly and keep it constantly in contact with the filler until you have finished in order to avoid sparks due to static electricity Do not fill the tank completely in order to leave room for the fu el to expand RWA01340 Let the engine and the radiator cool down before checking the coolant level in the radiator If it is necessary to remove the cap...

Page 52: ...able At the end of the operation reconnect first the positive ca ble and then the negative cable If electrical welding operations are to be carried out on the ma chine it is necessary to disconnect the battery and also the al ternator Start the engine only when correctly seated in the driving posi tion Do not attempt to start the engine by causing a short circuit with the terminals of the starter ...

Page 53: ...mpletely release the pres sures and the residual pressure present in the tank Small leakages from pipes under pressure and the resulting jets are extremely dangerous since they can perforate the skin and penetrate in the blood circulation or injure the eyes For this reason always wear goggles and thick gloves during the inspections and use a piece of cardboard or a sheet of ply wood to check for o...

Page 54: ...harmful substances such as oil fuel solvents used filters and batteries RWA01680 When being inflated the tyres may explode and come off thus causing serious accidents Before inflating the tyres always check the conditions of the rims and the outer conditions of the tyres themselves in order make sure that there are no dents cuts torn plies or other de fects It is advisable to have these checks and...

Page 55: ...cab and there fore towards the operator A RWA33390 6 0 1 2 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 biodegradable oil can be used onl...

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Page 57: ...THE MACHINE AND ITS OPERATIONS ...

Page 58: ...ovided with two safety locks that have two distinct essential functions a SAFETY LOCK 1 for the position of the arm when the machine is subjected to maintenance on the engine unit and inspection of the hydraulic system equipment and of the auxiliary equipment housed in the engine compart ment and in any case to the inspections and maintenance operations that must be carried out with raised arm A b...

Page 59: ...cations of the safety locks concern a Installation of the front bucket swing lock 1 b Engaging of the front loader 2 control lever lock c Installation of the teeth protection casings 3 RWA04370 C 3 1 RWA26210 2 1 RWAA0770 RWA03640 3 ...

Page 60: ...tioned on the side dashboard See 3 3 2 pos 20 3 Raise the boom completely and engage the safety lock 1 by pressing the switch again led off 4 Rotate the boom and insert the antirotation pin 2 5 Install the safety chains 5 for the stabilizers 6 Stop the engine and shift the levers 3 to settle the safety locks 7 Engage the control lever lock 4 IMPORTANT If the machine is equipped with backhoe servo ...

Page 61: ...WS 3 2 GENERAL VIEWS 3 2 1 FRONT GENERAL VIEW 1 Front bucket 2 Bucket dumping cylinder 3 Bucket lifting arm 4 Cab 5 Rear axle 6 Fuel tank 7 Lifting cylinder 8 Front axle 1 2 4 5 6 7 8 3 RWA30480 2 LEFT RIGHT FORWARD ...

Page 62: ... cylinder 3 Arm 4 Boom 5 Arm cylinder 6 Boom cylinder 7 Hydraulic oil tank 8 Stabilizers 9 Backhoe sliding guides 10 Backhoe locking cylinders 11 Boom swing cylinders 12 Sliding plate 13 Revolving support LEFT RIGHT FORWARD RWA02130 1 2 3 4 5 6 7 8 9 10 12 11 13 ...

Page 63: ...erator pedal 8 Brake pedals 9 Side dashboard 10 Hand accelerator 11 Parking brake 12 Arm and swing control lever Standard version ISO system controls Boom and swing control lever On request Komatsu and X system controls 13 Boom and bucket control lever Standard version ISO system controls Arm and bucket control lever On request Komatsu and X system controls 14 Right stabilizer control lever 15 Lef...

Page 64: ...dal 8 Brake pedals 9 Side dashboard 10 Hand accelerator 11 Parking brake 12 Arm and swing control lever Standard version ISO system controls Boom and swing control lever On request only with Komatsu system controls Pattern Change 13 Boom and bucket control lever Standard version ISO system controls Arm and bucket control lever On request only with Komatsu system controls Pattern Change 14 Left sta...

Page 65: ...1 2 3 4 5 6 7 8 9 14 13 12 10 11 RWA31470 1 2 3 4 RWA02580 1 2 3 4 This warning light comes on together with the acoustic alarm when the transmission oil exceeds the maximum temperature al lowed when it comes on immediately stop the machine select the neutral gear and let it cool down with the engine running at about 1200 rpm until the warning light goes out If this inconven ience occurs repeatedl...

Page 66: ... It comes on when the high beam is operated through the dimmer switch pos 9 This warning light indicates that the parking brake has been ap plied or that the brake fluid level is low if it comes on for the lat ter cause stop the machine and top up the brake fluid If this occurs repeatedly check the braking system in order to eliminate any leakage It comes on when the differential is locked by mean...

Page 67: ...o signal left pull the lever backward position B to signal right Press C to sound the horn 12 11 10 RWA31480 12 10 11 This is a two position switch When it is pressed it remains pressed lights up and engages the four wheel drive In this position also the warning light pos 3 comes on When the switch is pressed again it returns to its initial position and disengages the four wheel drive while the ma...

Page 68: ... 13 This is a two position switch When pressed it remains in the low position the relevant red led comes on and the safety valves installed on the cylinders of the front loader are deactivated When released it returns to its original position the safety valves are activated and at the same time the red led goes out IMPORTANT Always deactivate the electric safety valves when the load stabilizer sys...

Page 69: ...warning light 8 Engine coolant temperature warning light 9 Available for optional equipment warn ing lights 10 Acoustic alarm 11 Rear working light switch 12 Rear windshield wiper washer switch 13 Revolving light switch 14 Rear horn 15 Air conditioner switch if provided 16 Load stabilizer system switch if provid ed 17 Ignition switch 18 Fan switch 19 Backhoe speed control button 20 Backhoe boom lo...

Page 70: ...coustic alarm 11 Rear working light switch 12 Rear windshield wiper washer switch 13 Revolving light switch 14 Rear horn 15 Air conditioner switch if provided 16 Load stabilizer system switch if provid ed 17 Ignition switch 18 Fan switch 19 Backhoe speed control button 20 Backhoe boom lock switch 21 Backhoe sliding lock switch 22 Backhoe control locking switch only in the version with servo contro...

Page 71: ...ey is in position I see pos 17 This is a combined instrument that indicates the engine running speed with a pointer while the number of operating hours ap pears on the lower displays The reading is to be considered valid for the calculation of the maintenance intervals RWA02630 5 10 15 20 25 30 RPM x 100 electronic 2 RWA02640 5 10 15 20 25 30 RPM x 100 electronic 3 It indicates the engine coolant ...

Page 72: ... the machine immediately and try to find the cause of the failure It comes on when the ignition key is turned to position for the cold start of the engine see 3 6 2 2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES This warning light comes on together with the acoustic alarm when the starting circuit is energized and goes out when the en gine exceeds the idling rpm if this warning light remains on e...

Page 73: ...tch by turning it to position I and is automati cally disconnected when the engine starts The sounding of the alarm when the machine is working signals the following anomalies Insufficient engine oil pressure Overheating of the engine cooling circuit Overheating of the transmission oil Faulty alternator or worn belt Incorrect position of the seat while the machine is moving 10 RWA02720 This switch...

Page 74: ... the LSS system see 6 11 LOAD STABILIZER SYSTEM LSS The ignition switch is a rotary key switch with four positions marked with the following symbols OFF I START For further details on the use of this switch see 3 6 2 STARTING THE ENGINE 0 1 2 RWA31210 17 It is a three speed switch and operates the fan motor Turn the switch clockwise to increase the fan speed If operated after the opening of the ta...

Page 75: ...ling The safety lock is en gaged when the switch is off led off while its disengagement takes place when the switch is on led on See 3 3 6 1 pos 8 IMPORTANT If the machine is equipped with backhoe servo controls the switch 20 is positioned on the upper part of the side dash board as shown in Fig A The specific function of the switch 20 can be disabled through the control locking switch 22 For furt...

Page 76: ...For further information on the operation of this switch see 3 3 6 2 MACHINE CONTROLS Version with servo controls pos 27 23 22 23 RWA37780 22 24 24 This switch controls the lifting and lowering of the left stabiliz er Push the switch 23 towards the outside of the cab to lower the left stabilizer To lift the stabilizer pull the switch 23 towards the inside of the cab The function of the switch 23 ca...

Page 77: ...utton must be used with low gears and reduced speed only when it is necessary to make the rear driving wheels integral with each other in case of slipping See 3 3 6 pos 11 DIFFERENTIAL LOCKING PUSH BUT TON Press the push button to open the bucket when the push button is released the bucket stops See 3 3 6 pos 12 4IN1 BUCKET OPENING CONTROL Press the push button to fold the bucket when the push but...

Page 78: ... of the side dash board and is powered by a 12V supply It is used to for the inser tion of the cigarette lighter and is perfectly compatible with the cigarette lighters available on the market The same outlet can also be used to recharge mobile phones before using it remove the safety plug A RWA37790 4 The battery disconnection switch 4 is positioned on the left side of the machine inside the engi...

Page 79: ...ch 10 Declutch push button 11 Differential locking push button 12 4in1 bucket opening control push button 13 4in1 bucket folding control push button 14 Front loader speed control push button 15 Declutch push button 16 Left backhoe control lever 17 Right backhoe control lever 18 Left stabilizer control lever 19 Right stabilizer control lever 20 Steering wheel adjustment locking lever RWA34950 0 1 2...

Page 80: ...ontrol switch 10 Declutch push button 11 Differential locking push button 12 4in1 bucket opening control push button 13 4in1 bucket folding control push button 14 Front loader speed control push button 15 Declutch push button 16 Left backhoe control lever 17 Right backhoe control lever 18 Left stabilizer control switch 19 Right stabilizer control switch 20 Steering wheel adjustment locking lever 1...

Page 81: ...servo control system 28 Offset boom left swing control push button if installed and only with servo control system 29 Offset arm right swing control push button if installed and only with servo control system 30 Horn push button only with servo control system 31 Telescopic arm extension control push button if installed and only with servo control system 32 Telescopic arm retraction control push bu...

Page 82: ...nce with these rules may cause serious accidents IMPORTANT Operate the lever only when the engine is running at low speed The engine can be started only with the lever in neutral position N If the operator deems it necessary the machine may also be equipped with an acoustic alarm for move ments in reverse This device can be installed on an apposite area on the rear part of the frame see 2 4 3 CHEC...

Page 83: ...ns to the left When the pedals 2 are used individually reduce the speed and keep the bucket as low as possible The pedals must always be connected with each other by means of the connection pin A when using the higher gears and travelling on roads IMPORTANT When the machine is running at high speed and only with the 4th gear engaged the braking power is increased with the automatic connection of t...

Page 84: ... right and controls the raising and lowering of the arm and the folding and dumping of the bucket according to the orthogonal movements listed below If the machine is properly equipped the shifting of the lever to position E defined by a click sets the loader to a free or floating position that is to a position in which it can automatically follow the undulation of the ground Furthermore when the ...

Page 85: ... hydraulic dis tributors corresponding to each single function are engaged at the same time N Neutral A Arm lowering Bucket folding B Arm lowering Bucket dumping C Arm raising Bucket dumping D Arm raising Bucket folding IMPORTANT All the movements are locked when the safety pin is en gaged See 3 1 1 FRONT LOADER LOCKS CAUTION Always insert the safety pin when travelling on roads D A B C N RWA00550...

Page 86: ...aving the machine even if temporarily By means of the lever 5 it is possible to engage one of the four available gears which are arranged according to the diagram The choice of the gear to be engaged is up to the operator it is advisable to use the low gears for heavy duty applications and to use the high gears for movements on flat surfaces or high speed travelling This precaution serves to prote...

Page 87: ...r even death The parking brake must be released if the machine breaks down and it is necessary to remove it Braking is obtained by pulling the lever completely upwards until the safety device is coupled release is obtained by pressing the lower safety device while releasing the lever which automatically returns downward CAUTION The warning light 7 positioned on the front dashboard see 3 3 1 pos 7 ...

Page 88: ... pushed forward since in this way consumptions will be consider ably reduced and the life of either the engine and the machine will be longer For a correct use of the lever keep to the indications given on the plate 1 applied inside the right dashboard The plate 1 is characterized by two coloured areas the green area A and the red area B referring to different engine rotation speeds Green area A t...

Page 89: ...e safety lock To engage the safety lock proceed as follows Select the uncoupling position by pressing the switch 8 led on fold the arm and the bucket raise the boom completely and engage the lock by pressing the switch again led off Before moving the machine make sure that the lock is properly positioned in its seat IMPORTANT If the machine is equipped with backhoe servo controls the switch 8 is p...

Page 90: ...rt of the side dashboard as shown in Fig B The switch 9 can be disabled by means of the switch 27 For further information see BACKHOE CONTROL LOCK ING SWITCH pos 27 CAUTION Before starting any operation make sure that the backhoe is locked on its guides RWA37840 B 27 9 RWA03300 10 DANGER Do not use this button for more than 15 20 seconds Do not use this button during travel on normal roads and esp...

Page 91: ...s stuck in sand or mud The locking of the differential is obtained by simply pressing the button 11 and only with the gears engaged 1st 2nd or 3rd The locking is automatically disconnected when the wheels re turn to two wheel drive RWA03320 12 On the machines provided with the 4in1 bucket the distributor for the opening of the bucket is controlled through the push but ton 12 positioned on the load...

Page 92: ...elivery when the push button is released the oil delivery returns to the standard operat ing values It is advisable to use the push button without interruption for no more than 5 6 seconds RWA03350 A A 15 DANGER Do not use this push button for more than 15 20 seconds Do not use this push button when travelling downhill since this function releases the clutch and sets the ma chine in neutral The pu...

Page 93: ...with the backhoe equipment or in any case with the seat rotated by 180 with respect to the regular driving posi tion Remember that the operator must carry out any movement of the machine while seated in the correct driv ing position with locked seat and fastened safety belt Before leaving the working position lower the equipment to the ground and do not stop the engine if the safety lock is not en...

Page 94: ... lower the equipment to the ground always engage the safety device to lock the backhoe controls by pressing the switch 27 and raise both joysticks 16 17 towards the rear of the machine Before starting to use the controls check the control pat tern by carrying out short manoeuvres in order to make sure the all the movements corresponds to those shown on the decals When travelling on roads always en...

Page 95: ...ated by the going out of the relevant warning light 5 At the end of work if possible lower the equipment to the ground and engage the control locking device by pressing the switch 27 again The locking of the controls is confirmed by the coming on of the relevant warning light 6 Before rotating the seat to the driving position press the le vers 21 22 and at the same time raise the joysticks 16 17 t...

Page 96: ...erated in directions that are inclined with respect to the machine axis simultaneous move ments 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 opening Boom swing to the left B Arm opening Boom swing to the right C Arm folding Boom swing to the right D Arm folding Boom swin...

Page 97: ... operated in directions that are inclined with respect to the machine axis simultaneous move ments 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 Boom lowering and swing to the left B Boom lowering and swing to the right C Boom raising and swing to the right D Boom raising and...

Page 98: ...erated in directions that are inclined with respect to the machine axis simultaneous move ments 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 Boom raising and swing to the left B Boom lowering and swing to the left C Boom lowering and swing to the right D Boom raising and swi...

Page 99: ...mpletely raised When travelling on roads withdraw the stabilizers com pletely and engage the safety locks Engage also the backhoe control locking device by press ing the switch 27 These lever switches are positioned on the upper part of the side dashboard and control the lowering and lifting of the machine stabilizers during digging operations Push the switches 18 and 19 towards the outside of the...

Page 100: ...s of the operator It is possible to choose among different positions for the adjust ment proceed as follows 1 After stopping the machine and the engine turn the lever 20 anticlockwise to release the steering wheel see Fig A 2 Adjust the steering wheel by moving it forward and backward until finding the desired position see Fig B Turn the lever 20 clockwise to lock the steering wheel in the desired...

Page 101: ... moderately trying to accompany them to the desired positions At the end of digging operations with the backhoe always bring the joysticks back to the vertical position 21 22 RWA37920 RWA37970 DANGER The operator must adjust the supports while seated in the driving position before starting work and with the ma chine completely still Before adjusting these knobs always make sure that the backhoe co...

Page 102: ... 26 anticlockwise as indicated by the arrow B 2 After adjusting both joysticks make sure that their position is within the desired values It is also possible to adjust the stroke of the joysticks when these are not used and are brought to the vertical position Once they have been lifted make sure that the safety distance between the joystick 2 and the rear window 3 is such as to prevent any contac...

Page 103: ...be disabled by pressing the switch 27 positioned on the upper part of the side dashboard The locking of the controls is confirmed by the coming on of the cor responding warning light To enable the backhoe controls press the switch 27 again and keep it pressed until the warning light goes out Every time the machine is stopped the control locking device 27 is automatically reset and all the backhoe ...

Page 104: ...ICATION OF THE OFFSET DEVICE IMPORTANT When the control safety device 27 is engaged all the movements are inhibited See 27 BACKHOE CONTROL LOCKING SWITCH Only with servo controls 28 RWA37980 27 RWA37860 This is a single function push button positioned on the right joy stick lever and allows the offset boom to be swung to the right To swing the boom press the push button 29 to stop the boom release...

Page 105: ...ice 27 is engaged the func tion of the horn is inhibited See 27 BACKHOE CONTROL LOCKING SWITCH Only with servo controls 30 RWA38000 27 RWA37860 This is a single function push button positioned on the right joy stick lever and controls the extension of the telescopic arm To extend the arm press the push button 31 to stop the arm re lease the push button For the use of the telescopic arm see 6 5 BAC...

Page 106: ... the use of the telescopic arm see 6 5 BACKHOE TELE SCOPIC ARM IMPORTANT When the control safety device 27 is engaged all the movements are inhibited See 27 BACKHOE CONTROL LOCKING SWITCH Only with servo controls RWA38020 32 27 RWA37860 To operate the demolition hammer press this push button to stop the hammer release the push button For the use of the demolition hammer see 6 6 ARRANGE MENT FOR TH...

Page 107: ...ge control lever 34 has two positions Pos 1 ISO control pattern Lever in position A Pos 2 OPTIONAL control pattern Lever in position B The pattern change control lever 34 is held in its position by means of a safety screw 1 When it is necessary to change the control pattern raise the mat and loosen the safety screw 1 un til releasing the lever 34 completely Select the desired control pattern by ro...

Page 108: ... replace them only with new fuses having the same capacity If the engine does not turn when the ignition switch is brought to posi START check the engine start fuse and if necessary change it The fuses and relays are grouped on a single base positioned inside the front dashboard and protected by a flap door 1 The following tables indicate the characteristics and the func tions of the single fuses ...

Page 109: ...hts Return to dig if installed Optional solenoid valve Transmission disengagement relay power supply F4 A B C Brown Red Light blue 7 5 10 15 Four wheel drive Front windshield wiper Direction selector High beam F5 A B C Red Light blue Light blue 10 15 15 Heating motor relay Power Economy unit Seat electronic unit Rear working lights Front working lights F6 A B C Light blue Brown Red 15 7 5 10 Rear ...

Page 110: ...l drive relay K4 Start relay K5 Low beam relay K6 High beam relay K7 Direction selector power supply relay K8 Front horn relay K9 Blinking relay K10 4th gear signalling relay The fuses and relays are grouped on a single base positioned inside the engine compartment and are protected by a cover 1 This unit can be reached by opening the engine hood See 3 5 1 ENGINE HOOD RWAB0650 RWAB0640 1 ...

Page 111: ... Orange 40 Engine start circuit F4 Orange 40 Heating and air conditioning fan High and low beam Electric outlet POSITION DESCRIPTION 1 Engine stop enabling timer 2 Preheating timer 3 Glow plug preheating relay 4 Solenoid pull relay engine stop 5 Safety relay against repeated start 6 Battery alarm warning light resistance F3 F2 F1 F4 4 3 RWA38210 6 2 1 5 ...

Page 112: ...8 POSITION DESCRIPTION 1 Differential locking stop lights 2 Seat safety relay 3 Automatic power relay 4 Return to dig relay if installed 5 Fan 3rd speed relay only with A C system 6 Fan relay RWA38220 8 7 1 2 3 4 5 6 RWA38230 5 4 1 2 F3 The relay 1 the unit 2 and the fuse F3 are installed only if the machine is equipped with backhoe servo controls They are positioned inside the right dashboard and...

Page 113: ... out any maintenance operation inside the engine compartment park the machine on firm and flat ground raise the loader arm and engage the safety lock Non compliance with these rules may result in serious accidents After releasing the lock press the push button 1 raise the hood 2 and open it completely To close the hood lower it slowly and push it downwards until the lock snaps Lock the hood RWAB01...

Page 114: ...b features a rear upper window that can be opened completely once opened this window must be se cured to the upper part of the cab parallel to the roof The rear lower window instead is fixed The side windows can be opened partially or completely even if the doors are completely closed These solutions are particularly useful during the summer since they ensure constant air circulation and therefore...

Page 115: ...t the same time push the lever toward the outside of the cab After lifting the lever 3 push its end downwards in order to engage it in the upper coupling pin 5 as shown in Fig B 3 B RWAB0180 5 If it is necessary to open the rear side windows completely pro ceed as follows 1 Release the lever 3 from the upper coupling pin 5 follow ing the direction indicated by the arrow shown in Fig C 3 C RWAB0190...

Page 116: ...t always be engaged in the lower 4 or upper 5 coupling pin by means of the lever 3 When the rear windows are rotated towards the front of the machine in order to open them completely make sure that they are perfectly locked in the relevant rubber blocks 7 Periodically lubricate the rubber blocks 7 with specific greases in order to facilitate the coupling operation 7 E 6 RWAB0210 The cab access doo...

Page 117: ...t exchange di rectly from the engine cooling circuit The water supply flow is divided or excluded by means of a tap operated by the handwheel 2 positioned on the side dashboard The flow intensity is adjusted by rotating the handwheel clock wise The ventilation and heating system can also provide for the recir culation of the air inside the cab which is obtained by opening the outlet 3 This functio...

Page 118: ...ter in the engine by rotating the valve 7 po sitioned in the engine compartment clockwise 1 Press the switch 1 positioned on the right dashboard 2 Turn the knob 2 anticlockwise 3 Turn the knob 3 to select the desired air flow among the 3 options available pos 1 2 or 3 4 Once one of the three air flow speeds has been selected the green warning light of the switch 1 will come on to indicate that the...

Page 119: ... cab and is very useful when working in extremely polluted areas tunnels very dusty places small or closed places ecc To switch off the air conditioner bring the switch 1 to its initial position the going out of the relevant green warning light con firms that the air conditioner is off CAUTION Even in the periods in which the air conditioner is not used operate the compressor at low speed for appr...

Page 120: ... operator s body The adjustment of the suspension is carried out with the snap le ver 3 and can be controlled by observing the position of the in dicator 4 The operator must carry out this adjustment while seated the right suspension degree is reached when the indica tor is positioned in correspondence with the seat frame If the indicator protrudes from the frame it is necessary to oper ate the le...

Page 121: ...he back the back will automatically adapt to the physical structure of the op erator The degree of suspension can be adjusted by rotating the knob 3 and checking the graduated scale on the knob itself The ideal position is reached when the weight indicated on the scale corresponds to the operator s weight In any case the op erator can choose the degree of suspension at his sole discre tion Turn th...

Page 122: ...f the operator fears that he may need a fire extinguisher 1 on the machine he must position it on the appropriate hole provid ed on the right console RWA16490 1 CAUTION Periodically make sure that the first aid kit contains the necessary disinfectants bandages medicins etc and check their condition and expiry date The first aid kit case 1 must be positioned inside the cab and precisely in the comp...

Page 123: ... box 1 can be used to store specific tools to be used for some maintenance op erations or other tools that may be useful for the operator IMPORTANT The vibrations of the machine may cause the tools stored inside the box to come out with the risk of getting entan gled in the working equipment After putting the tools in the box make sure that the cover 2 is perfectly closed RWAA10570 2 1 ...

Page 124: ...122 THIS PAGE WAS INTENTIONALLY LEFT EMPTY ...

Page 125: ...ndition of the safety 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 DANGER Do not smoke during fuel and oil topping up and do not use naked flames or non homologated lighting means to check the fuel and oil level in order not to cause fires If fuel oil or lubricant are spil...

Page 126: ...ays engage the control locking safety device by press ing the relevant switch see 3 3 6 2 MACHINE CONTROLS Version with servo controls pos 27 The checks concern 1 The coupling of the safety locks of the front bucket and the backhoe control levers 2 The hand accelerator idling position 3 The reversing gear neutral position 4 The gearshift neutral position 5 The application of the parking brake The ...

Page 127: ...that the transmission and the reversing gear control are in neu tral position A safety device does not allow the machine to be started with engaged gears or selected travel direction The machine is also equipped with an acoustic alarm that is activated when the opera tor with the engine running shifts the reversing gear control lever from the neutral position with the seat rotated and not in the c...

Page 128: ...cording to the outside temperature and the ratio is approx 1 second for each de gree below 0 C 2 Press the accelerator pedal completely and turn the ignition key to position START for maximum 15 seconds 3 As soon as the engine starts release the ignition key which will automatically return to position I and reduce the speed to idling IMPORTANT If the engine does not start at the first attempt repe...

Page 129: ...iced any anomaly must be verified and its cause must be eliminated When warming up the engine especially in the cold season it is advisable to heat also the hydraulic system oil For this reason when the coolant temperature has reached approximately 60 C proceed as follows 1 Extract the safety pin of the front bucket control lever See 3 1 SAFETY LOCKS 2 Raise and rotate the front bucket slowly and ...

Page 130: ... hydraulic oil make sure that the stabilizers have been raised and that both the front bucket and the backhoe are in transport position The control levers must be in the neutral position N At this point release the parking brake Select 1 The travel direction by shifting the control lever 1 forward F or backward R 2 The gear by means of the gearshift lever 2 3 Gradually accelerate with the accelera...

Page 131: ...ted with the rear wheels at rest In exceptional cases the locking of the differential can be per formed even with the machine running straight at very low speed that is with equal rotation speed of the rear wheels RWA03380 1 DANGER The four wheel drive must be engaged only with machine at rest or travelling at low speed When travelling on roads or removing the machine disen gage the four wheel dri...

Page 132: ...to be carried out are the following 1 Always check the work area for snow landslips gravel loose ground and anything that may suddenly modify the work con ditions 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 travelling uphill the front bucket must al ways be directed upward 4 Whe...

Page 133: ...ou are working is sufficently firm If it is necessary to work with the machine immersed in water make sure that the maximum depth does not ex ceed 50 cm and in any case that the engine cooling fan does not touch the water since it may get damaged or even break CAUTION When working in water or on muddy ground lubricate the articulations more frequently than usual After work remove any dirt or mud a...

Page 134: ...r lever to position N and apply the parking brake 3 Rest the front bucket and the backhoe bucket onto the ground if this is not possible because the space is insuffi cient the backhoe must be folded in the transport position and secured with the appropriate lock 4 Insert the safety pin of the front bucket control lever and the safety lever of the backhoe levers IMPORTANT If the machine is equipped...

Page 135: ...ral position and apply the parking brake 3 Operate the backhoe controls until the bucket teeth are in the digging position and thrust them into the ground 4 Insert the safety pin of the bucket control lever and the safety lever of the backhoe levers IMPORTANT If the machine is equipped with backhoe servo controls always engage the control locking safety device by press ing the relevant switch see ...

Page 136: ...re stopping it Before stopping the engine proceed as follows 1 Rest the front loader and backhoe equipment onto the ground 2 Shift the levers to the neutral position and connect the safety devices IMPORTANT If the machine is equipped with backhoe servo controls always engage the control locking safety device by press ing the relevant switch see 3 3 6 2 MACHINE CONTROLS Version with servo controls ...

Page 137: ...auge Position the ramps with a maximum inclination of 15 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 The machine must get on the ramps with the front bucket 1 directed forward and raised from the ground 2 Once the machine has been loaded rest the fro...

Page 138: ...pe 6 RWA01940 A RWA01950 B CAUTION During transport the machine must be secured to the vehicle with closed doors and windows 1 Check the overall dimensions the height width and weight of the means of transport machine included must be compatible with the road and any tunnel subway bridge electric or telephone line that may be found on the way 2 Keep to the regulations in force regarding signals sp...

Page 139: ...ion inhibitors and antifoam products 2 The antifreeze water ratio must be 1 1 50 antifreeze and 50 water 3 Do not use plugging additives either alone or added to the antifreeze to eliminate leakages 4 Do not mix antifreezes of different brands 5 The use of permanent antifreeze requires only the check of the level and the periodical change of the fluid It is not necessary to wash the cooling circui...

Page 140: ...ovements either forward and in reverse and operate all the bucket and backhoe cylinders slowly more than once These operations serve to warm up and fluidize the oil in the hydraulic circuit the transmission the axles and the brakes 1 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 in ...

Page 141: ...MPORTANT The coolant must be changed only if it is not permanent For the relevant specifications see 4 3 FUEL COOLANT AND LUBRICANTS 2 Make sure that the cooling fan belt is in good conditions 3 Make sure that the fins of the radiator and of the heat exchanger are clean 4 Check the radiator cap gasket and spring in case of doubt regarding tightness and setting change the cap ...

Page 142: ...he rod 1 to the guide tube level 2 If the machine is provided with automatic RETURN TO DIG de vice the horizontal position of the bucket with respect to the ground is determined by the sensor 3 positioned on the cylin der and is reached when the sensor does not detect the rod 1 any longer In case of malfunction of the device check and if necessary carry out the required adjustments To adjust the s...

Page 143: ...he return to dig device of the loader hydraulic system to accel erate the operations Once the device has been connected it lowers the arm completely and at the same time brings the bucket in perpendicular position with respect to the ground This is particularly useful for the operator since in this way the machine is ready for the successive loading phase For the correct use of the return to dig d...

Page 144: ...ER When the coupling pins are removed or installed chips may come off always use gloves goggles and helmet The change of the equipment must be carried out by two persons who must decide together the words and signals to use during operations Do not use your fingers to center the holes since the may be injured or even cut The described procedures are valid also for the coupling of the mechanical co...

Page 145: ...e machine while seated in the correct driving position with locked seat and fastened safety belt Always fasten the safety belt before starting any manoeuvre Always lower the stabilizers before starting any digging operation Before starting work alert the persons in the vicinity by means of the acoustic signal integrated in the side dashboard or in the left backhoe control lever if the machine is e...

Page 146: ... 3 13 3 SLIDING THE BACKHOE UNIT SIDEWARDS 2 Remove the boom antirotation pin introduce it in the apposite hole and release the boom from the safety lock 3 Lower the front bucket 1 to the ground force this position until lifting the front wheels 2 in order to transfer the weight onto the bucket Apply the parking brake 4 Make sure that the machine is in neutral and lock the front bucket control lev...

Page 147: ...the boom form an angle of approx 90 plant the bucket teeth onto the ground 4 Release the backhoe unit see 3 3 6 MACHINE CONTROLS pos 9 5 Make the unit slide by manoeuvring the arm CAUTION Carry out this manoeuvre by operating the arm opening folding lever smoothly in such a way as to maintain the sliding support in vertical position and therefore facilitate its sliding 6 Lock the unit IMPORTANT If...

Page 148: ...ts facilitate the filling of the bucket and therefore increase productivity 4 The removal depth must be correct and suitable to the type of ground excessive depth may lock the move ments overload the engine and the pump and slow down the digging operations 5 To dump on heaps dump the bucket as soon as it gets near the dumping area the inertia resulting from the movement will ensure the compaction ...

Page 149: ...described procedures are valid also for the coupling of the mechanical constraints of the optional equipment 1 Position the bucket on level ground directing it so that the flat part of the bucket back rests on the ground 2 Remove first the tie rod pin 1 and then the arm connection pin 2 3 Change the bucket taking care to clean the pins and bush ings perfectly and to grease the pins slightly before...

Page 150: ...ed flames near the machine Place a container under the machine to gather the fuel and prevent it from spreading around If some fuel is spilt clean the dirty surface immediately IMPORTANT To protect the cylinder rods when the machine is not used position the work equipment as shown in the figure This serves to prevent the cylinder rods from rusting RWA30600 ...

Page 151: ...anent coolant 6 Drain the normal fuel and fill the tank with at least 10 liters of special washing and protecting fuel 7 Let the engine run for about 10 minutes in such a way as to eliminate the residual 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 d...

Page 152: ...engine oil coolant fuel hydraulic circuit oil 3 Make sure that the battery charge is sufficient and install the battery 4 Disconnect the engine stop solenoid 5 Turn the ignition 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 R...

Page 153: ...ing only its motive power or in case of breakdown use a wire rope as shown in the figures on the right IMPORTANT Before recovering the machine shift the gear lever to neu tral and disengage the four wheel drive RWA30610 RWA30620 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 necessa...

Page 154: ...rinse the involved part with plenty of water If the acid gets into the eyes immediately rinse with plen ty of water and consult a doctor without delay When working on the battery always wear goggles and gloves When removing the battery disconnect first the earth ca ble when installing the battery connect first the posi tive cable If a tool comes into contact with the positive terminal and the mach...

Page 155: ...current load that must be transferred The battery to be used for the starting must have greater capacity or at least the same capacity as the battery of the machine to be started Make sure that the cables and pliers are neither corroded nor damaged Make sure that the pliers hold the terminals firmly 1 Make sure that the ignition key is in position 2 Connect the positive poles of the two batteries ...

Page 156: ...eck and repair Charge battery Change Starter pinion engages and then dis engages Battery charge insufficient Charge battery Starter makes engine run slowly Battery charge insufficient Faulty starter Charge battery Change Starter disengages before engine has started Faulty cables Battery charge insufficient Check and repair Charge battery Engine oil pressure warning light does not come on when engi...

Page 157: ...very pump Clutch shaft or piston rings Leakages due to clutch piston pump locked open Top up Clean element and seat Change Change rings Clean valve carefully Pump delivery insufficient Oil level Suction filter clogged Faulty pump Top up Clean filter Change Overheating Damaged rings Faulty pump Oil level Dirty heat exchanger Damaged heat exchanger Remove disassemble and reas semble the unit Change ...

Page 158: ...tor Change Temperature indicator pointer always on the left end of the scale Faulty thermostat Faulty indicator Change Change Engine does not start with starter run ning 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 ...

Page 159: ...MAINTENANCE ...

Page 160: ... onto the machine Instructions for arc welding 1 Turn the ignition key to position 2 Disconnect the battery first the negative pole and then the positive pole 3 Disconnect the alternator 4 Do not apply more than 200V continuously 5 Connect the earth cable within 1 m from the point in which the welding must be carried out 6 Avoid placing gaskets and bearings between the welding area and the earth c...

Page 161: ...ank with the oil of the new brand DANGER Oils filters the coolant and the battery are considered special waste and must be collected and dis posed of according to the regulations in force The 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 the fumes ...

Page 162: ...ion oil GM DEXRON II D Front and rear axle oil UTTO FLUID Braking system oil GM DEXRON II D Fuel With ambient temperature over 10 C ASTM D975 no 2 diesel oil With ambient temperature under 10 C ASTM D975 no 1 diesel oil Radiator Permanent ethylene glycol based antifreeze with corrosion inhibitor for protection up to 36 C The engine oil must be selected very carefully since it lubricates the engine...

Page 163: ...lling make sure that there is no water on the fuel drum cover and take care not to draw the conden sate from the drum bottom If fuel runs out or if the fuel filter has been replaced it is necessary to bleed the circuit Be extremely careful when performing maintenance operations on the hydraulic system since soon after work the oil is very hot The circuit is pressurized not only during work but als...

Page 164: ... optional device to the fuses ignition switch battery relays etc for the installation of any optional equipment contact your Komatsu Utility Dealer If any electric welding operation has to be carried out disconnect the battery and the alternator 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 ...

Page 165: ...ity ITEM CODE DESCRIPTION Q TY CHANGE INTERVAL Hydraulic oil filter 848101178 Cartridge 1 EVERY 500 HOURS Engine oil filter YM119005 35100 Cartridge 1 EVERY 500 HOURS Fuel filter YM123907 55800 Cartridge 1 EVERY 500 HOURS Converter oil filter CA0040952 Cartridge 1 EVERY 1000 HOURS Air cleaner 848101189 848101190 Main cartridge Safety cartridge 1 1 WHEN REQUIRED WHEN REQUIRED Front bucket 312204054...

Page 166: ... 4 3 1 150 92 Front axle Differential OIL UTTO FLUID 6 5 6 5 Final reduction gear ea 1 1 Rear axle Differential 14 5 14 5 Final reduction gear ea 1 5 1 5 Hydraulic transmission OIL GM DEXRON II D DEXRON is a registered trademark of General Motors Corporation 20 17 Braking system 0 8 0 8 Fuel tank DIESEL OIL 130 Engine cooling system PERMANENT COOLANT 15 LUBRICATION POINTS CONSISTENCY TYPE Articula...

Page 167: ...ngine oil change interval by a half Use Komatsu Utility genuine products whose characteristics have been specifically formulated and approved for use in the engine in the work equipment hydraulic circuit in the transmission and in the axles and brakes First filling quantity total quantity of oil including the oil for the components and pipes Oil change quantity quantity of oil necessary to fill th...

Page 168: ...radable oil in the hydraulic system empty the system com pletely disconnecting the cylinders and all the parts that may contain ordinary oil and replace the drain filter with a new one Start the engine and let it idle without using the work equipment wait until the oil reaches a tempera ture of at least 40 C then start moving the equipment so that all the parts of the system are filled with oil St...

Page 169: ...5 1 23 2 45 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16 18 20 22 24 2 2 5 2 5 2 5 3 24 27 30 32 36 19 5 2 27 3 38 4 52 6 66 7 191 21 262 28 372 40 511 57 644 70 27 3 37 4 53 6 73 8 92 10 268 29 366 36 524 57 719 80 905 98 27 30 3 3 5 41 46 96 10 131 14 945 100 1287 140 135 15 184 20 1329 140 1810 190 ITEM DESCRIPTION kgm Nm Cab Front support screw...

Page 170: ...ICATION 4 5 1 LUBRICATION DIAGRAM IMPORTANT For the lubrication procedures for the single points see 4 7 MAINTENANCE PLAN 1000 h 500 h 250 h 50 h 10 h RWA00720 2000 h Hydraulic oil Grease Engine oil Transmission oil Brake oil ...

Page 171: ...s see 4 5 1 LUBRICATION DIAGRAM The points indicated are symmetrical and must be lubricated every 10 hours The fork sliding bars and the safety pins must be lubricated with grease only to protect them from oxi dation The fork joints A must be lubricated only if the forks are used 10 h A RWA34410 Grease Grease ...

Page 172: ... 5 3 LUBRICATION DIAGRAM Front bucket rapid couplings IMPORTANT For the other greasing points see 4 5 1 LUBRICATION DIAGRAM The points indicated are symmetrical and must be lubricated every 10 hours RWAA9200 10 h Grease ...

Page 173: ... DIAGRAM Telescopic arm IMPORTANT For the other greasing points see 4 5 1 LUBRICATION DIAGRAM Lubricate the telescopic arm guides only if the sliding shoes are made of brass Plastic shoes do not require lubrication 10 h RWA35390 Grease ...

Page 174: ...LUBRICATION 172 4 5 5 LUBRICATION DIAGRAM Offset device IMPORTANT For the other greasing points see 4 5 1 LUBRICATION DIAGRAM 10 h RWA03080 Grease ...

Page 175: ...ediately in case of failures or anomalies even if the time interval prescribed for their change has not elapsed yet If the pipe clamps show signs of deterioration like deformations or cracks provide for changing them together with the pipes In addition to the periodical change of the components listed in the following page the inspections described here below are to be carried out on the hydraulic...

Page 176: ...ts that must be pe riodically changed When changing pipes always change O rings gaskets and analogous components No Components related to safety that periodically need changing Q ty Change interval 1 Fuel pipe Fuel tank precleaner 1 Every 2 years or 4000 hours which ever occurs first 2 Fuel pipe Precleaner fuel pump 1 3 Fuel pipe Fuel pump fuel filter 1 4 Fuel pipe Fuel filter injection pump 1 5 F...

Page 177: ... pe riodically changed When changing pipes always change O rings gaskets and analogous components No Components related to safety that periodically need changing Q ty Change interval 1 Hydraulic pipe Hydraulic pump iron tube 1 Every 2 years or 4000 hours which ever occurs first 2 Hydraulic pipe Iron tube backhoe distributor 1 3 Hydraulic pipe Iron tube loader distributor 1 4 Hydraulic pipe Hydraul...

Page 178: ...ing Q ty Change interval 6 Hydraulic pipes Cylinders loader arm 4 Every 2 years or 4000 hours which ever occurs first 7 Hydraulic pipes Cylinders loader bucket 4 8 Hydraulic pipes Cylinders 4in1 bucket 4 9 Hydraulic pipes Cylinders Backhoe boom 2 10 Hydraulic pipes Cylinders Backhoe arm 2 11 Hydraulic pipes Cylinders Backhoe bucket 4 RWA31540 8 7 6 6 7 8 8 8 ...

Page 179: ...spare parts catalogue section regarding the components connected with safety and the components that must be pe riodically changed When changing pipes always change O rings gaskets and analogous components 10 9 RWA31550 11 OPERATOR S SAFETY No Components related to safety that periodically need changing Q ty Change interval 1 Safety belt 1 Every 4 years 1 RWA31240 ...

Page 180: ...cuit Wash 185 e Water separator Clean 186 f Front wheels Adjust toe in 186 g Parking brake Check and adjust 187 h Service brake Check braking 188 j Brake pedals Adjust stroke 189 k Return to dig Adjust 189 l Stabilizers Check and adjust clearance 190 N PART OPERATION PAGE a Hydraulic oil drain filter Change cartridge 191 b Hydraulic oil Change 191 N PART OPERATION PAGE a Various checks 192 b Coola...

Page 181: ... MAINTENANCE EVERY 250 HOURS OF OPERATION N PART OPERATION PAGE a Joints Lubricate 196 N PART OPERATION PAGE a Hydraulic oil drain filter Only for machines with synthetic biodegrad able oil Change 209 N PART OPERATION PAGE a Radiator Check level 198 b Braking system Check oil level 198 c Propeller shafts Lubricate 6 points 199 d Front axle joints and central coupling Lubricate 5 points 200 e Front...

Page 182: ...d tension 203 c Battery Check electrolyte level 204 d Front axle Check levels n 3 205 e Rear axle Check levels n 3 205 f Hydraulic transmission Check level 206 g Front and rear wheels Check screw tightening 206 N PART OPERATION PAGE a Hydraulic oil and suction filter Only for machines with synthetic biodegrad able oil Change oil and clean filter 219 N PART OPERATION PAGE a Engine oil Change 207 b ...

Page 183: ...smission filter Change 218 e Engine valves Check clearance 218 N PART OPERATION PAGE a Hydraulic oil and suction filter Change oil and clean filter 219 b Coolant Change 222 c Braking system oil Change 224 d Alternator and starter Check 225 e A C system coolant only for machines with air conditioner Check quantity 225 N PART OPERATION PAGE a A C system filter dehydrating filter only for machines wi...

Page 184: ...ering element 3 4 Slightly strike the filtering element 3 on the palm of your hand in such a way as to remove the dust and blow com pressed air on the inner surface keeping the air jet at a dis tance of approximately 15 cm and taking care to prevent the pressure from exceeding 4 5 bars 5 Carefully clean the inside of the filter case 4 taking care to prevent foreign bodies from getting into the suc...

Page 185: ...ion for the ventilation of the cab is protected by a fil ter positioned on the right side of the cab This filter blocks all the impurities contained in the air and must be cleaned whenever a decrease in air circulation is observed The filter can be reached from the outside of the cab To clean the filtering element proceed as follows 1 Remove the screws 1 remove the external protection 2 and extrac...

Page 186: ...erved The filter can be reached from the inside of the cab and to clean the filtering ele ment it is necessary to proceed as follows 1 Remove the screws 4 remove the outer guard 5 and ex tract the filtering element 6 2 Hit the element slightly on the palm of your hand to eliminate the dust and blow compressed air on its surfaces keeping the jet at a distance of about 15 cm and making sure that the...

Page 187: ...keeping it pressed loosen the drain screw 1 of the relevant brake until the ped al reaches the end of stroke Use a 13 mm spanner 3 Keeping the pedal at the end of its stroke tighten the drain screw 1 4 Release the brake pedal wait for a few minutes and repeat the operations described above until no air bubbles can be noticed in the oil that flows out of the drain screw 1 IMPORTANT When bleeding th...

Page 188: ...If the filtering element is excessively clogged or damaged provide for changing it This check must be carried out according to time intervals fixed by the operator since any anomaly regarding the wheel toe in is due to impacts or vibrations that depend on the type of surface on which the machine works Another reason that shoud lead the operator to perform this check is the excessive wear of the fr...

Page 189: ...the machine in travel position on a straight road section and proceed up the slope with 1 5 gradient with empty buck et 3 Stop the machine with the service brake shift the reversing gear control lever to the neutral position N and stop the en gine 4 Apply the parking brake lock position release the service brake slowly and make sure that the machine does not move ADJUSTMENT 1 With the engine off r...

Page 190: ...arried out after setting the work equipment in the travel or transport position and engaging all the safety locks 1 Connect the brake pedals 2 with the pin 1 2 Release the parking brake and start the engine See 3 6 2 STARTING THE ENGINE 3 Engage the 2nd gear and the forward gear 4 Accelerate until reaching the maximum speed 5 Press the brake pedals The machine must brake smoothly on a straight lin...

Page 191: ...measure A 303 mm and adjust the brake pump rods 3 until they touch the pumping pistons lock them in this position Use a 22 mm spanner RWA13980 1 A RWA16470 2 3 RWA38040 The device for the automatic return of the front bucket to the dig ging position automatically brings the front bucket to the loading position when it is lowered to the ground The sensor is posi tioned on the right dumping cylinder...

Page 192: ...sting shoe 2 is included between 0 5 and 1 0 mm If the slack exceeds the values indicated loosen the screws 3 remove the adjusting plate 4 and remove one or more washers 5 from both the adjusting points according to the needs Once they have been removed the washers 5 must be po sitioned again between the adjusting plate 4 and the screws 3 During the adjustment check the condition of the adjusting ...

Page 193: ...ccessive changes keep to the indica tions given in the table on the right If the machine contains synthetic biodegradable oil type HEES the filter must be changed after the first 50 hours of operation 0 20 40 60 80 100 500 2000 Breaker operating ratio Replacement interval H Replacement interval for hydraulic oil RWA10900 1500 1000 Replacement interval for element Change the hydraulic oil in the ta...

Page 194: ...ing plates 8 Cleanliness of the ladders and handles used to reach the driver s seat cleanliness inside the driver s cab DANGER Do not remove the radiator cap the coolant must be checked with cold engine through the compensation tank The coolant level must be checked on the compensation tank 1 with cold engine and must be included between the lower MIN and MAX marks The check must be carried out th...

Page 195: ...ler cap 2 thoroughly and lock it RWA02620 5 10 15 20 25 30 RPM x 100 electronic 1 2 RWA38050 DANGER Soon after the machine has been stopped the engine is very hot and may cause burns let the engine cool down before carrying out any check The dipstick 1 can be reached after opening the engine hood See 3 5 1 ENGINE HOOD The oil level must be checked with cold engine and the machine at rest on level ...

Page 196: ... The oil level must be visible through the window 1 provided on the tank and it must be included between the MIN and MAX marks If the level is near the MIN mark top up through the filler 2 with the prescribed oil see 4 3 FUEL COOLANT AND LUBRI CANTS Put back the filling cap 2 Use a 24 mm hexagon spanner IMPORTANTE Do not add oil beyond the MAX mark in order to avoid damaging the hydraulic circuit ...

Page 197: ...st be carried out with full tank in order to prevent air from entering the fuel supply circuit The condensate must be drained at the end of work before the engine has completely cooled down in order to prevent freezing if the temperature gets very low The water separator can be reached after opening the engine hood See 3 5 1 ENGINE HOOD The condensate is drained by loosening the plug 1 and waiting...

Page 198: ...indicated in the figure Use a syringe and the prescribed grease See 4 3 FUEL COOLANT AND LUBRICANTS and diagram 4 5 1 IMPORTANT As a general rule it is important to consider that each cylinder is provided with two grease nipples po sitioned on the couplings and that each pin serving as fulcrum point for a movement is provided with at least one grease nipple JOINT LUBRICATION POINTS 1 Tie rod bucke...

Page 199: ...er base pin 1 point 16 Lifting cylinder head pin 1 point 17 Arm fulcrum pin 1 point 18 Arm cylinder head pin 1 point 19 Bucket cylinder base pin 1 point 20 Lever fulcrum pin 1 point 21 Bucket fulcrum pin 1 point 22 Bucket cylinder head pin 1 pointo 23 Tie rod lever coupling pin 2 points 24 Tie rod bucket coupling pin 2 points 25 Boom locking fulcrum pin 2 points RWA38060 23 24 22 19 17 18 16 10 11...

Page 200: ...and cause burns Loosen the cap slowly to release the pressure before re moving it The radiator cap can be reached after opening the engine hood See 3 5 1 ENGINE HOOD Remove the cap 1 and make sure that the fluid is very near the filling hole IMPORTANT If the level of the fluid in the radiator is low and the expan sion tank is filled with coolant check the tightness and make sure that there are no ...

Page 201: ...s by applying the greasing pump supplied together with the machine and using the prescribed grease See 4 3 FUEL COOLANT AND LUBRICANTS Once the lubrication has been carried out make sure that all the points have been lubricated and remove the contaminated grease that may have spread out of the joints RWAA10820 RWAA10830 RWAA10840 RWAA10850 ...

Page 202: ... and using the prescribed grease See 4 3 FUEL COOLANT AND LUBRICANTS Once the lubrication has been carried out remove the contami nated grease that may have spread out of the joints and of the central coupling RWAA0330 1 1 2 RWA03430 DANGER Inflate the tyres only after positioning them in a protection cage To inflate the tyre stand beside the external belt Do not exceed the pressures prescribed in...

Page 203: ...he ignition key is in position If there are signs of short circuit on the cables find out the cause and repair them always contact your Komatsu Utility Dealer for the troubleshooting Make sure that there are no disconnected cables or signs of short circuit in the electrical system Make sure that all the cables are well tightened in the relevant terminals tighten any loose cables In particular chec...

Page 204: ... and adjustments contact your Komatsu Utility Dealer Carry out the following operations together with those to be performed every 50 HOURS The fan belt can be reached after opening the engine hood See 3 5 1 ENGINE HOOD The control is manual press the belt 1 with a thumb on the in dicated pont with a force equal to approx 10 kg the resulting de flection must be approximately 10 15 mm If the deflect...

Page 205: ...ee 3 5 1 ENGINE HOOD The check is manual and consists in exerting pressure on the belt 1 with a thumb at the centre of the section between the compressor 2 and the pulley 3 If the pressure exerted is approx 10 kg the resulting deflection must be approx 7 10 mm When the belt is still new the resulting deflection must be ap prox 4 6 mm If the deflection exceeds these values loosen the screw 4 that f...

Page 206: ...t fastening screws 3 Use a 17 mm hexagon span ner The electrolyte level in each cell must be about 6 mm above the plate edge if necessary top up with distilled water only To reach the filling holes of the cells first remove the guard 4 If on the contrary the level is low because some fluid has been spilled add sulphuric acid after having diluted it until reaching the concentration suitable for the...

Page 207: ...reaches the hole 2 if this does not occur top up using the prescribed oil See 4 3 FUEL COOLANT AND LUBRICANTS Use a 17 mm spanner RWAA0300 1 RWAA0310 2 DIFFERENTIAL This check is visual and serves to verify if the lubricant reaches the hole 1 if necessary top up using the prescribed oil See 4 3 FUEL COOLANT AND LUBRICANTS The level hole 1 must be used also as filling hole use a 1 2 square spanner ...

Page 208: ...must be checked with the engine idling and the oil at running temperature The oil must always reach the maximum level or be very near it To top up use the dipstick opening 1 and the prescribed oil See 4 3 FUEL COOLANT AND LUBRICANTS RWAB0310 MAX MIN 1 This check serves to restore the correct driving torque of the wheels on the hubs The driving torque must be checked by means of a dynamomet ric spa...

Page 209: ...ing the change makes the ground slippery therefore use anti slip shoes and imme diately remove any trace of oil from the floor Oils filters the coolant and the battery are considered special waste and must be collected and disposed of ac cording to the anti pollution regulations in force When changing the engine oil change also the filter See 4 7 10 b CHANGING THE ENGINE OIL FILTER Proceed as foll...

Page 210: ...d special waste and must be collected and disposed of ac cording to the anti pollution regulations in force This operation must be carried out at every oil change Proceed as follows 1 Unscrew and remove the old filter 1 by means of the special spanner provided 2 Clean the contact surface between the gasket and the filter support 2 3 Fill the new filter with engine oil lubricate the gasket and scre...

Page 211: ...ar The filter can be reached after removing the upper platform 1 with the relevant fastening screws 2 Use a 17 mm hexagon spanner 1 Remove the filling cap 3 Use a 24 mm spanner 2 Remove the screws 4 that fix the filter cover 5 remove the cartridge 6 and the filter casing 7 Use a 13 mm spanner 3 Carefully clean the filter casing 7 making sure that the filter gasket 8 and the casing gasket 9 are in ...

Page 212: ...WA10710 DANGER Change the filtering element after work when the engine has cooled down to 40 45 C When these operations are carried out fuel may be spilled clean the dirty areas immediately in order to pre vent any risk of slipping or fire Oils filters the coolant and the battery are considered special waste and must be collected and disposed of ac cording to the anti pollution regulations in forc...

Page 213: ...d above and repeat the operation at least twice RWA01960 RWA01970 DANGER When draining the fuel tank avoid spilling fuel since this may cause fires If some fuel is accidentally spilled clean the dirty area im mediately in order to prevent it from getting slippery and to avoid fires This operation serves to let all the impurities and the condensate flow out of the tank remove the lower plug 1 and w...

Page 214: ...ttom flow out of the tank itself for this purpose carry out the following operations in the given sequence 1 Remove the screws 1 and the platform 2 Use a 17 mm spanner 2 Loosen the filling cap 3 to release the residual pressure from the tank use a 24 mm spanner 3 Remove the drain plug 4 until the condensate has flown out of the tank completely Use a 41 mm spanner 4 Put back the filling cap 3 and t...

Page 215: ...th a low pressure water or steam washing cycle the specific products available on the mar ket can certainly be used provided that the instructions given on the package are followed and that the washed parts are carefully dried at the end of the operations After the washing cycle put back the guard 1 with the relevant fastening screws 2 Use a 17 mm hexagon spanner IMPORTANT Do not use products cont...

Page 216: ...e specific products available on the market can certainly be used provided that the instructions given on the package are followed and that the washed parts are carefully dried at the end of the operations IMPORTANT Do not use products containing even a slight quantity of oily substances since these facilitate the adhesion of dust which affects the heat exchange adversely Carry out this operation ...

Page 217: ...the oil flows out remove the plug 1 Use a 17 mm spanner 2 Once the oil has been drained put back the plug 2 and pour oil of the prescribed type through the hole 1 until reaching the level corresponding to the lower edge of the hole itself 3 Put back the plug 1 FINAL REDUCTION GEARS 1 Move the machine until the plug 3 is in low position on the vertical axis 2 Remove the plug 3 and let the used oil ...

Page 218: ...aching the level corresponding to the lower edge of the hole itself IMPORTANT With this operation both axle shafts are filled with oil be fore checking the level definitively and putting back the plug wait a few minutes in order to permit the uniform distribution of the oil 3 Put back the plug 1 FINAL REDUCTION GEARS 1 Move the machine until the drain plug 4 is in low position on the vertical axis...

Page 219: ...l change also the filter See 4 7 11 d CHANGING THE HYDRAULIC TRANSMISSION FIL TER Proceed as follows 1 Open the engine hood See 3 5 1 ENGINE HOOD 2 Remove the drain plug 1 and let the oil flow into a container with suitable capacity Use a 27 mm spanner 3 Carefully remove the filter and change it See 4 7 11 d CHANGING THE HYDRAULIC TRANSMISSION FILTER 4 Put back the plug 1 and pour oil until reachi...

Page 220: ...ge of the trans mission oil Proceed as follows 1 Raise the front mat and remove the cover 1 Use a 13 mm spanner 2 Unscrew and remove the old filter 2 by means of the special spanner provided 3 Clean the contact surface between the gasket and the filter support 3 4 Lubricate the gasket fit it in its seat and screw the filter thor oughly until it touches the gasket 5 Give another half turn by hand 6...

Page 221: ...e coolant and the battery are considered special waste and must be collected and disposed of ac cording to the anti pollution regulations in force The filter can be reached after removing the platform 1 with the relevant fastening screws 2 Use a 17 mm spanner 1 Remove the filling cap 3 Use a 24 mm spanner 2 Remove the drain plug 4 and let the oil flow out gathering it into a container with suitabl...

Page 222: ...ck the filling cap 3 start the engine and operate the machine making each piston move several times in order to bleed the system Stop the machine in maintenance position check the oil level again and if necessary top up Always use oil of the prescribed type see 4 3 FUEL COOLANT AND LUBRICANTS 11 Put back the upper platform 1 with the relevant fastening screws 2 IMPORTANT Do not start the engine wi...

Page 223: ...eteriorates more rapidly than the oil of the machines used for simple digging operations Perform the oil changes according to the indications giv en in the table beside 0 20 40 60 80 100 500 2000 Breaker operating ratio Replacement interval H Replacement interval for hydraulic oil RWA07630 1500 1000 ...

Page 224: ... Remove the front guard 1 after removing the relevant fas tening screws 2 Use a 17 mm hexagon spanner 2 Open the engine hood See 14 1 ENGINE HOOD 3 Loosen and remove the upper cap 3 of the radiator 4 Open the radiator drain cock 4 see Fig A loosen the drain valve 5 positioned on the filter carrier head and let the fluid flow out collecting it in a container with suitable capacity re member that th...

Page 225: ...223 7 Fill the tank 6 until reaching the maximum level 8 Close the engine hood 9 Put back the front guard 1 with the relevant fastening screws 2 Use a 17 mm hexagon spanner 4 90 B RWA38080 RWAB0420 5 RWAB0430 6 MAX MIN ...

Page 226: ...arried out with the machine positioned on level ground and locked by means of the parking brake Drain the oil and wash the system proceeding as follows 1 Apply a small pipe for the collection of the oil to the drain screws 1 and loosen them Use a 13 mm spanner 2 Open the engine hood See 3 5 1 ENGINE HOOD and re move the cap 2 of the tank 3 3 Operate the brake pedals connected with each other until...

Page 227: ...e eyes or in case of contact with the skin it may cause blindness or frostbite Furthermore to avoid any explosion do not generate sparks and do not use naked flames near the air conditioner Oils filters coolants and batteries are considered special waste and must be recovered and disposed of according to the antipollution regulations in force The maintenance of the air conditioning system must be ...

Page 228: ...ny explosion do not generate sparks and do not use naked flames near the air conditioner Oils filters coolants and batteries are considered special waste and must be recovered and disposed of according to the antipollution regulations in force Have the dehydrating filter changed only by specialized personnel and for this purpose contact your Komatsu Utility Dealer The filter 1 must be replaced eve...

Page 229: ...TECHNICAL SPECIFICATIONS ...

Page 230: ...A 5 1 1 STANDARD OVERALL DIMENSIONS 5 1 1 1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE 5 1 1 2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE 2080 2175 2930 7185 2750 3650 2320 RWA00420 2080 2175 1650 5905 2750 3650 2320 RWA00430 ...

Page 231: ... rpm EEC 80 1269 kW 61 Maximum torque 1500 100 rpm EEC 80 1269 Nm 310 ELECTRICAL SYSTEM Alternator 12V Electrical output 80 A Earthing negative Battery 160 Ah 12V Starter kW 3 0 TRAVEL SPEEDS calculated with 18 4 26 tyres and engine at 2200 rpm GEARS 1a 2a 3a 4a R1 R2 R3 R4 km h 6 11 21 39 6 11 21 39 FRONT TYRES SIZE MAKE INFLATION PRESSURE Std 12 5 80 18 PR 10 GOOD YEAR bar 3 1 Opt 365 70 R18 SPT...

Page 232: ...69 kW 72 Maximum torque 1500 100 rpm EEC 80 1269 Nm 375 ELECTRICAL SYSTEM Alternator 12V Electrical output 80 A Earthing negative Battery 160 Ah 12V Starter kW 3 0 TRAVEL SPEEDS calculated with 18 4 26 tyres and engine at 2200 rpm GEARS 1a 2a 3a 4a R1 R2 R3 R4 km h 6 11 21 39 6 11 21 39 FRONT TYRES SIZE MAKE INFLATION PRESSURE Std 12 5 80 18 PR 10 GOOD YEAR bar 3 1 Opt 365 70 R18 SPT9 DUNLOP bar 3...

Page 233: ...s only with the machine positioned on firm and flat ground A Standard arm length L 1850 mm B Telescopic arm completely retracted C Telescopic arm completely extended D Standard operating mass E Standard backhoe bucket width and mas W 600 mm kg 160 F Operating hydraulic pressu G Lowered stabilizers P Lifting capacity Z Distance of the lifting point from the ground X Distance between the boom swing ...

Page 234: ...ax 2 m 1 m 0 1 m 2 m 1 m 0 1 m 18 5 MPa 185 Bar W 600 mm 160 Kg 7450 Kg D F E G A B C W Min 1850 Max 990 980 880 550 990 980 840 540 990 980 790 530 990 980 750 520 980 960 790 340 980 950 750 330 980 940 720 320 970 930 680 310 370 240 360 230 650 610 350 220 620 580 340 210 P Z X 1000 Kg RWA04560 ...

Page 235: ...m 1 m 0 1 m 2 m 1 m 0 1 m 18 5 MPa 185 Bar W 600 mm 160 Kg 8000 Kg D F E G A B C W Min 1850 Max 990 970 670 430 960 920 640 410 910 870 610 410 870 830 570 420 920 880 580 330 880 840 550 300 830 790 520 300 790 750 500 320 220 180 210 170 460 420 200 170 440 410 190 180 P Z X 1000 Kg RWA04570 Max Max ...

Page 236: ...Max 2 m 1 m 0 1 m 2 m 1 m 0 1 m 20 MPa 200 Bar W 600 mm 160 Kg 7450 Kg D F E G A B C W Min 1850 Max 990 980 950 550 990 980 910 540 990 980 850 530 990 980 810 520 980 970 850 340 980 970 810 330 980 970 760 320 980 970 730 310 400 240 390 230 700 660 380 220 670 620 370 210 P Z X 1000 Kg RWA04580 ...

Page 237: ... m 1 m 0 1 m 2 m 1 m 0 1 m 20 MPa 200 Bar W 600 mm 160 Kg 8000 Kg D F E G A B C W Min 1850 Max 990 980 950 550 980 970 910 540 960 950 850 530 940 890 810 520 990 950 850 340 950 900 810 330 890 850 760 320 850 810 730 310 400 240 390 230 490 450 380 220 470 430 370 210 P Z X 1000 Kg RWA04590 Max Max ...

Page 238: ...236 THIS PAGE WAS INTENTIONALLY LEFT EMPTY ...

Page 239: ...AUTHORISED OPTIONAL EQUIPMENT ...

Page 240: ...ly with this rule Komatsu Utility declines any responsibility for accidents or damage DANGER When removing or installing any equipment take the following precautions and be careful to the safety conditions Carry out installation and removal on a firm and flat surface When the operations are carried out by two or more operators decide the communication signals in advance and respect them during the...

Page 241: ...also limited according to the capacity stamped on the forks see 6 4 PAL LET FORKS Measure referred to the tool diameter Measure referred to the tool length MACHINE EQUIPMENT MAX WEIGHT kg MAX DIMENSIONS MAX ISO CAPACITY cu m MAX OPERATING PRESSURE bar MAX FLOW RATE l min Width mm Height mm Front bucket 450 2320 940 1 1 Front 4in1 bucket 750 2340 1015 1 0 185 75 Forks on front bucket 190 Pallet for...

Page 242: ...to the capacity stamped on the forks see 6 4 PAL LET FORKS Measure referred to the tool diameter Measure referred to the tool length MACHINE EQUIPMENT MAX WEIGH kg MAX DIMENSIONS MAX ISO CAPACITY m3 MAX OPERATING PRESSURE bar MAX FLOW RATE l min Width mm Height mm Front bucket 450 2320 940 1 1 Front 4in1 bucket 750 2340 1015 1 0 200 75 Forks on front bucket 190 Pallet forks 320 1800 800 BACKHOE Ba...

Page 243: ...ver 1 in such a way as to make the fulcrum pins move backwards 2 Start the machine and position it so that it is perfectly perpen dicular to the equipment to be installed 3 With the bucket control lever 2 operate in such a way as to position the fixed coupling pins 3 under the upper seats 4 on the bucket 5 4 Raise the bucket lifting arm 6 to engage the fixed pins 3 in the upper seats 4 on the buck...

Page 244: ... and the engagement of the fulcrum pins which are obtained by means of the push buttons 8 and 9 located on the lever 2 See 3 3 6 MACHINE CONTROLS pos 12 13 RWA28670 2 8 9 The 4in1 bucket and the hydraulic equipment that can be in stalled must be provided with quick couplings In this case the backward movement and the engagement of the fulcrum pins are obtained by connecting the quick couplings 10 ...

Page 245: ... hy draulic cylinders 1 controlled by an additional distributora The distributor control for the opening and folding of the bucket is operated by two push buttons 5 and 6 positioned on the loader control lever 7 that also maintains all the normal func tions See 3 3 6 pos 4 FRONT LOADER CONTROL LEVER 3 4 RWA34490 RWA34500 1 The 4in1 bucket is provided with teeth protection casing 3 If the bucket is...

Page 246: ...er to release the residual pressure that may be present in the circuits apply the parking brake When connecting the pipes take care to prevent any im purities from getting into them Proceed as follows 1 Loosen the protection plugs and remove them from the rigid pipes provided on the machine 2 Loosen and remove the protection plugs from the flexible pipes 8 and 9 of the bucket 3 Carry out the conne...

Page 247: ...rs function opening and closing by using the teeth provided on the mo bile jaw 4 to grasp them 4 Flushing and levelling with open bucket IMPORTANT To flush the ground open the bucket and move the ma chine forward working with the fixed part of the bucket To level the ground open the bucket and move the ma chine backward working with the mobile part of the buck et The operator can check the opening...

Page 248: ... the forks RWA38740 Max 500 mm Max 500 mm G F They are usually applied to the 4in1 bucket and when they are not used they must be overturned towards the back of the machine and secured with the safety pins provided The pallet forks 1 make it possible to use the machine as a normal lift truck and the controls for the lifting and oscillation are the same used to control the standard bucket See 3 3 6...

Page 249: ...ven cut Is advisable this operation should be carried out by two persons Use the lifting oscillation and shifting controls slowly and smoothly in order to avoid vibrations that may cause the load to move Maintain the greatest possible distance between the forks The forks must always rest on the blade and be positioned between two teeth in order to avoid any sideward slip ping RWA35840 1 Overturn t...

Page 250: ...e the stop nut 10 and loosen the adjusting screw 11 until completely eliminating the slack between the fork and the safety pin 3 Use a 22 mm hexagon spanner After the adjustment tighten the stop nut 10 thoroughly If the adjusting screw 11 should be excessively worn do not hesitate to replace it CAUTION The check and adjustment of the forks must be carried out on both sides with the forks at rest D...

Page 251: ...6 and the pins 7 If also the supports 8 must be removed 3 Loosen and remove the screws 9 that hold the slide bar 2 4 Hold one of the supports 8 and withdraw the slide bar 2 repeat the same operation for the other support RWA34570 A 9 B 7 6 A 8 B 2 8 1 To install the pallet forks repeat the procedure described for the removal in the reverse order taking the same precautions No specific maintenance ...

Page 252: ... of the backhoe control lever unit the movements of the levers de scribed in 3 3 6 1 pos 16 17 BACKHOE CONTROL LEVERS remain unchanged The movements of the telescopic arm are controlled as follows 1 The extension of the arm is obtained by pressing the pedal 3 with the toe 2 The retraction of the arm is obtained by pressing the pedal 3 with the heel RWA35070 3 If the machine is equipped with backho...

Page 253: ...ot used In operating conditions the safety pin 6 must be positioned as shown in Fig B RWAB0470 7 6 A 2 RWAB0460 7 6 B 2 DANGER Before releasing and extending the arm make sure that the stabilizers rest on firm ground If possible work with the backhoe centered on the guides and unload the material as near the machine as possible If it is necessary to work with misaligned backhoe or with the backhoe...

Page 254: ...eaving the operator s seat for the adjustment of the guides remove the ignition key Adjust the screws and guides one by one Do not place tools in the space between the safety locks and the arm 1 Position the machine on flat ground and lower the stabilizers 2 Raise the boom fold the bucket completely and extend the telescopic part 7 completely 3 Fold the arm until the slide guides 8 are perpendicul...

Page 255: ...the adjusting dow els 9 by 270 3 4 turn and lock them with the lock nuts 10 8 Start the machine extend and retract the telescopic arm more than once to make sure that it slides correctly CAUTION The wear limit allowed for the shoes is represented by the minimum engagement of the adjusting dowels 9 in the lock nuts the shoes must be replaced when the heads of the dowels 9 are 5 mm back with respect...

Page 256: ... since in this way pressurized oil is conveyed into the circuit when the pedal is released the oil flow is interrupted and there fore the hammer is stopped If the machine is equipped with backhoe servo controls the hammer is operated by means of the foot operated button 5 positioned on the cab floor The movements of the levers described in 3 3 6 2 MACHINE CONTROLS Version with servo controls pos 1...

Page 257: ...r compactor 1 Make sure that the position of the hammer with respect to the material to be broken is as perpendicular as possible and that the arm thrust is sufficient so that all the power of the hammer can be exploited 2 Keep the pressure of the excavator on the hammer constant as the bit penetrates in the material Always follow the hammer while it penetrates and operate the excavator arms in or...

Page 258: ...lways correct the hitting position of the ham mer by means of the bucket and arm control 5 Always make sure that the arm thrust is optimal in order to avoid harmful and useless strokes IMPORTANT During work do not use the demolition hammer with the bucket cylinder at the end of its stroke but always leave a minimum space of 5 cm RWA06450 RWA30640 ...

Page 259: ...T USES 1 Gathering or moving stones with the demolition hammer 2 Rotating the upper structure while using the hammer 3 Moving the tool while it is hitting the material to be broken 4 Working with the hammer in horizontal position or even with greater inclination RWA06480 RWA30750 RWA06460 RWA30760 ...

Page 260: ...ITION HAMMER 5 Levering with the tool after driving it into the material to be broken 6 Hitting the ground with the hammer bit 7 Lifting the machine by levering on the hammer bit with the bucket cylinder completely extended RWA29260 RWA30770 RWA06500 ...

Page 261: ... the filling cap Immediately clean any area dirty with oil For the installation of the demolition hammer it is necessary to connect the mechanical constraints of the backhoe bucket as described in 3 13 5 CHANGING THE BACKHOE BUCKET and to carry out the hydraulic connections using the pipes provided After connecting the mechanical constraints carry out the hy draulic connections by proceeding as fo...

Page 262: ...ting into them 5 Start the machine and raise the demolition hammer position ing it vertically 6 Stop the machine again and lubricate the joints See 4 5 1 LUBRICATION DIAGRAM and the hammer see the specif ic operation and maintenance manual 7 Before starting work check the tightness of the circuit DANGER Always wear thick gloves and safety goggles during this check To check the system for leaks use...

Page 263: ...Fit the pipe sealing plugs complete with the relevant gaskets DANGER Make sure that the plugs are properly tightened and that there are no leakages if the circuit is inadvert ently pressurized small leakages can be turned into thin jets that may perforate the skin or injure the eyes Always wear thick gloves and safety goggles to carry out this check To check the system for leaks use a piece of car...

Page 264: ... speed in order to ensure the stability of the machine The offset device is an integral part of the boom 3 and makes it possible to carry out digging operations beyond the machine outline If the offset device is in neutral position the boom can be used as a standard boom if it is necessary to dig beyond the machine outline the backhoe must be translated and the offset device must be operated to re...

Page 265: ...ls pos 16 and 17 The movements of the arm are controlled as follows 1 when the push button 7 is pressed the arm swings to the left and when the button is released the arm stops 2 when the push button 8 is pressed the arm swings to the right and when the button is released the arm stops IMPORTANT All the movements of the boom the arm and the equip ment are inhibited when the control safety device i...

Page 266: ...is delivered to the right side of the circuit and discharged from the left side of the same 2 when the pedal 1 is pressed with the heel oil is delivered to the left side of the circuit and discharged from the right side of the same The movements obtained with the backhoe levers remain un changed see 3 3 6 1 pos 16 17 BACKHOE CONTROL LE VERS except for the bucket control which is used for the posit...

Page 267: ...e the controls After releasing the residual pressure completely from the circuits turn the ignition key to position O CAUTION During the successive steps take care to prevent any im purities from getting into the circuit 2 Remove the plugs of the two pipes and of the installed equip ment 3 Connect the delivery and return pipes 4 Start the machine carry out several manoeuvres with the pedal 1 or wi...

Page 268: ...dent hydraulic cir cuit controlled by an additional distributor while for its opening and folding it is possible to use the circuit used for the opening and folding of the standard bucket excluding the control cylinder see 6 9 2 INSTALLING THE CLAMSHELL BUCKET The additional distributor that manages the swing of the clamshell bucket is controlled by means of a pedal 1 positioned on the left side o...

Page 269: ...e standard bucket is used also for opening and closing the clamshell bucket exclud ing the control cylinder See 3 3 6 2 MACHINE CONTROLS Version with servo con trols pos 16 17 and 6 9 2 INSTALLING THE CLAMSHELL BUCKET The swing movements of the bucket are controlled as follows 1 when the push button 2 is pressed the bucket swings clock wise 2 when the push button 3 is pressed the bucket swings ant...

Page 270: ...emove the standard bucket from the backhoe See 3 13 5 CHANGING THE BACKHOE BUCKET 2 Retract the bucket control piston completely 3 Connect the clamshell bucket to the arm 4 Stop the machine and move the controls in all directions to release the residual pressures IMPORTANT If the machine is equipped with backhoe servo controls to release the residual pressure from the machine circuits it is necess...

Page 271: ...gs for the opening and closing of the clamshell buck et 8 Remove the plugs from the rigid pipes of the system and connect the pipes 9 Start the machine and raise the clamshell bucket a few cen trimetres from the ground 10 Open close and swing the bucket several times in order to check the tightness of the system DANGER Always wear thick gloves and safety goggles during this check To check the syst...

Page 272: ...eturn 2 couplings for the use of a manual hydraulic hammer the con nection to the machine is made up by two flexible pipes 3 The hammer circuit is separated from the normal circuits of the machine by means of a solenoid valve controlled by a push but ton positioned on the side dashboard The operation of the push button 4 which includes a connec tion warning light energizes the solenoid valve that ...

Page 273: ...trol locking device see 3 3 6 2 MACHINE CON TROLS Version with servo controls pos 27 and operate the controls After releasing the residual pressure from the circuits completely turn the ignition key to position O 2 Turn the ignition key to positi and press the hammer control push button 4 to release the residual pressure from the hammer delivery pipe 3 Turn the ignition key to position 4 Make sure...

Page 274: ...elevant gaskets on the couplings of the machine and of the hammer DANGER Make sure that the plugs are properly tightened and that there are no leakages if the circuit is inadvert ently pressurized small leakages can be turned into thin jets that may perforate the skin or injure the eyes Always wear thick gloves and safety goggles to carry out this check To check the system for leaks use a piece of...

Page 275: ...ion the loader pressure in low position is limited to that supplied by the weight of the arms and the bucket The bucket weight is hydraulically cushioned when the machine is moving To operate the load stabilizer system LSS press the switch positioned on the side dashboard see 3 3 2 pos 16 LOAD STABILIZER SYSTEM SWITCH IMPORTANT If the machine is provided with safety valves on the front loader see ...

Page 276: ...ets drills hydraulic hammers or other equipment provided that their instal lation is authorized by Komatsu If necessary the bucket can be attached to the rapid coupling 1 even in reversed position as shown in Fig A For the assembly or disassembly of the rapid coupling device 1 on from the backhoe arm keep to the indications given in para graph 3 13 5 CHANGING THE BACKHOE BUCKET The rapid coupling ...

Page 277: ... its flat part rests on the ground 2 Insert the pins 2 and 3 in this order in the apposite cou pling holes in the bucket Lock the pins 2 and 3 with the rel evant safety retainers 4 Clean the pins 2 3 and the bushings carefully before insert ing them in the bucket and if necessary grease them slightly 3 Remove the safety pin 5 with the relevant retainer 6 from the rapid coupling 1 4 Move the arm ne...

Page 278: ...d disengage the coupling pin 2 from the bucket using the bucket control levers 5 Insert the safety pin 5 with the relevant retainer 6 in the rapid coupling 1 6 Put the release lever 9 in the apposite space inside the cab DANGER Be particularly careful when releasing the equipment from the rapid coupling 1 Before definitively releasing the equipment from the rapid coupling 1 make sure that the form...

Page 279: ...R EQUIPMENT RAPID COUPLING DEVICE 277 6 12 2 MAINTENANCE For the various maintenance operations and for the checks to be carried out on the equipment rapid coupling de vice see the specific manual provided ...

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