WEAM005102
Operation & Maintenance
Manual
SK820-5 turbo
SKID-STEER LOADER
SERIAL NUMBER
SK820-5 turbo 37BTF50112
and up
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or
maintaining this machine.
This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
FOREWORD
1.1 FOREWORD
q This manual is supplied by Komatsu Utility S.p.A. in order to provide customers with all the necessary informa-
tion on the machine and the safety regulations related to it, together with the use and maintenance instructions
that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
q The operation manual, together with the spare parts catalogue, is an integral part of the machine and must ac-
company it, even when it is resold, until its final disposal.
q The manual must be handled with the greatest care and always kept on board the machine, so that it can be
consulted at any moment; it must be placed in the appropriate compartment, where also the ownership documents and the logbook are usually kept.
q This manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu or to your Komatsu Dealer.
q The illustrations contained in this manual may represent machine configurations that are available on request.
Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums
up all the information regarding the most recent techniques applied at the moment in which the machine is
marketed.
For any updated information, contact your Komatsu Dealer.
q Punctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan
frequently.
q Over the years Komatsu Dealers have gathered considerable experience in customer service.
If more information is needed, do not hesitate to contact your Komatsu Utility Dealer: he always knows how to
get the best performance from the machine, he can suggest the use of the equipment that is most suitable for
specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules.
Furthermore, Komatsu Dealers also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability.
q The table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
CAUTION
q Improper use and maintenance of this machine may be hazardous and cause serious injuries and even
death.
q Operators and maintenance personnel must carefully read this manual before using the machine or per-
forming maintenance operations.
q Some actions involved in the operation and maintenance of the machine may cause serious injuries or
even death, if they are not performed in compliance with the instructions given herein.
q The procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
INFORMATION ON SAFETY
1.2 INFORMATION ON SAFETY
Many accidents are caused by insufficient knowledge of and failure to comply with the safety regulations prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to understand all the information and warnings contained in this manual and given on the plates applied on to the machine.
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
q Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This signal word is to be limited to most extreme situations.
WARNING
q Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
q Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is are useful to know.
IMPORTANT
q This word is used for precautions that must be taken to avoid actions which could shorten the life of the
machine.
NOTE
q This gives information that is useful to know.
Komatsu cannot reasonably predict every circumstance that might involve a potential hazard during the operation
or maintenance of the machine; for this reason, the safety messages included in this manual and applied on to the
machine plates may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity of the machine will work in total safety, with no risk of injuries or damage. In case of doubt regarding the safety measures necessary for some procedures, contact Komatsu or your local Dealer.
DANGER
q Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and of the controls and stop the engine.
DANGER
q To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine hood is
open, unless this is expressly prescribed for some specific maintenance operations.
2
INFORMATION ON SAFETY
WARNING
q It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be
held liable for any damage to persons, property or the machine, if this has been tampered with by modifying the standard setting of the hydraulic system.
WARNING
q Before carrying out any electrical welding, disconnect the battery and the alternator (see "2.8.13 PRE-
CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR").
WARNING
q Install only authorized additional equipment (see "6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIP-
MENT OF THE MACHINE VERSION WITH HIGH-FLOW AND SUPER-FLOW HYDRAULIC SYSTEM").
WARNING
q Travel on roads is allowed only if the machine is provided with appropriate lighting, signalling and safety
devices and properly authorized by the relevant papers.
Before travelling on roads, make sure that the equipment installed on the machine is homologated and
that the safety locks are correctly engaged.
DANGER
q It is absolutely forbidden to operate the machine while standing on the ground.
Every single manoeuvre must be carried out by the operator, correctly seated in driving position.
3
INTRODUCTION
1.3 INTRODUCTION
1.3.1 INTENDED USES
The Komatsu MACHINES described in this manual have been designed and constructed to be used by duly trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point "6.1 AUTHORIZED OPTIONAL EQUIPMENT".
1.3.2 IMPROPER OR UNAUTHORIZED USES
CAUTION
q This paragraph describes some of the improper or unauthorized uses of the machine; since it is impos-
sible to predict all the possible improper uses, if the machine happens to be used for particular applications, contact your Komatsu Dealer before carrying out the work.
IMPORTANT
q The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are attached to this
manual.
q The instructions regarding the assembly of the authorized equipment, the controls requiring special ar-
rangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.
Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials;
therefore, the following uses are absolutely forbidden:
q USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
q USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
q TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
q USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
q USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
1.3.3 MAIN CHARACTERISTICS
q Simple and easy operation.
q Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors opera-
ting epicyclic reduction gears.
q Four driving wheels always engaged through oil-immersed roller chains.
q Main equipment and travel control through servo levers ensuring also combined movements that can be modu-
lated proportionally and continually.
q Foot control for the optional equipment (if installed).
q Foot accelerator.
q Lever accelerator.
q Parking brake control.
q Complete series of instruments visible from the operating position.
q Easy maintenance with simplified intervals.
q Road travel (on request).
4
INTRODUCTION
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its functionality will be untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
q After starting the engine, let it idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
q Avoid operating the machine with the limit loads allowed or at high speed.
q Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
q After the first 50 hours of use, carry out the following operations, in addition to those to be performed every 50
hours:
1 - Check the gearing chain tension.
2 - Check the wheel nut tightening.
q After the first 250 hours of use, carry out the following operations, in addition to those to be performed every 250
hours:
1 - Change the hydraulic circuit drain filter.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
On machines in which the synthetic biodegradable oil type HEES is used, carry out the following operations in addition to the routine maintenance:
q After the first 50 hours of operation, change the hydraulic circuit drain filter.
q After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
q When changing the oil filters (cartridges), check their inner part to make sure that there are no deposits.
If considerable deposits can be observed, find out what may have caused them before restarting the machine.
q The number of operating hours is indicated by the hour meter.
5
PRODUCT IDENTIFICATION
1.4 PRODUCT IDENTIFICATION
The Komatsu COMPACT LOADER and its main components are identified by serial numbers stamped on the
identification plates.
The serial number and the identification numbers of the components are the only numbers that must always be indicated to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial number is stamped on the inner wall of the
rear right pillar.
RWAA13090
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
The Komatsu MACHINES described in this manual are provided with the CE mark, which certifies that they are in compliance with the CE harmonized standards.
The plate with the mark is applied on to the inner wall of the rear right pillar.
MODELLO - MODEL
TYP - MODELE
MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.
ANNO - YEAR
BAUJAHR - ANNEE
MASSA TOTALE - TOTAL WEIGHT
GESAMTGEWICHT - POIDS TOTAL
POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR
Product Identification Number
PIN
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
MODEL
SERIAL N˚
YEAR
TOTAL WEIGHT
ENGINE POWER
Product Identification Number
PIN
RWAA13100
kg
kw
37A-98-11820
RWA39300
kg
kw
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) - ITALY
6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The plate (1) indicating the engine serial number and the
exhaust gas emission plate are positioned on the upper side of
the tappet cover.
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
The serial number of the travel reduction gear is stamped on
the plate positioned on the hydraulic motor cover.
PRODUCT IDENTIFICATION
2
1
RWAB0720
1.4.5 CAB SERIAL NUMBER
The cab serial number is stamped on the plate positioned on
the right side of the base cross member.
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)
The excavator identification number is stamped on the plate
positioned on the left side of the control panel.
RWAA9670
RWAA9680
RWAA2520
7
PRODUCT IDENTIFICATION
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine N° Model
Engine N°
Product identification number (PIN)
Travel reduction gear N°
Cab N°
Excavator (if installed) N°
Dealer:
Address:
Person to contact:
NOTES:
Te l.
8
TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD
1.1 FOREWORD.......................................................................................................................................... 1
1.2 INFORMATION ON SAFETY ................................................................................................................ 2
1.3 INTRODUCTION ................................................................................................................................... 4
1.3.1 INTENDED USES .................................................................................................................... 4
1.3.2 IMPROPER OR UNAUTHORIZED USES ................................................................................ 4
1.3.3 MAIN CHARACTERISTICS...................................................................................................... 4
1.3.4 RUNNING-IN ............................................................................................................................ 5
1.4 PRODUCT IDENTIFICATION ............................................................................................................... 6
1.4.1 MACHINE SERIAL NUMBER................................................................................................... 6
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) ... 6
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE ................................... 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER ................................................................... 7
1.4.5 CAB SERIAL NUMBER ........................................................................................................... 7
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed) .............................................................. 7
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS .................................................................... 8
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES....................................................................................... 16
2.1.1 POSITION OF THE SAFETY PLATES .................................................................................... 16
2.1.1.1 SAFETY PLATES ................................................................................................... 16
2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR ..................................... 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS......................................................................... 20
2.1.3 POSITION OF THE NOISE PLATES ...................................................................................... 23
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED ................................................ 23
2.2 GENERAL PRECAUTIONS .................................................................................................................. 24
2.2.1 GENERAL SAFETY RULES .................................................................................................... 24
2.2.2 SAFETY DEVICES AND GUARDS .......................................................................................... 24
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS ............................................................ 24
2.2.4 UNAUTHORIZED MODIFICATIONS ....................................................................................... 25
2.2.5 LEAVING THE OPERATORS SEAT ....................................................................................... 25
2.2.6 GETTING ON AND OFF THE MACHINE ................................................................................ 26
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed) ........................................................... 26
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL ..................................................................... 27
2.2.9 PREVENTING BURNS ............................................................................................................ 27
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER .................................................... 28
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ........................................ 28
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT ........................................................................ 29
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE ...................................................... 29
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT ............................................................... 29
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE................................................. 30
2.3.1 SAFETY ON THE WORK SITE ............................................................................................... 30
2.3.2 FIRE PREVENTION ................................................................................................................ 30
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB ............................................. 30
2.3.4 ROOM VENTILATION ............................................................................................................. 31
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)............................................. 31
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING
THE WINDSHIELD WIPER BLADES (if installed) ................................................................... 31
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TABLE OF CONTENTS
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING............................................................................. 32
2.4.1 STARTING THE ENGINE......................................................................................................... 32
2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS ............................................. 32
2.4.3 CHECKS FOR TRAVELLING IN REVERSE ........................................................................... 33
2.4.4 MOVING THE MACHINE ........................................................................................................34
2.4.5 WORKING ON SLOPES .........................................................................................................34
2.4.6 PREVENTING ELECTROCUTION........................................................................................... 36
2.4.7 VISIBILITY ................................................................................................................................ 37
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES......................................................... 37
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT ......................................... 37
2.4.10 WORKING ON LOOSE GROUND ........................................................................................... 37
2.4.11 PARKING THE MACHINE ....................................................................................................... 38
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 39
2.5.1 LOADING AND UNLOADING THE MACHINE ........................................................................ 39
2.5.2 THE ROUTE ............................................................................................................................. 39
2.6 BATTERY .............................................................................................................................................. 40
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ........................................................ 40
2.6.2 STARTING WITH BOOSTER CABLES ................................................................................... 40
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY ............................................................................... 41
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ................................................................. 43
2.8.1 WARNING PLATES ................................................................................................................. 43
2.8.2 TOOLS ..................................................................................................................................... 43
2.8.3 PERSONNEL............................................................................................................................ 44
2.8.4 EQUIPMENT ........................................................................................................................... 44
2.8.5 WORKING UNDER THE MACHINE ........................................................................................ 44
2.8.6 KEEPING THE MACHINE CLEAN .......................................................................................... 44
2.8.7 USE OF THE ENGINE DURING MAINTENANCE ................................................................... 45
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY..................... 45
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION .................................................................................................................... 45
2.8.10 RULES FOR REFUELLING AND ADDING OIL ...................................................................... 46
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR ....................................................... 46
2.8.12 USING LAMPS ........................................................................................................................ 46
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR ......................... 47
2.8.14 PRECAUTIONS CONCERNING THE STARTER ................................................................... 47
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES.................................................. 48
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS ........ 48
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES
AND PRESSURES ..................................................................................................................48
2.8.18 COOLING FAN AND FAN BELT ............................................................................................. 49
2.8.19 WASTE MATERIALS ............................................................................................................... 49
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES .......................................... 49
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE
OIL TYPE «HEES»................................................................................................................... 50
10
TABLE OF CONTENTS
DESCRIPTION AND USE OF THE MACHINE
3.1 SAFETY LOCKS ................................................................................................................................... 52
3.1.1 LOADER LOCKS ..................................................................................................................... 52
3.1.2 EXCAVATOR LOCKS (if installed) ........................................................................................... 54
3.1.3 ASPHALT CUTTER LOCKS (if installed) ................................................................................. 56
3.2 GENERAL VIEWS................................................................................................................................. 57
3.2.1 FRONT GENERAL VIEW .........................................................................................................57
3.2.2 REAR GENERAL VIEW ........................................................................................................... 58
3.2.3 CAB INSIDE GENERAL VIEW ................................................................................................ 59
3.3 INSTRUMENTS AND CONTROLS ....................................................................................................... 61
3.3.1 INSTRUMENTS........................................................................................................................ 61
3.3.2 WARNING LIGHTS .................................................................................................................. 63
3.3.3 SWITCHES UND PUSH BUTTONS......................................................................................... 68
3.3.4 ELECTRICAL ACCESSORIES ............................................................................................... 73
3.3.5 MACHINE CONTROLS ............................................................................................................ 75
3.4 FUSES AND RELAYS........................................................................................................................... 95
3.4.1 MACHINE FUNCTION FUSES ............................................................................................... 95
3.4.2 MAIN FUSE ............................................................................................................................. 96
3.4.3 RELAYS .................................................................................................................................. 97
3.5 GUARDS AND DRIVER’S SEAT .......................................................................................................... 99
3.5.1 ENGINE HOOD ........................................................................................................................ 99
3.5.2 REAR PANEL .......................................................................................................................... 100
3.5.3 CAB .......................................................................................................................................... 101
3.5.3.1 RAISING THE CAB ................................................................................................ 102
3.5.4 STANDARD SEAT .................................................................................................................. 104
3.5.5 CUSHIONED SEAT ................................................................................................................. 104
3.5.6 SAFETY BELT.......................................................................................................................... 105
3.5.7 EMERGENCY EXIT ................................................................................................................. 105
3.5.8 TECHNICAL DOCUMENTATION CASE.................................................................................. 106
3.5.9 FIRE EXTINGUISHER ............................................................................................................ 106
3.5.10 FIRST AID KIT ......................................................................................................................... 106
3.6 USE OF THE MACHINE........................................................................................................................ 107
3.6.1 CHECKS BEFORE STARTING THE ENGINE......................................................................... 107
3.6.1.1 VISUAL CHECKS ................................................................................................... 107
3.6.1.2 DAILY CHECKS ...................................................................................................... 107
3.6.1.3 OPERATIONAL CHECKS ...................................................................................... 108
3.6.2 STARTING THE ENGINE ........................................................................................................ 109
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES ................... 109
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES ................................ 110
3.6.3 WARMING THE ENGINE ......................................................................................................... 111
3.6.4 HEATING THE HYDRAULIC OIL ............................................................................................. 111
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEMERN) ........................ 111
3.6.5.1 STEERING (CHANGING DIRECTION) .................................................................. 113
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM).................... 115
3.6.6.1 STEERING (CHANGING DIRECTION) .................................................................. 117
3.6.7 MOVING ON SLOPES ............................................................................................................. 119
3.6.8 MAXIMUM IMMERSION DEPTH ............................................................................................. 120
3.7 PARKING THE MACHINE .................................................................................................................... 121
3.7.1 PARKING ON LEVEL GROUND ............................................................................................. 121
3.7.2 PARKING ON SLOPES............................................................................................................ 122
3.8 STOPPING THE ENGINE ..................................................................................................................... 123
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TABLE OF CONTENTS
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES ................................................................. 124
3.9.1 LOADING AND UNLOADING THE MACHINE ......................................................................... 124
3.9.2 TRANSPORT............................................................................................................................ 125
3.10 HOW TO LIFT THE MACHINE.............................................................................................................. 126
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON ................................................................... 127
3.11.1 FUEL AND LUBRICANTS ........................................................................................................ 127
3.11.2 COOLANT ................................................................................................................................ 127
3.11.3 BATTERY ................................................................................................................................. 128
3.11.4 OTHER PRECAUTIONS .......................................................................................................... 128
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK ...................................................... 128
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON .................................................................. 129
3.13 USING THE WORK EQUIPMENT......................................................................................................... 130
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE ........................................ 130
3.13.2 ORGANIZING THE WORK ARE .............................................................................................. 131
3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES .......................................... 132
3.13.4 LOADING MATERIAL ON SLOPES ........................................................................................ 133
3.13.5 DIGGING METHOD.................................................................................................................. 134
3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING ... 135
3.13.6.1 RELEASING THE BUCKET .................................................................................... 136
3.13.6.2 COUPLING THE BUCKET ...................................................................................... 136
3.13.7 CHANGING THE BUCKET OR THE EQUIPMENT WITH OPTIONAL RAPID COUPLING .... 138
3.13.7.1 REMOVING THE BUCKET OR THE EQUIPMENT ................................................ 139
3.13.7.2 CONNECTING THE BUCKET ................................................................................ 140
3.13.7.3 CHECKING THE POSITION OF THE LOCKING PINS .......................................... 141
3.13.7.4 ADJUSTING THE LOCKING PINS ......................................................................... 142
3.14 LONG PERIODS OF INACTIVITY ........................................................................................................ 143
3.14.1 BEFORE THE PERIOD OF INACTIVITY ................................................................................ 143
3.14.2 DURING THE PERIOD OF INACTIVITY .................................................................................. 144
3.14.3 AFTER THE PERIOD OF INACTIVITY .................................................................................... 144
3.15 TROUBLESHOOTING .......................................................................................................................... 145
3.15.1 HOW TO REMOVE THE MACHINE......................................................................................... 145
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED ............................................................ 145
3.15.3 IF THE BATTERY IS DEPLETED ............................................................................................ 146
3.15.3.1 STARTING WITH BOOSTER CABLES .................................................................. 147
3.15.4 OTHER TROUBLES................................................................................................................. 148
3.15.4.1 ELECTRICAL CIRCUIT........................................................................................... 148
3.15.4.2 HYDRAULIC SYSTEM ............................................................................................ 148
3.15.4.3 ENGINE................................................................................................................... 149
3.15.4.4 HYDROSTATIC TRANSMISSION ......................................................................... 150
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TABLE OF CONTENTS
MAINTENANCE
4.1 GUIDE TO MAINTENANCE .................................................................................................................. 154
4.2 MAINTENANCE NOTES ....................................................................................................................... 156
4.2.1 NOTES REGARDING THE ENGINE ....................................................................................... 156
4.2.1.1 ENGINE OIL............................................................................................................ 156
4.2.1.2 COOLANT ............................................................................................................... 156
4.2.1.3 FUEL ....................................................................................................................... 157
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM................................................................. 157
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM ............................................................... 157
4.2.4 NOTES REGARDING LUBRICATION ..................................................................................... 158
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.............................. 158
4.3 FUEL, COOLANT AND LUBRICANTS................................................................................................. 159
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES ................... 161
4.4 DRIVING TORQUES FOR SCREWS AND NUTS ................................................................................ 162
4.4.1 STANDARD DRIVING TORQUES ........................................................................................... 162
4.4.2 SPECIFIC DRIVING TORQUES .............................................................................................. 162
4.5 LUBRICATION ...................................................................................................................................... 163
4.5.1 LUBRICATION DIAGRAM........................................................................................................ 163
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY.............................. 164
4.6.1 CRITICAL PARTS FOR SAFETY............................................................................................. 165
4.7 MAINTENANCE PLAN.......................................................................................................................... 171
4.8 MAINTENANCE PROCEDURE ............................................................................................................ 173
4.8.1 WHEN REQUIRED................................................................................................................... 173
4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE ....... 173
4.8.1.b TYRE ROTATION .................................................................................................. 174
4.8.1.c DRAINING THE FUEL TANK ................................................................................. 175
4.8.1.d RELEASING THE PARKING BRAKE .................................................................... 176
4.8.1.e CHECKING THE BATTERY CHARGE LEVEL ....................................................... 177
4.8.2 CHECKS BEFORE STARTING................................................................................................ 178
4.8.2.a VARIOUS CHECKS ................................................................................................ 178
4.8.2.b CHECKING THE COOLANT LEVEL ...................................................................... 178
4.8.2.c CHECKING THE FUEL LEVEL............................................................................... 179
4.8.2.d CHECKING THE ENGINE OIL LEVEL ................................................................... 180
4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT ............................... 181
4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER .......... 182
4.8.2.g CHECKING THE WIRING SYSTEM ....................................................................... 182
4.8.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION ........................................ 183
4.8.4 MAINTENANCE EVERY 50 HOURS OF OPERATION ........................................................... 183
4.8.4.a CHECKING THE TYRE PRESSURE ..................................................................... 183
4.8.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR ...................................... 183
4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION ...................................... 184
4.8.6 MAINTENANCE EVERY 250 HOURS OF OPERATION ......................................................... 184
4.8.6.a ADJUSTING THE FAN BELT TENSION................................................................. 184
4.8.6.b CHECKING THE GEARING CHAIN TENSION ...................................................... 185
4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS................................................. 187
4.8.6.d CHECKING THE WHEEL NUT DRIVING TORQUE............................................... 187
4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS .......................... 188
4.8.6.f LUBRICATING THE JOINTS .................................................................................. 189
4.8.6.g CHANGING THE ENGINE OIL ............................................................................... 190
4.8.6.h CHANGING THE ENGINE OIL FILTER.................................................................. 191
4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines filled with synthetic biodegradable oil type HEES) .................................... 192
13
TABLE OF CONTENTS
4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION ......................................................... 192
4.8.8.a CHANGING THE FUEL FILTER ............................................................................. 192
4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER .............................................. 194
4.8.8.c CLEANING THE WATER SEPARATOR................................................................. 195
4.8.8.d DRAINING THE HYDRAULIC OIL TANK
(Only for machines filled with synthetic biodegradable oil type HEES) ................... 196
4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION ....................................................... 197
4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION ......................................... 197
4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION
FILTER .................................................................................................................... 198
4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE ..................... 199
4.8.10 MANUTENZIONE OGNI 2000 ORE ......................................................................................... 200
4.8.10.a CHANGING THE COOLANT .................................................................................. 200
4.8.10.b CHANGING THE SUCTION FILTER ...................................................................... 201
4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER ......................................... 202
TECHNICAL SPECIFICATIONS
5.1 TECHNICAL DATA ............................................................................................................................... 204
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS ................................................................... 204
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT.................................... 206
5.1.3 TECHNICAL CHARACTERISTICS .......................................................................................... 210
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT ............................................................................................. 214
6.1.1 PRECAUTIONS REGARDING SAFETY .................................................................................. 214
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................. 215
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT.................. 216
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION
WITH HIGH-FLOW AND SUPER-FLOW HYDRAULIC SYSTEM ............................................ 217
6.2 CHANGING THE AUTHORIZED EQUIPMENT .................................................................................... 218
6.2.1 CONNECTING THE EXCAVATOR .......................................................................................... 218
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT............................................................................ 219
6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK ........ 221
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR .................................... 222
6.2.5 USING THE MACHINE WITH THE EXCAVATOR ................................................................... 222
6.3 PALLET FORKS ................................................................................................................................... 223
6.4 CHANGING THE OPERATING PATTERN ........................................................................................... 224
6.4.1 HOW TO CHANGE THE OPERATING PATTERN .................................................................. 226
6.5 HAND & FOOT CONTROL SYSTEM ...................................................................................................227
6.5.1 MACHINE CONTROLS ............................................................................................................ 227
6.5.1.1 TRAVEL AND STEERING CONTROL LEVERS..................................................... 228
6.5.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET).......... 230
6.5.1.3 AUXILIARY HYDRAULIC KIT CONTROL ............................................................... 233
6.5.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM) ............................... 236
6.5.2.1 STEERING (CHANGING DIRECTION) .................................................................. 238
14
SAFETY AND
ACCIDENT PREVENTION
15
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
q The safety plates must always be legible and in good conditions; for this reason, if they are dirty with dust, oil or
grease, it is necessary to clean them with a solution made of water and detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or to your Komatsu Dealer.
q In case of replacement of a component provided with a safety plate, make sure that this plate is applied also on
the new part.
q The machine can be provided with other plates in addition to those indicated below; in any case, keep also to the
instructions given in the additional plates.
2.1.1.1 SAFETY PLATES
RWA37010
16
RWA00030
RWA37020
SAFETY, NOISE AND VIBRATION PLATES
RWA00010
17
SAFETY, NOISE AND VIBRATION PLATES
2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR
RWA37030
RWA00020
RWA00030
18
RWA37040
SAFETY, NOISE AND VIBRATION PLATES
RWA00020
RWA00010
19
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied on to the machine are accompanied or represented by pictograms.
The personnel in charge with the operation and maintenance of the machine must know the symbols contained in
the pictograms perfectly; the following description illustrates what they look like and their respective meanings.
DANGER IN THE WORK AREA
(Only for machines with excavator)
q Do not approach or stand within the equipment operating ra-
dius when the boom and the bucket of the excavator are raised.
RWA00020
DO NOT OPEN THE HOOD
q Do not open or remove the hood while the engine is running.
CONSULT THE MANUAL
q Carefully read the contents of the manual before using the
machine or performing maintenance operations.
HYDRAULIC OIL TOPPING UP
RWA00010
RWA00030
20
RWA00050
BIOLOGICAL HYDRAULIC OIL TOPPING UP
SAFETY, NOISE AND VIBRATION PLATES
REFUELLING
ENGINE LUBRICATING OIL FILTER
FUEL FILTER
BIO-OIL
D
RWA00040
RWA00080
RWA34380
ENGINE AIR SUCTION FILTER
ENGINE COOLANT
D
RWA00060
RWA00090
RWA00130
21
SAFETY, NOISE AND VIBRATION PLATES
ENGINE COOLANT PRESSURE
HYDRAULIC OIL LEVEL
HYDRAULIC OIL FILTER
RWA00110
RWA00100
ELECTRIC OUTLET
ANCHORAGE POINT
EMERGENCY EXIT
RWA00120
RWA00070
12 V
RWA00200
LIFTING POINT
22
RWA00190
RWA04920
2.1.3 POSITION OF THE NOISE PLATES
q The noise plates must always be legible and in good condi-
tions; for this reason, if they are dirty with dust, oil or grease,
it is necessary to clean them with a solution made of water
and detergent.
Do not use fuel, petrol or solvents.
q If the plates are damaged, ask for new ones to Komatsu or
to your Komatsu Dealer.
q In case of replacement of a component provided with a noi-
se plate, make sure that this plate is applied also on the new
part.
NOISE OUTSIDE THE CAB
q This value indicates the noise level outside the machine and
refers to the noise perceived by the persons who are in the
vicinity of the work area.
SAFETY, NOISE AND VIBRATION PLATES
RWA37050
10
NOISE INSIDE THE CAB
q This value indicates the maximum noise level perceived by
the operatorís ears inside the cab.
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
q According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, the upper limbs are subjected to vibrations lower than 2.5 m/sq.sec., while the seated part of the body is
subjected to vibrations lower than 0.5 m/sq sec.
4
2000/14/EC
8
6
ISO 6396
dB
RWA36340
dB
RWA36350
23
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
q Only trained and authorized personnel can use the machine and perform maintenance operations.
q When using the machine or performing maintenance operations, follow all the safety rules, precautions and in-
structions.
q When working with other operators or when the work site is often occupied by other operators, make sure that
everyone knows and understands all the agreed signals and, in any case, that everyone works in such a way as
to be able to see the machine and to be visible to the operator.
2.2.2 SAFETY DEVICES AND GUARDS
q Make sure that all the guards and covers are in the correct position. Have guards and covers changed or repai-
red if damaged. Neither use the machine without guards, nor remove the guards when the engine is running.
q Always use the proper safety devices to lock the machine when parking and remember to fasten the safety belt.
q For the safety devices, see "3.1 SAFETY LOCKS".
q For the safety belt, see "3.5.6 SAFETY BELT".
q Do not remove the safety devices and always keep them in good operating conditions.
q Improper use of the safety devices may lead to serious injuries or even death.
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
q 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 serious injuries and damage.
Avoid also wearing clothes dirty with oil or fuel, since they are
flammable.
q Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing
maintenance operations.
q Always wear safety goggles, a hard hat and heavy gloves if
your job involves scattering metal chips or minute materials;
these precautions are particularly useful when driving the
equipment connection pins with a hammer and when blowing
compressed air into the air filter and the radiator to clean
them.
During these operations, make also sure that no one is standing or working near the machine without the necessary protections.
q When working for 8 hours with a noise level exceeding 90
dBA, it is necessary to use headphones or ear plugs and to
be particularly careful, especially at the end of the work shift.
RWA00960
24
GENERAL PRECAUTIONS
P
2.2.4 UNAUTHORIZED MODIFICATIONS
q Any modification made without the authorization of Komatsu can involve hazards.
q Before making a modification, consult your Komatsu Dealer. Komatsu declines any responsibility for injuries or
damage caused by unauthorized modifications.
2.2.5 LEAVING THE OPERATORS SEAT
q When leaving the operatorís seat, even if temporarily, make
sure that the machine is in a safe position (see "2.4.11
PARKING THE MACHINE").
q Before leaving the operatorís seat, carry out the following
operations in the sequence indicated below:
1 - Rest the equipment on the ground.
RWA37070
2 - Apply the parking brake.
3 - Engage the safety device of the optional equipment con-
trol pedal (if installed).
4 - Lock the equipment and travel control by shifting the safe-
ty bars to the lock position.
5- Stop the engine (see "3.8 STOPPING THE ENGINE").
If you have to go so far away that you will not be able to see
the machine, extract the ignition key.
RWAA11160
RWAA12610
RWAA13110
25
GENERAL PRECAUTIONS
2.2.6 GETTING ON AND OFF THE MACHINE
q Do not jump on or off the machine, either when it is at rest
and when it is moving.
q When getting on or off the machine, always use the appro-
priate handles and footboards; get on and off the machine
very carefully.
q Never hold or rest on the control levers.
q Either when getting on and when getting off the machine,
always maintain three points of contact (holding or resting
points), in order to avoid losing your balance and falling
down.
q Clean the handles and footboards if they are dirty with oil or
grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud
or rubble.
RWA37080
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)
q Make sure that the rear-view mirrors are clean and correctly
directed; the operator must be able to check the area behind
the machine with no need to move the trunk with respect to
his normal operating position.
q If the rear-view mirrors should move or break during the ope-
rations, stop the machine immediately and fix or change
them.
q Working without checking the area behind the machine in-
volves the risk of running over persons who have incautiously approached the machine or colliding with fixed obstacles
or manoeuvring vehicles.
RWA18670
RWA37090
26
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL
Fuel, oil and some types of antifreeze can be easily ignited if
they get in contact with a flame. Fuel is particularly flammable
and therefore extremely hazardous.
q Keep any naked flame away from flammable fluids.
q Stop the engine and do not smoke when refuelling.
q Top up with fuel and oil only after stopping the engine and in
well ventilated areas.
q Top up with fuel and oil in a well delimited area and do not al-
low unauthorized persons to approach.
q When refuelling, hold the fuel gun firmly and keep it constan-
tly in contact with the filler until you have finished, in order to
avoid sparks due to static electricity.
q After topping up, tighten the safety caps of the fuel and oil
tanks securely.
q Do not fill the tank completely, in order to leave room for the
fuel to expand.
q In case some fuel is spilled, wipe it up immediately.
GENERAL PRECAUTIONS
RWA00970
2.2.9 PREVENTING BURNS
q If the engine coolant, the engine oil and the hydraulic oil are
hot, use heavy cloths and wear gloves, heavy clothing and
safety goggles before carrying out any check or touching the
hot parts.
q Before checking the coolant level, stop the engine and let
the fluid cool down.
If a check is necessary due to the overheating of the engine,
slowly loosen the radiator cap to release any residual pressure before removing it. The hot fluid that spurts out may
cause serious burns.
q Before checking the engine oil and the hydraulic circuit oil le-
vels, stop the engine and let the oil cool down. The hot oil
that can be sprayed out of the tank may cause serious burns.
RWA00980
RWA00990
27
GENERAL PRECAUTIONS
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
q Asbestos powder can be hazardous to your health if it is
inhaled.
q If you handle materials containing asbestos fibers, keep to
the instructions given below contenga fibre di amianto, utilizzare le seguenti precauzioni:
1 - Do not use compressed air, but only aspirators to clean
the machine and make sure that the room in which you
are working is properly ventilated.
2 - Use low-pressure water to keep down the dust when clea-
ning.
3 - If there is danger that there may be asbestos powder in
the air, operate the machine with the wind to your back
whenever possible.
4 - Even if the cab provides suitable protection, use an ap-
proved and homologated respirator.
5 - The powder gathered during the cleaning operations must
be dampened and put in a sealed and marked container,
so that it can be safely disposed of according to the regulations in force.
RWA01000
RWA01010
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
q Do not stand within or approach the operating radius of the
work equipment, even when the operator is on board the
machine and the engine is running.
q Do not stand or work under the arms or the articulated joints
when the arms are lifted, if you are not sure that the safety
locks have been duly engaged.
q Do not carry out any operation requiring the lifting of the ar-
ms, if you are not sure that the locks are correctly positioned
and coupled to the arms.
RWA21910
28
GENERAL PRECAUTIONS
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT
q Make sure that fire extinguishers have been provided and
check their position.
q Periodically make sure that the fire extinguishers are loaded
and that you know how to use them.
q Find out where the first aid kit has been located.
q Periodically make sure that the first aid kit contains the ne-
cessary disinfectants, bandages, medicins, etc.
q It is necessary to know what to do in case of fire.
q Make sure that the phone numbers of the persons or organi-
RWA01030
zations/bodies you may need to contact in case of an emergency are at hand (either at the work site and where
maintenance operations are performed).
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE
q If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent
reduction of its stiffness and of the safety that must be guaranteed to the operator.
Consult Komatsu or your Komatsu Dealer to have the cab structure and resistance checked in case of impact or
damage.
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT
q When installing and using optional equipment, carefully read the relevant instruction manual and keep to the in-
dications given therein.
q Do not use optional or special equipment without the authorization of Komatsu or the Komatsu Dealer.
The installation and use of unauthorized equipment may create safety problems and adversely affect the efficiency and life of the machine.
q Komatsu cannot be held liable for any damage, accident, product failure resulting from the installation and use of
unauthorized equipment.
29
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.1 SAFETY ON THE WORK SITE
q Before starting the engine, thoroughly check the area for any
unusual condition of the ground due to which work may be
dangerous.
q Check the conditions of the ground at the work site and befo-
re starting the engine define the work plan and the best and
safest operating procedure.
q Make the ground surface as level as possible before car-
rying out any operation.
q In case of work on the road, protect pedestrians and cars by
designating a person for work site traffic duty and install fences around the work site.
q If water lines, gas lines, and telephone or high-voltage
electrical lines are located under the work site, contact the
relevant utility company in order to find out their exact positions or to make them ineffective until the end of the operations. Be careful not to sever or damage any of these lines.
RWA37100
q Check the depth and flow of water before operating in water
or on river banks.
2.3.2 FIRE PREVENTION
q Carefully remove all wood chips, rubbish, paper and other
flammable materials that may have accumulated inside the
engine compartment, since they can cause fires.
q Check the fuel and hydraulic system pipes for leaks and if
necessary repair them. Wipe up any leakage of oil, fuel or
other flammable fluids.
q Make sure that fire extinguishers are available for use in the
work area.
RWA01040
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB
q Do not keep objects or tools in the operator's cab. They may hinder the operation of the controls and cause se-
rious accidents.
q Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as
far as the floor is concerned, remove any excess dirt (earth, stones, etc.).
q Check the safety belt and change it if it is broken or damaged.
Replace any component only with homologated parts supplied by Komatsu or its Dealers.
30
PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.4 ROOM VENTILATION
q Before starting the machine in confined or poorly ventilated
places, make sure that there is proper ventilation or connect
the engine exhaust pipe to a suction duct. The engine
exhaust gases can be deadly.
RWA01050
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)
q Remove any trace of dirt from the lights, in such a way as to ensure perfect visibility on the work area.
q Make sure that all the bulbs and the working lights are functioning properly. If necessary, replace any faulty bulbs
with new ones, making sure that their power is correct.
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS CHECKING THE WINDSHIELD WIPER BLADES (if installed)
q Remove any trace of dirt from the cab windows and clean the rear-view mirrors, in order to ensure perfect visibi-
lity on the work area.
q Adjust the rear-view mirrors that may have moved, so that the operator seated in the driving position can clearly
see the area behind the machine.
If any glass is damaged, replace it with a new one.
q Check the conditions of the windshield wiper blades; the scraping wire must be smooth, with no indentations and
attached to the rubber back of the blade.
In case of doubts on the efficiency of the scraping wire, change the blades.
31
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.1 STARTING THE ENGINE
q Before getting on the machine, walk around it and check for people and objects that might be in the way.
q Do not start the engine if warning plates have been attached to the control levers.
q When starting the engine, sound the horn to give an alert signal to the persons in the vicinity.
q Start the engine only when seated with fastened safety belt.
q Do not allow anyone to get on the machine.
2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS
q The machines homologated for travel on roads are provided
with safety locks to be used for this purpose.
q When it is necessary to travel on roads, proceed as follows:
1 - Lower the arm completely, fold the bucket, engage the
antirotation lock (1) and apply the teeth guard (2).
1
2 - Engage the safety lock (3) of the optional equipment con-
trol pedal (if installed).
RWAA11750
2
RWAA4010
3
32
RWAA12620
3 - Lock the equipment control by shifting the safety device
lever (4) to the lock position.
q When travelling on roads, keep to the traffic rules and opera-
te the flashing light.
IMPORTANT
q If the machine is provided with optional equipment, ap-
ply all the locks required according to the homologation
and the traffic safety rules (see "3.1 SAFETY LOCKS").
2.4.3 CHECKS FOR TRAVELLING IN REVERSE
q When operating in areas that may be hazardous or where vi-
sibility is poor, designate a person to direct the movements
of the machine and the traffic on the work site.
q Make sure that no unauthorized person is standing within
the machine operating radius or in its travel direction.
If necessary, put up appropriate fences.
q Before moving the machine, sound the horn in order to warn
the persons near the work area.
q There are blind spots behind the machine, which cannot be
seen by the operator and where someone may be standing:
therefore, it is necessary to make sure that there is no one
behind the machine before travelling in reverse.
PRECAUTIONS TO BE TAKEN WHEN WORKING
4
RWAA11540
RWA37090
33
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.4 MOVING THE MACHINE
IMPORTANT
q The use of the speed increase function is allowed only
for the fast speed transfers of the machine.
q When moving the machine, lower the arm and fold the buc-
ket completely; this position makes it possible to evaluate
the space required for the movements more precisely and at
the same time ensures the stability of the machine.
q If the equipment control levers must be used during travel,
avoid moving them abruptly; sudden manoeuvres change
the attitude of the machine and make driving difficult.
q When travelling on rough ground, keep the speed low and
avoid sudden movements of the bucket arm.
q If possible, avoid moving on obstacles.
If the machine has to travel over an obstacle, keep the equipment as close to the ground as possible and travel at low
speed.
Never move on obstacles that may incline the machine considerably (over 10°).
RWA37110
WRONG
q If one of the two wheels goes over an obstacle or gets into a
hole in the ground, the machine may overturn.
In these cases, reduce the speed to minimum and be very
careful to the balance of the machine.
2.4.5 WORKING ON SLOPES
q Operations on slopes and on river or lake banks with damp
ground may result in the tipping over or slipping of the machine.
q Do not operate with the bucket before the tractor.
q On hills, banks or slopes, keep the arm lowered and the buc-
ket folded and in case of emergency quickly lower it to the
ground to help the machine stop.
q Do not change direction and if possible avoid travelling obli-
quely when working on slopes. It is advisable to go down or
up to a flat surface before performing these manoeuvres.
RWA21950
WRONG
RWA37130
CORRECT
34
RWA37240
q Travel up or down slopes with the heaviest part of the loader
facing the top of the slope.
q Do not travel on wet grass or thick layers of leaves: if the
machine moves obliquely in these conditions, it may slip.
q Before carrying out any operation on a slope, always check
the functionality of the parking brake.
q Do not go down slopes at high speed; you may lose control
of the machine and cause serious damage and even death.
q Do not move on slopes with inclination exceeding 15°, since
the machine may overturn.
q When the fuel level indicator reaches the red reserve area
during work on a slope, immediately provide for refuelling;
due to the inclination of the machine, the engine may suck in
air and stop suddenly, which represents a grave risk for the
safety of the operator and of the persons before the machine.
q If the engine should stop all of a sudden, immediately lower
the bucket to the ground and apply the parking brake.
PRECAUTIONS TO BE TAKEN WHEN WORKING
RWA37340
RWA37350
RWA37360
RWA37370
35
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.6 PREVENTING ELECTROCUTION
q Digging operations near overhead electric lines are extremely dangerous and they may also cause death due to
electrocution; for this reason, when working near overhead electrical lines, always respect the minimum safety
distances prescribed by the competent authorities and by the accident-prevention rules in force.
q As far as underground long-distance lines are concerned, the minimum distance depends on the covering of the
ducts in which the cables are laid.
q The basic safety precautions to be taken to prevent this risk are the following:
1 - Wear shoes with thick rubber or leather soles.
2 - Request the aid of another person who can warn you if the machine gets too close to the electric line.
3 - Operate at low speed.
4 - Learn what is 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.
q If the work equipment accidentally gets entangled in the cables, the operator must remain still and must not lea-
ve the cab until the electricity company has insulated the line.
q When carrying out this kind of operations, warn everyone standing in the work area to keep at the minimum di-
stance prescribed from the machine and the work equipment.
q Ask the electricity company in advance what are the voltage of the cables and the minimum safety distance.
DANGER
q The minimum distances from overhead lines can vary in the different countries, according to the climate
and to the percentage of humidity in the air.
Indicatively, the distances shown in the table should be respected.
Cable voltage Min. safety distance
1.0 kV (distribution line) 5 m
6,6 kV (2÷3 insulators) 5.2 m
33 kV (min. 3 insulators) 5.5 m
66 kV (min. 6 insulators) 6 m
154 kV (min. 10 insulators) 8 m
275 kV (min. 19 insulators) 10 m
RWA37380
36
PRECAUTIONS TO BE TAKEN WHEN WORKING
2.4.7 VISIBILITY
q Switch on the working lights as soon as visibility starts decreasing.
q If visibility decreases due to mist, smoke or heavy rain, stop the machine in a safe position and wait for the wea-
ther to improve until visibility becomes accepta.
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES
q If the ground is icy or covered with snow, even a slight slope may cause the machine to slip sidewards, therefore
it is advisable to move at low speed and to avoid abrupt starts, stops or turns.
q When it has snowed heavily, the road shoulders and any obstacle are buried in the snow and are not visible, the-
refore proceed with care when clearing the snow.
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
q When working in tunnels, galleries, under electric cables or other ducts (air, telephone lines) and wherever the
height is limited, proceed with the greatest care to prevent the bucket or the arms from causing any damage.
2.4.10 WORKING ON LOOSE GROUND
q Avoid operating the machine too close to the edge of cliffs, overhangs and deep ditches.
These areas may collapse, making the machine fall down or tip over and this could result in serious injuries or
even death.
Remember that after heavy rain or earthquakes these dangerous conditions usually get worse.
q The earth laid near ditches is loose and can easily collapse due to the weight or vibrations of the machine.
Be extremely careful and remember to fasten the safety belt.
37
PRECAUTIONS TO BE TAKEN WHEN WORKING
P
2.4.11 PARKING THE MACHINE
q Park the machine on firm and level ground. If this is not pos-
sible and it is necessary to park on a slope, position the machine with the bucket directed downwards and carry out the
following operations:
1 - Rotate the bucket forward and rest it on the ground.
2 - Apply the parking brake.
3 - Stop the engine.
4 - Put wedges or safety blocks under the wheels.
q 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 (see "3.1 SAFETY LOCKS").
q Always lock the equipment and travel control by shifting the
safety bars to the lock position (see "3.3.5 MACHINE CONTROLS").
q When leaving the machine, always apply the parking brake
and remove the ignition key.
q If it is necessary to park on public roads, provide for signal-
ling the presence of the machine according to the local regulations in force (signalling fires, fences, road works ahead,
alternated direction and direction signs, etc.).
RWA37390
RWAA11160
RWA02000
RWAA13110
38
TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.5.1 LOADING AND UNLOADING THE MACHINE
q Loading and unloading the machine on/from another vehicle
always involve potential hazards. Proceed with extreme care.
q Perform loading and unloading on firm, level ground. Main-
tain a safety distance from the edges of ditches or from road
sides.
q If the vehicles used have not been appositely equipped, put
support blocks under the ramps, in order to avoid any bending.
q Always lock the wheels of the transporting vehicle with wed-
ges.
q Always use ramps that are sufficiently wide and can support
the weight of the machine. The longitudinal axes of the ramps must be parallel to each other and perpendicular to the
loading board and their distance from each other must be
suitable for the tread of the machine.
q Make sure that the ramps are securely positioned and an-
chored to the loading board and that they have the same
length.
Ramps
Max.15˚
Blocks
Blocks
RWA00240
q Position the ramps with a maximum inclination of 15°.
q Make sure that the ramp surface is clean and there is no tra-
ce of grease, oil, soil and ice; remove any dirt from the wheels before starting to load the machine on the vehicle.
q If the bucket is empty or no optional accessories are fitted on
the machine, this must be loaded on the transporting vehicle
in reverse.
q Do not correct the trajectory of the machine on the ramps. If
necessary, get down the ramps and start the operation
again.
q After loading the machine, block the wheels with wedges
and secure it with tie-downs or chains that prevent even any
sideward shift (see "3.9 TRANSPORTING THE MACHINE
ON OTHER VEHICLES").
2.5.2 THE ROUTE
q Define the route to be followed, taking into account the width, height and weight of the transporting vehicle plus
the machine.
Make sure that the overall dimensions of the vehicle and its load are compatible with the roads and any tunnel,
underpass, bridge, power and telephone line, etc. along the route.
q Keep to the regulations in force regarding the permissible width, height, weight and speed of heavy vehicles.
39
BATTERY
2.6 BATTERY
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES
q Electrolytic batteries contain sulphuric acid which can cause
burns. It can also corrode clothing and make holes in it. If
you inadvertently splash battery acid on yourself or on someone else, immediately wash the affected part with plenty
of water.
q Battery acid may cause blindness if it comes into contact
with the eyes.
If acid accidentally gets into your eyes, wash them immediately with plenty of water and consult a doctor right away.
q If you accidentally swallow battery acid, drink a large quanti-
ty of water or milk, beaten egg white or vegetable oil and in
any case antiacid substances like magnesia, bicarbonate,
etc.; call a doctor or a poison treatment center immediately.
q Always wear safety goggles when working on batteries.
q Batteries produce hydrogen, which is highly explosive and
can be easily ignited with small sparks or naked flames.
q Before working with batteries, stop the engine and remove
the ignition key.
RWA01060
WRONG
q Avoid short-circuiting the battery terminals through acciden-
tal contact with metal objects or tools or through the inversion of the terminals.
q Tighten the battery terminals securely. Loose terminals may
generate sparks and even cause the explosion of the battery.
2.6.2 STARTING WITH BOOSTER CABLES
q When starting the machine with booster cables, always wear
safety goggles.
q When starting the engine by means of another machine,
avoid any contact between the two machines.
q Be sure to connect the positive cable (+) first and then the
negative or earth cable (-) when connecting the booster cables. After the start, disconnect first the negative or earth (ñ)
cable and then the positive cable (+).
q Connect the batteries in parallel: positive to positive and ne-
gative to negative.
q When connecting the earth cable to the frame of the machi-
ne to be started, operate as far as possible from the battery.
(See "3.15.3 IF THE BATTERY IS DEPLETED").
RWA01080
RWA01180
RWA01190
40
PRECAUTIONS FOR EMERGENCY RECOVERY
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
q The removal hooks are to be used exclusively for emergen-
cy recovery and not for towing vehicles.
q Before moving the machine, make sure that all the controls
are in neutral.
q Release the parking brake of the travel hydraulic motors
(see "4.8.1.d RELEASING THE PARKING BRAKE").
q Incorrect manoeuvres may result in serious injuries or even
death.
q To move the machine, use properly dimensioned steel ca-
bles; do not use worn cables or cables with broken strands
(A), twisted cables (B), deformed cables (C).
q During the recovery operation, no one can be allowed to ap-
proach the machines or the cable.
q Do not stand astride the cablecavo.
RWA05380
RWAA13120
RWAA11200
RWAA13130
41
PRECAUTIONS FOR EMERGENCY RECOVERY
q Move the machine just far enough to permit the required re-
pairs.
q Do not remove the machine in any way other than that indi-
cated in paragraph "3.15.1 HOW TO REMOVE THE MACHINE".
CAUTION
q The maximum pulling force for the emergency recovery
is the following
F=2600 kg.
q Use cables having the same length and pull continuou-
sly, without jerks.
q Arrange and couple the machine to be removed by posi-
tioning it on the same axis as the towing vehicle; the
force must be parallel to the axis of movement.
RWAA11220
42
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.1 WARNING PLATES
q Before starting any maintenance operation, position the ma-
chine on a firm and level surface, rest the equipment on to
the ground, engage the safety locks of either the equipment
and the controls and stop the engine.
q If another person starts the engine and operates the control
levers while the operator is providing for service, this may result in serious injuries or even death.
q To avoid these risks, always attach warning plates to the
control levers and to the ignition key before performing any
maintenance operation; if necessary, attach additional warning tags also around the machine and in particular on the
cab handles.
DO NOT
START
ENGINE
RWA01210
2.8.2 TOOLS
q Use only the tools provided with the machine and high-quali-
ty tools suitable for the tasks to be performed.
q 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.
q After use, always put the tools in the appropriate compart-
ment (1) positioned behind the driverís seat.
N
O
N
E
R
E
T
T
E
M
O
T
O
M
IN
RWA37400
RWA01310
1
RWAA11770
43
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.3 PERSONNEL
q Only authorized and duly trained personnel can service and repair the machine; additional precautions must be
taken when grinding, welding and using a sledge hammer or heavy hammers.
q When assemblying the equipment or cylinder connection pins, use wooden, plastic or in any case not excessi-
vely hard tools to check the centering of the holes.
Do not use your fingers, since you run the risk of cutting them.
2.8.4 EQUIPMENT
q The normal or special equipment that must be installed on
the machine or that have been removed must be stored in
safe places, preventing them from falling down. If they fall on
someone, they can cause serious bodily harm.
q When assemblying or removing any equipment, make sure
that the cables and the lifting hook are in good conditions
and properly dimensioned for the load to be lifted.
RWA01320
2.8.5 WORKING UNDER THE MACHINE
q Always lower the work equipment to the ground or in any ca-
se to its lowest position before performing service or repairs
under the machine.
q Always lock the machine wheels securely.
q Do not work under the machine, if this is not sufficiently sup-
ported.
2.8.6 KEEPING THE MACHINE CLEAN
q Spilled oil or grease, scattered tools or broken pieces are
dangerous, because they may cause someone to slip or trip.
Always keep the machine and the work site clean and tidy.
q To clean the machine, use a pressurized jet of warm water or
steam and the appropriate detergents available on the
market. Do not use diesel oil, oil or solvents, since the former leave an oily coat that favours the sticking of dust, while
the latter (even if weak) damage the painted surfaces and
therefore facilitate rusting.
q While cleaning the machine, keep the pressurized jet at a
minimum distance of approximately 60 cm, in order to avoid
damaging the warning plates and the pictograms.
If one or more plates should be damaged, request for spare
ones to Komatsu or to your Komatsu Dealer and provide for
replacing them.
RWA02520
RWA01330
q Water into the electrical system provokes the oxidation of
the contacts and may hinder the start of the machine or even
make it start suddenly and abruptly. For this reason, never
use water or steam jets to clean sensors, connectors or the
inside of the operator's cab.
44
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.7 USE OF THE ENGINE DURING MAINTENANCE
q During maintenance operations, run the engine only when indispensable. If it is necessary to have the engine
running (for example, to wash the cooling circuit or to check the functionality of the alternator), an operator
should constantly remain in the cab, in order to be able to stop the engine whenever this is required.
q During maintenance operations with running engine, never disengage the safety locks of the controls from the
normal LOCK position.
Service personnel must not move any control lever.
q When carrying out maintenance operations, do not touch the moving parts of the machine and avoid wearing lar-
ge and loose clothes.
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
q Periodically change the following parts, which are important to prevent fires.
Fuel supply system: fuel delivery and return pipes.
Hydraulic system: main delivery pipes of the hydraulic pump.
q Even if they seem to be in good conditions, these components must be periodically changed with new ones. In
fact, these components tend to deteriorate over time.
q If one of these parts is defective, change or repair it even if the recommended change interval has not elapsed
yet (see "4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY").
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE
OPERATION OR INSPECTION
q Stop the machine only on firm and level ground and stop the
engine before carrying out any maintenance operation or inspection.
q If the engine must be running during a maintenance opera-
tion, shift the safety bars to the LOCK position and carry out
the maintenance operation with the help of another person;
one operator must remain on the machine and the words
and signs to be used must be agreed upon in advance.
q The person who carries out the maintenance operations
must be very careful not to touch any moving part of the engine.
RWA02000
RWAA13110
45
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.10 RULES FOR REFUELLING AND ADDING OIL
q Keep away from naked flames while refuelling or adding oil.
q Spilled fuel or oil make the ground slippery and may cause
accidents; clean any dirty area immediately and carefully.
q Always tighten the fuel tank and the hydraulic circuit oil sa-
fety caps securely.
q Do not use fuel to clean any part of the machine that is dirty
with oil or dust.
q Always top up the fuel and oil tanks in properly ventilated
areas and refrain from smoking.
q When refuelling, hold the fuel gun firmly and keep it constan-
tly in contact with the filler until you have finished, in order to
avoid sparks due to static electricity.
q Do not fill the tank completely, in order to leave room for the
fuel to expand.
RWA00970
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
q Let the engine and the radiator cool down before checking
the coolant level.
q If it is necessary to remove the cap with hot engine, wear su-
itable clothes and protections and loosen the cap slowly, in
order to release the pressure gradually.
2.8.12 USING LAMPS
q Use only homologated explosion-proof lamps to check the
fuel, oil, coolant and battery electrolyte levels.
Unsuitable lamps can cause fires or explosions.
RWA00980
RWA01340
46
RWA01350
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
q When repairing the electrical system, disconnect the battery
in order to stop the flow of current.
IMPORTANT
q Disconnect first the negative earth cable (-) and then the
positive cable (+).
At the end of the operation, reconnect first the positive
cable (+) and then the negative cable (-).
q If electrical welding operations are to be carried out on the
machine, it is necessary to disconnect the battery and also
the alternator.
REMOVAL
12
RWA01370
RKAB0460
2.8.14 PRECAUTIONS CONCERNING THE STARTER
q Do not start the engine by tampering with the terminals of
the starter, since the machine may move.
q Sudden or accidental movements of the machine may cause
serious injuries or even death.
RWA04890
RKAB1520
47
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES
q Do not bend high-pressure hoses or rub them with sharp or abrasive objects.
Do not use bent or cracked rigid tubes or hoses that were previously rejected because of leaks or fastening defects, since they may burst during use.
q Always repair or replace any loose or faulty fuel or oil pipe. Any leakage of fuel or oil may cause fires.
2.8.16 PRECAUTIONS TO BE TAKEN
WHEN WORKING ON HIGH-PRESSURE SYSTEMS
q 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 service or inspect the hydraulic circuit,
it is advisable to lower the equipment to the ground and
completely release the pressures and the residual pressure
present in the tank.
Small leakages from pipes under pressure and the resulting
jets are extremely dangerous, since they can perforate the
skin and penetrate in the blood circulation or injure the eyes.
For this reason, always wear goggles and thick gloves during the inspections and use a piece of cardboard or a sheet
of plywood to check for oil leakages.
If you are struck by a jet of high-pressure oil or are injured,
even if slightly, consult a doctor immediately.
DANGEROUS!
RWA01480
CORRECT
RWA01580
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH
TEMPERATURES AND PRESSURES
q When the machine is stopped at the end of work, the engine
coolant, the oil and all the components are hot and the
hydralic circuits are under pressure.
In these conditions, if the coolant, the hydraulic oil and the
engine oil are to be drained in order to change them or the
filters, there are serious risks of injuries and burns.
Wait for the temperature to lower within the normal operating
range (40-45ºC) before carrying out the maintenance operations in accordance with the procedures indicated in the relevant sections of this manual.
RWA00990
48
2.8.18 COOLING FAN AND FAN BELT
q Be careful to the rotating 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.
q If hands, clothes, or tools get entangled in the fan blades or
the fan belt, they may be cut, torn or seriously damaged; for
this reason, avoid touching the rotating parts.
2.8.19 WASTE MATERIALS
q Do not dispose of used oil in the sewer system, rivers, etc.
q Always put used oil in containers. Never drain oil directly on
to the ground.
q Keep to the laws and regulations in force when disposing of
harmful substances such as oil, fuel, solvents, used filters
and batteries.
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
RWA01660
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES
q Always bear in mind that tyres can burst while being inflated,
causing serious accidents.
q Before inflating the tyres, always check the wheel rims and
the tyre walls and tread for dents, cuts, broken plies, or other
defects.
q Have a tyre expert perform checks and tyre maintenance.
q When inflating the tyres, use a compressed air gun with ex-
tension hose and pressure gauge.
q Make sure that there is nobody in the vicinity before starting
to inflate a tyre. Stand at the tread or outer belt side of the
tyre to inflate it.
q Never exceed the inflation pressures specified for each type
of tyre. Always make sure that the tyre pressures are identical on both sides of the machine .
RWA01670
RWA20900
49
PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»
q It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the
temperature increases insoluble compounds are generated, which are deposited on the filters and clog them
(the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
q The biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic engine,
the transmissions, the braking system, etc.
q Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, discon-
necting 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 40ºC, then start moving the equipment, so that all the parts of the system are filled with oil. Stop the engine
and check the oil level (see "4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT").
50
THE MACHINE AND
ITS OPERATIONS
51
SAFETY LOCKS
3.1 SAFETY LOCKS
DANGER
q If it is necessary to stop the machine with raised loader arm, always engage the mechanical safety lock
on the arm and lock the equipment and travel control by lifting the safety bars (see "3.3.5 pos. 1 - SAFETY BARS").
q When travelling on roads with a machine homologated for this purpose, lower the loader arm complete-
ly, engage the bucket antirotation lock, apply the teeth guard and lock the equipment control by shifting
the safety device lever to the lock position.
q When travelling on roads with a machine homologated for this purpose and equipped with excavator,
fold the bucket completely, apply the lock between boom and arm, the antirotation lock between boom
and sliding plate and the centre lock of the sliding plate.
Raise the stabilizer supports completely, couple the relevant safety chains and finally lock the equipment control by shifting the safety device lever to the lock position. If the machine is also equipped with
rear stabilizers, raise the supports and lock them with the relevant safety chains.
q When travelling on roads with a machine homologated for this purpose and equipped with asphalt cut-
ter, apply the lock on the lifting jack in order to keep the equipment at a given distance from the ground,
lower the loader arm completely, install the antirotation lock of the front equipment and finally lock the
equipment control by shifting the safety device lever to the lock position.
q Non-compliance with these rules may lead to serious accidents.
3.1.1 LOADER LOCKS
q The loader arm is provided with a safety lock (1) to be used
to keep the arm raised when the machine is serviced or routine operations are carried out.
q The engagement of the safety lock must be carried out by
two persons, one seated in driving position to check the
movements of the machine and the other standing on the
ground to engage the lock correctly.
q It is important to remember that in operating conditions the
safety lock (1) must be positioned against the arm and kept
in this position by means of the safety pin (2).
DANGER
q After engaging the lock (1), fasten it with the safety pin
(2) held by the split pin (3).
q Do not carry out any operation under the raised loader
arm if the safety lock (1) has not been engaged.
IMPORTANT
q Always open the engine hood (see "3.5.1 ENGINE
HOOD") before lifting the loader arm.
q The safety lock must always adhere to the hydraulic cyl-
inder rod.
q The safety lock must be brought to its definitive position
by moving the contact surfaces slowly and continuously, in such a way as not to damage the cylinder head surface.
2
1
RKAB1080
3
2
1
RKAB1090
52
q The safety bars (4) positioned in front of the operator seated
in the driving position make it possible to lock the equipment
and travel control.
For the operation of the safety bars (see "3.3.5 pos. 1 - SAFETY BARS".
q The retainer (5) locks the optional equipment control pedal in
the neutral position.
SAFETY LOCKS
4 4
RWAA13160
5
q The other applications of the safety locks concern exclusive-
ly the use of the machine for travelling on roads, and are the
following:
1 - Installation of the front bucket swing lock (6).
2 - Installation of the teeth guard (7).
RWAA13170
6
RWAA13180
7
RWAA13190
53
SAFETY LOCKS
3 - Locking of the safety device (8) for the inhibition of the
equipment control.
3.1.2 EXCAVATOR LOCKS (if installed)
IMPORTANT
q When travelling on roads, always position the excavator
following the longitudinal axis of the vehicle, apply the
safety locks and lock the equipment control by shifting
the safety device lever to the lock position.
The excavator safety locks must be used for travelling on
roads and applied by proceeding as follows.
q After folding the bucket completely, apply the lock (1) be-
tween boom and arm, the connection lock (2) between boom
and sliding plate, the centre pin (3) that locks the sliding
plate on the frame, raise the stabilizer supports completely
and engage the relevant safety chains (4).
8
RWAA13200
RWA37410
54
1
2
3
4
RWA23280
q If the machine is equipped with rear stabilizers, raise the
supports completely and engage the relevant safety
chainsza (5).
SAFETY LOCKS
1
RWAA4140
2
RWAA4150
3
RWAA4160
4
5
RWA37420
RWAA4170
55
SAFETY LOCKS
3.1.3 ASPHALT CUTTER LOCKS (if installed)
IMPORTANT
q When travelling on roads, always position the asphalt
cutter following the longitudinal axis of the vehicle, apply the safety locks and lock the equipment control by
shifting the safety device lever to the lock position.
q If the machine is equipped with asphalt cutter, besides ap-
plying the antirotation lock already described for the standard machine (see "3.1.1 LOADER LOCKS"), it is also
necessary to apply the lock (1) on the lifting jacks, in such a
way as to keep the equipment at a given distance from the
ground.
RWAA4190
1
RWAA4200
56
3.2 GENERAL VIEWS
3.2.1 FRONT GENERAL VIEW
RWA37430
2
GENERAL VIEWS
6
5
4
1
Bucket
2
Bucket cylinder
3
Wheels
4
5
6
3
2
1
Frame
Arm
Cab
57
GENERAL VIEWS
3.2.2 REAR GENERAL VIEW
RWA37440
4
3
2
1
1
Rear panel
2
Engine hood
3
Lifting cylinder
4
Exhaust silencer
58
3.2.3 CAB INSIDE GENERAL VIEW
GENERAL VIEWS
2
4
1
7
1 - Safety bars
2 - Left servo control lever
- (ISO PATTERN) - travel and steering
- (OPTION PATTERN) - left wheel travel and loader arm
control
3 - Right servo control lever
- (ISO PATTERN) - loader arm and bucket control
- (OPTION PATTERN) - right wheel travel and bucket control
4 - Auxiliary hydraulic kit control pedal (if installed)
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Equipment control locking lever (if installed)
9 - Dashboard
3
5
1
6
RWA31880
8
RWAA11560
9
RKAB1100
59
GENERAL VIEWS
10 - Left console switches
11 - Right console switches
10
RWAA11260
11
RWAA9720
60
3.3 INSTRUMENTS AND CONTROLS
3.3.1 INSTRUMENTS
INSTRUMENTS AND CONTROLS
1
H
C
P
2
F
E
3
RWA31900
1
Hour meter
2
Engine coolant temperature indicator
1 - HOUR METER
This instrument indicates the total number of operating hours
of the engine. The count is continuous and the number is increased by 1 when the engine has run for one hour, independently of its speed. When the engine is running, the led (A)
positioned under the instrument flashes for the count of the
seconds.
The hour meter keeps functioning even if the machine is not
travelling or working.
The reading of the hour meter is to be considered valid for the
calculation of the maintenance intervals.
3
Fuel level indicator
RYA13640
61
INSTRUMENTS AND CONTROLS
2 - ENGINE COOLANT TEMPERATURE INDICATOR
This instrument indicates the temperature of the engine coolant, which in normal conditions should be 80-85°C.
After starting the engine and before starting work, let it warm
up until the temperature indicator reaches the green range.
If the indicator exceeds the limit values while the engine is running and reaches the overheating red range, let the engine
idle until the indicator returns to the normal temperature green
range.
When the indicator reaches the overheating red range, the
acoustic alarm sounds, too.
If this inconvenience occurs repeatedly, try to find out the
cause (see TROUBLESHOOTING "3.15.4.3 ENGINE").
RYA13650
3 - FUEL LEVEL INDICATOR
This instrument indicates the fuel level in the tank; this information is available only with the ignition key in position «I»
(see "3.3.3 pos. 9 - IGNITION SWITCH").
The green range indicates the normal fuel level, while the red
range indicates that the fuel level is low.
NOTE
q If the indicator reaches the reserve red range while the ma-
chine is working, stop it and refuel it up to the correct level.
RYA13660
RYA13670
62
3.3.2 WARNING LIGHTS
INSTRUMENTS AND CONTROLS
1
2
3
4
5
H
F
C
P
E
6
1
Generator warning light
2
Preheating warning light
3
Engine oil pressure warning light
4
Air cleaner clogging warning light
5
Hydraulic oil filter clogging warning light
6
Parking brake warning light
1 - GENERATOR WARNING LIGHT
This warning light comes on when the starting circuit is energized and goes out when the engine exceeds the idling speed;
if this warning light remains on even when the engine is running at the normal operating speed, this means that the alternator does not work and the battery is not charged correctly.
8
7
10
9
11
10
11
7
Speed increase warning light
8
Floating device warning light
9
Direction indicator warning light
Working light warning light
Safety device functionality control unit
RWA31890
NOTE
q If the warning light remains off when the ignition key is
turned to position «I» this means that the alternator is faulty
or broken.
RWA07150
63
INSTRUMENTS AND CONTROLS
2 - PREHEATING WARNING LIGHT
This warning light comes on when the ignition key is turned to
position « » to start the engine at low temperatures and
goes out automatically after approximately 13 seconds (see
"3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES").
3 - ENGINE OIL PRESSURE WARNING LIGHT
This warning light comes on and activates the acoustic alarm
with engine at rest when the starting circuit is energized and
goes out as soon as the engine lubrication circuit is pressurized.
If this warning light remains on or comes on with the engine
running, stop the machine immediately and try to locate the
trouble.
RWA07160
4 - AIR CLEANER CLOGGING WARNING LIGHT
This warning light comes on when the engine air filter needs
cleaning.
5 - HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT
This warning light comes on when the hydraulic circuit filter
needs replacing.
RWA07130
RWA31710
64
RWA22340
6 - PARKING BRAKE WARNING LIGHT
This warning light comes on when the parking brake circuit
isn't pressurised (brake applied).
If the warning light comes on during routine operations, stop
the machine and try to locate the cause of the malfunction.
7 - SPEED INCREASE WARNING LIGHT
It comes on when the high speed is selected (see "3.3.3 pos.
13 - SPEED INCREASE BUTTON").
INSTRUMENTS AND CONTROLS
P
RWA20230
8 - FLOATING DEVICE WARNING LIGHT
It comes on when the floating device is connected (see "3.3.3
pos. 14 - FLOATING DEVICE SWITCH (if installed)").
9 - DIRECTION INDICATOR WARNING LIGHT
This warning light comes on intermittently when the lever on
the dashboard is operated (see "3.3.3 pos. 8 - DIRECTION
INDICATOR SWITCH") or when the emergency switch is operated (see «"3.3.3 pos. 6 - EMERGENCY SWITCH (HAZARD)").
RWA18440
RWA23300
RWA20200
65
INSTRUMENTS AND CONTROLS
10 - WORKING LIGHT WARNING LIGHT
It comes on when the working lights are turned on with the
switch positioned on the dashboard (see "3.3.3 pos. 5 WORKING LIGHT SWITCH").
11 - SAFETY DEVICE FUNCTIONALITY CONTROL UNIT
This control unit is positioned on the dashboard and checks
the condition of the safety devices installed on the machine.
The signals are shown on the display by the coming on and
going out of the warning lights.
The functions are the following:
RWA07180
C
E
A
A - RED WARNING LIGHT
LED off - This means that all the safety devices are on
and therefore all the machine functions are normal (the
solenoid valve ensures the lifting of the work equipment
and the machine travel).
LED on - This means that at least one safety function is
lacking; in this case the solenoid valve is closed and does
not permit the lifting and therefore the use of the work
equipment and the machine travel.
B - GREEN WARNING LIGHT
LED on - This means that the operator is correctly seated
in the driving position and that the operator presence sensor is on.
LED off - (With the red warning light coming on at the
same time) This means that the operator is standing or
that he is not inside the cab.
B
A
B
C
RWA31910
RWA22370
NOTE
q The operator presence signal (seat) starts the emergency
condition with a delay of 1.5 seconds.
With this solution the operatorís jerks (especially when working on uneven ground) are sensed without signalling repeated emergencies.
66
RWA22380
INSTRUMENTS AND CONTROLS
C - GREEN WARNING LIGHT
LED on - This means that the safety bars are down and
therefore safety is ensured.
LED off - (With the red warning light coming on at the
C
same time) This means that the safety bars are not completely down and therefore the work equipment and the
travel function cannot be used.
RWA22390
CAUTION
q The sounding of the acoustic alarm (buzzer) signals that the solenoid valve coil is jammed.
This alarm sounds even with the engine at rest and disconnected ignition key.
q Be particularly careful in the following conditions:
A) Safety bars lifted and temporary jamming of the valve. (The engine stops and the acoustic alarm
sounds).
Lower the work equipment to the ground (see "3.3.5 MACHINE CONTROLS"), get off the machine and
try to locate the trouble.
B) Coil jamming with engine off. (The acoustic alarm sounds).
Lower the work equipment to the ground (see "3.3.5 MACHINE CONTROLS"), get off the machine and
try to locate the trouble.
q When the troubleshooting takes long, disconnect the negative pole (-) of the battery, in order not to de-
plete it completely.
NOTE
q The green leds (seat and bar) come on only if the operator has engaged all the safety locks and released the
parking brake (red led on). The leds go out whenever the bar is lifted (servocontrols off); to reactivate the servocontrols, seat in the driving position, lower the safety bar and press the parking brake push button (green and
red leds on).
67
INSTRUMENTS AND CONTROLS
3.3.3 SWITCHES UND PUSH BUTTONS
1 - Parking brake push button
2 - Revolving light switch
3 - Left stabilizer button (if installed)
4 - Right stabilizer button (if installed)
5 - Working light switch
6 - Emergency switch (HAZARD)
7 - Parking light and low beam switch
8 - Direction indicator switch
9 - Ignition switch
10 - Horn
11 - "High flow" hydraulic system switch (3 lines)
for front equipment (if installed)
21 43
RWAA10590
5
6
87
10
RWAA9740
9
RWAA9750
11
13
68
RWAA11940
12 - “Super flow" hydraulic system switch (5 lines)
for front equipment (if installed)
13 - Speed increase button
14 - Floating device button (if installed)
15 - Available for other functions
INSTRUMENTS AND CONTROLS
12
10
13
RWAA11950
1 - PARKING BRAKE PUSH BUTTON
When pressed, this button comes on and applies the parking
brake.
When pressed again (LED off), it releases the parking brake.
NOTE
q The parking brake is automatically engaged whenever the
engine stops; this is due to the lack of pressure in the hydraulic circuit.
q The push button releases the brake only when the engine is
running and all the safety devices are in function (warning
lights off).
14
15
15
RWAA11960
P
RWA20230
2 - REVOLVING LIGHT SWITCH
Switches on the revolving light and must be operated when it
is necessary to travel on roads.
RWA07210
69
INSTRUMENTS AND CONTROLS
3 - LEFT STABILIZER BUTTON (if installed)
This is a button with two temporary positions and the neutral
position at its centre.
Press the button forward or backward to lower or raise the stabilizer.
For use, see "3.3.5 pos. 14 - LEFT STABILIZER CONTROL
(IF INSTALLED)".
4 - RIGHT STABILIZER BUTTON (if installed)
This is a button with two temporary positions and the neutral
position at its centre.
Press the button forward or backward to lower or raise the stabilizer.
For use, see "3.3.5 pos. 13 - RIGHT STABILIZER CONTROL
(IF INSTALLED)".
RWA23320
5 - WORKING LIGHT SWITCH
Enables the circuit of the working lights.
6 - EMERGENCY SWITCH (HAZARD)
Operates all the direction lights at the same time and must be
used whenever the machine is temporarily parked on the roadside or in anomalous position while travelling on roads.
RWA23310
RWA07180
70
RWA20210
7 - PARKING LIGHT AND LOW BEAM SWITCH
This is a two-position switch:
st
The 1
click enables the circuit of the instrument lights and the
parking lights.
nd
The 2
click enables the general circuit of the low beam or
working lights, according to the position of the switch (2).
8 - DIRECTION INDICATOR SWITCH
This is a lever switch with three positions. The neutral position
is at the centre.
Shift the switch lever to the right or to the left to indicate the
turn direction.
INSTRUMENTS AND CONTROLS
RWA22400
9 - IGNITION SWITCH
This is a rotary key switch with four positions marked by the
following symbols « » - (OFF) - I - « » (START).
For further details on the use of this switch, see "3.6.2 STARTING THE ENGINE".
10 - HORN
This push button is positioned on the left lever grip and serves
to warn the persons in the vicinity of the machine at the beginning of work and in case of danger.
RWA20200
RWA23290
RWA20870
71
INSTRUMENTS AND CONTROLS
11 - FRONT EQUIPMENT «HIGH-FLOW» HYDRAULIC SYS-
TEM SWITCH (3 LINES) (if installed)
This switch allows the oil delivery of the hydraulic pump to be
constantly increased.
For use, see "3.3.5 pos. 9 - "HIGH FLOW" HYDRAULIC SYSTEM CONTROL (3 LINES) (IF INSTALLED)".
12 - FRONT EQUIPMENT «SUPER-FLOW» HYDRAULIC
SYSTEM SWITCH (5 LINES) (if installed)
This is a double-function switch and allows the oil delivery of
the hydraulic pump to be constantly increased.
For use, see "3.3.5 pos. 9 - “SUPER FLOW” HYDRAULIC SYSTEM CONTROL (5 LINEE) (IF INSTALLED)".
RWA35980
13 - SPEED INCREASE BUTTON
This button is positioned on the left joystick grip and serves to
increase the machine speed.
For use, see "3.3.5 pos. 10 - SPEED INCREASE CONTROL".
14 - FLOATING DEVICE SWITCH (if installed)
This switch is positioned on the right joystick grip and when
pressed enables the electrohydraulic circuit of the floating device.
For use, see "3.3.5 pos. 11 - FLOATING DEVICE CONTROL
(IF INSTALLED)".
RWA35980
RWA18440
15 - AVAILABLE FOR OTHER FUNCTIONS
72
RWA23300
3.3.4 ELECTRICAL ACCESSORIES
1 - Acoustic alarm
2 - Electric outlet
3 - Accumulator disconnection switch (if provided)
INSTRUMENTS AND CONTROLS
1
RWAA9760
2
1 - ACOUSTIC ALARM
This acoustic alarm sounds when the circuits are energized
with the ignition key (rotation to position ìIî) and is automatically disconnected when the engine is started.
The sounding of the alarm during operation signals:
q insufficient engine oil pressure;
RWAA11570
3
RWAA12480
q overheating of the engine cooling circuit;
q jamming of the servo control solenoid valve coil
RWA07200
73
INSTRUMENTS AND CONTROLS
2 - ELECTRIC OUTLET
An electric outlet is positioned on the right side of the cab inner
wall for the connection of a lighting device for routine and
maintenance operations.
It is a two-pole outlet and is in compliance with the ISO 41651979 standard.
Power supply 12 V.
3 - ACCUMULATOR DISCONNECTION SWITCH
(if provided)
This is a removable lever-type switch positioned near the accumulator; to reach it, it is necessary to open the engine hood
(see "3.5.1 ENGINE HOOD").
The current transmitted by the accumulator to the electric system of the machine can be interrupted by rotating the switch
clockwise (position B).
Always rotate the switch to “position B” if it is necessary to
work on the accumulator or the electric system, or if electric
welds must be carried out on the machine.
The electric contact can be restored by rotating the switch anticlockwise (position A).
RWA07250
A
RWAA12490
B
RWAA12500
74
INSTRUMENTS AND CONTROLS
3.3.5 MACHINE CONTROLS
CAUTION
q The procedures to be followed to use any control systems different from the ISO and OPTION PATTER-
NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM").
Carefully read and be sure to understand the contents of this section before using the machine.
2
4
1
7
1 - Safety bars
2 - Left servo control lever
- (ISO PATTERN) - travel and steering
- (OPTION PATTERN) - left wheel travel and loader arm
control
3 - Right servo control lever
- (ISO PATTERN) - loader arm and bucket control
- (OPTION PATTERN) - right wheel travel and bucket control
4 - Auxiliary hydraulic kit control pedal (if installed)
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Equipment control locking lever (if installed)
9 - "High flow" hydraulic system control (3 lines) (if installed)
- "Super flow" hydraulic system control (5 lines) (if installed)
10 - Speed increase control
3
5
1
6
RWA31880
8
RWAA11560
9
10
RWAA10500
75
INSTRUMENTS AND CONTROLS
11 - Floating device control (if installed)
12 - Pattern shifting control (if installed)
13 - Right stabilizer control (if installed)
14 - Left stabilizer control (if installed)
15 - Optionals
11
RWAA10490
14
15
12
RWAA11590
13
RWA36000
15
76
RWAA11610
1 - SAFETY BARS
WARNING
q Before leaving the operating position, lower the equip-
ment to the ground and lock the safety bars.
q The safety devices of the machine are composed of
electric parts.
Therefore, before modifying or replacing wirings and
electrical components, which may result in malfunctions of the devices, contact your Komatsu Dealer.
The locking of the servo control safety device is obtained by
lifting the bars (1) in vertical position.
The safety device can be released by lowering the bars to the
horizontal position and pressing the parking brake push button
(warning light off).
NOTE
q The equipment movements and the travel function are inhib-
ited when the safety bars (1) are locked.
INSTRUMENTS AND CONTROLS
1
1 1
1
RWAA13210
RWAA13220
77
INSTRUMENTS AND CONTROLS
ISO PATTERN CONTROL SYSTEM
CAUTION
q The procedures to be followed to use any control systems different from the ISO and OPTION PATTER-
NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM").
Carefully read and be sure to understand the contents of this section before using the machine.
2 - LEFT SERVO CONTROL LEVER (TRAVEL AND STEERING)
WARNING
q Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with
fastened safety belt; before every manoeuvre the operator must take all the precautions indicated "3.6.5
HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEMERN)".
q Before moving, make sure that the parking brake is disengaged.
q When travelling on roads, make sure that all the safety devices have been engaged.
q Failure to comply with these rules may lead to serious accidents.
The travel control lever (2) is positioned on the operatorís left
and serves to control the forward and reverse movements and
the steering of the machine, according to the movements indicated in the diagram.
2
N - Neutral
A - Forward gear
B - Counterrotation to the right
C - Reverse gear
D - Counterrotation to the left
RWAA9780
F
A
D
N
B
C
R
RWA22410
78
INSTRUMENTS AND CONTROLS
If the lever is operated in directions that are inclined with respect to the machine axis, simultaneous steering movements
proportional to the angle of inclination are obtained, since the
two hydraulic pumps corresponding to each single function are
engaged at the same time.
A
B
N
N - Neutral
A - Forward left steering
B - Forward right steering
C - Reverse left steering
D - Reverse right steering
D
C
RWA22420
CAUTION
q Always travel at moderate speed, in order to obtain maximum precision and maximum efficiency during
work.
q During work, the use of the lever must be proportional to the required effort and such as to obtain con-
stant engine speed.
q Manoeuvre the lever smoothly, without abrupt movements and avoid counterrotations as much as pos-
sible, since these manoeuvres involve untimely wear of the tyres.
NOTE
q The lever grip is provided with the horn, which must be used to warn the persons in the vicinity of the machine at
the beginning of work and in case of danger.
q To inhibit all movements, lock the controls by lifting the safety bars in vertical position "3.3.5 pos. 1 - SAFETY
BARS").
79
INSTRUMENTS AND CONTROLS
3 - RIGHT SERVO CONTROL LEVER (LOADER ARM AND BUCKET)
WARNING
q Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with
fastened safety belt; before any manoeuvre he must perform the operations described in"3.13 USING
THE WORK EQUIPMENT".
q When travelling on roads, always lock the equipment control (see "3.3.5 pos. 8 - EQUIPMENT CONTROL
LOCKING LEVER (IF INSTALLED)").
q Before leaving the operating position, lower the equipment to the ground and lock the safety bars (verti-
cal position), then stop the engine.
q Failure to comply with these instructions may lead to serious accidents.
CAUTION
q The self-leveling system is operated automatically only when the loader arm is lifted with loaded bucket.
When the arm is in the lowering phase the system cannot be operated.
q At the maximum height the self-leveling system keeps the bucket partially folded to prevent the material
from falling out of the bucket itself.
The equipment control lever (3) is positioned on the operatorís
right and controls the loader arm lifting and lowering and the
bucket dumping and folding functions.
The following diagrams show the basic manoeuvres and the
possible combined manoeuvres.
BASIC MANOEUVRES
N - Neutral
A - Loader arm lowering
B - Bucket dumping
C - Loader arm lifting
D - Bucket folding
3
RWAA9790
A
D
N
B
C
80
RWA22430
If the lever is operated in directions that are inclined with respect to the machine axis, simultaneous movements proportional to the angle of inclination are obtained, since the two
hydraulic distributors corresponding to each single function
are engaged at the same time.
INSTRUMENTS AND CONTROLS
A
B
N
COMBINED MANOEUVRES
N - Neutral
A - Loader arm lowering - Bucket folding
B - Loader arm lowering - Bucket opening
C - Loader arm lifting - Bucket opening
D - Loader arm lifting - Bucket folding
NOTE
q To inhibit all movements, lock the controls by lifting the safe-
ty bars in vertical position . (see "3.3.5 pos. 1 - SAFETY
BARS").
D
C
RWA22440
81
INSTRUMENTS AND CONTROLS
OPTIONAL PATTERN CONTROL SYSTEM
CAUTION
q The procedures to be followed to use any control systems different from the ISO and OPTION PATTER-
NS are described in section "OPTIONAL EQUIPMENT" (See "6.5 HAND & FOOT CONTROL SYSTEM").
Carefully read and be sure to understand the contents of this section before using the machine
2 - LEFT SERVO CONTROL LEVER (LEFT WHEEL TRAVEL AND LOADER ARM CONTROL)
WARNING
q Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with
fastened safety belt; before every manoeuvre the operator must take all the precautions indicated in
"3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)" and "3.13 USING THE
WORK EQUIPMENT".
q Before moving, make sure that the parking brake is disengaged.
q When travelling on roads, always lock the equipment control (see "3.3.5 pos. 8 - EQUIPMENT CONTROL
LOCKING LEVER (IF INSTALLED)".
q When travelling on roads, make sure that all the safety devices have been engaged.
q Before leaving the work position, lower the equipment to the ground and lock the safety bars (vertical
position), then stop the engine.
q Failure to comply with these rules may lead to serious accidents.
CAUTION
q The self-leveling system is operated automatically only when the loader arm is lifted with loaded bucket.
When the arm is in the lowering phase the system cannot be operated.
q At the maximum height the self-leveling system keeps the bucket partially folded to prevent the material
from falling out of the bucket itself.
The servo control lever (2) is positioned on the Operator's left
and controls the forward and reverse movements of the machine, as weel as the steering to the right and the lifting and
lowering of the loader arm according to the movements indicated in the diagram.
IMPORTANT
q To move the machine forward or backward, shift the
control levers (2) and (3) at the same time and in the
same direction.
3
2
RWAA9780
82
RWAA9790
INSTRUMENTS AND CONTROLS
N - Neutral
A - Forward right steering
B - Loader arm lowering
C - Reverse right steering
D - Loader arm lifting
F
A
D
N
B
C
R
RWA32220
CAUTION
q Always travel at moderate speed, in order to obtain maximum precision and maximum efficiency during
work.
q During work, the use of the lever must be proportional to the required effort and such as to obtain con-
stant engine speed.
q Manoeuvre the lever smoothly, without abrupt movements and avoid counterrotations as much as pos-
sible, since these manoeuvres involve untimely wear of the tyres.
NOTE
q The lever grip is provided with the horn, which must be used to warn the persons in the vicinity of the machine at
the beginning of work and in case of danger.
q To inhibit all movements, lock the controls by lifting the safety bars in vertical position "3.3.5 pos. 1 - SAFETY
BARS").
83
INSTRUMENTS AND CONTROLS
3 - RIGHT SERVO CONTROL LEVER (RIGHT WHEEL TRAVEL AND BUCKET FOLDING)
WARNING
q Before carrying out any manoeuvre with this lever, the operator must be seated in the work position with
fastened safety belt; before every manoeuvre the operator must take all the precautions indicated in
"3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)" and "3.13 USING THE
WORK EQUIPMENT".
q Before moving, make sure that the parking brake is disengaged.
q When travelling on roads, always lock the equipment control (see "3.3.5 pos. 8 - EQUIPMENT CONTROL
LOCKING LEVER (IF INSTALLED)").
q When travelling on roads, make sure that all the safety devices have been engaged.
q Before leaving the work position, lower the equipment to the ground and lock the safety bars (vertical
position), then stop the engine.
q Failure to comply with these rules may lead to serious accidents.
The servo control lever (3) is positioned on the Operator's right
and controls the forward and reverse movements of the machine, as weel as the steering to the left and the bucket folding
and dumping according to the movements indicated in the diagram.
IMPORTANT
q To move the machine forward or backward, shift the
control levers (2) and (3) at the same time and in the
same direction
3
N - Neutral
A - Forward left steering
B - Bucket dumping
C - Reverse left steering
D - Bucket folding
RWAA9790
2
RWAA9780
F
A
D
N
B
C
R
84
RWA32230
INSTRUMENTS AND CONTROLS
CAUTION
q Always travel at moderate speed, in order to obtain maximum precision and maximum efficiency during
work.
q During work, the use of the lever must be proportional to the required effort and such as to obtain con-
stant engine speed.
q Manoeuvre the lever smoothly, without abrupt movements and avoid counterrotations as much as pos-
sible, since these manoeuvres involve untimely wear of the tyres.
NOTE
q To inhibit all movements, lock the controls by lifting the safety bars in vertical position (see "3.3.5 pos. 1 - SA-
FETY BARS").
85
INSTRUMENTS AND CONTROLS
4 - AUXILIARY HYDRAULIC KIT CONTROL PEDAL
(IF INSTALLED)
CAUTION
q The procedures to be followed to use any control sy-
stems different from the ISO and OPTION PATTERNS
are described in section "OPTIONAL EQUIPMENT" (See
"6.5 HAND & FOOT CONTROL SYSTEM"). Carefully read
and be sure to understand the contents of this section
before using the machine.
WARNING
q Always apply the safety guard (2) when the use of this
control is not required, during travel and when parking
the machine.
q When installing any hydraulic control equipment, make
sure that the control pedal (1) is always in neutral position and covered by the safety guard (2).
q Never set the control pedal in the "maximum flow" posi-
tion (B), unless the machine is stationary, with raised safety bars, and the operator is seated in driving position
with fastened safety belt.
A
2
RKAB1530
2
3
1
RKAB1540
The pedal (1) controls the opening and closing of the oil flow to
the equipment and has three fixed positions (left, neutral, right).
NOTE
q To use the pedal (1), lift the safety guard (2).
1 - Neutral position (A) (HYDRAULIC CIRCUIT CLOSED).
When the pedal is in this position, it isn't possible to use
the optional equipment in any way.
2 - Pressed pedal (B) (HYDRAULIC CIRCUIT OPEN)
When the pedal is pressed with the left side of the foot
and locked in this position with the lever (3), a continuous
oil flow is delivered to the equipment (excavator, demolition hammer, asphalt cutter, etc.).
To release the pedal (1) and set it in neutral or horizontal
position, push the locking lever (3) forward as indicated in
the figure (A).
3 - Bidirectional flow position.
The pedal is also used to control the oil flow to the equipment with bidirectional hydraulic circuit (multi-purpose
buckets, drills, asphat cutters, etc.). Shift the locking lever
(3) to the release position and press the pedal (1) to position L or R to control the oil flow to the equipment. The
quantity of oil conveyed in each direction is proportional to
the pressure exerted on the pedal.
B
1
3
RWAA12660
L
3
R
1
RWAA12670
86
5 - FOOT ACCELERATOR
The accelerator pedal (1) is positioned on the operator’s right
and serves to control the engine speed and power.
Use the accelerator pedal with care, especially when the machine is under strain or is working in difficult conditions.
Avoid useless accelerations, in order to reduce consumption
and extend the life of both the engine and the machine.
6 - HAND ACCELERATOR
INSTRUMENTS AND CONTROLS
1
RWAA12700
WARNING
q The use of the hand accelerator is allowed only under
the indicated conditions; its use in other conditions may
lead to accidents.
The hand accelerator must be used during the warming up of
the engine and successively when operations with the optional
equipment are to be carried out; it can also be used for some
maintenance operations.
q Idling position (A):
lever completely pushed forward.
q Maximum speed position (B):
lever completely pulled backward.
A
RWAA9890
B
RWAA9900
87
INSTRUMENTS AND CONTROLS
7 - PARKING BRAKE
WARNING
q The parking brake must be applied whenever the opera-
tor leaves the driving position, even if for a short time.
q The machine must be positioned with the wheels resting
firmly on the ground. If one of the wheels is unstable or
is resting on a small obstacle, the machine may move.
q Periodically check the functionality of the parking brake.
Failure to comply with these instructions may lead to
serious accidents or even death.
q In case of failure of the hydraulic system, before the re-
covery of the machine release the negative brake installed on the travel hydraulic motors (see "4.8.1.d
RELEASING THE PARKING BRAKE").
The braking action is obtained by pressing the switch (1) (LED
ON); the release is obtained by pressing the switch again
(LED OFF).
1
RWAA10460
IMPORTANT
q The parking brake is automatically engaged whenever
the engine stops; this is due to the lack of pressure in
the hydraulic system.
q Every time the engine is started or restarted, it is neces-
sary to release the parking brake before moving the machine.
8 - EQUIPMENT CONTROL LOCKING LEVER
(IF INSTALLED)
WARNING
q When travelling on roads, always lock the equipment
control.
When shifted to the lock position, the lever inhibits the equipment control.
Before travelling on roads, always lock the equipment control.
The positions of use of the lever are those indicated in the figures.
RWAA11520
88
RWAA11530
9 - STANDARD FLOW HYDRAULIC SYSTEM CONTROL
(2 LINES)
INSTRUMENTS AND CONTROLS
WARNING
q Avoid connecting any equipment to the hydraulic lines
before said equipment has been correctly installed from
a mechanical point of view and secured to the machine
front coupling.
q Avoid connecting any manually-controlled equipment or
tool (for example, hand hammer) to the hydraulic lines
while the equipment/tool is working.
q Connect the hydraulic lines only with the engine off and
the parking brake applied.
q To avoid serious injury, always operate the equipment
while seated in driving position. Do not allow anyone to
get too close the machine or the equipment.
q Read the contents of the equipment instruction manual
carefully before using the machine or carrying out maintenance operations.
The bidirectional oil flow to the equipment is controlled by the
pedal (A) (see "3.3.5 pos. 4 - AUXILIARY HYDRAULIC KIT
CONTROL PEDAL (IF INSTALLED)") and is proportional to
the pressure exerted on the pedal in both directions. The
hydraulic lines are positioned on the left side of the arm.
A
RKAB1370
RKAB01340
89
INSTRUMENTS AND CONTROLS
9 - "HIGH FLOW" HYDRAULIC SYSTEM CONTROL
(3 LINES) (IF INSTALLED)
WARNING
q Avoid connecting any equipment to the hydraulic lines
before said equipment has been correctly installed from
a mechanical point of view and secured to the machine
front coupling.
q Avoid connecting any manually-controlled equipment or
tool (for example, hand hammer) to the hydraulic lines
while the equipment/tool is working.
q Connect the hydraulic and electric lines only with the
engine off and the parking brake applied.
q To avoid serious injury, always operate the equipment
while seated in driving position. Do not allow anyone to
get too close the machine or the equipment.
q Read the contents of the equipment instruction manual
carefully before using the machine or carrying out maintenance operations.
IMPORTANT
q When the HIGH FLOW hydraulic button (1) is pressed,
the flow conveyed to the hydraulic connections positioned on the left side of the loader arm for the operation of
the equipment is higher than the standard flow.
1
RWAA10480
A
RKAB1370
DANGER
q If the engine is running and the parking brake isn't ap-
plied, when the HIGH FLOW button (1) is pressed the
LED on the button comes on and the hydraulic oil flow
rate through the front auxiliary rapid couplings is high.
q The HIGH FLOW hydraulic system can be operated only
with the equipment installed on the machine.
q Press the HIGH FLOW button again to stop the increa-
sed hydraulic flow.
The "High Flow" to the equipment is bidirectional, is controlled
by the pedal (A) (see "3.3.5 pos. 4 - AUXILIARY HYDRAULIC
KIT CONTROL PEDAL (IF INSTALLED)") and is proportional to
the pressure exerted on the pedal in both directions. The
hydraulic and electric lines are positioned on the left side of
the loader arm.
RKAB01350
90
9 - “SUPER FLOW” HYDRAULIC SYSTEM CONTROL
(5 LINEE) (IF INSTALLED)
INSTRUMENTS AND CONTROLS
WARNING
q Avoid connecting any equipment to the hydraulic lines
before said equipment has been correctly installed from
a mechanical point of view and locked to the machine
front coupling.
q Avoid connecting any manually-controlled equipment or
tool (for example, hand hammer) to the hydraulic lines
while the equipment/tool is working.
q Connect the hydraulic lines only with the engine off and
the parking brake applied.
q To avoid serious injury, always operate the equipment
while seated in driving position. Do not allow anyone to
get too close the machine or the equipment.
q Read the contents of the equipment instruction manual
carefully before using the machine or carrying out maintenance operations.
The Super Flow hydraulic controls can be used when the operator needs to increase the oil delivery to the hydraulic system
of the equipment. With the SUPER FLOW hydraulic system it
is possible to use equipment that require a high-flow hydraulic
line (left) and at the same time a standard-flow hydraulic line
(right) with limited oil flow for secondary functions (auxiliary
hydraulic kit control pedal).
Thanks to the Super Flow hydraulic control, the operator can
use two independent hydraulic circuits (positioned on the right
and on the left side of the loader arm). In the Super Flow
hydraulic system, the standard-flow lines are positioned on the
right side of the arm. The quantity of oil in the right hydraulic lines and the flow reversal are controlled by the pedal (see
"3.3.5 pos. 4 - AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED)").
The left hydraulic lines are used only for equipment requiring
high flow rates and are controlled by the buttons (1) and (2) on
the left joystick.
To deliver oil to the equipment, press the push button (2) (red
LED on the button ON); press the button again to stop the oil
flow in the hydraulic lines completely (red LED OFF).
To deliver the oil flow in the reverse direction, press the button
(1) and keep it pressed. Release the button (1) to restore normal operating conditions.
21
RWAA11580
A
RKAB1370
RKAB1360
RKAB01350
91
INSTRUMENTS AND CONTROLS
10 - SPEED INCREASE CONTROL
The button (1) that allows the machine travel speed to be increased is positioned on the left joystick grip.
When the button is pressed, the speed increases; release the
button to return to normal speed.
CAUTION
q The speed increase function should be used only for the
fast speed transfers of the machine; in any other case, it
is advisable to use the normal speed.
q Do not use the speed increase control when performing
steering or counterrotation manoeuvres.
11 - FLOATING DEVICE CONTROL
(IF INSTALLED)
The right joystick grip is provided with a switch (1) that when
pressed (WARNING LIGHT ON) (see "3.3.2 pos. 8 - FLOATING DEVICE WARNING LIGHT"), frees the loader arm (floating position), that is, allows it to automatically follow the
undulations of the ground.
Press the switch again to restore the standard operating conditions (WARNING LIGHT OFF) ("3.3.2 pos. 8 - FLOATING
DEVICE WARNING LIGHT").
1
RWAA11320
1
RWAA11330
92
RWA35990
INSTRUMENTS AND CONTROLS
12 - PATTERN SHIFTING CONTROL (IF INSTALLED)
WARNING
q Before changing the setting of the pattern change valve, lower the equipment to the ground, engage the
safety locks and stop the engine.
q After changing the control operating pattern, carry out the first manoeuvres slowly and very carefully, in
order to understand the new controls correctly and avoid any damage or fatal injury that may be caused
by incorrect movements.
The pattern change valve (1) is positioned inside the engine
hood, on the cab's rear wall, and it can be reached after opening the engine hood.
The valve controls the selection of:
q ISO PATTERN CONTROL SYSTEM
q OPTION PATTERN CONTROL SYSTEM
NOTE
q For details on the procedure to be followed to change the
operating pattern of the machine, see "6.4 CHANGING THE
OPERATING PATTERN".
RWA37070
1
RKAB1380
93
INSTRUMENTS AND CONTROLS
13 - RIGHT STABILIZER CONTROL (IF INSTALLED)
WARNING
q Before moving the machine in any way, make sure that
the stabilizer feet are completely raised.
q Before travelling on roads, make sure that the safety
locks of the stabilizer feet have been applied.
The right stabilizer is operated by means of the button (1) installed on the left console and according to the indicated positions.
1 - Press the button forward to lower the stabilizer feet.
2 - Press the button backward to raise the stabilizer feet.
14 - LEFT STABILIZER CONTROL (IF INSTALLED)
WARNING
q Before moving the machine in any way, make sure that
the stabilizer feet are completely raised.
q Before travelling on roads, make sure that the safety
locks of the stabilizer feet have been applied.
1
N
RWA36010
1
N
The left stabilizer is operated by means of the button (1) installed on the left console and according to the indicated positions.
1 - Press the button forward to lower the stabilizer feet.
2 - Press the button backward to raise the stabilizer feet.
15 - OPTIONALS
The right three-button joystick is used when the operator
needs to connect electro-hydraulic equipment with several
functions.
Each push button corresponds to an electric line activated by
a pulse control: press the push button to activate the electric
contact; release the push button to deactivate the contact.
RWA36020
AB
C
BA
C
C
A
-
+
B
RWAB1120
94
FUSES AND RELAYS
3.4 FUSES AND RELAYS
CAUTION
q When changing a fuse, make sure that the ignition key is in position « ».
q If the fuses are oxidized, corroded or do not fit perfectly in their seat, replace them only with new fuses
having the same capacity.
q If the engine does not run when the ignition switch is brought to position « » STARTcheck the main
fuse and if necessary change it.
3.4.1 MACHINE FUNCTION FUSES
The fuses relevant to the machine functions are grouped on a single base positioned on the dashboard behind the
seat.
1
9
5
2
10
67
4
3
11
8
RWA35800
STANDARD VERSION
POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT
1
2
3
4
5
6
Violet 3 Left parking lights
Violet 3 Control panel lights, (right parking lights)
Light blue 15 Horn, low beam or front working lights
Brown 7.5 Switch lights
Light blue 15 Rear working lights
Red 10 Power supply of joystick switches, floating device, pattern shifting
RWAA11340
10
11
7
8
9
Red 10 12 V electric outlet, revolving light
Red 10
Brown 7.5 Reverse alarm
Brown 7.5 Fuel pump, safety relay (against repeated starting), generator
Green 30 Solenoid pull relay, servo control safety pressure switch
Power supply of control panel, safety unit, solenoid valve stop, control
bar sensor, seat sensor, brake switch
95
FUSES AND RELAYS
VERSION WITH OPTIONALS
POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT
10
11
1
2
3
4
5
6
7
8
9
Violet 3 Left parking lights, number plate light
Violet 3 Control panel lights, right parking lights
Light blue 15 Horn, low beam or front working lights
Red 10 Switch, direction indicator lights
Light blue 15 Rear working lights, stop lights
Red 10 Power supply of joystick switches, floating device, pattern shifting
Red 10 12 V electric outlet, revolving light, emergency lights (HAZARD)
Red 10
Brown 7.5
Brown 7.5 Fuel pump, safety relay (against repeated starting), generator
Green 30 Solenoid pull relay, servo control safety pressure switch
Power supply of control panel, safety unit, solenoid valve stop, control
bar sensor, seat sensor, brake switch
Reverse alarm, power supply of High-flow 3-way equipment hydraulic
system, stabilizers, safety valves
3.4.2 MAIN FUSE
The main fuse (1) is positioned near the battery and can be
reached by raising the cab (see "3.5.3.1 RAISING THE CAB").
POSITION COLOUR CAPACITY (A) INVOLVED CIRCUIT
1
Red 50 System general circuit
1
RWAA13500
96
3.4.3 RELAYS
The relays are positioned inside the engine compartment and
can be reached by raising the cab (see "3.5.3.1 RAISING THE
CAB").
Some relays are grouped inside the container fixed to the right
side of the machine frame and can be reached by removing
the cover (A).
FUSES AND RELAYS
A
RWAA9800
POSITION DESCRIPTION
1
2
3
Other relays are grouped inside the base installed on the panel (B) behind the seat and can be reached by removing the
panel (B).
Solenoid pull timer (1”)
Solenoid pull relay (engine stop)
Safety relay (against repeated starting)
RWAA9810
1
3
2
RWA32540
B
RWAA11740
97
FUSES AND RELAYS
POSITION DESCRIPTION
4 Safety unit
POSITION DESCRIPTION
4
RWA36050
Relay board:
A - Stop lights
B - 1 way
5
POSITION DESCRIPTION
6 Parking brake relay
C - 3 way
D - Momentary high-flow
E - 2 way
F - Blinking
G - Detent high-flow
BC
A
EFG
6
D
5
RWA36060
RWA36070
POSITION DESCRIPTION
7 Floating device control relay
98
7
RWA36080
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