Komatsu Utility 97SF11205 Operation & Maintenance Manual Download

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TABLE OF CONTENTS

Page

MAINTENANCE

GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178

4.2

MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

4.2.1

NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

4.2.1.1

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

4.2.1.2

COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

4.2.1.3

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181

4.2.2

NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181

4.2.3

NOTES REGARDING THE ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

4.2.4

NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

4.2.5

PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . .

183

4.3

FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

184

4.3.1

HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS . . . . . . . . . . . . . .

186

4.4

DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187

4.4.1

STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187

4.4.2

SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187

4.5

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

4.5.1

LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

4.5.2

LUBRICATION DIAGRAM (4in1 bucket and pallet forks) . . . . . . . . . . . . . . . . . . . . . . . . . . .

189

4.5.3

LUBRICATION DIAGRAM (Front bucket rapid couplings) . . . . . . . . . . . . . . . . . . . . . . . . . .

190

4.5.4

LUBRICATION DIAGRAM (Telescopic arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191

4.5.5

LUBRICATION DIAGRAM (Offset device). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192

4.6

PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY . . . . . . . . . . . . . .

193

4.6.1

CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194

4.7

MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198

4.7.1

WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202

4.7.1.a

CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE . .

202

4.7.1.b

CHECKING AND CLEANING THE CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . .

203

4.7.1.c

CHECKING AND CLEANING THE RECIRCULATING AIR FILTER
(only for machines with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204

4.7.1.d

BLEEDING THE BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205

4.7.1.e

CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206

4.7.1.f

CHECKING AND ADJUSTING THE WHEEL TOE-IN . . . . . . . . . . . . . . . . . . . . .

206

4.7.1.g

CHECKING AND ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . .

207

4.7.1.h

CHECKING THE BRAKING EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208

4.7.1.j

CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE. . . . . . . . . . . . . .

209

4.7.1.k

ADJUSTING THE AUTOMATIC RETURN-TO-DIG DEVICE
OF THE FRONT BUCKET (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

209

4.7.1.l

CHECKING AND ADJUSTING THE STABILIZER SLACK . . . . . . . . . . . . . . . . .

210

4.7.2

MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER . . . . . .

211

4.7.2.a

CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211

4.7.2.b

CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211

4.7.3

CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

4.7.3.a

VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

4.7.3.b

CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

4.7.3.c

CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

4.7.3.d

CHECKING THE ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

4.7.3.e

CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL . . . . . . . . . . . . . . . . . . . . .

214

4.7.3.f

DRAINING THE WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215

4.7.4

MAINTENANCE EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216

4.7.4.a

LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216

Summary of Contents for 97SF11205

Page 1: ... 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: ...enance plan set on the electronic unit of the machine frequently The display of the maintenance plan can be obtained by means of an appropriate screen positioned on the upper part of the front dashboard In any case the main tenance plan can be also consulted on the relevant manual provided Keep to the various maintenance inter vals indicated on the screen and on the use and maintenance manual Over...

Page 4: ...or injuries 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 mes...

Page 5: ...sconnect the battery the alternator and the connector of the gearshift unit installed under the steering wheel see 2 8 13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR 2 8 15 PRECAUTIONS CONCERNING THE GEARSHIFT 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 ...

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: ...achine must be used carefully 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...

Page 8: ... in compliance 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 TOT...

Page 9: ...e plate 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 RWAA8910 The serial number of the front axle is stamped on the plate posi tioned on the right side of the axle body RWAA8920 The serial number of the rear axle is stamped on the plate posi tioned on the left side of the axle body ...

Page 10: ...ded RWA02540 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: ...PRODUCT IDENTIFICATION 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 Cab n Canopy n ...

Page 12: ...10 THIS PAGE WAS INTENTIONALLY LEFT EMPTY ...

Page 13: ...S WITH CAB 26 2 1 4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 27 2 2 GENERAL PRECAUTIONS 28 2 2 1 GENERAL SAFETY RULES 28 2 2 2 SAFETY DEVICES AND GUARDS 28 2 2 3 CLOTHING AND PERSONAL PROTECTION ITEMS 28 2 2 4 UNAUTHORIZED MODIFICATIONS 29 2 2 5 LEAVING THE OPERATOR S SEAT 29 2 2 6 GETTING ON AND OFF THE MACHINE 30 2 2 7 CHECKING THE REAR VIEW MIRRORS 30 2 2 8 PREVENTING FIRES DUE TO FUEL AND...

Page 14: ...4 EQUIPMENT 45 2 8 5 WORKING UNDER THE MACHINE 45 2 8 6 KEEPING THE MACHINE CLEAN 45 2 8 7 USE OF THE ENGINE DURING MAINTENANCE 46 2 8 8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 46 2 8 9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 47 2 8 10 RULES FOR REFUELLING AND ADDING OIL 48 2 8 11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 48 2 8 12 USING LAM...

Page 15: ...n 86 3 3 5 2 MACHINE CONTROLS Version with servo controls available upon request 87 3 4 FUSES AND RELAYS 127 3 4 1 EQUIPMENT FUSES AND RELAYS 127 3 4 1 1 FUSES 128 3 4 1 2 RELAYS 129 3 4 2 ENGINE LINE FUSES AND RELAYS 129 3 4 2 1 FUSES 130 3 4 2 2 RELAYS 130 3 4 3 SIDE DASHBOARD RELAYS 131 3 4 4 SIDE DASHBOARD RELAYS AND FUSES Only with servo controls 131 3 4 4 1 RELAYS 131 3 4 4 2 FUSES 131 3 5 G...

Page 16: ... SEASON 159 3 12 USING THE MACHINE AS A LOADER 160 3 12 1 BUCKET POSITION INDICATOR 160 3 12 2 ORGANIZING THE WORK AREA 160 3 12 2 1 LOADING HEAPED AND LEVEL MATERIAL 161 3 12 2 2 LOADING OPERATIONS ON SLOPES 162 3 12 3 CHANGING THE STANDARD FRONT BUCKET 162 3 13 USING THE MACHINE AS AN EXCAVATOR 163 3 13 1 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT 163 3 13 2 POSITIONING THE M...

Page 17: ... WHEN REQUIRED 202 4 7 1 a CHECKING CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE 202 4 7 1 b CHECKING AND CLEANING THE CAB AIR FILTER 203 4 7 1 c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER only for machines with air conditioner 204 4 7 1 d BLEEDING THE BRAKING CIRCUIT 205 4 7 1 e CLEANING THE WATER SEPARATOR 206 4 7 1 f CHECKING AND ADJUSTING THE WHEEL TOE IN 206 4 7 1 g CHECKING AND ADJ...

Page 18: ...RATION 229 4 7 10 a CHANGING THE ENGINE OIL 229 4 7 10 b CHANGING THE ENGINE OIL FILTER 230 4 7 10 c CHANGING THE HYDRAULIC SYSTEM OIL FILTER 230 4 7 10 d CHANGING THE FUEL FILTER 233 4 7 10 e DRAINING THE FUEL TANK 234 4 7 10 f DRAINING THE HYDRAULIC OIL TANK Only for machines in which the synthetic biodegradable oil type HEES is used 235 4 7 10 g CLEANING THE OUTSIDE OF THE RADIATORS 236 4 7 10 ...

Page 19: ... 2 3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW 258 6 3 4in1 BUCKET 259 6 3 1 DESCRIPTION AND CONTROLS 259 6 3 2 SAFETY DEVICES 259 6 3 3 INSTALLING THE 4in1 BUCKET 260 6 3 4 USING THE 4in1 BUCKET 261 6 3 5 MAINTENANCE 261 6 4 PALLET FORKS 262 6 4 1 DESCRIPTION 262 6 4 2 SAFETY DEVICES 262 6 4 3 USING THE FORKS 263 6 4 3 1 PREPARING THE PAL...

Page 20: ... 280 6 8 1 1 VERSION WITH STANDARD CONTROLS 280 6 8 1 2 VERSION WITH SERVO CONTROLS if installed 280 6 8 2 INSTALLING AND CONNECTING THE EQUIPMENT 281 6 8 3 MAINTENANCE 281 6 9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET 282 6 9 1 DESCRIPTION AND CONTROL 282 6 9 1 1 VERSION WITH STANDARD CONTROLS 282 6 9 1 2 VERSION WITH SERVO CONTROLS if installed 283 6 9 2 INSTALLING THE CLAMSHELL B...

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 RWA26150 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: ...r 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 vicinity o...

Page 29: ...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 30: ...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 31: ...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 32: ...se mud or rubble RWA25760 Safety canopy RWA25860 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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 Fasten the backhoe with the anti...

Page 38: ...the machine is equipped with this acoustic alarm 1 before any reversal make sure that it functions correctly See 3 3 5 pos 1 REVERSING GEAR LEVER to check the functionality of the alarm RWAB0630 1 30 40 cm RWA25870 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 39: ...n these conditions it may slip 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 40: ...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 41: ...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 42: ...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 5 2 MACHINE CONTROLS Version w...

Page 43: ...t they 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 ...

Page 44: ...ks 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 booste...

Page 45: ...n strands 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...

Page 46: ...ls provided with the machine and high quality tools suitable for the tasks to be performed Do not use worn damaged low quality tools or tools that are not suitable for the tasks to be performed in order to avoid any personal injury After use carefully clean the tools and put them in the com partment obtained inside the seat support If the operator plans to keep on the machine some tools whose dime...

Page 47: ...cattered tools 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 ...

Page 48: ...ackhoe servo controls always engage the control locking safety de vice by pressing the relevant switch see 3 3 5 2 MACHINE CONTROLS Version with servo controls pos 26 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 supp...

Page 49: ...ment control 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 5 2 MACHINE CONTROLS Version ...

Page 50: ...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 51: ...itive cable 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 s...

Page 52: ...ose or faulty fuel or oil pipe Any leakage of fuel or oil may cause fires RWA01480 DANGEROUS RWA01580 CORRECT Do not forget that the work equipment circuits are always un der pressure for this reason when it is necessary to add or drain hydraulic oil or to perform maintenance operations or in spections on the hydraulic circuit it is advisable to lower the equipment to the ground and completely rel...

Page 53: ...within the normal operating range 40 45 before carrying out the maintenance operations in accordance with the procedures indicated in the relevant sections of this manual RWA01660 Be careful to the revolving parts and do not allow anyone to get too close to these parts since clothes or parts of the body may get caught into them If hands clothes or tools touch the fan blades or the belt they may be...

Page 54: ...re that there is no one in the vicinity and position yourself in front of the tread Do not exceed the inflation pressures prescribed for the single types of tyre and make sure that all the tyres have the same pressure 1 2 RWA33380 When the machine is stopped at the end of work the exhaust pipe 1 and the tailpipe 2 are very hot In these conditions if any maintenance operation has to be carried out ...

Page 55: ...n be used only in the hydraulic system it cannot be used for the endothermic engine the transmissions the braking system etc Before introducing the synthetic biodegradable oil in the hydraulic system empty the system completely dis connecting 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 ...

Page 56: ...54 THIS PAGE WAS INTENTIONALLY LEFT EMPTY ...

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

Page 58: ... RWA04350 A 1 3 The loader arm is provided with two safety locks that have two distinct functions regarding a LOCK 1 the position of the arm when the machine is subjected to maintenance on the engine unit and inspec tion of the hydraulic system equipment and of the auxiliary equipment housed in the engine compartment and in any case to inspections and maintenance operations to be car ried out with...

Page 59: ...ications 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 casing 3 RWA04370 C 3 1 RWA31270 2 1 RWAA0770 RWA26220 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 LEFT RIGHT FORWARD RWA26240 1 2 2 4 5 6 7 8 3 ...

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 RWA26350 4 7 8 9 10 12 11 13 3 2 5 6 1 ...

Page 63: ...Front loader control lever 7 Accelerator 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 Rig...

Page 64: ...der control lever 7 Accelerator 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 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 c...

Page 65: ... 1 2 3 4 RWA02580 1 2 3 4 This warning light comes on and the acoustic alarm sounds when the transmission oil temperature exceeds the maximum value allowed when it comes on immediately stop the machine shift the gears into neutral and let it cool down with the engine running at about 1200 rpm until the warning light goes out When the warning light 1 comes on the operator is warned about the failur...

Page 66: ...ght side and controls the direction indicators the lights and the horn By rotating it one click anticlockwise it is possible to switch on the parking lights and the instrument lighting while with two clicks the low beam comes on It is possible to switch over from low beam to high beam by pushing the lever downwards position D while the lights blink when the lever is pushed upwards position E Push ...

Page 67: ... travel whenever the machine is temporarily stopped on the roadway or however in anomalous positions 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...

Page 68: ... 1 only with the rear ax le aligned 1 Partial service hours Storage and display of the service hours between two succes sive maintenance operations To set the number of service hours to zero keep the SERVICE button 2 pressed for approximately 5 seconds The display 16 will show some symbols with the respective service hours in the following order Engine oil Engine oil filter Fuel filter Air cleaner...

Page 69: ...e operations to be performed every 500 hours en gine oil fuel filter air cleaner and engine oil filter Maintenance operations to be performed every 1000 hours transmission filter Maintenance operations to be performed every 2000 hours engine coolant hydraulic oil and brake oil RWA26530 1000H RWA26520 500H RWA26540 2000H ...

Page 70: ...By pressing the CHECK button 1 it is possible to display what maintenance operation must be performed If more than one maintenance operation must be performed at the same time they can be displayed in sequence by pressing the SERVICE button 2 Every 500 hours Engine oil Fig C Engine oil filter Fig D Fuel filter Fig E Air cleaner Fig F RWA26580 500H MOTOR OIL C D 500H MOTOR FILTER CHECK SERVICE 1 2 ...

Page 71: ...n the display 17 and keeping the SERVICE button 2 pressed for approximately 5 seconds The partial number of hours is thus cancelled and the count starts again for each maintenance function from the moment in which the reset of the alarm is carried out IMPORTANT Set the service hours to zero only after performing the re quired maintenance operation The maintenance alarms must be accompanied by the ...

Page 72: ...pressure Display of the correct tyre pressure for the front and rear tyres The pressure measured when checking the tyres must corre spond to that indicated on the display For further information on the tyre pressure check see 4 7 6 e CHECKING THE TYRE PRESSURE and 5 1 3 TECHNICAL CHARACTERISTICS IMPORTANT On this screen page it is possible to select the tyre cir cumference by keeping the SERVICE b...

Page 73: ...tenance alarms and are accompanied by an acoustic sig nal When the machine is started while the steering system per forms the tests on the solenoid valves the writing KOMATSU appears for a few seconds on the display 17 Successively if no malfunction has been found the speedome ter appears on the display 17 see Figure A or B RWA27820 CHECK SERVICE 17 RWA27840 CHECK SERVICE 17 KOMATSU RWA27850 CHECK...

Page 74: ...the solenoid valve presenting the failure Crab steering solenoid valve failure All wheel steering solenoid valve failure Four wheel steering solenoid valve failure Two wheel steering solenoid valve failure RWA27260 MISTAKE CRAB ELECTROVALVE CHECK SERVICE RWA27380 MISTAKE ROUND ELECTROVALVE CHECK SERVICE RWA27440 MISTAKE 4RS ELECTROVALVE CHECK SERVICE RWA27500 MISTAKE 2RS ELECTROVALVE CHECK SERVICE...

Page 75: ...CHECK SERVICE Other operation alarms that can be shown on the display 17 are the following Alternator failure Insufficient engine oil pressure Maximum coolant temperature RWA27870 CHECK SERVICE 17 BATTERY RWA27890 CHECK SERVICE 17 LOW PRESSURE OIL RWA27900 CHECK SERVICE 17 OVERTEMP COOLANT FLUID ...

Page 76: ...y locks and carry out the necessary re pair The acoustic alarm sends out two different sounds an in termittent sound for the steering alarms and a continuous sound for all the other types of alarm For further information on the acoustic alarm see 3 3 2 SIDE INSTRUMENTS pos 10 RWA27910 CHECK SERVICE 17 AIR FILTER STOPPING RWA27920 CHECK SERVICE 17 OVERTEMP GEARING OIL ...

Page 77: ...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 78: ...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 79: ...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 80: ...mes on when the engine is running stop the machine immediately and try to find the cause of the failure When the warning light 5 comes on the operator is warned about the inconvenience even through the electronic display positioned on the front dashboard See 3 3 1 FRONT INSTRUMENTS pos 17 It comes on when the ignition key is turned to position for the cold start of the engine see 3 6 2 2 STARTING ...

Page 81: ...ed by means of the ignition key by turning it to position I and is automatically disconnected when the engine starts The sounding of the continuous alarm during the use of the ma chine signals the following Insufficient engine oil pressure Overheating of the engine cooling circuit Overheating of the transmission oil Faulty alternator or worn belt Air cleaner clogged Incorrect position of the seat ...

Page 82: ...switch must be operated when it is necessary to travel on roads and after connecting the light to the outlet see 3 3 4 pos 2 5 10 15 20 25 30 RPM x 100 electronic 16 15 14 RWA33740 15 14 R 16 It serves to warn the persons in the surrounding area before starting work and in case of danger when working with the back hoe When this switch is pressed the relevant green led comes on and the air conditio...

Page 83: ...erated after the opening of the cock installed on the heater it ensures the circulation of warm air and serves as heating switch see 3 5 4 VENTILATION AND HEATING The temperature of the air conveyed by the heater is regulated through the knob T Turn the knob clockwise to increase the temperature and coun terclockwise to reduce it If the machine is provided with air conditioning system the three kn...

Page 84: ...elling 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 5 pos 9 IMPORTANT If the machine is equipped with backhoe servo controls the switch 20 is positioned on the upper part of the side dashboard as shown in Fig A The specific function of the switch 20 can be disabled through the control locking switch 22 For furth...

Page 85: ...For further information on the operation of this switch see 3 3 5 2 MACHINE CONTROLS Version with servo controls pos 26 23 22 23 RWA37780 22 24 24 This switch controls the lifting and lowering of the left stabilizer 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 can...

Page 86: ...button is used to transform all the engine power into hydraulic power for the lifting of materials See 3 3 5 pos 11 DECLUTCH CONTROL Press the push button to open the bucket when the push button is released the bucket stops see 3 3 5 pos 12 4IN1 BUCKET OPENING CONTROL Press the push button to fold the bucket when the push button is released the bucket stops see 3 3 5 pos 13 4IN1 BUCKET FOLDING CON...

Page 87: ... 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 88: ...ck control switch 10 Backhoe sliding lock control switch 11 Declutch push button 12 4in1 bucket opening control push button 13 4in1 bucket folding control push button 14 Front loader speed control push button 15 Left backhoe control lever 16 Right backhoe control lever 17 Left stabilizer control lever 18 Right stabilizer control lever 19 Steering wheel adjustment locking lever 1 RWA38270 3 4 5 CHE...

Page 89: ... lock control switch 10 Backhoe sliding lock control switch 11 Declutch push button 12 4in1 bucket opening control push button 13 4in1 bucket folding control push button 14 Front loader speed control push button 15 Left backhoe control lever 16 Right backhoe control lever 17 Left stabilizer control switch 18 Right stabilizer control switch 19 Steering wheel adjustment locking lever 1 RWA38270 3 4 ...

Page 90: ...servo control system 27 Offset boom left swing control push button if installed and only with servo control system 28 Offset arm right swing control push button if installed and only with servo control system 29 Horn push button only with servo control system 30 Telescopic arm extension control push button if installed and only with servo control system 31 Telescopic arm retraction control push bu...

Page 91: ...y accidents since the gear storage gear selec tion and travel direction selection microcircuits may be irreversibly damaged IMPORTANT The engine can be started only with the gearshift lever in neutral position N If the operator deems it necessary the machine may also be equipped with an acoustic alarm for movements in re verse This device can be installed on an apposite area on the rear part of th...

Page 92: ...r the connection or disconnection of the anti theft function The connection is achieved by pressing the push button for more than 3 seconds with the engine running 10 Safety code green led when this led lights up it indicates that the anti theft function is in operation When the engine is started again it is necessary to enter the secret code to be able to move the machine 11 Automatic logic conne...

Page 93: ... is pressed more than once the function is connected and disconnected in se quence with the led 10 coming on and going out alternately IMPORTANT After the engine start and the self test phase if the anti theft function has been previously connected led 10 on the secret code must be entered by keying the figures in one by one with the UP DOWN buttons while the push button 12 DIM must be used to con...

Page 94: ... braking in 3rd or 4th gear the logic automatical ly engages the 4WD and the green led 8 lights up without flashing RWA12470 7 8 After the engine start the self test phase and the entry and confirmation of the antitheft code if any the electronic control always sets to the 2nd gear with semiautomatic logic SA From the 2nd gear with reversing gear in neutral position it is possible to engage the 1s...

Page 95: ...ed RWA17320 13 15 With the machine at rest and reversing gear lever in neutral position after 3 seconds the system signals an emergency condition and the red warning light N 4 comes on Press the UP DOWN buttons again and start again within 3 seconds IMPORTANT After the engine start during the self test phase and the entry of the safety code if any before the 2nd gear is dis played if the reversing...

Page 96: ...HE FWD REV GEAR Even the forced 1st gear remains preselected In case of damage to the solenoid valve of the 2nd or 3rd gear signalled by 3 long beeps 1 sec and by the flashing of the figure message on the display 15 the system passes directly from automatic AU to semiautomatic SA logic FWD REV N RWA12510 15 11 3 The FWD REV reversal is carried out in 1st and 2nd gear and must take place in the sho...

Page 97: ...tted When the optimal rpm has been reached the led goes out and the 1st gear is engaged If the KICK DOWN function is selected 2nd from 1st gear the engagement of the 2nd gear takes place immediately The functions of the UP DOWN button override the functions of the KICK DOWN button The electronic control acquires a differentiated selection if be tween two selections a mininum time of 0 5 seconds el...

Page 98: ...14 flashing 3 long beeps 1 sec Figure message flashing on the display 15 as an alterna tive to the indication of the engaged gear IMPORTANT In case of damage to the gear clutch pressure sensors the system does not engage the clutches corresponding to the damaged sensors In case of damage to the 2nd and 3rd gear clutch pressure sensors the system passes auto matically from the automatic logic AU to...

Page 99: ...estion For further details see 3 3 1 FRONT INSTRUMENTS pos 17 ELECTRONIC DISPLAY This is a control with coupled microswitches and is used to se lect the steering mode that is most suitable for the conditions of the ground and the type of work to be performed The selection is obtained by pressing two coupled switches at the same time with consequent coming on of the corresponding LED This sys tem m...

Page 100: ...re aligned before checking the alignment of the wheels stop the machine press the push buttons 1 2 3 shown in Fig c at the same time keeping the three buttons pressed turn the key to posi tion I to activate the electric signal after a few seconds the writing KOMATSU will appear on the monitor 17 followed by the symbol that indi cates the alignment of the rear wheels press the push button 1 shown i...

Page 101: ...nly with 1st 2nd and 3rd gear engaged with the machine either in operation or at rest provided that the speed does not exceed 13 km h 8MP h CHECK SERVICE RWA34790 2 A 1 FRONT AXLE B 17 CHECK SERVICE RWA28500 17 CHECK SERVICE 17 000KM h 000MP h Press buttons 1 and 3 at the same time and turn the steering wheel clockwise or anticlockwise to align the front wheels The misalignment of the front wheels...

Page 102: ...elling on roads use only the two wheel steering mode CAUTION If during travel with two wheel steering the acoustic alarm sounds this means that the rear wheels are misaligned The misalignment of the rear wheels is signalled also on the display 17 through the alternate presence of the symbols and see Fig F Stop the machine immediately and turn the steering wheel clockwise or anticlockwise until the...

Page 103: ...igned The red led B will go out and the red led C will come on at the same time During the alignment phase the symbol will appear on the display 17 positioned on the front dashboard and will go out as soon as the rear wheels are aligned At this point the speedometer will appear on the display 17 IMPORTANT It is possible to switch over from all wheel steering to crab steering only in 1st 2nd gear a...

Page 104: ...ver from crab steering to two wheel steering with the machine either moving or at rest For travelling on roads use only the two wheel steering mode CAUTION If during travel with two wheel steering the acoustic alarm sounds this means that the rear wheels are misaligned The misalignment of the rear wheels is signalled also on the display 17 through the alternate presence of the symbols and see Fig ...

Page 105: ...he red led B will come on at the same time During the alignment phase the symbol will appear on the display 17 positioned on the front dashboard and will go out as soon as the rear wheels are aligned At this point the speedometer Km h or MP h will appear on the display 17 IMPORTANT It is possible to switch over from crab steering to all wheel steering with the machine either moving or at rest The ...

Page 106: ...e to make sharp turns to the left When the pedals 3 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 higher gears are engaged the braking action is strengthened due to the automatic connection of the four wheel driv...

Page 107: ...s 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 108: ...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 No movement can be performed if the locking pin is con nected in the safety position See 3 1 1 FRONT LOADER LOCKS CAUTION Always engage the safety pin when travelling on roads D A B...

Page 109: ...face If one of the rear wheels is unsta ble or rests on a small obstacle the machine may move Periodically check the brake efficiency Non compliance with these rules may cause serious acci dents or 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 r...

Page 110: ...ly 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...

Page 111: ...lock To engage the safety lock proceed as follows Select the uncoupling position by pressing the switch 9 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 engaged in its seat IMPORTANT If the machine is equipped with backhoe servo controls the switch 9 is positioned on...

Page 112: ...per part of the side dashboard as shown in Fig B The switch 10 can be disabled by means of the switch 26 For further information see BACKHOE CONTROL LOCK ING SWITCH pos 26 CAUTION Before starting any operation make sure that the backhoe is locked on its guides RWA38300 B 26 10 RWA28180 11 DANGER Do not use this button for more than 1520 seconds Do not use this button during travel on normal roads ...

Page 113: ...30 13 On the machines provided with the 4in1 bucket the distributor for the folding of the bucket is controlled through the push button 13 positioned on the loader control lever Press the button to fold the bucket when the button is released the bucket movement stops RWA03340 14 The push button 14 makes it possible to use the maximum quantity of oil delivered by the hydraulic pump when the machine...

Page 114: ...ith 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 eng...

Page 115: ...at lower the equipment to the ground always engage the safety device to lock the backhoe controls by pressing the switch 26 and raise both joysticks 15 16 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 ...

Page 116: ...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 26 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 20 21 and at the same time raise the joysticks 15 16 t...

Page 117: ...perated 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 swi...

Page 118: ...e 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 an...

Page 119: ...perated 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 sw...

Page 120: ...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 26 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 17 and 18 towards the outside of the...

Page 121: ...cs 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 19 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 19 clockwise to lock the steering wheel in the desire...

Page 122: ...d 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 20 21 RWA38390 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 c...

Page 123: ...4 25 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 conta...

Page 124: ...be disabled by pressing the switch 26 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 26 again and keep it pressed until the warning light goes out Every time the machine is stopped the control locking device 26 is automatically reset and all the backhoe ...

Page 125: ...ICATION OF THE OFFSET DEVICE IMPORTANT When the control safety device 26 is engaged all the movements are inhibited See 26 BACKHOE CONTROL LOCKING SWITCH Only with servo controls 27 RWA38430 26 RWA38330 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 28 to stop the boom release...

Page 126: ...ice 26 is engaged the func tion of the horn is inhibited See 26 BACKHOE CONTROL LOCKING SWITCH Only with servo controls 29 RWA38450 26 RWA38330 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 30 to stop the arm re lease the push button For the use of the telescopic arm see 6 5 BAC...

Page 127: ... the use of the telescopic arm see 6 5 BACKHOE TELE SCOPIC ARM IMPORTANT When the control safety device 26 is engaged all the movements are inhibited See 26 BACKHOE CONTROL LOCKING SWITCH Only with servo controls RWA38470 31 26 RWA38330 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 128: ...ge control lever 33 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 33 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 129: ...place them only with new fuses having the same capacity If the engine does not turn when the ignition switch is brought to position START check the en gine 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 fuse...

Page 130: ...oid valve F4 A B C Brown Red Lightblue 7 5 10 15 Front windshield wiper EGM power supply relay High beam F5 A B C Red Lightblue Lightblue 10 15 15 Heating motor relay Power Economy unit Seat electronic unit Rear working lights Front working lights F6 A B C Lightblue Brown Red 15 7 5 10 Rear horn Rear windshield wiper Dimmer switch Front horn relay Direction indicators F7 A B C Brown Red Brown 7 5 ...

Page 131: ...heel drive relay K4 Start enabling relay K5 Low beam relay K6 High beam relay K8 Horn relay K9 Blinking relay K10 EGM power supply relay The fuses and relays are grouped on a single base positioned inside the engine compartment and 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 132: ... 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 133: ... screws 8 POSITION DESCRIPTION 1 Stop light relay 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 to reac...

Page 134: ... 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 135: ...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 solu tions are particularly useful during the summer since they ensure constant air circulation and therefor...

Page 136: ...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 137: ...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 138: ...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 dash board 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 functi...

Page 139: ...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 140: ... 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 141: ... 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 142: ...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 143: ...eed a fire extinguisher 1 on the machine he must position it on the appropriate hole provid ed on the right console RWA16490 1 CAUTION Controllare periodicamente che la cassetta di primo soc corso sia rifornita dei disinfettanti bende medicinali e controllarne l integrità e la validità La cassetta 1 con il necessario per il primo soccorso deve es sere installata all interno della cabina a cura del...

Page 144: ...e 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 DANGER 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 145: ...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 146: ...the control locking safety device by press ing the relevant switch see 3 3 5 2 MACHINE CONTROLS Version with servo controls pos 26 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 following c...

Page 147: ...n Before starting the engine make sure 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...

Page 148: ...d according to the outside temperature and the ratio is approx 1 second for each de gree below 0 C 2 Press the accelerator pedal slightly 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 and reduce the speed to idling IMPORTANT If the engine does not start at the first attempt repe...

Page 149: ...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 Release the safety pin of the front bucket control lever see 3 1 SAFETY LOCKS 2 Raise and rotate the front bucket slowly and ...

Page 150: ... transport position The control levers must be in the neutral position N At this point release the parking brake Select 1 The desired steering mode 2 The gear by pressing the UP DOWN buttons and checking the engaged gear on the display 3 The travel direction by shifting the control lever forward F or backward R within 3 seconds after engaging the gear 4 Gradually accelerate with the accelerator pe...

Page 151: ...chine disen gage the four wheel drive The four wheel drive is engaged and disengaged by means of the push button 1 on the gearshift control It is normally used when the machine must move on muddy icy gravelly ground on slopes and in any situation in which it is difficult to move the ma chine The four wheel drive must be used even when the ma chine is provided with the optional equipment to be empl...

Page 152: ...o 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 When...

Page 153: ...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 154: ...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 Engage the safety device of the front bucket control lever and the safety lever of the backhoe levers IMPORTANT If the machine is equippe...

Page 155: ...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 156: ...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 5 2 MACHINE CONTROLS Version with servo controls ...

Page 157: ...lination 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 front bucket on the floor set the machine in ...

Page 158: ...pe 6 RWA28250 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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...the return to dig device of the loader hydraulic system to accel erate the operations Once the device has been connected it lowers the arm com pletely and at the same time brings the bucket in perpendicu lar 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 di...

Page 164: ...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 165: ...chine 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 equip...

Page 166: ... 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 167: ...he boom form an angle of approx 90 plant the bucket teeth onto the ground 4 Release the backhoe unit see 3 3 5 MACHINE CONTROLS pos 10 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 168: ...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 169: ...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 170: ...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 RWA38500 ...

Page 171: ...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 fil ters 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 ...

Page 172: ...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 173: ... out using 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 RWA38510 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 ...

Page 174: ...y 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 ma...

Page 175: ...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 176: ...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 177: ...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 178: ...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 179: ...MAINTENANCE ...

Page 180: ... 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 Disconnect the gearshift reversing gear unit connector positioned under the steering wheel 5 Do not apply more than 200V continuously 6 Connect the earth cable within 1 m from the point in which the welding must be carried out 7 Avoid placing gaskets and be...

Page 181: ...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 182: ...tion DEXRON II D Front and rear axle oil Classification UTTO FLUID Braking system oil GM classification 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 ...

Page 183: ...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 184: ... 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 the alternator and the gearshift reversing gear connector Lubrication makes the operations carried out with the machine and work equipment smoother while preventing wear and the noise that may...

Page 185: ...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 186: ...odegradable oil SEE 4 3 1 150 92 Front axle Differential OIL UTTO FLUID 10 5 10 5 Final reduction gear ea 1 3 1 3 Rear axle Differential 9 9 Final reduction gear ea 1 3 1 3 Hydraulic transmission OIL GM DEXRON II D DEXRON is a registered trademark of General Motors Corporation 24 5 21 5 Braking system 0 8 0 8 Fuel tank DIESEL OIL 130 Engine cooling system PERMANENT COOLANT 15 SAE 40 SAE 30 SAE 20W...

Page 187: ...n if oil with CC classification is used reduce the engine 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 ...

Page 188: ...gradable oil in the hydraulic system empty the system complete ly 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 temperature of at least 40 C then start moving the equipment so that all the parts of the system are filled with oil St...

Page 189: ... 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 screws R...

Page 190: ...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 RWA28330 2000 h Hydraulic oil Grease Engine oil Transmission oil Brake oil ...

Page 191: ...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 192: ... 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 193: ... 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 194: ...LUBRICATION 192 4 5 5 LUBRICATION DIAGRAM Offset device IMPORTANT For the other greasing points see 4 5 1 LUBRICATION DIAGRAM 10 h RWA03080 Grease ...

Page 195: ...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 196: ...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 197: ... 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 198: ...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 RYA11270 8 7 6 6 7 8 8 8 ...

Page 199: ...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 200: ...leed 205 e Water separator Clean 206 f Front and rear wheels Adjust toe in 206 g Parking brake Check and adjust 207 h Service brake Check braking 208 i Brake pedals Adjust stroke 209 k Return to dig Adjust 209 l Stabilizers Check and adjust clearance 210 N PART OPERATION PAGE a Hydraulic oil drain filter Change cartridge 211 b Hydraulic oil Change 211 N PART OPERATION PAGE a Various checks 212 b C...

Page 201: ...CE EVERY 250 HOURS OF OPERATION N PART OPERATION PAGE a Joints Lubricate 216 N PART OPERATION PAGE a Hydraulic oil drain filter Only for machines with synthetic biodegrad able oil Change 230 N PART OPERATION PAGE a Radiator Check level 218 b Braking system Check oil level 218 c Propeller shafts Lubricate 6 points 219 d Front axle joints and central coupling and rear axle joints Lubricate 9 points ...

Page 202: ... and tension 224 c Battery Check electrolyte level 225 d Front axle Check levels n 3 226 e Rear axle Check levels n 3 226 f Hydraulic transmission Check level 227 g Front and rear wheels Check screw tightening 227 N PART OPERATION PAGE a Hydraulic oil and suction filter Only for machines with synthetic biodegrad able oil Change oil and clean filter 242 N PART OPERATION PAGE a Engine oil Change 229...

Page 203: ...smission filter Change 241 e Engine valves Check clearance 241 N PART OPERATION PAGE a Hydraulic oil and suction filter Change oil and clean filter 242 b Coolant Change 244 c Braking system oil Change 246 d Alternator and starter Check 246 e A C system coolant only for machines with air conditioner Check quantity 247 N PART OPERATION PAGE a A C system filter dehydrating filter only for machines wi...

Page 204: ...tside 2 Rotate the cover 2 anticlockwise by approximately 12 5 3 Lift the cover 2 and extract the filtering 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...

Page 205: ...n 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 extract the filtering elemen...

Page 206: ...ter 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 pressure doe...

Page 207: ...eeping 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 the...

Page 208: ...ed 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 tyres The machine has been designed with a toe in equal to...

Page 209: ...INE 2 Align 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 ...

Page 210: ...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 211: ...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 212: ... 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 shoe ...

Page 213: ...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 214: ...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 215: ... cap 2 thoroughly and lock the tank 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 lev...

Page 216: ...2 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 IMPORTANT Do not add oil beyond the MAX mark in order to avoid damaging the hydraulic circuit ...

Page 217: ...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 218: ... shown 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 bucket c...

Page 219: ...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 point 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 220: ...r 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 n...

Page 221: ...les 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 RWAA9040 RWAA9050 RWAA9060 RWAA9070 ...

Page 222: ...hine 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 RWAA9020 1 1 RWAA9030 2 2 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 prescri...

Page 223: ...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 224: ...rmed EVERY 250 HOURS FRONT AXLE OIL CHANGE REAR AXLE OIL CHANGE HYDRAULIC TRANSMISSION OIL CHANGE HYDRAULIC TRANSMISSION OIL FILTER CHANGE ENGINE VALVE CLEARANCE CHECK AND ADJUSTMENT HYDRAULIC OIL DRAIN FILTER CHANGE For details on the various maintenance operations see the sections EVERY 500 HOURS and EVERY 1000 HOURS For checks and adjustments contact your Komatsu Utility Dealer ...

Page 225: ...n the in dicated pont with a force equal to approx 10 kg the resulting de flection must be approximately 10 15 mm If the deflection exceeds this value loosen the screw 2 that fas tens the alternator 3 and with a lever inserted between the en gine block and casing make the alternator slide Lock the screw 2 again and check again Use a 12 mm spanner A Fan pulley B Alternator pulley IMPORTANT If the b...

Page 226: ...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 227: ... 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 228: ...ches the hole 2 if this does not occur top up using the prescribed oil See 4 3 FUEL COOLANT AND LUBRICANTS Use a 1 2 square spanner RWAA9100 1 RWAA9110 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 17 mm spanner FIN...

Page 229: ...5 1 ENGINE HOOD The oil level 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 b...

Page 230: ...ble oil type HEES is used The following maintenance operation must be carried out after the first 500 hours of operation together with the maintenance operations to be carried out EVERY 500 HOURS HYDRAULIC OIL CHANGE AND SUCTION FILTER CLEANING For further details on the various maintenance operations see section EVERY 2000 HOURS ...

Page 231: ...l comes on on the electronic display positioned on the front dashboard After performing this maintenance operation set the partial service hours to zero For further details see 3 3 1 FRONT INSTRUMENTS pos 17 When changing the engine oil change also the filter see 4 7 10 b CHANGING THE ENGINE OIL FILTER Proceed as follows 1 Open the engine hood see 3 5 1 ENGINE HOOD 2 Remove the drain plug 1 of the...

Page 232: ... support 2 3 Fill the new filter with engine oil lubricate the gasket and screw thoroughly 4 Give another half turn by hand Start the engine make sure that there are no leakages and that the oil pressure warning light goes out IMPORTANT Do not use the spanner to lock the filter since it may be damaged and cause oil leakages The engine oil filter must be changed when the relevant alarm signal comes...

Page 233: ...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 perfect conditions 4 Clean the magnetic rings 10 that are positioned on the cov er to block the metal particles 5 Change the cartridge 6 6 Reassemble the whole by proceeding in the reverse order and make sure that the gasket 11 of the...

Page 234: ...machines change the filter after the first 100 150 hours of operation and for the successive changes keep to the indications given in the table beside 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 80 100 500 100 800 Breaker operating ratio Replacement interval H Replacement interval for element RWA10710 ...

Page 235: ...horoughly 4 Given another half turn by hand 5 Bleed the fuel supply circuit BLEEDING THE CIRCUIT After filling the tank turn the ignition key to position and wait approx 15 20 seconds in such a way as to bleed the fuel circuit IMPORTANT After bleeding the circuit turn the ignition key to position for a few seconds and wait at least two minutes be fore starting the engine If the engine starts regul...

Page 236: ...s and the condensate flow out of the tank remove the lower plug 1 and wait until clean fuel flows out Use a 19 mm spanner IMPORTANT The tank must be drained before starting the engine with temperatures exceeding 0 C when the temperature is be low 0 C the tank must be drained at the end of work or in any case with the machine at operating temperature to prevent the condensate from freezing The cond...

Page 237: ...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 238: ...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 239: ...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 240: ...e 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 fl...

Page 241: ...ole 1 until reaching 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 3 is in low position on the...

Page 242: ...il 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 reach...

Page 243: ...eration set the partial service hours to zero For further details see 3 3 1 FRONT INSTRU MENTS pos 17 This operation must be carried out at every change 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 filt...

Page 244: ...he 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 suitab...

Page 245: ... 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 with empty tank since this would certainly damage the pump The hydraulic oil must be changed when the relevant alarm signal comes on on the...

Page 246: ...ous burns let the engine cool down until it reaches approxi mately 4045 C before changing the coolant Slowly loosen the radiator cap in order to release the re sidual pressure 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 IMPORTANT The change of the permanent coolant does not require...

Page 247: ...member that the capacity of the cooling system is approxi mately 14 liters Use 12 mm spanners 5 Close the radiator drain cock 4 see Fig B tighten the valve 5 on the filter carrier head and fill the radiator with new fluid See 4 3 FUEL COOLANT AND LUBRICANTS 6 Start the engine and let it idle for a few minutes check the level again and top up before putting back the upper cap 2 7 Fill the tank 6 un...

Page 248: ...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 the oil contained in the tank 3 runs out 4 Fill the tank 3 with new oil and keep pumping fill the tank 3 more than once until the used oil about 0 8 l has been changed completely eliminate the residual air...

Page 249: ...losion 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 carried out exclusively by specialized person nel Specific equipment is required to check the coolant have ...

Page 250: ...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 every ...

Page 251: ...TECHNICAL SPECIFICATIONS ...

Page 252: ...A 5 1 TECHNICAL DATA 5 1 1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE 5 1 2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE 2150 2175 3035 7360 2930 3650 2420 RWA26170 2150 2175 1640 5965 2930 3650 2420 RWA26180 ...

Page 253: ...put 80 A Earthing negative Battery 160 Ah 12V Starter kW 3 0 TRAVEL SPEEDS calculated with 16 9 24 tyres and engine at 2200 rpm GEARS 1st 2nd 3rd 4th R1 R2 R3 R4 km h 6 5 12 23 40 6 5 12 23 40 The machines for the German and Italian markets are not homologated with the 4th reverse gear FRONT TYRES SIZE MAKE INFLATION PRESSURE Std 16 9 24 PR12 149A8 GOOD YEAR bar 2 2 Opt 16 9 28 PR12 152A8 GOOD YEA...

Page 254: ...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 mass W 600 mm kg 160 F Operating hydraulic pressure G Lowered stabilizers P Lifting capacity Z Distance of the lifting point from the ground X Distance between the boom swing...

Page 255: ...2 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 990 980 950 550 990 980 910 540 990 980 850 530 990 980 810 520 980 970 850 340 980 970 810 330 980 970 760 320 980 970 730 310 400 240 390 230 700 660 380 220 670 620 370 210 P Z X 1000 Kg RWA26190 ...

Page 256: ... 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 RWA26200 Max Max ...

Page 257: ...AUTHORISED OPTIONAL EQUIPMENT ...

Page 258: ...ht of the material handled 1 8 tons cu m Fork length 1140 mm Lifting capacity 2000 Kg The loads that can be handled are also limited according to the capacity stamped on the forks see 6 4 PAL LET FORKS Lifting capacity 2500 Kg The loads that can be handled are 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...

Page 259: ... 1 Turn the lever 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...

Page 260: ...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 5 MACHINE CONTROLS pos 12 13 RWA31450 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 1...

Page 261: ...o hy draulic cylinders 1 controlled by an additional distributor The distributor control for the opening and closing 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 5 pos 5 FRONT LOADER CONTROL LEVER 3 4 RWA34490 RWA34500 1 The 4in1 bucket is provided with teeth protection casing 3 If the bucket is...

Page 262: ...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 263: ...rs function opening and clamping by using the teeth provided on the mobile 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 264: ... 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 5...

Page 265: ...d even 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 Overtur...

Page 266: ...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 267: ...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 268: ... of the backhoe control lever unit the movements of the levers de scribed in 3 3 5 1 pos 15 16 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 269: ...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 270: ...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 271: ...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 272: ... 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 5 2 MACHINE CONTROLS Version with servo controls pos 15 16 r...

Page 273: ...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 274: ...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 RWA38520 ...

Page 275: ...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 RWA38530 RWA06460 RWA30760 ...

Page 276: ...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 RWA33700 RWA38540 RWA06500 ...

Page 277: ... 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 278: ...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 279: ...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 cardboard or a wooden bo...

Page 280: ...d work at low 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 dig beyond the outline of the machine If the offset device is in neutral position the boom can be used as a normal boom if it is necessary to dig beyond the machine s outline it is necessary to shift the backhoe and operate the de vice in order to restore...

Page 281: ...rols pos 15 and 16 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...

Page 282: ...l 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 5 1 pos 15 16 BACKHOE CONTROL LE VERS except for the bucket control which is used for the pos...

Page 283: ...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 284: ...ntrolled by an additional distributor is provided while for its opening and closing the standard bucket opening and folding circuit is used 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 of the backhoe control lever unit The other contr...

Page 285: ...e standard bucket is used also for opening and closing the clamshell bucket exclud ing the control cylinder See 3 3 5 2 MACHINE CONTROLS Version with servo con trols pos 15 16 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 286: ...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 287: ...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 fold 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 syste...

Page 288: ...rain 2 cou plings for the use of a manual hydraulic hammer the connection 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 p...

Page 289: ...control locking device see 3 3 5 2 MACHINE CON TROLS Version with servo controls pos 26 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 position 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...

Page 290: ...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 291: ...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 292: ...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 293: ... 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 294: ...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 rap id 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 for...

Page 295: ...R EQUIPMENT RAPID COUPLING DEVICE 293 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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Komatsu Utility 97SF11205, Operation & Maintenance Manual

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